CHAPTER I

1. INTRODUCTION
Centrifugal pumps are very common equipment used in residence, agriculture and
industrial applications. It is essential for a pump manufactured at low cost and consuming
less power with high efficiency. The overall performance is based on the impeller
parameters and it is essential to identify the optimized design parameter of the impeller.
FEM helps the designer to identify the optimal parameters of the impeller by numerical
flow simulation. The impeller is virtually analyzed using FEM software package SWFS.
The aim of the present paper is to investigate the performance of impeller by developing
the vane profile by circular arc method and point by point method and perform FEM
analysis of the impeller vane profile for forward and backward curved vane shown in Fig.
1. Impeller vane profile was developed and analysis was performed using SWFS by
Ragoth Singh, Nataraj, Surendar and Siva[12]. A investigation of internal flow in a
centrifugal pump impeller using FEM and RSM were done by Nataraj and
Ragothsingh[7]. A numerical approach was performed by Ji-fengwang, Januszpiechna[4]
and norbert mller[1] using FEM to examine the characteristics of static torque and
extracted power of turbine in a free stream with various hydrodynamic flow conditions.
Muller[3]. The performance of the pump was numerically optimized on a two-
dimensional centrifugal pump impeller to find the impeller geometry for maximizing the
pump efficiency by varying the design variables of blade angles at the leading and the
trailing edge by John Anagnostopoulos[5]. A methodology for optimizing the impeller
geometry using FEM and Response Surface Method were discussed by Ragothsingh and
flow behavior near the tongue region of a centrifugal pump for three-dimensional
unsteady flow regarding grid
size, time step size and turbulence model. Shojaeefard, Tahani, Ehghaghi, Fallahian and
Beglari carried out experimental study for performance improvement of centrifugal pump
by modifying the geometric characteristics using FEM for viscous fluid. Computational
investigation of water turbine based on three-dimensional
1.1.CENTRIPUGAL PUMP :

In impeller  is a rotor used to increase (or decrease in case of turbines) the pressure and flow of a
fluid.

1.1.1.in pumps

An impeller is a rotating component of a centrifugal pump, usually made of iron, steel, bronze, brass,
aluminium or plastic, which transfers energy from the motor that drives the pump to the fluid being
pumped by accelerating the fluid outwards from the center of rotation. The velocity achieved by the
impeller transfers into pressure when the outward movement of the fluid is confined by the pump
casing. Impellers are usually short cylinders with an open inlet (called an eye) to accept incoming
fluid, vanes to push the fluid radially, and a splined, keyed or threaded bore to accept a drive-shaft.

The impeller made out of cast material in many cases may be called rotor, also. It is cheaper to cast
the radial impeller right in the support it is fitted on, which is put in motion by the gearbox from an
electric motor, combustion engine or by steam driven turbine. The rotor usually names both
the spindle and the impeller when they are mounted by bolts.

1.1.2. Heart pumps in medicine:

In a failing heart, mechanical circulatory devices often utilize a continuous axial-flow impeller pump
design

Types[edit]

 Open
 Semi Open
 Closed or Shrouded

In centrifugal compressors[edit]
The main part of a centrifugal compressor is the impeller. An open impeller has no cover, therefore it
can work at higher speeds. A compressor with a covered impeller can have more stages than one
that has an open impeller.

In water jets[edit]
Some impellers are similar to small propellers but without the large blades. Among other uses, they
are used in water jets to power high speed boats.

Since impellers have no large blades to turn, they can spin at much higher speeds than propellers.
The water forced through the impeller is channelled by the housing, creating a water jet that propels
the vessel forward. The housing is normally tapered into a nozzle to increase the speed of the water,
which also creates aVenturi effect in which low pressure behind the impeller pulls more water
towards the blades, tending to increase the speed.

To work efficiently, there must be a close fit between the impeller and the housing. The housing is
normally fitted with a replaceable wear ring which tends to wear as sand or other particles are
thrown against the housing side by the impeller.

Vessels using impellers are normally steered by changing the direction of the water jet.

Compare to propeller and jet aircraft engines.
In agitated tanks[edit]

Axial flow impeller (left) and radial flow impeller (right).

Impellers in agitated tanks are used to mix fluids or slurry in the tank. This can be used to combine
materials in the form of solids, liquids and gas. Mixing the fluids in a tank is very important if there
are gradients in conditions such as temperature or concentration.

There are two types of impellers, depending on the flow regime created (see figure):

 Axial flow impeller

 Radial flow impeller

Radial flow impellers impose essentially shear stress to the fluid, and are used, for example, to mix
immiscible liquids or in general when there is a deformable interface to break. Another application of
radial flow impellers are the mixing of very viscous fluids.

Axial flow impellers impose essentially bulk motion, and are used on homogenization processes, in
which increased fluidvolumetric flow rate is important.

Impellers can be further classified principally into three sub-types

 Propellers
 Paddles
 Turbines

All these can be discussed immediately after example

VERTICAL PUMP IMPELLER:

The VTP vertical turbine pump is a diffuser type, single or multistage design for
continuous service in wet pit and deep well applications. With more than 300 bowl and
impeller designs, the VTP provides unsurpassed hydraulic coverage to ensure the best
pump selection for a wide variety of services.

Applications: 
Descaling, Flood Control, Drilling and Production, FPSO, Geothermal Well Services,
Ground Water Development and Irrigation, LNG, Agriculture, Nuclear Service,
Snowmaking, Offsites and Waste Treatment, Renewable Fuel Production, Shipping,
Transformer Cooling, Water Treatment, Auxiliary (chemical), Water Supply and
Distribution (water), Auxiliary Services (power), Cooling Water (metals), Cooling Water
(power), Dewatering and Water Supply (mining)

INDUSTRIES: 
General Industries, Mining, Oil and Gas, Chemical Processing, Primary Metals, Water
Resources, Power Generation
VTP pumps are available in a wide variety of configurations, constructions and materials
to suit application requirements. Among the options are:
 Open or enclosed lineshaft construction
 Enclosed or semi-open impellers, keyed or collet mounted
 Bowl and enclosed impeller wear rings
 Cast iron or fabricated steel discharge heads
 Sealing configurations for open lineshaft construction
 Packed box with flexible graphite packing
 Single or dual mechanical seal
 Sealing configurations for enclosed lineshaft construction
 Enclosing tube tension assembly for oil lubrication
 Water injection packing assembly
 Above ground or below ground discharge flanges
 Multiple drivers
 Electric motors, solid or hollow shaft
 Engines with right angle gear drives
 Steam turbines
 Separate axial thrust bearing assembly
 Standard and ISO 13709/API 610 (VS1), latest edition configurations
GOULD’S VERTICAL TURBINE PUMPS:

Pump Bowl Assembly

The bowl assembly is the heart of the vertical turbine pump. The impeller and
diffuser type casing are designed to deliver the head and capacity that your system
requires in the most efficient way possible. The fact that the vertical turbine pump can be
multi-staged allows maximum flexibility both in the initial pump selection and in the
event that future system modifications require a change in the pump rating. A variety of
material options allows the selection of a pump best suited for even the most severe
services. The many bowl assembly options available ensure that the vertical turbine pump
satisfies the users’ needs for safe, efficient, reliable and maintenance-free operation.

