Structural Analysis Simulations Wind Gears Ansys
Structural Analysis Simulations Wind Gears Ansys
Contents
1 - Abstract 5
2 - Acknowledgments 6
3 - Introduction 7
3.1 ERASMUS Placements Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.1 Background and Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.2 Business areas facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.3 Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.4 Achievements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.5 Wind Gears Key numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.6 Industrial Gears key numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.7 Moventas Briefly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Allocation and daily procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 - Placement Tasks 15
4.1 Initial steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Practical Tasks / Simulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 Housing Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Procedures and Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.2 Internship Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Web page Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.3 Inspection Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Initial approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Initial results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.4 Bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3
CONTENTS CONTENTS
Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.5 Gear Testing Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Modified components seeking optimization . . . . . . . . . . . . . . . . . . . 29
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Load Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Comparison of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Frame results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Welded bases results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Screws results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contact tool results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.6 Planet Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Trainings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.1 Femfat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.2 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.3 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Tampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Jyväskylä . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Copenhagen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4
1 - ABSTRACT
1 - Abstract
A practical placement taking part in a European Company, integrated in the studies plan,
with full recognition before graduating, is nowadays possible through the New ERASMUS
Programme - LLP (Lifelong Learning Programme) Placements.
This report focuses on the activities and achievements during the period of the placement.
This placement corresponds to the final project equivalence in MIEM (Integrated Master in
Mechanical Engineering) Degree, specialization in Structural Engineering and Machine Design,
contributing 30 ECTS (European Credits Transfer System), provided at UP (University of Porto).
5
2 - ACKNOWLEDGMENTS
2 - Acknowledgments
The author would like to thank Petri Lahtinen, Group Manager in Technical analysis of Struc-
tural components, from Moventas, in the role of a coordinator to this placement for providing
timely inputs based on his experience in the domain of wind gears.
Further more, the author would like to acknowledge Paulo Tavares de Castro and Jorge Seabra,
from FEUP - Engineering Faculty of Porto University, for enabling this placement and for pro-
viding constant support and follow-up.
In addition, the author would like to acknowledge the team spirit shown by the colleagues at
Moventas namely Petri, Teemu and Ismo for their valuable time and contributions.
The author would to mention the importance of European ERASMUS programme, which has
provided a remarkable change in the European educational scenario.
I would like also to thank my family and friends for their understanding and comradeship through-
out this placement period.
6
3 - INTRODUCTION
3 - Introduction
The framework of ERASMUS (European Community Action Scheme for the Mobility of
University Students ) was established in 1987 and is a major part of the European Union Lifelong
Learning Programme (LLP) period from 2007 to 2013. It is the operational framework for
the European Commission’s initiatives in higher education. The recently created ERASMUS
placements, differs from the ERASMUS Studies in that it is a type of placement combined with
a specified time period in an enterprise or organization in European, EFTA/EEE and Turkey
countries, with a view to help individuals to adapt to the requirements of the European labor
market, acquiring specific skills and improve understanding of the economic and social culture
of the country concerned while acquiring the work experience. The period may be supported,
as appropriate, by preparatory or refresher courses in the host language or working language.
Host organizations for student placements may be enterprizes, training centers, research centers
or other organizations.
The characteristics of the individual placements are:
• Full recognition is provided by the home higher education institution for the period spent
abroad.
• It is necessary to have a Training Agreement for the student, regarding the programme
of the placement period; this agreement must be endorsed by the home higher education
institution and the host organization.
• The period of placement is covered by a placement contract endorsed by the higher edu-
cation institution sending the student, the consortium sending the student (if applicable),
the host organization and the beneficiary.
In a company environment, this program provides work experience, enabling the use of
knowledge, tools, procedures, that in this specific situation, were acquired trough the MIEM
subjects,projects,work-groups,professors at FEUP. It also allows to achieve maturity and per-
sonal growth,in a different environment as a result of applied work experience.
