SKILL ADVANCED COURSE REPORT

(STATIC STRUCTURAL ANALYSIS USING

HYPERMESH &LS-DYNA)
A Skill Advanced Course

(STATIC STRUCTURAL ANALYSIS HELICAL BEVEL

GEAR USING HYPERMESH ANDLS-DYNA)

report submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, KAKINADA

In partial fulfilment for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN

MECHANICAL ENGINEERING
By

MARRAPU TEJA SAI PRAKASH

Regd.no : 22765A0348

Under the esteemed guidance of

K. VENKATESHWARA REDDY
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING (AUTONOMOUS)
(Approved by AICTE, Affiliated to JNTUK, KAKINADA, Accredited by NBA (Tier-I),
NAAC and an ISO 9001-2015 certified Institution) L. B. REDDY NAGAR, MYLAVARAM,
KRISHNA DIST –521230 ANDHRA PRADESH
 LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the Skill Advanced Course (STRUCTURAL ANALYSIS

USING HYPERMESH AND LS-DYNA) report entitled “STATIC
STRUCTURAL ANALYSIS OF HELICAL BEVEL GEAR USING HYPERMESH
& LS-DYNA” that is being submitted by MARRAPU TEJA SAI PRAKASH
bearing register number 22765A0348 in partial fulfillment for the award of the
degree of Bachelor of Technology in Mechanical Engineering is a record of
Skill Oriented course-II, work carried out by him under our guidance and
supervision.

Head of the Department

Dr.M.B.S.Sreekar Reddy

Internal Examiner External Examiner

 ACKNOWLEDGEMENT
The Satisfaction that accompanies that the successful completion of any task
would be incomplete without the mention of the people whose cease less co-
operation made it possible, whose constant guidance and encouragement crown
all efforts with success.

I humbly express my thanks to our management and Principal Dr. K. Appa Rao
for extending their support for providing us with an environment to complete our
internship successfully.

I indebted to our Head of the Department Dr. M. B. S. Sreekar Reddy who

modelled us both technically and morally for achieving greater success in life.

I humbly express my thanks to my guidance of K. VENKATESHWARA

REDDY for giving timely valuable suggestions and encouragement that make
the completion of theinternship successfully.

I would like to thank all the teaching and non- teaching staff members of
Mechanical Engineering, who have extended their full co-operation during the
course of this work.

I am thankful to my friends who helped me sharing knowledge and by

providing material to complete the internship in time.

MARRAPU TEJA SAI PRAKASH

(22765A0348)
s.no Chapter Pg.no

1. Introduction to hyper mesh and ls-Dyna 1-3

2. Introduction to structure of hyper mesh 4-8

3. Introduction to Bevel Gears 9-10

4. Procedure for the analysis 10-18

5. Conclusion 19

6. References 20
 INTRODUCTION TO HYPERMESH AND LS-DYNA
Hyper Mesh Software:

Hyper mesh is a preprocessing software where you divide the model into no. Of elements and
nodes for a solver to apply the mathematical functions on it. If you read FEM OR FEA you
would know the underlying theory behind the practice. Pre-processer is generally used to
'mesh' the model.
• Hyper Works delivers easy-to-learn solution- and domain-specific workflows across a
growing number of engineering applications to increase team productivity and
accelerate the development of today’s increasingly complex, connected products.

• Sim Lab minimizes the time users must spend creating finite element models and
interpreting results through automation. It can accurately analyze the performance of
complex assemblies in multiple physics types, including structural, thermal, and fluid
dynamics.

• Users can learn Inspire in just a few hours. Its intuitive interface provides the
dependable Altair solver power for analysts and designers so they perform what-if
studies faster, easier, and earlier. Inspire encourages collaboration, optimizes product
design, and reduces time to market.

Mesh generation is the premise of finite element analysis, Hyper Mesh as a high performance
finite element preprocessor, By analyzing the specific example of bearing gear system, the
key problems of geometry cleaning and mesh generation in the process of finite element
preprocessing are studied. The influence of different modeling methods on mesh generation
is analyzed. According to the basic principle of finite element mesh division, through the good
interface between Hyper Mesh and CAD and CAE software, the geometric model import
andmodal analysis are realized, and the quality and efficiency of finite element analysis are
improved.

The one-dimensional hyper mesh, referred to as a cluster, forms the basic topology upon which
higher-dimensional hyper mesh structures are formed. The cluster is a hypergraph consisting
of k nodes connected within a single hop. A k-array n-dimensional hyper mesh, is a regular
hypergraph with N=kn nodes, formed by taking the Cartesian n-productof the cluster
topology. This has the effect of imposing the cluster organization in every dimension, making
each node equally a member of n independent.