STANDARD DESIGN FEATURES

Suction Bell - Allows smooth entry of liquid into first stage impeller eye, minimizes
foundation opening.

Suction Bell Bearing - Provided for shaft stability.

Sand Collar - Prevents solids from entering suction bearing.

Impeller - Semi-open or enclosed for appropriate service.

Pump Shaft - Heavy duty 416SS standard, other alloys available for strength and
corrosion resistance.

Flanged Bowls - Registered fits ensure positivealignment, ease of maintenance.

Diffuser Bowl - Available in variety of cast materials.

Sleeve Type Bearing - Provided at each stage to assure stable operation.

Keyed Impellers - Standard for API applications, 18” and larger sizes; furnished on all
pumps for
temperatures above 180° F (82° C) and on cryogenic services. Regardless of size, keyed
impellers provide ease of maintenance and positive locking under fluctuating load and
temperature conditions.

FATIGUE OF MATERIAL:

In materials science, fatigue is the weakening of a material caused by repeatedly applied

loads. It is the progressive and localized structural damage that occurs when a material is
subjected to cyclic loading. The nominal maximum stress values that cause such damage may be
much less than the strength of the material typically quoted as the ultimate, or the yield stress
limit.

Fatigue occurs when a material is subjected to repeated loading and unloading. If the loads are
above a certain threshold, microscopic cracks will begin to form at the stress concentrators such
as the surface, persistent slip bands (PSBs), and grain interfaces. [1] Eventually a crack will reach
a critical size, the crack will propagate suddenly, and the structure will fracture. The shape of the
structure will significantly affect the fatigue life; square holes or sharp corners will lead to
elevated local stresses where fatigue cracks can initiate. Round holes and smooth transitions or
fillets will therefore increase the fatigue strength of the structure.

FATIGUE LIFE:

In materials science, fatigue is the weakening of a material caused by repeatedly applied

loads. It is the progressive and localised structural damage that occurs when a material is
subjected to cyclic loading. The nominal maximumstress values that cause such damage may be
much less than the strength of the material typically quoted as theultimate tensile stress limit, or
the yield stress limit.

Fatigue occurs when a material is subjected to repeated loading and unloading. If the loads
are above a certain threshold, microscopic cracks will begin to form at the stress concentrators
such as the surface, persistent slip bands (PSBs), and grain interfaces. [1] Eventually a crack will
reach a critical size, the crack will propagate suddenly, and the structure will fracture. The shape
of the structure will significantly affect the fatigue life; square holes or sharp corners will lead to
elevated local stresses where fatigue cracks can initiate. Round holes and smooth transitions or
fillets will therefore increase the fatigue strength of the structure.

CHARACTERISTICS OF FATIGUE:

`
Fracture of an aluminium crank arm. Dark area of striations: slow crack growth. Bright granular
area: sudden fracture.

 In metal alloys, when there are no macroscopic or microscopic discontinuities, the

process starts with dislocation movements, which eventually form persistent slip bands
that become the nucleus of short cracks.
 Macroscopic and microscopic discontinuities as well as component design features which
cause stress concentrations (holes, keyways, sharp changes of direction etc.) are common
locations at which the fatigue process begins.
 Fatigue is a process that has a degree of randomness (stochastic), often showing
considerable scatter even in well controlled environments.
  Fatigue is usually associated with tensile stresses but fatigue cracks have been reported
due to compressive loads.[8]
 The greater the applied stress range, the shorter the life.
 Fatigue life scatter tends to increase for longer fatigue lives.
 Damage is cumulative. Materials do not recover when rested.
 Fatigue life is influenced by a variety of factors, such as temperature, surface finish,
metallurgical microstructure, presence ofoxidizing or inert chemicals, residual stresses,
scuffing contact (fretting), etc.
 Some materials (e.g., some steel and titanium alloys) exhibit a theoretical fatigue
limit below which continued loading does not lead to fatigue failure.
 In recent years, researchers (see, for example, the work of Bathias, Murakami, and
Stanzl-Tschegg) have found that failures can occur below the theoretical fatigue limit at
very high fatigue lives (109 to 1010 cycles). An ultrasonic resonance technique is used in
these experiments with frequencies around 10–20 kHz.[citation needed]
 High cycle fatigue strength (about 104 to 108 cycles) can be described by stress-based
parameters. A load-controlled servo-hydraulic test rig is commonly used in these tests,
with frequencies of around 20–50 Hz. Other sorts of machines—like resonant magnetic
machines—can also be used, to achieve frequencies up to 250 Hz.
 Low cycle fatigue (loading that typically causes failure in less than 104 cycles) is
associated with localized plastic behavior in metals; thus, a strain-based parameter should
be used for fatigue life prediction in metals. Testing is conducted with constant strain
amplitudes typically at 0.01–5 Hz

HIGH-CYCLE FATIGUE

Historically, most attention has focused on situations that require more than 104 cycles to failure
where stress is low and deformation is primarily elastic.

S-N curve

In high-cycle fatigue situations, materials performance is commonly characterized by an S-N

curve, also known as a Wöhler curve . This is a graph of the magnitude of a cyclic stress (S)
against the logarithmic scale of cycles to failure (N).
S-N curves are derived from tests on samples of the material to be characterized (often
called coupons) where a regular sinusoidal stress is applied by a testing machine which also
counts the number of cycles to failure. This process is sometimes known as coupon testing. Each
coupon test generates a point on the plot though in some cases there is a runout where the time to
failure exceeds that available for the test (see censoring). Analysis of fatigue data requires
techniques from statistics, especially survival analysis and linear regression.