7
3 - INTRODUCTION 3.2. APPLICATION
3.2 Application
The author had experience of undertaking ERASMUS studies in Hungary in Spring semester
2007. After receiving the confirmation from the department of cooperation at FEUP about the
eligibility of the placement program, in November 2007, several countries were considered for the
placement program.
The country of placement was finalized as Finland because of previously established network
relationships.
After many applications, to companies like Outokumpu, Wärtsilä, Aker Yards, Ruukki, re-
sponse to take part in this challenging Programme, was sent by Moventas . The placement works
as a Final Project Equivalence in MIEM ( Integrated Master in Mechanical Engineering) Degree,
the final part of the studies plan, summing 30 ECTS ( European Credits Transfer System).
The report states the practical work placement, structured by date, performed at Moventas
Wind Oy, Jyväskylä , FINLAND in the framework of ERASMUS LLP - Placements pro-
gramme.
3.3 Company
Moventas, earlier Metso Drives, is one of the leading experts in mechanical power transmis-
sion. The company designs, manufactures and markets power transmission solutions and services
for process and energy industries. Moventas operates in a rapidly growing market. The com-
pany’s e 207 million sales revenue grew by 25 % in 2006, and grew by more than a third in 2007,
Figure 3.1. Moventas aims to double its sales by 2010 through organic growth.
8
3 - INTRODUCTION 3.3.2 Business areas facts
With its headquarters in Jyväskylä, Finland, the company has more than a century of en-
gineering experience. Well-known company names namely, Metso Drives, Santasalo and Valmet
are among the predecessors of Moventas, Figure 3.2. Having this solid background, the company
nowadays deals with both Wind (WG) and Industrial gears (IG). Today the company has nine lo-
cations globally, in Finland, Sweden, Germany, Canada, the United States and Singapore. With
its dedicated 24/7 service commitment, the company intends to further strengthen its global
reach to bring it closer to its customers.
Wind Gears
9
3 - INTRODUCTION 3.3.2 Business areas facts
Monitoring
Monitoring the performance and condition of key components, such as the mechanical
power-transmission systems, which are at the heart of a wind turbine, is vital to ensure
that wind-turbines maintain high levels of reliability. Moventas has launched a sophisticated
condition-management system, that not only monitors the turbine’s operation, but also
provides the operator with an early warning of potential risk factors before actual damage
is done. The system can be integrated into new turbine designs or fitted to machines already
in operation.
The gears Life Cycle takes in account all aspects and consequences, Figure 3.3.
Industrial Gears
Moventas has a strong position in the process industry also. It is the leading supplier of
mechanical drives for the pulp and paper industry and one of the leading players in the
growing mining and minerals sector. The most promising growth prospects in Moventas
industrial-gear business are in service and maintenance programmes covering the entire
lifespan of equipment. Moventas has been keen to adopt a life-cycle approach which plays
an important role in creating top-class customer satisfaction. First-time installations in the
mining and minerals sector are also growing strongly. In particular, demand for servicing
and renewal of machinery is on the increase in the wood-processing industry
10
3 - INTRODUCTION 3.3.3 Expansion
3.3.3 Expansion
In response to growing market demand, the company has begun a substantial investment
programme totalling e100 million. Part of the visionary growth strategy is to expand production
capacity in Finland which will create approximately 100 new jobs this year and roughly the same
number again over the next few years with an extensive investment programme . Presently Moven-
tas employs about 1200 individuals, Figure 3.4. The first project in the investment programme
has now been completed, with the opening of an expanded facility for wind-turbine production in
Jyväskylä, Finland in March. A new construction project aimed at further increasing production
capacity for wind-turbine gears in Jyväskylä has already started. The Karkkila plant in Southern
Finland, which concentrates on industrial gears, will increase its large gear-manufacturing and
assembly capacity. The full additional capacity will come on stream in 2009.
3.3.4 Achievements
• Wind turbine main gears for the major wind turbine manufacturers
• Uncompromising reliability
11
3 - INTRODUCTION 3.3.5 Wind Gears Key numbers
The section of Wind Gears, represents nowadays more than 50 % of the business, Figures 3.5
and 3.6.
