FINITE ELEMENT ANALYSIS ON ALUMINIUM ALLOY...

ISSN: 2278 – 7798 International Journal of Science, Engineering and Technology Research (IJSETR)

Volume 5, Issue 5, May 2016

1295

All Rights Reserved © 2016 IJSETR

FINITE ELEMENT ANALYSIS ON

ALUMINIUM ALLOY COMPOSITE WITH

VARIOUS BOUNDARY CONDITIONS

L.Vijayabaskar1

Asst.Professor, CK College of Engineering & Technology, Cuddalore, India1

Abstract- Composite materials have interesting

properties such as high strength to weight ratio, ease

of fabrication, good electrical and thermal properties

compared to metals. Design engineer must consider

several alternatives such as best stacking sequence,

optimum fibre angles that are orientations. The

development of composite material with reduced

weight and increase strength relative to conventional

metals has played a critical role in achieving higher

operating performance, long life and reduced cost.

One such composite material is Boron/Aluminium

composite [1]. These materials are being widely used

in a variety of high performance structures. Reliable

use and optimum design requires accurate methods

for predicting their mechanical behaviour, among

other things. In this work, modelling of composite

specimen will be carried out by using ANSYS and by

finite element analysis stress and displacement

behaviour of such a specimen is analyzed with ansys

software. It is observed that the stress value is

maximum 15188 N/mm2 while considered the

boundary condition 2 at 30 degree. Also the stress

value is minimum 422 N/mm2 while considered

boundary condition 4 at 30 degree. It is also observed

that displacement value is maximum 17.525 mm while

considered boundary condition 2 at 60 degree. From

the result it is observed that the orientation at 30

degree with boundary condition 4 is safe while

comparing other boundary conditions. Index Terms- Boron/Aluminium composite, ANSYS,

finite element analysis, boundary condition 2 at 60

degree.

I INTRODUCTION

COMPOSITE MATERIALS

Composite materials have been used in

structures for long time. In recent times composite

parts have been used extensively in aircrafts,

automobiles, sporting goods, and many consumer

products.

Composite materials (also called

composition materials or shortened to composites)

are materials made from two or more constituent

materials with significantly different physical or

chemical properties, that when combined produce a material with characteristics different from the

individual components[1]. The individual

components remain separate and distinct within the

finished structure.

DIFFERENT TYPES OF FIBRE ORIENTATION

Fig.1 Unidirectional Laminate

Composites are used in the form of

unidirectional laminates, since one of their great

merits is that the fibers can be arranged so as to give specific properties in any desired direction.

Thus, in any given structural laminate,

predetermined proportions of the unidirectional

plies will be arranged at some specific angle, θ, to

the stress direction. In order to calculate the

properties of such a multi-ply laminate, it is first

necessary to know how the elastic response of a

single unidirectional lamina, such as that which we

have been considering so far, will vary as the angle

to the stress direction is changed. This is done by

transforming the axes through some arbitrary angle, θ, a procedure that will familiar to anyone who has

studied the derivation of the Mohr’s circle

construction.

II CHOOSING THE PROPER ELEMENT TYPE

The following element types are available

are available to model layered composite materials:

SHELL99, SHELL91, SHELL181, SOLID46, and



1296 All Rights Reserved © 2016 IJSETR

SOLID191. Which element you choose depends on

the application the type of results that need to be

calculated and so on. Check the individual element

descriptions to determine if a specific element can

be used in your ansys product. All layered element allow failure criterion calculations.

SHELL99

Used for layered applications of a

structural shell model or for modeling thick

sandwich structures. Up to 100 different layers are

permitted for applications with the sandwich option

turned off. Allows more layers. The element has six degrees of freedom at each node: translations in the

nodal x, y, and z directions and rotations about the

nodal x, y, and z-axes [6].

Shell 99 IS AN 8 N0DE 3D shell element

with six degree of freedom at each node. For

structure with smaller ratios, you consider using

SOLID 46. The SHELL99 element allows a total of

250 uniform thickness layers.

