Welding Residual Stress Calculation & Fatigue life Estimation for Large Pressure Vessel, Abaqus, Fe Safe, Manufacturing Simulation, Weld Process Optimization, Goldak Heat Flux Model, The residual stress developed due to welding passes can significantly alter the estimated design life of the welded assembly in long term under fluctuating loading condition. In this project, a large cylindrical pressure vessel is having several nozzles welded in circumferential locations. In total of 173 passes of inside and outside welding is being created from both the inside and outside location of the nozzles. A sequentially coupled thermal structural analysis is being performed for total of 173 welding passes with the usage of Fortran subroutine for element activation and Goldak Heat flux model to account for the heating and cooling cycle due to the different welding passes. Also due to these thermal cycles the accumulated residual stress and deformation has been compared with the real manufacturing results. The deformation pattern and magnitude were within the close proximity with the real-life result. Further with the additional pressure vessel fluctuating load, the damage and life is calculated for the welding locations. Contact Mechanics and Wear Mechanics study Knee Implants, Abaqus Knee Simulator (AKS), Subroutine, Implant analysis, Wear Calculation, The work scope of the project has multiple parts, and each part is worked on after obtaining the approval and all the necessary data from the customer side. Several revisions to the Total Knee Arthroscopy implants have been developed by the client. Abaqus Knee Simulator (AKS) analyses are performed several times to evaluate the effectiveness of each implant to the original blueprint. The initial contact mechanics model is intended to verify for a cumulative contact patch of various sizes in the implant design. In addition, several models of wear mechanics are checked for volumetric wear after a total of 5 million cycles. The calibrated Archard model is meant to compare the amount of wear amongst implant designs. The FEA result is validated against the ISO test data. Air Blast Analysis of Armour Tank due to Surface Explosion, Ansys Abaqus Explicit, Air Blast, CONWEP, CEL, The integrity of the vehicle's bottom hull is evaluated in this study for a new armour tank design. A 5kg TNT burst at a different location of the truck could cause damage to both the vehicle and the inside crew. A coupled Eulerian Lagrangian (CEL) analysis is performed for the surface blast scenario, and the yield stress is evaluated to determine the integrity of the hull bottom in various configurations. Simultaneously, an analytical technique using the CONWEP model is employed to verify the findings. Outputs such as G-force on the vehicle, acceleration, escalation distance, and so on are also monitored to check the outcome with the test scenario. Press Fit Force Analysis, Hypermesh, Abaqus, Ansys, Static and dynamic analysis, Contact, Force required to do a press fit of knurled cylindrical component in a hole is analyzed through FEA. Bilinear isotropic material is used for the analysis. For the analysis 1/4th model is used to reduce the calculation time. The meshing is done using Hypermesh. Interference contact is modeled for both the Abaqus and Ansys solver to compare and evaluate the result variation. The required force is evaluated exactly within 2% as per manufacturing feedback. Development of Python Scripting and Automation Workflow of Geomechanics Reservoir, Abaqus, Isight, Python, Geotechnical Analysis, Python Scripting, Simflow Development, Parametric Study, A robust general-purpose python script is developed to perform geomechanical analysis that begins with a geostatic step that introduces initial stress, pore pressure and overburden load. This is followed by a depletion step and several drawdown steps. A 1D well is included, both for depletion and drawdown step, to monitor the plastic strain in the well. The well is overlaid as 1D embedded elements to check the deformation and possible failure of the well casing. An Isight simflow is further developed to automate pre-processing, analysis and post-processing for the parametric optimization study. Customized training is carried out at the client site to enable them to develop python scripting and Isight simflow. FE Modeling and Analysis of Harvester Cutter Assembly, Ansys, Hypermesh, Static analysis, Contact mechanics, 1D Analytical Model, Bolt Pretension, The project included FE modeling and analysis of a harvesting equipment cutter assembly. The FE model was developed for the ANSYS solver. The meshing is done using shell elements to ensure that the mesh pattern matches with the components in contact. Bolt connections are represented as 1D beam elements, while other connections are represented by rigid, cp_struct equations and 1D elements based on the degree of freedom necessary. The mesh quality is maintained in accordance with the client's specifications. The standardized format is used to record deflection, stress, and responses at various locations. Hand calculations are performed to support the FBD and the load transfer path via the assembly's interconnections. Composite failure and Delamination under Impact Condition, Abaqus, Composite modeler, Cohesive Zone Modelling, Damage Initiation and Propagation, The Composite layup is modeled using Abaqus composite modeller for a typical impact analysis. The interface between the multiple layups is simulated using a zero-thickness cohesive element to study the delamination behavior. The material model for the cohesive elements is based on traction separation, with the addition of energy-based mixed mode failure behavior. Furthermore, the status variable for the interface zone is monitored during simulation to recreate the identical experimental outcome. For further correlation, the force displacement behavior, energy plot, and fractured energy are being examined. Reducing Vibration in HVAC tubes, Ansys, Linear Modal analysis, Transient Analysis, In HVAC products, the tube vibration plays a crucial role in determining the product quality. Tubes are designed in ProE and are imported in Ansys by using CAD configuration manager to create a direct connection between CAD and CAE numerical packages. Linear material model is considered for this analysis. A normal modal analysis is carried to identify natural frequencies and the configuration of tubes is modified to avoid resonance with the frequencies of the sources-compressor, fan, etc. By vibration experimentation, the modal frequencies are correlated with the predicted frequencies. Further, a transient analysis is carried out to find the stress level at compressor start and stop condition. Vibration Analysis of Compressor tubes and motor mounting bracket, Ansys, Frequency response analysis, Fatigue analysis, The project involved the Frequency response analysis of compressor tubing and mounting bracket due to vibrations from Compressor, Motor, etc. From physical measurements using an accelerometer, the source data is obtained in the time domain. This data is converted to the frequency domain and is input to the FEA model as a loading condition at the excitation location. The results are validated with experiments. In addition, the FEA results are utilized to calculate the fatigue life of the components. Condenser tube failure investigation, Ansys, ProE, Frequency Response, In chiller model with shell tube condenser, the inside tubes are susceptible to steady-state vibration due to pulsation received from the inlet hot refrigerant. In the chiller model, the compressors can run for a wide range of speed. Thus, for a particular inlet angle, two rows of tubes were failing in a particular model. FEA analysis was performed with refrigerant pressure as load whose value is obtained from a CFD analysis. The model involves frequency response analysis for the range of compressor running speed. The most critical frequencies are determined and correlated with experimentation. Contact Analysis of an Ace tabular Reconstruction through Finite Element Analysis (M. Tech Project), Finding Suitable Material for Ace tabular Implant, Finding Contact Sensitivity to Different Contact Parameters, Finding Optimum Thickness of Implant Material, SolidWorks, Ansys 12.0, Matlab, Four biomaterials are being considered for this research, and the optimal design parameters will be determined by considering the stress values and micro-motion between the various layers. This work was real-time and individual to one patient. Strain gauge measurements were used in the lab to determine the optimal values for the input parameters. Path specific failure criterion (Hoffman failure criteria) was adopted to find the failure mode.