The section of Industrial Gears, represented worldwide, offers solutions for all high demand
industries, Figures 3.7,3.8.
12
3 - INTRODUCTION 3.3.7 Moventas Briefly
13
3 - INTRODUCTION 3.4. ALLOCATION AND DAILY PROCEDURES
The department where the placement took place is the department of Research and Design,
integrated part of Moventas Wind Oy division. It is organized in different sub-sections; Struc-
tural (Fatigue [2], Eigen frequencies, Classification, . . . ), Modeling, Lubrication, Gears [8], ,
Documentation , with respective responsibilities.
The placement specifically was held in the Structural analysis subsection, which is responsible
for research, analysis and certification of all Wind Energy products.
At the Structural section, the work-tools consist of a Cluster - Fujitsu Celsius 2 processor -
Books, Internet, Applications and respective Help [1], [3], manuals [2], [10], [13]; and guide-
lines, [11]. Software licenses are limited.
The working schedule is flexible, consisting of average 37,5 hours a week. For security and prac-
tical reasons, for crossing the doors, magnetic keys are used, and this is the also the support to
store data such as working hours and vacations period. Periodical meetings are held at the de-
partment. Archive and backup of information is an important issue, existing a network drive and
Tape support ( 20-50 Gb). The organization of the space is open, easing contacts , suggestions
and permanent follow-up. There is a help desk for all kinds of software and hardware problems.
• Team of Structural Analysis included in the Research and Design division.Stress and dy-
namic analysis performed
• Usage of numerous compulsory softwares, Table 3.1, and procedures for full structural
analysis.
Software
CatiaV5 Solidworks Miktex Linux(CentOS) Ansys(Classic/Workbench) FEMFat
14
4 - PLACEMENT TASKS
4 - Placement Tasks
The initial step was integration which involved understanding all processes, departments,
factory layout and internal activities, organization, guidelines, personnel. The tools for work,
mainly the workstation, software, literature and objectives were made available in the first weeks
by installing all the software required and by providing hardware and cables.
Meanwhile, some individual personal training with the support of the software help [1], [3], [13],
internet, colleagues and books, in softwares like Ansys Classic ( developing the basics previously
done during the MIEM course in subjects namely Mecânica das Estruturas II , Mecânica da
Fractura), Catia V5 tutorials , Network configurations and data exchange between computers
and Cluster ( 8 processors, for Heavy FEM calculations).
All internal section reports are made using LaTex2ε, [4], [5], [6], [7], [9],. Also the usage of
tools for e-mail, software for bills like SAP, reservations, internal mail between departments, and
others, were acquired.
15
4 - PLACEMENT TASKS 4.2. PRACTICAL TASKS / SIMULATIONS
The software required to perform all sort of different tasks, was not fully available initially.
When new tasks were required, new software was sequently added as soon as possible, so that
the tasks were naturally performed. After gaining experience and confidence, through both per-
sonal and interpersonal ways, the tasks could be developed more easily, more confidently and
autonomously. A brief review of the activities and tasks that took place during placement pe-
riod, can be seen in Table 4.1.
Description
The housing of a 2MW power wind turbine (Figure 4.1), that was modeled in Catia V5,
needed simplification and preparation for modal analysis in Ansys Workbench. The steps are
to deactivate, hide or even change sketches in Catia V5, so that the global model is suitable,
incorporating good sense, for eliminating possible problems of elements size and shape when
meshing. The materials and constraints of the structure need to be carefully assigned for the
future Modal analysis.
16
4 - PLACEMENT TASKS 4.2.1 Housing Simplification
18
4 - PLACEMENT TASKS 4.2.1 Housing Simplification
Comments
This task allowed the author contact with parts of gear and allowed to realize and see the
functional components, size and geometry of Wind Turbines. The Softwares Catia V5 and Ansys
Workbench , were initially explored ( March 2008 ). Later on, the Ansys capabilities in Eigen
frequencies, allowed to study the behavior of the structure for further considerations.
