Ex.

No:7
DESIGN AND ANALYSIS OF A MACHINE ELEMENT
04/09/19

Aim:
1. To Design the given Machine Element analytically.
2. To Model the Machine Element using any 3D Parametric Modelling Software.
3. To Analyse the Machine Element for displacement and stresses using FEA software.

Tools required:
i. Ansys Workbench 19.0 Software
ii. CREO parametric 2.0 Software
iii. Personal Computer with 2GHz processor, 2 GB of RAM and 500 GB HDD.

Problem Statement:
1. Design a bushed-pin type flexible coupling for connecting a motor shaft to a pump shaft for the
following service conditions: Power to be transmitted = 40 kW; speed of the motor shaft = 1000 r.p.m. ;
diameter of the motor shaft = 50 mm ; diameter of the pump shaft = 45 mm. The bearing pressure in the
rubber bush and allowable stress in the pins are to be limited to 0.45 N/mm2 and 25 MPa respectively.

Procedure:

1. Numerical Calculation using FEA software (WORKBENCH):

1. Static structural:
File → New project → ok
Tool box→Analysis system→Static Structural.
Double click on the Static structural or Drag the static structural into the
workspace.

Creating a
Step: 1
new project

The above options are displayed in the Workspace.

 2. Engineering Data:
Defining the
Double click on the Engineering Data option→ A dialogue Box opens
Step: 2 material
Since material data is not given, keep the default structural steel as the materia l
properties
for the coupling.

3.Geometry:
In Geometry option we have to insert the 3D CAD model.
Right click on the Geometry→Import geometry →Import the .igs file of the 3D
CAD model
After importing the CAD model, a green tick appears which means the model
has been successfully imported

Defining the
geometry
Step: 3

Importing Right Click on model → Edit → Static structural – Design Modeler

the CAD
In Static structural, select import 1 and then click Generate
model

4.Model:
In Model (A4) → Geometry → Select individual part → choose structural steel
Modeling
for all parts and then click Ok.
the problem
In Model (A4) → Connections → Contacts → Contact regions and select bonded
for all the connections and then click Ok.
Step: 4 In Model (A4) → Mesh → Sizing →

By selecting the Body option → select entire body

Meshing the
Change Relevance centre → fine
problem
Element size → 50 mm
Click on Update and then finally Meshing is done.
 5.Setup:
Defining the Right click on the Static structural(A5) → Insert → Fixed support
constraints Then select the face of the pump shaft which is to be fixed(x=0, y=0, z=0) by
clicking the option.

Right click on the Static structural(A5) → Insert → Standard earth gravity and
apply in negative y direction.
Step: 5
Right click on the Static structural(A5) → Insert → Moment
Define by → Change the definition of moment from vector to components and
Defining the
the moment value of 5.7296e5 N.mm is applied along the X direction.
loads
X component = 5.7296e5 N.mm
Y component = 0 N.mm
Z component = 0 N.mm
The loads and constraints are applied as shown in figure 1.

Solving the 6.Solution:

Step: 6
problem Static structural(A5) → Solution → Solve

7.Results:
Determining
Static structural(A5) → Solution → Insert → deformation → Total deformatio n
the
and then click on evaluate all results.
deformation
The deformation plot is obtained as shown in figure 2.
Step: 7
Static structural(A5) → Solution → Insert → stress → Equivalent(von- mis es)
Determining
and then click on evaluate all results.
the stresses
The stress plot is obtained as shown in figure 3 and figure 4.

Saving the
Step: 8
results

Thus the coupling has been analysed using ANSYS workbench 19.0.
After completing this analysis, all the sections in the static structural gets Green
tick (Completed).
The project file is Saved using Top menu → File → Save as → Enter the file
name and click Ok.
The results are then compared with the analytical results.
Figure 1: Applied loads and constraints for the coupling

Figure 2: Deformation plot for the coupling (mm)

Figure 3: Equivalent stress plot for the coupling (MPa)

Figure 4: Equivalent stress plot for the bolt pin (MPa)

3.Comparison of Results:

Maximum allowable static Maximum Yield

S.No. Component
stress (N/mm2 ) (ANSYS) Strength ( N/mm 2 )

1. Coupling 72.711 125

2. Bolt pin 7.7293 25

4.Inference:
On the Software:
1. The units can be defined in ANSYS Workbench.
2. ANSYS Workbench is a latest software which contain all ANSYS product in a single platform which
means if there is any error in input data, the error can be easily handled.
On the Procedure:
1. ANSYS workbench support only .iges file format of CAD model.
2. In ANSYS workbench other file format are supported but we have to the change the configura tio n
with the help of CAD configuration manager.

3. After importing the model, it is necessary to select import 1 and then click Generate In Static
structural.
4. While applying torque to a coupling, one of the shaft should be fixed with respect to all 6 DOF’s and
torque value has to be applied on the other shaft.

On the Results:
1. The maximum total deformation is on the outermost flange and is only 0.037592 mm, which is very
less compared to the dimensions of the coupling. Hence, the strain will be almost negligible.
2. The maximum stress observed is 72.711 N/mm2 , which is less than the yield strength of the material
(125 N/mm2 ). Hence, the design is safe with a FOS of 1.719.
3. The maximum stress observed in the bolt pin is 7.7293 N/mm2 , which is less than the given yield
strength of the bolt pin. Hence, the design is safe with a FOS of 3.235.
4. But, the analytical calculations show that the bush pin is not safe, since the theoretical stress induced
is 126.249 N/mm2 .

5.Result:
Thus, the given machine element has been designed and FEA analysis has been carried out by using
ANSYS software and verified with analytical results and suitable inference has been made from the results.