The progression of the S-N curve can be influenced by many factors such

as corrosion, temperature, residual stresses, and the presence of notches. The Goodman-Line is a
method to estimate the influence of the mean stress on the fatigue strength.

Probabilistic nature of fatigue

As coupons sampled from a homogeneous frame will display a variation in their number of
cycles to failure, the S-N curve should more properly be an S-N-P curve capturing the probability
of failure after a given number of cycles of a certain stress. Probability distributions that are
common in data analysis and in design against fatigue include the log-normal
distribution, extreme value distribution, Birnbaum–Saunders distribution, and Weibull
distribution.

Complex loadings

Spectrum loading
In practice, a mechanical part is exposed to a complex, often random, sequence of loads, large
and small. In order to assess the safe life of such a part:

1. Reduce the complex loading to a series of simple cyclic loadings using a technique such
as rainflow analysis;
2. Create a histogram of cyclic stress from the rainflow analysis to form a fatigue damage
spectrum;
3. For each stress level, calculate the degree of cumulative damage incurred from the S-N
curve; and
4. Combine the individual contributions using an algorithm such as Miner's rule.

For multiracial loading

Since S-N curves are typically generated for uniaxial loading, some equivalence rule is needed
whenever the loading is multiaxial. For simple, proportional loading histories,Sines rule may be
applied. For more complex situations, such as nonproportional loading, Critical plane
analysis must be applied.

Miner's Rule

In 1945, M. A. Miner popularised a rule that had first been proposed by A. Palmgren in
1924. The rule, variously called Miner's rule or the Palmgren-Miner linear damage hypothesis,
states that where there are k different stress magnitudes in a spectrum, Si (1 ≤ i ≤ k), each
contributing ni(Si) cycles, then if Ni(Si) is the number of cycles to failure of a constant stress
reversal Si, failure occurs when:

C is experimentally found to be between 0.7 and 2.2. Usually for design purposes, C is
assumed to be 1. This can be thought of as assessing what proportion of life is consumed by
a linear combination of stress reversals at varying magnitudes.

Though Miner's rule is a useful approximation in many circumstances, it has several major
limitations:
 1. It fails to recognise the probabilistic nature of fatigue and there is no simple way to
relate life predicted by the rule with the characteristics of a probability distribution.
Industry analysts often use design curves, adjusted to account for scatter, to
calculate Ni(Si).
2. There is sometimes an effect in the order in which the reversals occur. In some
circumstances, cycles of low stress followed by high stress cause more damage than
would be predicted by the rule. It does not consider the effect of an overload or high
stress which may result in a compressive residual stress that may retard crack
growth. High stress followed by low stress may have less damage due to the
presence of compressive residual stress.

Paris' Law

Typical fatigue crack growth rate graph

In Fracture mechanics, Anderson, Gomez and Paris derived relationships for the stage II
crack growth with cycles N, in terms of the cyclical component ΔK of the Stress Intensity
Factor K[13]

where a is the crack length and m is typically in the range 3 to 5 (for metals).

This relationship was later modified (by Forman, 1967 [14]) to make better allowance for
the mean stress, by introducing a factor depending on (1-R) where R = min stress/max
stress, in the denominator.

Goodman Relation[edit]
 In the presence of a steady stress superimposed on the cyclic loading, the Goodman
relation can be used to estimate a failure condition. It plots stress amplitude against mean
stress with the fatigue limit and the ultimate tensile strength of the material as the two
extremes. Alternative failure criteria include Soderberg and Gerber

LOW-CYCLE FATIGUE

Where the stress is high enough for plastic deformation to occur, the accounting of the
loading in terms of stress is less useful and the strain in the material offers a simpler and more
accurate description. Low-cycle fatigue is usually characterised by the Coffin-Manson
relation (published independently by L. F. Coffin in 1954 and S. S. Manson 1953):

where,

Δεp /2 is the plastic strain amplitude;

εf' is an empirical constant known as the fatigue ductility coefficient, the failure strain for a
single reversal;

2N is the number of reversals to failure (N cycles);

c is an empirical constant known as the fatigue ductility exponent, commonly ranging from -0.5
to -0.7 for metals in time independent fatigue. Slopes can be considerably steeper in the presence
of creep or environmental interactions.

A similar relationship for materials such as Zirconium, is used in the nuclear industry

FATIGUE AND FRACTURE MECHANICS

The account above is purely empirical and, though it allows life prediction and design
assurance, life improvement or design optimization can be enhanced using Fracture mechanics. It
can be developed in four stages.
Crack nucleation;

Stage I crack-growth;

Stage II crack-growth; and

Ultimate ductile failure.

FACTORS THAT AFFECT FATIGUE-LIFE:

 Cyclic stress state: Depending on the complexity of the geometry and the loading, one
or more properties of the stress state need to be considered, such as stress amplitude,
mean stress, biaxiality, in-phase or out-of-phase shear stress, and load sequence.
 Geometry: Notches and variation in cross section throughout a part lead to stress
concentrations where fatigue cracks initiate.
 Surface quality: Surface roughness can cause microscopic stress concentrations that
lower the fatigue strength. Compressive residual stresses can be introduced in the
surface by e.g. shot peening to increase fatigue life. Such techniques for producing
surface stress are often referred to as peening, whatever the mechanism used to produce
the stress. Low plasticity burnishing, laser peening, and ultrasonic impact treatment can
also produce this surface compressive stress and can increase the fatigue life of the
component. This improvement is normally observed only for high-cycle fatigue.
 Material Type: Fatigue life, as well as the behavior during cyclic loading, varies
widely for different materials, e.g. composites and polymers differ markedly from
metals.
 Residual stresses: Welding, cutting, casting, grinding, and other manufacturing
processes involving heat or deformation can produce high levels of tensile residual
stress, which decreases the fatigue strength.
 Size and distribution of internal defects: Casting defects such as gas
porosity voids, non-metallic inclusions and shrinkage voids can significantly reduce
fatigue strength.
 Air or Vacuum: Certain materials like Metals are more prone to fatigue in air than in a
vacuum. Depending upon the level of humidity and temperature, the lifetime for metals
such as aluminum or iron might be as much as 5 to 10 times greater in a vacuum. This is
 mostly due to the effect of the oxygen and water vapour in the air which will
aggressively attack the material and so encourage the propagation of cracks. Other
environments such as oil or seawater may reduce the fatigue life at an even greater rate.
 Direction of loading: For non-isotropic materials, fatigue strength depends on the
direction of the principal stress.
 Grain size: For most metals, smaller grains yield longer fatigue lives, however, the
presence of surface defects or scratches will have a greater influence than in a coarse
grained alloy.
 Environment: Environmental conditions can cause erosion, corrosion, or gas-phase
embrittlement, which all affect fatigue life. Corrosion fatigue is a problem encountered
in many aggressive environments.
 Temperature: Extreme high or low temperatures can decrease fatigue strength.
 Crack Closure: Crack closure is a phenomenon in fatigue loading, during which the
crack will tend to remain in a closed position even though some external tensile force is
acting on the material. During this process the crack will open only at a nominal stress
above a particular crack opening stress. This is due to several factors such as plastic
deformation or phase transformation during crack propagation, corrosion of crack
surfaces, presence of fluids in the crack, or roughness at cracked surfaces etc. this will
provide a longer fatigue life for the material than expected, by slowing the crack growth
rate