(a) 1st
(b) 2nd
Figure 4.3: Housing Eigen Frequencies - 1st and 2nd Natural Modes
19
4 - PLACEMENT TASKS 4.2.2 Internship Webpage
Description
The webpage concerning the Internship was created in April 2008 with TextoHtml and also
basic HTML Language. This webpage was continuously reanalyzed and modified structurally.
Improvements were also made later, adding suitable information and also correcting some errors.
(http://paginas.fe.up.pt/˜em03078/).
• Placement Info
• Updated Workplan
• Downloads of Documents
Comments
The Webpage creation, maintenance and design, gives an idea of the structure, data stor-
age and procedures in order to provide essential information with direct and clear basis on the
Internet.
20
4 - PLACEMENT TASKS 4.2.3 Inspection Covers
Initial results
The initial results, trial attempt, leading to the right direction of objectives, observed the
change in the vibration mode from axial to bending, and the removal of the ribs,Figure 4.7. The
obtained values for 1st /fundamental Frequency can be seen on Table 4.5.
Table 4.5: Inspection covers initial improvement aiming a higher fundamental frequency
Inspection covers assembly details Weight (Kg) 1st Frequency - Fundamental (Hz) MODAL
Original 55 1703
Modified 55,9 2057
22
4 - PLACEMENT TASKS 4.2.3 Inspection Covers
Figure 4.7: Inspection covers improvement aiming higher 1st /fundamental frequency
23
4 - PLACEMENT TASKS 4.2.3 Inspection Covers
Figure 4.9: 1st /fundamental frequency - Results for Final optimum solution
Comments
The inspection cover resolution, led the author to deal closely with a practical application
using the knowledge and tool of frequency analysis. It shows the sort of problems, encountered
when the gears (multi-body drive-train) are under run. The experience gained in modeling
provided a necessary skill in a practical work environment for a mechanical engineer.
25
4 - PLACEMENT TASKS 4.2.4 Bearing cover
Approach
The modeling performed in Catia V5, allowed various options for changing the geometry. The
main design changes was the addition of ribs/stiffners due to limitation in the functional areas
(ex. bearings, shaft ,. . . ). After importing this CATParts to Ansys Workbench, the boundary
conditions were maintained and solved towards the solution sequentially. The mesh and fixed
support boundaries are displayed in Figure 4.12
27
4 - PLACEMENT TASKS 4.2.4 Bearing cover
Results
The values achieved for this purpose are presented in Table 4.7. The Mode shape for the 4th
Natural frequency is displayed in Figure 4.13.
Comments
The best result was obtained when adding stiffeners in the exterior face. This was considered
because of the location and functionality, which did not allow a wide area of maneuverability,
resulting in adding stiffeners in the exterior face instead of interior face for solving the eigen
frequency resonance problem.
Functional details, such as forced lubrication pointing out the flow proprieties were also taken in
account.
28
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Procedure
The Original cut section submodel/structure, constructed from the whole gear testing struc-
ture, was analyzed first,so that reference results could be obtained for the most important parts
like: welded frame, welded bases and housing. The material is considered as structural steel for
all components, Table 4.8.
30
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
NEW CONCEPT
Since is New concept version is substantially different, the analysis was done with some differ-
ent aspects. In the New concept. cut structure, some components were completely removed and
there were changes in several components. The welded plates are different, the screws are only
6xM16, the holes housing, frame, spacers and welded plates are 17,5 mm diameter The screws
pre-tension and fixed support are repeated and also the contacts definition. The contacts are
kept the same, as others parameters moment, preload, and so on. The housing and the weld
frame holes were changed according to the screw’s size.
The location of screws is different Figure4.21 and Table 4.11.
33
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Comparison of Results
Stress and Strain Analysis for Housing The Ansys Workbench results are displayed in 2x
Auto (380x real).
The deformations, Figure 4.24, and Figure 4.25, for Original and Modified respectively, high-
light the maximum deformation in the housing and the much higher deformation in the screws
caused by the pre-tension.
