FEA Assignment 3

Samuel Quek Wei Yuen

S3921324
Content Page
Abstract------------------------------------------------------------------------2
Introduction ------------------------------------------------------------------3
Design optimization using Abaqus--------------------------------------4
Rection Forces----------------------------------------------------------------6
S11 and S22--------------------------------------------------------------------7
U1 and U2----------------------------------------------------------------------8
S11 Comparison--------------------------------------------------------------9
U2 Comparison--------------------------------------------------------------10
Mesh Sensitivity Check----------------------------------------------------11
Solid 3D Model--------------------------------------------------------------11
Tabulated Data--------------------------------------------------------------12
Validation---------------------------------------------------------------------13
Conclusion--------------------------------------------------------------------14

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Abstract
This project is aimed at designing a torque wrench with the given dimensions.
The design is based on the stress analysis using abaqus and the final conclusion
will be drawn from the results of the analysis

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Introduction
TorQ Wrench a Melbourne based producer of precision torque wrenches has
been introduced via a business incubator support program.
TorQ Wrench is keen on expanding their product range by introducing a new
product called bicycle wrench.
This project shows the design optimization process using FEA to find solutions
that are cheap and require the least amount of bulk material.
Student Number: S3921324
N = 1.0 + (0.001 x 324) = 1.324

Radius N X 10 NX9 NX7 N X 40

19.86 13.23 11.916 9.268 52.96

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 Design Optimization using Abaqus
Table 1 shows the materials used and the material properties

Material Modulus of Elasticity (Gpa) Yield Strength Cost per kg

Steel-4130 205 800-1000 $0.95
Aluminium-6061 72 193-290 $2.42
Table 1: Material Properties

Figure 1: Von Mises Shell (Steel 4061 5mm thickness)

Figure 2: Von Mises Shell (Steel 4061 10mm thickness)

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 Figure 3: Von Mises Shell (Aluminium 6061 5mm thickness)

Figure 4: Von Mises Shell (Aluminium 6061 10mm thickness)

Figure 1 and 2 shows the von mises diagram when steel 4061 is used to design
the torque wrench at 5mm and 10mm thickness respectively. Figure 3 and 4
shows the von mises diagram when aluminium 6061 is used for 5mm and 10mm
thickness respectively. The highest stress for both materials and dimensions are
lesser than the material yield strength so both materials fit the design
requirements, however since steel 4061 is significantly cheaper, it will be used
as the material for this torque wrench.

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Reaction Forces

Figure 5: Von Mises Shell (Steel 4061)

Figure 6: Reaction Force 2 Shell (Steel 4061)

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S11 and S22

Figure 7: S11 Shell (Steel 4061)

Figure 8: S22 Shell (Steel 4061)

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U1 and U2

Figure 9: U1 Shell (Steel 4061)

Figure 10: U2 Shell (Steel 4061)

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S11 Comparison

Figure 11: S11 Plane Stress

Figure 12: S11 Shell

Figure 13: S11 Plane Strain

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U2 Comparison

Figure 14: U2 Plane Strain

Figure 15: U2 Shell

Figure 16: U2 Plane Stress

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Comparing the S11 stress for the shell, plane stress and plane strain model, the
plane stress model has the higher stress as compares to the plane strain model
as it has more deformation. The shell model would most likely have a stress
between the plane stress and strain model.
Comparing the U2 results between the shell, plane stress and plane strain model,
the shell and plane stress model have very similar results and both have higher
displacement as compared to the plane strain model. This is because the plane
strain model does not have the poisson effect as it is assumed to have infinite
thickness as compared to the shell and plane stress model which is very thin and
has a poisson effect resulting in a higher stress.

Mesh sensitivity check

Mesh Size Max Mises Max U2 Max S11
N = 2.341 Mpa 0.1184mm 2.360 Mpa
4mm

N = 2.413 Mpa 0.1187mm 2.433 Mpa

3mm

N = 2.493 Mpa 0.1190mm 2.473 Mpa

2mm

Table 2: Mesh sensitivity check

Solid 3d model

Figure 17: Solid 3d model

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 Tabulated Data
Node Label U.U2@Loc 1 S.11 @Loc 6 S.11 @Loc 7
1 -5.93E-06 -1.03E-01 -1.03E-01
2 -4.35E-06 -7.97E-05 -7.97E-05
3 -9.37E-06 -1.31E-05 -1.31E-05
4 -1.09E-05 -8.93E-03 -8.93E-03
5 -5.92E-06 1.06E-01 1.06E-01
6 -1.09E-05 8.67E-03 8.67E-03
7 -1.23E-05 1.86E-02 1.86E-02
8 -1.11E-05 -2.38E-05 -2.38E-05
9 -5.81E-06 -1.10E-01 -1.10E-01
10 -1.04E-05 2.82E-01 2.82E-01
1125 5.19E-05 8.47369 8.47369
1126 5.86E-05 9.49993 9.49993
1127 3.63E-05 -9.45841 -9.45841
1128 4.91E-05 -8.70848 -8.70848
1129 6.62E-05 -9.33682 -9.33682
1130 7.13E-05 -10.0288 -10.0288
1131 2.99E-05 9.72824 9.72824
1132 2.60E-05 9.18834 9.18834
1133 3.00E-05 -9.72817 -9.72817
1134 2.61E-05 -9.18513 -9.18513
Minimum -1.40E-05 -24.7325 -24.7325
Maximum 1.19E-01 24.733 24.733
Table 3: Tabulated data from Abaqus

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 Validation

Figure 18: Validation

Comparison of Results

FEA Analytical % Diff

S11 26.18 24.733 5.85
RF 50 50 0
Table 4: Comparison of results

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Conclusion
The company TorQ Wrench is able to conclude that steel 4061 is sufficient to
design this model of torque wrench. Using steel to manufacture this torque
wrench would cost lesser as compared to aluminium and it also has better
mechanical properties. The difference between the FEA and the analytical
results differs by 5.85% for the S11 showing that FEA can be considered to be
reasonably accurate and the company can use this model to aid in the design of
the torque wrench.

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