DESIGN AGAINST FATIGUE:

Dependable design against fatigue-failure requires thorough education and supervised experience
in structural engineering, mechanical engineering, or materials science. There are four principal
approaches to life assurance for mechanical parts that display increasing degrees of
sophistication:

1. Design to keep stress below threshold of fatigue limit (infinite lifetime concept);

2. fail-safe, graceful degradation, and fault-tolerant design: Instruct the user to replace parts
when they fail. Design in such a way that there is no single point of failure, and so that
when any one part completely fails, it does not lead to catastrophic failure of the entire
system.
 3. Safe-life design: Design (conservatively) for a fixed life after which the user is instructed
to replace the part with a new one (a so-called lifed part, finite lifetime concept, or "safe-
life" design practice); planned obsolescence and disposable product are variants that
design for a fixed life after which the user is instructed to replace the entire device;
4. Damage tolerant design: Instruct the user to inspect the part periodically for cracks and
to replace the part once a crack exceeds a critical length. This approach usually uses the
technologies of nondestructive testing and requires an accurate prediction of the rate of
crack-growth between inspections. The designer sets some aircraft maintenance
checks schedule frequent enough that parts are replaced while the crack is still in the
"slow growth" phase. This is often referred to as damage tolerant design or "retirement-
for-cause".

STOPPING FATIGUE:

Fatigue cracks that have begun to propagate can sometimes be stopped by drilling holes,
called drill stops, in the path of the fatigue crack. This is not recommended as a general practice
because the hole represents a stress concentration factor which depends on the size of the hole
and geometry, though the hole is typically less of a stress concentration than the removed tip of
the crack. The possibility remains of a new crack starting in the side of the hole. It is always far
better to replace the cracked part entirely.

Material change:

Changes in the materials used in parts can also improve fatigue life. For example, parts
can be made from better fatigue rated metals. Complete replacement and redesign of parts can
also reduce if not eliminate fatigue problems. Thus helicopter rotor blades and propellers in
metal are being replaced by composite equivalents. They are not only lighter, but also much
more resistant to fatigue. They are more expensive, but the extra cost is amply repaid by their
greater integrity, since loss of a rotor blade usually leads to total loss of the aircraft. A similar
argument has been made for replacement of metal fuselages, wings and tails of aircraft.
Example of a HFMI treated steel highway bridge to avoid fatigue along the weld transition.

Peening treatment of welds and metal components:

Increases in fatigue life and strength are proportionally related to the depth of the
compressive residual stresses imparted by surface enhancement processes such as shot peening
but particularly by laser peening. Shot peening imparts compressive residual stresses
approximately 0.005 inches deep, laser peening imparts compressive residual stresses from 0.040
to 0.100 inches deep, or deeper. Laser peening provide significant fatigue life extension through
shock wave mechanics which plastically deform the surface of the metal component changing
the material properties. Laser peening can be applied to existing parts without redesign
requirements or incorporated into new designs to allow for lighter materials or thinner designs to
achieve comparable engineering results.

High Frequency Mechanical Impact (HFMI) treatment of welds:

The durability and life of dynamically loaded, welded steel structures are determined often
by the welds, particular by the weld transitions. By selective treatment of weld transitions with
the High Frequency Mechanical Impact (HFMI) treatment method, the durability of many
designs can be increased significantly. This method is universally applicable, requires only
technical equipment and offers high reproducibility and a high grade of quality control.

TESTING MATERIAL FOR IMPELLER :

INCONEL Alloy 740:

INCONEL alloy 740H is a nickel-base, precipitation hardenable superalloy that offers a unique
combination of high strength and creep resistance at elevated temperatures along with resistance
to coal ash corrosion. The alloy was originally targeted for use as A-USC boiler tubes in the
superheater sections of these plants but was then adapted for application as a material for the
steam headers to which the boiler tubes are connected. A-USC boiler tubes are conventional
sizes [typically 1.5 to 3 inch (38 to 76 mm) outside diameter]. Main steam header pipe sizes
occupy a much larger size range, with outer diameter greater than 12 inches (305 mm) and wall
thickness likely exceeding 1.5 inches (38 mm). Seamless steam reheat piping, at up to 30 inch
(760 mm) outer diameter, is also a feasible product line with INCONEL alloy 740H.

Chemical Composition
INCONEL alloy 740H (UNS N07740) is derivation of NIMONIC alloy 263. With its higher
content of chromium (24.5%), alloy 740H offers a significant improvement is resistance to high
temperature corrosion mechanisms. Alloy 740H is age hardened by the precipitation of a second
phase, gamma prime (γ’). By balancing the hardener content(niobium, aluminum and titanium),
alloy 740H exhibits good thermal stability in addition to high strength.
Metallurgy & Microstructure
Alloy 740H exhibits an austenitic structure and is age hardened by the precipitation of a
gamma prime (γ’) Ni3(Al,Ti,Nb) phase. During heat treatment, niobium, aluminum, and titanium
form the gamma prime precipitates required for strengthening. The microstructure of alloy 740H
extruded pipe in the solution annealed and aged condition is seen in Figure 1. Second phases
observed in this condition include primary carb-nitrides of the
(Nb,Ti)(C,N) type, Cr23C6 type carbides, and gamma prime. Additional exposure across the
temperature range anticipated for A-USC service serves simply to modify the relative amounts
of these same phases. Figure 2 shows an SEM image of the microstructure of INCONEL alloy
740H after solution annealing followed by exposure for 5,000 hours at 1380°F (750°C).