The tension values, for this Original and Modified retrieve unrealistic results, reason why they
are not shown, thus the maximum stress is at the screws, 10X bigger than in the frame.
For the New concept, the Von Mises stresses, Figure 4.26, are very low, displaying the places
where the direct effect of the moment applied is visible.
The deformation of the elements can be noticed on the screw because of the magnification
and element characteristics.
In addiction, for the housing, the stress/strain values, due to screws elements distortion, are
not reliable and should not be taken in the analysis. However, the housing stresses are low and
acceptable.
35
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
36
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Figure 4.27: ORIGINAL - Frame stress (Von Mises)- maximum near bolt head
Frame results
Stress Analysis
Original :
The welding locations in the frame (top and bottom faces) were simulated with bonded contact.
The pretension inflicts stresses on this weldings. However, the high pretension of the screws
leads to maximum stress in a very localized area around the holes. The frame verifies almost no
changes when moment is applied, Figure 4.27.
Modified :
In the modified structure, the behavior is the same, so that from the Original to the Modified
structure we jump from 20 MPa to 30 MPa in surface areas near holes, which is still a reasonable
value, Figure 4.28.
New concept:
In this substantially changed structure, the behavior is the same, but from the Original or Modi-
fied to this one, the realistic results come to surface. There is a reduction of stresses, because the
pretension of M16 screws is 10x smaller (leads from 20/30 MPa originally to 5 MPa ) in surface
areas near holes, Figure 4.29.
37
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Figure 4.28: MODIFIED - Frame stress (Von Mises)- maximum near bolt head
Figure 4.29: NEW CONCEPT - Frame stress (Von Mises)- maximum near bolt head
38
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Deformation Analysis
The deformation results of the frame behavior, Original and Modified, inflicted by the bolts
pre-tension, followed by a moment, retrieve the expected traction side/compression side, which
effectively brings notice to the bigger displacements, Figures 4.30, 4.31.
The main differences occur in the holes location and edges.
For the New Concept, the loads are in a different level with lower magnitude, resulting in
deformations which are three times smaller.
39
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
40
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Since there were high pre-tensions, stresses were analyzed in parts with direct connections
with the bolts. The welding locations between the frame and weld bases, simulated with bonded
contact, have to be taken in account that are not very close to reality, as said before, because
in real welding situation only the edges are welded while in simulation the entire surface on the
plane is selected and by consequence simulated as welded. The pretension of the screws inflict
the maximum stress in the opening located below the part. The contact areas of pressure in
this component caused by the M30 Screw, are located here, Figures 4.33, 4.34. Furthermore, for
different geometries of holes (opposing original/Modified versus New Concept), the stresses are
much smaller in the New concept, Figure 4.35
41
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
42
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Screws results
The results for the screws are provided in the tables given below, without any important
differences between the original, modified and New concept sub structures, concerning the ad-
justment and variation of working load, Tables 4.14, 4.15 and 4.16.
Bolt M30 M16 (Long) M16 (Short) M30 M16 (Long) M16 (Short) M30
Max Work Load (N) 3e5 3,012e4 3,014e4 2,997e5 2,989e4 2,99e4 3,00e5
Bolt M30 M16 (Long) M16 (Short) M30 M16 (Long) M16 (Short) M30
Max Work Load (N) 3e5 3,013e4 3,012e4 2,997e5 2,989e4 2,986e4 3,00e5
43
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
The contact tool was used to visualize the properties of the frictional contacts present, only
for original, modified . These are between the spacers/housing and cylinder/weld base , Figures
4.36 and 4.37, respectively. The sliding exists practically only due to the pretension of screws.
Note also the gap created by the parallel screws pretension (M30 and long M16), Figure 4.36. An-
alyzing the sequence in the contact, through the animation, because of the moment and bonded
contact simulating the welding, it is observed that there is penetration in the elements, caused
initially by the pre-tension, but afterwards by the pure moment applied.