Altair Hyper Mesh is a high-performance finite element pre-processor to prepare even the
largest models, starting from import of CAD geometry to exporting an analysis run for various
disciplines.

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LS-DYNA SOFTWARE:

Ansys LS-DYNA is a general-purpose finite element software solution capable of

simulating complex, real-world problems such as impact and crash related problems in
automotive industries, as well as blade containment, bird strike, metal forming, fluid
splashing, metal cutting, blast and biomechanics in other industries.
It is a post processing soft ware

The key features of the software: -

➢ Understand the keyword structure of LS-DYNA

➢ Understand key concepts of penalty and kinematic contacts
➢ Have awareness of unit consistency while setting up your units for materials, element
length and time
➢ Distinguish between an acceptable "Normal Termination" and incorrect results

✓ ANSYSAUTODYN-Explicit dynamic solver for transient non‐ linear simulations

involving large deformations and strains, non‐ linear material behaviour, non‐linear
buckling, complex contact, fragmentation, and shock wave propagation.
✓ ANSYS LS ‐DYNA–LSTC’s LS‐DYNA explicit dynamic solver technology with the
pre/postprocessing power of ANSYS software. This powerful pairing can be used to
simulate crash tests, metal forging, stamping, and catastrophic failures.

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STEPS INVOLVED IN THE ANALYSIS OF A COMPONENT:

PRE-PROCESSING

SOLVER

POST-PROCESSING

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 HYPERMESH WORKSPACE

Hyper Mesh Introduction: The User Interface of hyper mesh softwear

• Graphics area – displays the model

• Toolbar – Gives access to commonly used tools via icons

• Pull Down Menu – places functionality into groups, accessible via pull downs

• Menu Pages – divides the main menu into groups based on function

• Main Menu – contains “panels” grouped in columns

• Panels – menu items / functions for interacting with HyperMesh

• Sub-panels – divides panel into similar tasks related to panel’s main function

• Command Window – lets the user type in and execute tcl commands
• Available through the View drop down menu (turned off by default)

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 ✓ Tab Area – contains the following tabs:
• Solver, Model, Utility, Include, Import, Export, Connector, Entity State, etc.
• Status Bar – shows status of operations being performed
• Indicates the “current” Include file, Component Collector, and Load Collector

File Operations
• General terminology:
▪ Open : Loads a file into HyperMesh replacing the current session
▪ Save : Saves the current session contents to the file
namespecified
▪ Import : Loads a file into HyperMesh, merging with the
currentcontents
▪ Export : Saves data to the file name specified and
Generally refers to file types other than a HyperMeshbinary file

Importing Geometry:
• Import geometry data via:
• File > Import > Geometry drop-down menu

• Toolbar > > Geometry

• Common types of geometry files supported:
• Unigraphics (NX2, NX3, NX4, NX5, NX6)
• CATIA (V4 & V5)
• IGES
• STEP
Model Organization: Collectors
• The Hyper Mesh model is organized using “collectors”
• There are many types of collectors
• Most entities in Hyper Mesh must be placed in a collector
• Each collector type holds a specific type of entity

Collector Types Can contain entity types:

Component Elements, Points, Lines, Surfaces, Connectors
Multibody Ellipsoids, Mb-joints, Mb-planes, Sensors
Assembly Components, Multi-bodies, Assemblies
Load Collector Loads, Equations
Material

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 none (materials and properties don’t contain other
Property entities but are
still treated as collectors)
System Collector Systems
Vector Collector Vectors
Beam Section Beam Sections
Collector

Model Organization
Model browser

Create, delete, and rename collectors

Edit collector attributes

Organize collectors into assemblies

Drag and drop

Right-Click on
Collector for
advanced
options

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Model Organization: Tools
• Panels
• Collectors – Create new collectors

• Model Browser – Set the current collector for various entity types

• Organize – Move entities into a different collector than the

one they are currently contained in

• Rename – Change the name of an existing collector

• Reorder

• Collectors appear in a certain order when presented in a list to pick

from

• Reorder allows the order the collectors appear in to be changed

• Delete – Delete entities or collectors

STATIC STRUCTURAL
A static structural analysis calculates the effect of steady (or static) loading conditions on a
structure, while ignoring inertia and damping effects, such as those caused by time varying
loads. Static structural analyses are used for simple linear calculations as well as complex
material, geometric and contact nonlinear calculations. The analysis results help to identify
weak areas with low strength and durability