Physical Properties
Some physical constants for INCONEL alloy 740H are listed in. Values for modulus of
elasticity for annealed and aged material at various temperatures are shown in Table 3. Thermal
properties of annealed material are given for a range of temperatures in Table 4.
Density, g/cm3 ……………………..………8.05
lb/in3 ……………….….………..0.291
Melting Range, °C………………...1288-1362
°F…………..…….2350-2484
Electrical Resistivity, Ω-circ mil/ft.......….702.7

μ Ω -m…..….…….1.168

INCONEL Alloy 783:

The newest of the high-performance superalloys invented by Special Metals Corporation,
INCONEL® alloy 783 (UNS R30783/U.S. Patent 5,478,417), is an oxidation-resistant, low
expansion, nickel-cobalt-iron alloy with aluminum, chromium, and niobium additions. The new
alloy is of considerable interest to aircraft gas turbine engine designers and materials engineers
for containment and clearance control components such as rings, casings, shrouds and seals for
compressors, turbines and exhaust systems. The three-phase age hardenable alloy offers a range
of improvements for these applications over alternative alloys in current use:

A coefficient of thermal expansion approximately 20% lower than that of INCONEL alloy
718. Excellent resistance to oxidation, demonstrated in cyclic tests, at temperatures up to and
beyond 1300°F (704°C). Resistance to SAGBO (stress accelerated grain boundary oxidation)
comparable to that of INCONEL alloy 718, and significantly better than that of INCOLOY alloy
909. A density of 0.282 lb/in3 (7.81 g/cm3), 5% less than INCONEL alloy 718 or INCOLOY®
alloy 909, contributing to an important potential improvement in strength-to-weight ratios.
Manufacturing/processing characteristics comparable to those of INCONEL alloy 718, and less
limiting than those of INCOLOY alloy 909. Special Metals’ INCONEL alloy 783 is available as
forging billet (AMS 5940), rod and bar for machining, extruded section, and wire rod. Sheet
product is currently under development.

Mechanical Properties:
 In the age-hardened condition, INCONEL alloy 783 has high mechanical
properties at room temperature and retains much of its strength at temperatures to about
1300°F (704°C). All mechanical properties given here are for the standard heat treatment:
Solution anneal at 2050°F (1121°C)/1 hr, air cool, plus “beta age” at 1550°F (845°C)/4
hr, air cool to room temperature, plus age harden at 1325°F (718°C)/8 hr, furnace cool at
100°F (55°C)/ hr to 1150°F (621°C)/8 hr, and air cool.

WROUGH ALUMINUM ALLOY 2219:

Wrought aluminum alloy 2219

Chemical composition: Cu=6.3%, Mn=0.30%, Ti = 0.06%, V=0.10%, Zr=0.18%, Al balance

Property Value in metric unit Value in US unit

Density 2.84 *10³ kg/m³ 177 lb/ft³

Modulus of elasticity 73 GPa 10600 ksi

Thermal expansion (20 ºC) 22.3*10-6 ºCˉ¹ 12.4*10-6 in/(in* ºF)

Specific heat capacity 864 J/(kg*K) 0.207 BTU/(lb*ºF)

Thermal conductivity 171 W/(m*K) 1190 BTU*in/(hr*ft²*ºF)

Electric resistivity 3.99*10-8 Ohm*m 3.99*10-6 Ohm*cm

Tensile strength (annealed) 172 MPa 25000 psi

Yield strength (annealed) 76 MPa 11000 psi

Elongation (annealed) 18 % 18 %

Shear strength (annealed) 106 MPa 15400 psi

Hardness (annealed) 46 HB 46 HB

Tensile strength (T851) 455 MPa 66000 psi

Yield strength (T851) 352 MPa 51000 psi

Elongation (T851) 10 % 10 %
 Shear strength (T851) 285 MPa 41300 psi

Fatigue strength (T851) 103 MPa 15000 psi

Hardness (T851) 130 HB 130 HB

Annealing temperature 413 ºC 775 ºF

Solution temperature 535 ºC 995 ºF

Aging temperature 163-191 ºC 325-375 ºF

Aging time 18 hrs 18 hrs

2. CENTRIFUGAL PUMP IMPELLER VANE PROFILE

The concept of impeller design and the application of inverse design for the vane profile
construction are discussed in this chapter. The vane profile plays a vital role to develop the
streamlined flow. In conventional design, the designer uses vane arc method to develop the
profile. Due to this approach, the eddy and flow reversal may occur in the flow path. The main
focus on inverse design concept is explained here in detail for the vane profile construction.
Subsequently, the different vane profile geometry is constructed based on this approach. The
design of the centrifugal pump impeller is not a universally standardized one. Every firm
depends on its designer’s experience, expertise and technical intuition to design a good impeller.
The fact that the impeller flow physics has not been understood fully has led the designers to fall
back on tried and tested old design methodologies.

2.1 CONVENTIONAL DESIGN

Impeller dimensions have always been a direct fall down of the head it has to develop and
the discharge it has to supply. Previously used empirical formulae and thumb rules have always
been the design aid for designers. The different methods developed by highly experienced and
accomplished hydraulic engineers like Lebonoff, Kurowzski, Anderson and Lazarkiewicz also
have elements of empirical design.
2.2 DESIGN METHODOLOGY
The impeller dimensions are designed based on the head and discharge. The following
are the steps involved in designing a centrifugal impeller
• From the head (H) and discharge (Q), the kinematic specific
speed (nsQ) is calculated

• From the head and discharge, the shaft power (Psh) required is
calculated.

• Before finding the hub diameter, the shaft diameter (dsh) is

found using the formula

τ- Torsional Stress, (kP/cm2) (5.3)

Pump Impeller
• The hub diameter (dh) is calculated from the empirical relation
given below.
dh = (1.3 ~1.4) dsh
• The inlet velocity (u1) is estimated using,

u1 = 0.95 × cm1, where cm1 =

where Kcm1 is the velocity coefficient.