44
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
45
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Figure 4.37: Contact tool results for the frictional contacts - STATUS
46
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout
Comments
The model evaluated, does not consider the bonded/welded regions properly, since the whole
welded area is bonded and it should only be evaluating the edges with proper geometry and
thickness of the type of welding.The moment applied would be more realistic if the whole housing
with bearing loads was available. Switching from Original to Modified, there is an effect of 50 %
higher stresses in the frame which is still low and acceptable (30 Mpa).
By removing components and/or material for saving weight, results show a direction to modify
the actual parts. Ansys results demonstrate that the moment applied, together with boundary
conditions and screws pretension, result in reasonably acceptable results for the New concept
structure, having almost no visible effect on stresses (5 MPa). The proposed changes, made for
saving weight, show some components can be removed. The usage of only M16 screws is suitable,
analyzing the details of the holes. The implementation of this New concept solution is strongly
recommended.
47
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Description
A Planetary gears carrier, Figure 4.38 has to be optimized to achieve the reduction of weight.
It consists of a housing integrating four planetary gears which are in contact with an external ring
gear, Figure 4.39. The functional regions must be kept and the reduction must be done in regions
which will be highlighted in the FEM analysis in Ansys and Ansys Workbench. Subsequent
decisions will be made based on these results by the modeling team professionals.
48
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Procedure
Initially, 6 revisions were available, all with modifications to achieve mass reduction. The
list of revisions can be seen in Figure 4.40, pointing out that Revision 3 was not studied due
to numerous similarities comparing to Revision 4. The mesh has to be resized to achieve good
accuracy near fillets and areas with sudden geometry changes . The simulation is done by
analyzing the Planet Carrier as having the applied moment and four supports, simulating the
presence of the gear teeth contacts with ring gear.
49
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Materials The supports for simulation have 10 % of Young Modulus (E) of the carrier’s cast
iron GJS-700. The structural steel material proprieties are applied for the pins which in reality
will hold 2 bearings each for each planetary gear. The materials are described in Tables 4.18 4.19
4.17.
50
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Contacts The contacts must be set as frictional between carrier and the pins, Figure 4.44,
because it’s the most important contact for the load, and more close to reality.
Since there are bearings in the planetary gears, the contact here is considered frictionless,
Figure 4.45.
52
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
53
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Results
The results were obtained using structural analysis, obeying the same constraints, mesh sizes
and contacts. The revisions are listed sequentially.
Revision 1
The Revision 1 can be admitted as reference to others. It gathers the main ideas and func-
tionalities required for the function in the wind gear train, that is, the model to modify.
There are secondary maximums in the ribs edges. The maximum occurs, as always, inside
the pin hole.
54
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
55
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Revision 2
The changes in this revision are mainly for the inside and outside fillets, attempting a new
concept and direction. There are secondary maximums on the edges of the ribs. The max-
imum occurs, as always, inside the pin hole.
56
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
57
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Revision 4
There is a change in the thickness of the housing in this case, so that the pin has to be
modified (shortened) the same amount of length 15 mm. The external area is substantially
changed in order to save weight. There are secondary maximums on the edges of the ribs.
The maximum occurs, as always, inside the pin hole.
58
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
59
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Revision 5
In this revision, a new approach was utilized, keeping edges and modeling a deep gap, keep-
ing structural stiffness and removing some material at the same time. There are secondary
maximums on the edges of the ribs. The maximum occurs, as always, inside the pin hole.
60
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
61
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Revision 6
The main modifications are the added chamfer in front and holes crossing the hole carrier.
There are secondary maximums on the edges of the ribs. The maximum occurs, as always,
inside the pin hole.
62
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
63
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Revision 7
The final revision tries to achieve the maximum advantage of an external rib between gears.
The minimum stress is in this case with reversed color scale and the elements are visible.
The maximum occurs, as always, inside the pin hole.
64
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
65
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Shape optimization The availability of shape finder module in Workbench, confirmed the
initial assumption, about where are the locations for material removal or modifications, Figure
4.64. The main visible area to remove is easy to understand analyzing the low material stresses.
The advantage is that some details like near the pin hole or outer surface, can be seen more easily
and action can be taken to remove material in those locations.