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COMMANDS USED IN GEOMETRY

1. LINE– It can be used for making simple lines in the drawing.

2. RECTANGLE– This command will make a rectangle in the drawing.

3. CIRCLE– It is the command used for making a circle.

4. POLYGON - This command can be used for making a polygon.

5. POLY LINE– This command can be used to make a poly line.

6. ARC – This command can be used to make an arc.

7. ARRAY – This command can be used to make a rectangle, polar or path array.

8. TRIM– This command can be used to trim the objects.

9. Fillet- This is used to fill the edges of the body

10. Pad- This is used to create a 3D surface

HELICAL BEVEL GEAR

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 INTRODUCTION TO HELICAL BEVEL GEAR

A helical bevel gear is a bevel gear with helical teeth. The main application of this is in a vehicle differential,
where the direction of drive from the drive shaft must be turned 90 degrees to drive the wheels. The helical
design produces less vibration and noise than conventional straight-cut or spur-cut gear with straight teeth. A
spiral bevel gear set should always be replaced in pairs i.e. both the left hand and right hand gears should be
replaced together since the gears are manufactured and lapped in pairs.

Bevel gears are cone shaped gears which transmit motion between two intersecting shafts. Spiral bevel gears
are one type in which the teeth are curved spirally. Unlike straight bevel gears, these teeth contact each other
gradually and smoothly from one end to the other.

Purpose:

Spiral Bevel Gear Drives for High-Torque and High-Speed Applications. Because spiral bevel gears have a
greater tooth area, they can deliver more torque output than other gears of the same size. Spiral bevel gears, as
a result, can move faster than other gears, producing greater output in less time.

The 4 Primary Ways to Use Gears:

1. Speed. Different sized gears can be used to efficiently change the speed of a system. Large gears with many
teeth, when interlocking with small gears with few teeth, have to spin fewer times to keep up with the total
motion of the machine. The smaller gears have to spin faster, giving you a way to increase rotational speed.

2. Force. In a similar setup, you can use gears to increase the force of a system; that extra speed doesn’t appear
out of nowhere. Turning the small gear fast will make the larger gear turn slower, but with much more force.
This is useful for applications that deal with extra weight or pressure.

3. Rotation direction. Gears are also useful for changing the direction of rotational motion. Spur gears can
reverse direction, worm gears change rotation al direction by 90 degrees, and bevel gears can transmit
motion around corners.

4. Movement. Rack and pinion gears are sometimes used for direct movement within a machine. These use a
gear wheel (pinion) to mesh with a ridged bar-shaped gear (rack), which is sometimes fixed in place. This
can be used to climb hills (such as with roller coasters or trains), or even to steer your vehicle.

TYPES:
• Spur Gear: The spur gear has a helix angle of 0°.
• Worm Gear: Worm gears are found in right angle gearboxes. They “turn a corner.”
• Helical Gear: This is an angle toothed gear. ...
• Bevel Gear: Bevel gears tend to have a lower ratio and run at a higher efficiency than worm
gears.
APPLICATIONS:

These gears are however used for automobile differential gear system and other industrial
applications. The bevel gear has many diverse applications such as locomotives, marine applications,
automobiles, printing presses, cooling towers, power plants, steel plants, railway track inspection machines, etc.

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 STATIC STRUCTURAL ANALYSIS OF HELICAL BEVEL GEAR:

Static structural analysis of a helical bevel gear involves examining the power transmitting of
mechanical energy due to under various loads to ensure its structural integrity and reliability. This type
of analysis is crucial to determine whether the spiral bevel gear can withstand the applied forces without
failing, deforming excessively, or causing excessive stress in the connected components.
Static structural analysis is a fundamental tool for assessing the performance of a spiral bevel gear and
ensuring its reliability in practical applications. It helps engineers make informed decisions about the
power transmitting and materials, ensuring that it can withstand the forces and loads it will encounter
during its service life.

STATIC STRUCTURAL ANALYSIS OF HELICAL BEVEL

GEAR:

This structural analysis consists 11 steps

1. Meshing
2. Properties
3. Material
4. Assembly
5. Intersections and penetrations
6. Connections
7. Loads
8. Boundry conditions
9. Contacts
10. Control cards
11. Data base cards

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 STEPS FOR ANALYSIS OF HELICAL BEVEL GEAR

➢ First of all, design a helical bevel gear using Catia V5 software by taking the required dimensions.
➢

➢ Save the file in stp or igs format.