• From the inlet velocity and the new discharge (Q°) calculated
after accounting for volumetric efficiency, the inlet cross section
area (A0) is calculated
A0 = Q°/ u1

• From the area, the inlet diameter (d1) is calculated.

• Blade inlet angle (_1) is calculated as

• Breadth of the impeller (B1) at the inlet is

• Blade outlet angle (_2) is assumed to lie within the limits of 15°
to 35°, usually of the order of 25°.

• The outlet peripheral velocity (u2) can be calculated as follows

where Ku2 is the experimental velocity coefficient.
• The outlet diameter (d2) and the breadth of the impeller at the
outlet are

5.3 CONSTRUCTION OF VANE PROFILE

Having now found the dimensions of impeller like the hub diameter, inlet
diameter, breadth of the impeller at the inlet and the outlet, outside diameter and the vane angles,
the vane profile or the curve has to be generated. The vane profiles can be of different types and
the designer has the discretion to choose the type of curve to be drawn. The vane profile for the
impeller of the pump considered as model in this work is a multiple curvature profile with four
different radii ofcurvature with four different centers as shown in
The following are the steps involved in tracing the vane profile:
• The inlet and the outlet circles are drawn.
• Two axes of reference, one vertical and one horizontal, are drawn.
• In order to trace the profile with four radii of curvature, four more circles, that is, point 1 to 6,
are drawn at equal intervals on the axis. The curve is drawn through A, B, C, D and E based on
the positions G, H, I, J and K.
• From the point where inlet circle meets the horizontal axis, a line at an angle of inlet vane angle
(16°) is drawn to the length of the radius of curvature of the first arc (47 mm).
• An arc is drawn with the end point of this line as the centre and with the corresponding radius,
till the arc meets the next circle.
• From the point where the arc meets the next circle, a line is drawn to the length equal to the
next radius of curvature and passing through the previous centre.
• An arc is drawn with the end point of this line as the centre and with the corresponding radius
till the arc meets the next circle.
• This procedure is followed till the four arcs are drawn. The curve drawn along with the
dimensions found above, form the basis with which the impeller can be made.
Pump impeller dimensions
Inlet Diameter (d1) = 50 mm
Outer Diameter (d2) = 304 mm
Curvature Radius = 51 mm, 49 mm, 149 mm
Number of vanes (z) = 9 (18 mm thick)
Breadth of Impeller (B) = 40 to 5 mm (converging from inlet to outlet)
Inlet vane angle (_1) = 16 degrees
Exit vane angle (_2) = 23.5 degrees
 METHODOLOGY

Find a suitable material with low thermal conductivity and design a multilayer structure
to reduce the heat flow. Check the performance of the sheet by doing structural and thermal
analysis. Prove the new design for crash worthiness.

4.1 Tool used

1. Design tool :CATIA

2. Meshing & Analyses tool: Ansys

Select a material

Defining material properties

Modeling

Import

Meshing

Applying boundary conditions and process

parameters

Analysis

Results

Figure 4.1. Methodology flow chart

4.2 INTRODUCTION TO ANSYS

The ANSYS program has many finite element analysis capabilities, ranging from a
simple, linear, static analysis to a complex non – linear, transient dynamic analysis.

A typical ANSYS analysis has three distinct steps:

 Building the model

 Applying loads and obtains the solution
 Review the results.

4.2.1 BUILDING THE MODEL

Building a finite element model requires a more of an ANSYS user’s time than any
other part of the analysis. First you specify the job name and analysis title. Then, define the
element types, real constants, and material properties, and the model geometry.

4.2.2 DEFINING THE MODEL

The analysis element library contains more than 100 different element types. Each
element type has a unique number and a prefix that identifies the element category. Example:
beam, pipe, plant, shell, solid.

4.2.3 DEFINING THE ELEMENT REAL CONSTANTS

Element real constant are the properties that depend on the element type, such as cross
sectional properties of a beam element. For example real constants for BEAM3 , the 2-d beam
element, or area, moment of inertia(IZZ), height , shear deflection constant (SHEAR Z), initial
strain (ISTRN) different elements of same type may have different real constant values.

4.2.4DEFINING THE MATERIAL PROPERTIES

 Most elements types require material properties. Depending on the application, material
properties may be:

 Linear or non linear

 Isotropic, or an isotropic
 Constant temperature or temperature – dependant

As with element type and real constant, each set of material properties has a material
reference number. The table of material reference number verses material property set ids called
material property table. Within, one analysis you may have multiple material properties set.

4.2.5 MATERIAL PROPERTY TEST

Although you can define material properties separately for each element analysis, the
ANSYS program enables you to store a material property set in an archival material library file,
then retrieve the set and reuse it in multiple analysis. The material library files also enable
several ANSYS user to share common used material property data.

4.3 INTRODUCTION TO CATIA:

CATIA which stands for computer aided three dimensional interactive applications is
the most powerful and widely used CAD (computer aided design) software of its kind in the
world. CATIA is owned/developed by Dassault system of France and until 2010, was marketed
worldwide by IBM.

The Following general methodologies and best practices can be followed in the
modeling of components in CATIA. The Below methodologies and Best practices followed will
help in capturing the design intent of the Feature that is to be Modeled and will make the design
robust and easy to navigate through.

 Specification tree structuring

 Renaming appropriate features & bodies in specification tree
 Handling input data & foreign bodies
 Dimensioning & constraining in sketches
 Parameters and relations.
4.3.1 SPECIFICATION TREE STRUCTURING

a) The SPECIFICATION TREE is the place where the histories of the features modeled are captured.
So it is highly important to have an organized tree structure which gives ease for navigation of
the features when any modification takes place.

b) The SPECIFICATION TREE in a structured manner. The Machining Body features are
grouped under one body and base block features in another and so on with appropriate
feature operations.
c) It is also important in structuring the reference and construction element in the tree in an
orderly manner.
d) The points that would be often used (like the Global Origin Point 0, 0, 0,) can be created
under Points GEOMETRICAL SET and any reference planes defining legal limits can be
created in the planes GEOMETRICAL SET.