Tangential deformation While observing the functionality of the gears, the deflection has to
be analyzed., Figure 4.65. Probes for displacement are positioned in the front and the back, with
the suitable coordinate system, Figures 4.66 and 4.67, measuring the tangential displacement, in
order to have an approximation.
66
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
67
4 - PLACEMENT TASKS 4.2.6 Planet Carrier
Comments
The results show an optimum achievable mass reduction of about 500 Kg. The maximum
stress value occurs, as always, inside the pin hole. Design modifications need to be done for lower-
ing the stresses in this spot. Different designs can now be taken into consideration. It is possible
to conclude that the recommended way of achieving this goal was correct. The achievement of
higher safety factors can be considered as a future research area.. The deformation achieves the
best result for Revision 7, concerning the weight goal, among new revisions. On the other side,
the deformation is much higher than the original planet carrier , Table 4.20 . Future work will
be done to solve this problem.
68
4 - PLACEMENT TASKS 4.3. TRAININGS
4.3 Trainings
Various trainings were attended during this placement. These trainings allowed the author to
learn and understand interaction of companies, formal procedures, control and selection of infor-
mation, importance of IT (Information§Technology) and HPC (High Performance Computing).
1. FEMFAT
2. SKF
3. ANSYS
4. Ricardo
4.3.1 Femfat
A trainer from Austria was provided to Moventas facilities, in order to assure all the contents
for the training, transmitting theoretical background and practical utilization of the FEMFat
Software.
4.3.2 SKF
• ISO 281
• SKF AFC
• Galaxy
• SKF ECS
4.3.3 Ansys
Tampere
A presentation and discussion were arranged at the facilities of a new licences supplier com-
pany - Process Flow, showcasing problems and requirements.
Jyväskylä
Medeso Conference/Seminar was conducted for performing training and showcasing new prod-
ucts, clearing doubts, new softwares, meeting other colleagues from the sector.
69
4 - PLACEMENT TASKS 4.3.3 Ansys
Copenhagen
MEDESO CAE User conference: 26, 27 May 2008 Conference, with companies from all over
Scandinavia, sharing experience and applications, representing and establishing contacts.
This conference provided the author with the opportunity to have more theoretical background
and to absorb case studies in other companies namely:
• AlfaLaval
• Kanthal AB
• Grundfos
• SwereaSicomp
• XDIN
• Scania
• Siemens
• Validus Engineering
70
5 - CONCLUSIONS AND FUTURE WORK
This placement provided the author with an enriching personal and professional experience.
Since it was held in a company of extremely good environment, reputation, know-how and re-
sults through all existence, based on professionalism and excellence, numerous achievements and
experiences were possible.
The tasks performed allowed the author in understanding the problems that are faced in
practice, exploring softwares used in mechanical applications, learning new engineering contents,
such as contact analysis, mesh creation efficiency, developing problem questioning and method
of resolution, maturing skills and knowledge acquired previously.
From an engineering perspective, the usage of tools such as Ansys for FEM and Vibrations,
Femfat, for Fatigue, Catia V5 for Modeling were found to be extremely powerful and fast, while
analyzing huge amount of data, load cases and different geometries.
The tasks were performed as the primary present needs were discussed and settled in the struc-
tural analysis section. The optimization of components, structures is always an objective in mind.
It was sequently enjoyed the variety of challenges through out the placement in this organi-
zation. During the strong personal growth period the whole company has been able to improve
operations and utilize new capacity effectively, bringing even more challenges to future operations.
From a management perspective, the whole process of adapting to a new corporate environ-
ment, working in teams, cooperating between departments, and exposure to practical aspects of
running an enterprise helped in providing a sense of satisfaction for the author.
From a personal perspective, the author was glad to acquire the ability to adjust, accept
and adapt to a different culture in a new country, having a different language. In short,this
challenging role helped the author to develop soft and hard skills which are essential for an
international career.
