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DESIGN & DEVELOPMENT OF AIR INTAKE MANIFOLD THROUGH CONVERSION OF PLASTIC MATERIAL. 1) Rashmin Kukde. 2) Ankur Koul. 3) Ashutosh Nandkeolyar. 4) Soumya Kumar. 5) Neha Gawkar. OUT LINE. INTRODUCTION METAL TO PLASTIC CONVERSION MATERIAL SELECTION MODELING ANALYSIS
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DESIGN & DEVELOPMENT OF AIR INTAKE MANIFOLD THROUGH CONVERSION OF PLASTIC MATERIAL 1) Rashmin Kukde. 2) Ankur Koul. 3) Ashutosh Nandkeolyar. 4) Soumya Kumar. 5) Neha Gawkar
OUT LINE • INTRODUCTION • METAL TO PLASTIC CONVERSION • MATERIAL SELECTION • MODELING • ANALYSIS • RESULT AND DISCUSSION • MOLD FLOW ANALYSIS • CONCLUSION • REFRENACE
Why metal to plastic conversion 1. Decrease Piece Part Prices 2. Eliminate Time-Consuming and Costly Secondary Operations 3. Reduce Product Weight and Improve User Ease 4. Gain Greater Product Structural Strength 5. Increase Your Product Design Options
Selected Material classification Thermoplastics Recyclable Engineering plastics Meet the engineering & structural requirements Nylon for better strength & temperature stabilities Nylon 6,6 with Glass filled
Why 20% Glass filled Nylon 6,6? Thermoplastics shows up to a disadvantage when compare with metals. This are include: 1) Low rigidity and tensile strength, 2) Dimensional instability due to a high temperature coefficient of expansion and higher water absorption. 3) Low impact strength to fracture. 4) Low maximum service temperature. 5) Low creep resistance. 6) Low hardness and scratch resistance.
Properties of Nylon 6,6 with 20% glass fiber • Melting point = 252-265°C • Maximum service temperature = 227-254°C • Thermal conductivity = 0.42 W/ mK • Co efficient of thermal expansion (at 100°C) = 336um/m°C • Specific heat = 1.8J/g°C • Density = 1.25 g/cc • Modulus of elasticity = 4.5-7.2 Gpa • Ultimate tensile strength = 120 Mpa • Yield tensile strength = 130 Mpa • Poison’s ratio = 0.33 • Hardness = R 110 • Cost = Rs180/ kg
Properties of Aluminum casting alloy • Melting point = 557- 596°C • Thermal conductivity = 113W/mK • Co efficient of thermal expansion (at 100°C) = 22.9µm/m°C • Specific heat =0.963 J/g°C • Density = 2.68g/ CC • Modulus of elasticity = 71MPa • Ultimate tensile strength = 317MPa • Yield tensile strength = 165MPa • Poison’s ratio = 0.33 • Hardness, BHN = 75 • Cost = Rs135/ kg
Modeling For modeling a model of Inlet manifold, manufactured by Tata indica and is used by V2 diesel engine with turbocharger was taken as reference. When I begin to create model, I went for manual measurement. In my component some holes and, some angular profiles, fillet profiles & totally the component body is like a shell like structure with taper and fillet radius and with a base part. After taking the dimensions properly a 3D graphical model is created by the use of software PRO-ENGINEER.
Procedure of analysis • For analysis of the product, the analysis software, HYPERMESH & ANSYS has used. • The model is imported into HYPERMESH as an IGES file format. • Then midsurface for the component is created by using midsurface command. • Again for the midsurface geometry cleanupoptionis used to make it ideal one for meshing and analysis. • Then 2D mesh for that midsurface prepared using automesh command by applying Manual creation and tria type mesh • After finished these procedure in the HYPERMESH I try to applying the boundary conditions for the meshed midsurface at that time, but in my component to various temperature in outside and inside so I can’t apply various temperature in single surface. So I planned to create solid mesh (3D) in the HYPERMESH.
Mes MESH IN HYPERMESH Total Nodes 69651 Total Elements 38034 Total Body Elements 38034 10-Node Quadratic Tetrahedron Solid187
Boundary conditions applied: (Environments)in HYPERWORKS WORKBENCH • Static: Fixed support - Base of the Manifold which is fitted with Engine. Pressure - 0.138 Mpa constant pressures inside the shell. • Temperature: Convection 1 - 120°C outside the component. Convection 2 - 30°C Inside the shell. Conduction - 150°C base which is fitted with the Engine.
Results of 20% Glass filled Nylon 6,6 (Total deformation) Results of aluminum alloy (Total deformation)
Results of aluminum inlet manifold (Temperature distribution) Results of 20% Glass filled Nylon 6,6 (Temperature distribution)
Results of Equivalent Stress and Total Deformation in Aluminum Alloy.
In the inlet nylon manifold the temperature distribution is very equal through out the body of the component and the rises in boss and fillet areas, but in the aluminum material the temperature distribution is not good, so the stress developed is more in aluminum. The stress developed in the nylon material is with in factor of safety 3. NYLON RESULTS: • TOTAL DEFORMATION: 0. m minimum 3.2621e-004 m maximum • EQUIVALENT VON-MISES STRESS: 7.6319e-004 Pa minimum 4.9191e+007 Pa maximum • MAXIMUM PRINCIPAL STRESS: -1.3982e+007 Pa minimum 2.9388e+007 Pa maximum • TOTAL HEAT FLUX: 2.6606e-005 W/m² minimum • TEMPERATURE: 43.529 °C minimum 120. ° C maximum
MANUFACTURING OF PART The part can manufactured in two halves and then with the help of ultrasonic welding we can join two parts. The part can also be manufactured by another process that is called lost core injection molding process. I have here shows the process of manufacturing it with two halves and then ultra sonic welding it.
Material used FAMILY NAME: POLYAMIDE TRADE NAME: XYTEL MANUFACTURER: DU POINT FILLER: GLASS
COMPARISON OF COST & WEIGHT EFFECTIVE RESULTS: • Thus from the above results and their comparisons it can be concluded that though the nylon with 20% material can replace well Aluminum, then the comparison of the cost with aluminum is calculated. First we should consider the material costs of both materials: • Cost of Al casting alloy = Rs135/kg • Cost of Nylon 66 with 20% glass fiber = Rs180/kg • But it is Rs45 higher than that of Al casting alloy. But we think the density of them it is found that, • Density of Al casting alloy (2.68gm/cc) • Density of Nylon6,6 with 30% glass fiber (1.35gm/cc)