4.3.2 RENAMING APPROPRIATE FEATURES & BODIES IN SPECIFICATION TREE

a) The renaming of features within the design becomes mandatory as it will be useful for the end
users to by far identify things for modification.
b) For instance an end user who wants to identify the M5 holes on the model the
SPECIFICATION TREE helps easily in identifying the M5 holes in the model there by
making modifications easy.
c) Also renaming all the features every now and then as it is created will easy things at the
end.
d) “Base Block Sketch” and “Base Block” is which will be useful in identifying them at a
later stage.
e) Renaming the Bodies also helps in navigation.

4.3.3 HANDLING INPUT DATA AND FOREIGN BODIES

 a) Any external data that are to be handled in the model can be grouped under a
GEOMETRICAL SET called input data which can be used in the model when
situation demands.

b) Some foreign elements like planes, points, curves and surfaces that would be used in the
modeling process.

c) By grouping the foreign elements in a separate GEOMETRICAL SET it is easy to

identify them in the SPECIFICATION TREE.

4.3.4 DIMENSIONING AND CONSTRAINING IN SKETCHES

a) Planes should be intersected in the sketches and made as construction elements and
should be used as dimension reference for geometries, this helps in identifying the
dimension line clearly in a complex sketch.
b) Equivalent dimension should be used wherever possible to minimize modification time in
the sketches.
c) Usage of sketch analysis command is mandatory at the end of every sketch build which
helps in diagnosing the sketch thereby identifying abnormalities.
d) Robust design Intent can be Achieved with the Integration of Parameters and Relations.

4.3.5 PARAMETERS AND RELATIONS

a) The parameters functionality helps in building a robust design with ease of relating object.
b) Parameters can be declared globally and related to radius value thereby controlling the
radius value outside the command.
c) The advantage of declaring parameters is to control and relate the values to multiple
values.
d) A parameter “corner radius” which is related to the fillet radius, thereby now modifying
the corner radius parameter the fillet radius can be modified. Also there can be multiple
values associated to the same parameter
e)
Isometric views:

Front view:
Drafting of vertical Impeller blades :
Introduction to FEA
FEA consists of a computer model of a material or design that is stressed and analyzed
for specific results. It is used in new product design, and existing product refinement. A
company is able to verify a proposed design will be able to perform to the client's
specifications prior to manufacturing or construction. Modifying an existing product or
structure is utilized to qualify the product or structure for a new service condition. In case
of structural failure, FEA may be used to help determine the design modifications to meet
the new condition. FEA uses a complex system of points called nodes which make a grid
called a mesh. This mesh is programmed to contain the material and structural properties
which define how the structure will react to certain loading conditions. Nodes are
assigned at a certain density throughout the material depending on the anticipated stress
levels of a particular area. In practice, a finite element analysis usually consists of three
principal steps.
4.3.1. Preprocessing - The user constructs a model of the part to be analyzed in which
the geometry is divided into a number of discrete sub regions, or elements," connected at
discrete points called nodes." Certain of these nodes will have fixed displacements, and
others will have prescribed loads. These models can be extremely time consuming to
prepare, and commercial codes vie with one another to have the most user-friendly
graphical “preprocessor" to assist in this rather tedious chore. Some of these
preprocessors can overlay a mesh on a preexisting CAD file, so that finite element
analysis can be done conveniently as part of the computerized drafting-and-design
process.

4.3.2Analysis - The dataset prepared by the preprocessor is used as input to the finite
element code itself, which constructs and solves a system of linear or nonlinear algebraic
equations [K][U]=[F]
where u and f are the displacements and externally applied forces at the nodal points. The
formation of the K matrix is dependent on the type of problem being attacked, and this
module will outline the approach for truss and linear elastic stress analyses. Commercial
codes may have very large element libraries, with elements appropriate to a wide range of
problem types. One of FEA's principal advantages is that many problem types can be
addressed with the same code, merely by specifying the appropriate element types from
the library.
4.3.3 Postprocessing - In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot spots this
way, and modern codes use graphical displays to assist in visualizing the results. Typical
postprocessor display overlays colored contours representing stress levels on the model,
showing a full field picture similar to that of photo elastic or moiré experimental results.
4.4 Introduction to ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package. Finite
Element Analysis is a numerical method of deconstructing a complex system into very
small pieces (of user-designated size) called elements. The software implements
equations that govern the behaviour of these elements and solves them all; creating a
comprehensive explanation of how the system acts as a whole. These results then can be
presented in tabulated, or graphical forms. This type of analysis is typically used for the
design and optimization of a system far too complex to analyze by hand. Systems that
may fit into this category are too complex due to their geometry, scale, or governing
equations.

THERMAL ANALYSIS:

Thermal L Analysis is probably the most common application of the finite element
method. The term structural (or structure) implies not only civil engineering structures
such as bridges and buildings, but also naval, aeronautical, and mechanical structures
such as ship hulls, aircraft bodies, and machine housings, as well as mechanical
components such as pistons, machine parts, and tools. Thermal analysis to calculate the
heat flux, temperature gradient & temperature variation. For finite element Analysis of
Engine Head, SOLID92- Tetrahedral element has been used. Total number of elements
generated-4066.

Types of Solution Methods

Two solution methods are available for solving
structural problems.
 The h-method
 the p-method.
The h-method can be used for any type of analysis, but the p-method can be used only for
linear structural stati Depending on the problem to be solved, the hmethod usually
requires a finer mesh than the p-method. The 10702 p-method provides an excellent way
to solve a problem to a
desired level of accuracy while using a coarse mesh. ANSYS automatically calculates all
measures valid for a static analysis. Following points are important when specifying
loads and constraint sets for static analyses:
 If you delete a constraint or load set that you included in an analysis, you also delete
that set
from the analysis. Even if you create a new set with the same name as the set you deleted,
you must edit the analysis and reselect the set. Otherwise, you may invalidate the analysis
and any design studies in which you included the analysis. ANSYS calculates results
separately for each load set you include in the analysis
Contents

 Units

 Model (A4)
o Geometry
 Part1
o Coordinate Systems
o Mesh
o Static Structural (A5)
 Analysis Settings
 Loads
 Solution (A6)
 Solution Information
 Results

 Material Data
o Gray Cast Iron

Units

TABLE 1
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (A4)