Highlighting achievements from the placement, those can be summarized as follows:
1. The starting procedures were easily performed, and the integration was easy owing to the
cooperation and help of colleagues at Moventas.
2. The tasks performed required multiple skills in modeling and FEM based on discussion
with team members. The learning process was a step by step process,helping the author to
evolve professionally, socially and personally.
71
5 - CONCLUSIONS AND FUTURE WORK 5.2. IMPROVEMENTS
3. The tasks performed depended wholly on the dialogues between team elements and sections.
The specific areas dealt by the author did not have a resolution in advance and required
several trials and changes, experience and good sense in order to obtain results. This
provided the author with the unique opportunity of interaction with others to obtain best
results.
4. The placement made the author understand the importance of the role played by software,
information system and computational power in an enterprise.
Tasks were performed as per the current needs of the enterprise. The solutions provided by
the author were discussed and settled in the structural analysis section. The author has observed
that the optimization of components and structures is always an objective in the minds of Moven-
tas employees.
The main strengths in the organizational climate of the company can be described as follows:
5.2 Improvements
Computer administration plays a major role in the efficiency of an enterprise. The lack of
proper computer administration in a company leads rise to delay in effective problem resolutions
and difficulty in information sharing and access. In Moventas, efforts are being done to improve
the situation along with the growth of the company.
• Organization of work.
• Work in departments as well as decision-making are not regarded having the optimum
efficiency.
• Information flow (information flow between and inside the departments, high amount of
rumors).
The author was still under the placement at the date of report submission.
Present task is to study the 2D interaction between the pin and hole of planet carrier, as described
in section 4.2.6 , Page 48.
72
LIST OF FIGURES LIST OF FIGURES
List of Figures
73
LIST OF FIGURES LIST OF FIGURES
4.27 ORIGINAL - Frame stress (Von Mises)- maximum near bolt head . . . . . . . . . 37
4.28 MODIFIED - Frame stress (Von Mises)- maximum near bolt head . . . . . . . . . 38
4.29 NEW CONCEPT - Frame stress (Von Mises)- maximum near bolt head . . . . . . 38
4.30 Original Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.31 Modified Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.32 New concept Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . 40
4.33 ORIGINAL - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.34 MODIFIED - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.35 NEW CONCEPT - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . 42
4.36 Contact tool results for the frictional contacts-GAP . . . . . . . . . . . . . . . . . 45
4.37 Contact tool results for the frictional contacts - STATUS . . . . . . . . . . . . . . 46
4.38 Planetary Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.39 Planet Carrier detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.40 Revisions for study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.41 Planet Carrier - Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.42 Mesh - refinement locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.43 Planet carrier constraints and moment load . . . . . . . . . . . . . . . . . . . . . . 52
4.44 Frictional Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.45 Frictionless contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.46 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.47 Maximum Principal Stress - CUT - revision 1 . . . . . . . . . . . . . . . . . . . . . 55
4.48 Pin cut - stresses - Revision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.49 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.50 Maximum Principal Stress - CUT - revision 2 . . . . . . . . . . . . . . . . . . . . . 57
4.51 Pin cut - stresses - Revision 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.52 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.53 Maximum Principal Stress - CUT - revision 4 . . . . . . . . . . . . . . . . . . . . . 59
4.54 Pin cut - stresses - Revision 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.55 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.56 Maximum Principal Stress - CUT - revision 5 . . . . . . . . . . . . . . . . . . . . . 61
4.57 Pin cut - stresses - Revision 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.58 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.59 Maximum Principal Stress - CUT - revision 6 . . . . . . . . . . . . . . . . . . . . . 63
4.60 Pin cut - stresses - Revision 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.61 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.62 Maximum Principal Stress - CUT - revision 7 . . . . . . . . . . . . . . . . . . . . . 65
4.63 Pin cut - stresses - Revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.64 Shape optimization for Revision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.65 Deformation probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
74
LIST OF FIGURES LIST OF FIGURES
75
LIST OF TABLES LIST OF TABLES
List of Tables
76
REFERENCES REFERENCES
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77