Step-1
Import the geometry from the import panel and save it with the proper name.
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Step-2
Delete the solids if any present by clicking (f2) and delete the entities.

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Step-3
Delete the duplicate surfaces if any

Geometry – defeature—duplicates – select all – delete.

Selecting the arc centre nodes.

Step-4
Generate the 2D mesh

2D – auto mesh – select all surfaces – set the element length – generate.

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Step-5
Find the free edges and delete the free edges the component must enclose

Step-6
Generate the 3D mesh in 3D panel

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Step-7

Create section cards and assign to the component.

Step-8

Create Define curve and assign to components.

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Step-9
Create Boundary SPC nodes and assign to components.

Step-10
Create Material cards and assign to the component.

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Step-11
Apply loads and giving displacement on both sides.

Solver

Import the key file in ls run or ls manager and run the file

Once the file is terminated normally its ready for post processing in this we see the
deformations and loads acting on it

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 RESULT:

Von-mises stress or equivalent stress :

Total deformation:

++

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Factor of safty

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 CONCLUSION

The use of the import function in HYPER MESH AND LS-DYNA definitely has some
advantages. It can help to reduce the time it takes to produce the drawings needed in the work
environment. However, if the individual that has created the imported file does not receive
credit for their work, problems may arise in the future. As well ,by using the function people
may slowly start to place a lesser value on the intellectual property of others, which will
undoubtedly create future conflict .The use of the import function may also be relied on heavily
in order to create efficiencies within the industry .This could possibly lead to a decrease in the
rate of innovation .It's obvious that the import function has a place in the building industry ,but
its use will have to be regulated in order to create a balance between thenegative and the
positive effects it creates .

Mesh generation is the premise of finite element analysis, Hyper Mesh as a high performance
finite element preprocessor, By analyzing the specific example of bearing gear system, the
key problems of geometry cleaning and mesh generation in the process of finite element
preprocessing are studied. The influence of different modeling methods on mesh generation
is analyzed. According to the basic principle of finite element mesh division, through the good
interface between Hyper Mesh and CAD and CAE software, the geometric model import and
modal analysis are realized, and the quality and efficiency of finite element analysis are
improved.

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 REFERENCES

• Chandrakant M Patil Int. Journal of Engineering Research and Applications www.ijera.com ISSN:
2248-9622, Vol. 5, Issue 7, (Part - 3) July 2015

• Shivaji G. Chavan, Stress Analysis of Flanged Joint Using Finite Element Method, International Journal
of Science and Research (IJSR) ISSN (Online): 2319-7064 Volume 3 Issue 8, August 2014.

• S.B. Jaiswal1, M.D. Pasarkar, Failure Analysis of Flange Coupling In Industry, International Journal of
Emerging Technology and Advanced Engineering, ISSN 2250- 2459, Volume 2, Issue 5, May 2012.

• Mr. S.B. Jaiswal, Prof. M.D. Pasarkar, Failure Analysis of Flange Coupling in Industry,
InternationalJournal of Emerging Technology and Advanced Engineering , Websites- www.ijetae.com
(ISSN 2250-2459, Volume 2, Issue 5 May, 2012)

• Kondru Nagendra Babu and Dr. D Sunnel“Failure analysis of flange coupling with twodifferent
materials”. (IJERT), Vol. 4 Issue 04, April-2015, ISSN: 2278-0181

• Chandra Sekhar Katta, Kamana Srinivasa Rao , Design and Analysis of flange coupling , International
Journal of Professional Engineering Studies Volume VI /Issue 4 / AUG 2016

• Design and stress-Analysis of a Rigid Flange Coupling using FEM by Saurav Rajgadia Vol. 4, Issue 10,
October 2015 ISSN(Online) :2319- 8753

• Shaikh, A.A.S., Taji, S. And Verma, A., 2018. Analytical Analysis of Relationship among Modal
Parameters of Rigid Flange Coupling. Asian Journal For Convergence In Technology (AJCT), 4(3).

• Rajgadia, S., Das, D., Jaiswal, P., Basnet, A., Jha, A.R., Jaiswal, R., Karki, A. And Barman, R.N.,
Design and Stress-Analysis of a Rigid Flange Coupling using FEM. Vol.4, Issue 10, October
2015ISSN(Online) :2319- 8753 ISSN (Print) : 2347-6710International Journal of Innovative Research
in Science, Engineering and Technology(An ISO 3297: 2007 Certified Organization)

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