Geometry:
 TABLE 2
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\Users\NAUT\AppData\Local\Temp\WB_NAUT-
Source
PRAMO_NAUT_1260_2\unsaved_project_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler
Length Unit Meters
Element
Program Controlled
Control
Display
Body Color
Style
Bounding Box
Length X 120.65 mm
Length Y 120.65 mm
Length Z 80.066 mm
Properties
Volume 2.0749e+005 mm³
Mass 1.4939 kg
Scale Factor
1.
Value
Statistics
Bodies 1
Active 1
 Bodies
Nodes 33653
Elements 18734
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter
DS
Key
Attributes No
Named
No
Selections
Material
No
Properties
Advanced Geometry Options
Use
Yes
Associativity
Coordinate
No
Systems
Reader
Mode Saves No
Updated File
Use
Yes
Instances
Smart CAD
No
Update
Compare No
Parts On
 Update
Attach File
Via Temp Yes
File
Temporary
C:\Users\NAUT\AppData\Local\Temp
Directory
Analysis
3-D
Type
Decompose
Disjoint Yes
Geometry
Enclosure
and
Yes
Symmetry
Processing

TABLE 3
Model (A4) > Geometry > Parts
Object Name Part1
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
 Reference Temperature By Environment
Material
Assignment Gray Cast Iron
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 120.65 mm
Length Y 120.65 mm
Length Z 80.066 mm
Properties
Volume 2.0749e+005 mm³
Mass 1.4939 kg
Centroid X 0.22301 mm
Centroid Y -0.20028 mm
Centroid Z 17.874 mm
Moment of Inertia Ip1 1600.2 kg·mm²
Moment of Inertia Ip2 1615.7 kg·mm²
Moment of Inertia Ip3 1981.3 kg·mm²
Statistics
Nodes 33653
Elements 18734
Mesh Metric None

Coordinate Systems

TABLE 4
Model (A4) > Coordinate Systems > Coordinate System
 Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Mesh:
 TABLE 5
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Body Color
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
 Use Advanced Size Function Off
Relevance Center Fine
Element Size Default
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 2.0699e-003 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Patch Independent Options
Topology Checking No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
 Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 33653
Elements 18734
Mesh Metric None

Static Structural (A5)

TABLE 6
Model (A4) > Analysis
Static Structural
Object Name
(A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
 Environment Temperature 22. °C
Generate Input Only No

TABLE 7
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step
1.
Number
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Program Controlled
Solver Pivot
Program Controlled
Checking
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart
Program Controlled
Points
Retain Files After
No
Full Solve
Nonlinear Controls
Newton-Raphson Program Controlled
 Option
Force Convergence Program Controlled
Moment
Program Controlled
Convergence
Displacement
Program Controlled
Convergence
Rotation
Program Controlled
Convergence
Line Search Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact
No
Miscellaneous
General
No
Miscellaneous
Store Results At All Time Points
Analysis Data Management
Solver Files D:\OFFIFCE\PROJECTZ\2015-2016\Finished _Project\vertical
Directory blade impeller\cast iron_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files
Directory
Save MAPDL db No
 Delete Unneeded
Yes
Files
Nonlinear Solution No
Solver Units Active System
Solver Unit System nmm

TABLE 8
Model (A4) > Static Structural (A5) > Loads
Fixed
Object Name Force
Support
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face
Definition
Type Fixed Support Force
Suppressed No
Define By   Components
Coordinate
  Global Coordinate System
System
X Component   0. N (ramped)
Y Component   25. N (ramped)
Z Component   0. N (ramped)

FIGURE 1
Model (A4) > Static Structural (A5) > Force
Solution (A6)

TABLE 9
Model (A4) > Static Structural (A5) > Solution
Solution
Object Name
(A6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
Post Processing
Calculate Beam Section Results No

TABLE 10
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information
Solution
Object Name
Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
 Display All FE Connectors
Draw Connections Attached
All Nodes
To
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 11
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Directional Equivalent Elastic
Object Name Equivalent Stress
Deformation Strain
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Directional Equivalent Elastic Equivalent (von-Mises)
Type
Deformation Strain Stress
Orientation X Axis  
By Time
Display Time Last
Global Coordinate
Coordinate System  
System
Calculate Time
Yes
History
Identifier
 Suppressed No
Results
2.6898e-010
Minimum -3.6588e-004 mm 2.7863e-005 MPa
mm/mm
9.6395e-006
Maximum 9.6162e-005 mm 0.97249 MPa
mm/mm
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
Integration Point Results
Display Option   Averaged
Average Across
  No
Bodies

FIGURE 2
Model (A4) > Static Structural (A5) > Solution (A6) > Directional Deformation

TABLE 12
Model (A4) > Static Structural (A5) > Solution (A6) > Directional Deformation
Time [s] Minimum [mm] Maximum [mm]
1. -3.6588e-004 9.6162e-005

FIGURE 3
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic Strain
 TABLE 13
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic Strain
Time [s] Minimum [mm/mm] Maximum [mm/mm]
1. 2.6898e-010 9.6395e-006

FIGURE 4
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress

TABLE 14
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress
Time [s] Minimum [MPa] Maximum [MPa]
1. 2.7863e-005 0.97249

Material Data

Cast Iron

TABLE 15
Gray Cast Iron > Constants
Density 7.2e-006 kg mm^-3
Coefficient of Thermal Expansion 1.1e-005 C^-1
Specific Heat 4.47e+005 mJ kg^-1 C^-1
Thermal Conductivity 5.2e-002 W mm^-1 C^-1
Resistivity 9.6e-005 ohm mm

TABLE 16
Gray Cast Iron > Compressive Ultimate Strength
Compressive Ultimate Strength MPa
 820
0

TABLE 21
Gray Cast Iron > Isotropic Elasticity
Temperature Young's Modulus Poisson's Bulk Modulus Shear Modulus
C MPa Ratio MPa MPa
1.1e+005 0.28 83333 42969

CHAPTER V
RESULT AND DISCUSSION
Cast Iron :
Total Deformation:

Strain:
Stress:
Inconel alloy740:

Deformation:

Starin:
Inconel alloy 803:
Warpaloy
Conclusion ;
Material Deformation Strain Stress
Cast Iron 7.327x10-5 6.6601x10-6 0.086145MPa
Inconel Alloy 740 3.6315x10-5 3.2935x10-7 0.068703MPa
Inconel Alloy 830 4.1296x10-5 4.3518 x10-7 0.082155MPa
Warpaloy 3.8434 x10-5 4.266 x10-7 0.086145MPa

Compare to all these material detail and its failures conditions Inconel alloy 740 is
giving minimum failure