III MATERIAL PROPERTIES

Two different orthotropic materials are

used to analysis the effect of fiber orientation. The

material properties are given in the table 1, where

E, G, represent modulus of elastically, modulus of

rigidity and poisons ratio respectively.

Table.1 Material Properties

Materials

Properties

Boron/Aluminium

Aluminium EX 235 GPa

EY 137Gpa

EZ 137 Gpa

GXY 47 Gpa

GYZ 47 Gpa

GZX 47 Gpa

µXY 0.3

µYZ 0.3

µZX 0.3

IV MODELING AND ANALYSIS

MODELING OF STRUCTURE

To study influence of fiber orientation up

on deflection and scf for different stresses. A

laminated composite plate of dimension 200mm×100mm×1mm with a unidirectional cross

section using the finite element analysis software.

The following figure illustrates the basic model of

the problem.

Fig. 2 Isometric View of Lamina Plate

MESHING MODEL

In this method, a body or structure in

which the analysis is carried out is subdivided in to

smaller elements of finite dimensions called finite

elements. Then the body is considered as an

assemblage of these elements connected at a finite

number of joints called nodes or nodal point. These

properties of each type of finite element is obtained

and assembled together and solved as whole to get

solution

Fig.3 Meshed View of Lamina Plate

Fig.4 Solve the Lamina Plate

Fig.5 Solved Lamina Plate




V RESULTS AND DISCUSSION

BORON/ALUMINIUM STRESS RESULTS

The stress values of the lamina at different

boundary conditions at different orientations are shown in the Table 2.

Table.2 Stress Result of Boron/Aluminium

BOUNDARY

CONDITIONS 0° 30° 45° 60° 90°

B1 534.77 743.112 791.87 677.146 629.709

B2 11997 15188 13917 12208 11680

B3 857.55 745.174 633.13 544.495 559.941

B4 440.03

1

422.797 441.851 464.87 470.708

BORON/ALUMINIUM DISPLACEMENT RESULTS

The displacements values of the lamina at different boundary conditions at different orientations are

shown in the Table .3

Table. 3 Displacement Result of Boron/Aluminium

BOUNDARY

CONDITIONS 0° 30° 45° 60° 90°

B1 0.084049 .073604 .066993 .062143 .057395

B2 9.935 14.272 16.629 17.525 17.11

B3 .064126 .058969 .048966 .053663 .051065

B4 .020814 .019588 .017661 .015296 .012782

BORON/ALUMINIUM STRESS GRAPHS

Fig.6 Stress graph for the Boundary Condition 1

The stress values of the composite at

different orientation while considering the

boundary condition 1 is shown in figure 6. It is

observed that the while considering boundary

condition 1 stress value is maximum at the fiber orientation of 45 degree and it is very less when the

zero degree orientation is considered [8].

The stress values of the composite at different

orientation while considering the boundary

condition 2 is shown in figure 7. It is observed that

the while considering boundary condition 2 stress

value is maximum at the fiber orientation of 30 and

it is gradually decrease to 60 degree as shown

above.

Fig. 7 Stress graph for the Boundary Condition 2





condition 3 stress value is maximum at the fiber orientation of zero degree and is very low at 60 and

again increase in 90 degree orientations.

Fig. 8 Stress graph for the Boundary Condition

3

0

200

400

600

800

1000

STR

ESS

N/m

m2

B1

B1

0

5000

10000

15000

20000

0 d

egre

e

30d

egre

e

45d

egre

e

60d

egre

e

90d

egre

eSTR

ESS

N/m

m2

B2

B2

0200400600800

1000

STR

ESS

N/m

m2

B3

B3




Fig.9 Stress graph for the Boundary Condition 4





condition 4 stress value is maximum at the fiber

orientation of 90 degree and is very low at 30

degree orientation. The safe stress value is 30

degree orientation.

BORON/ALUMINIUM DISPLACEMENT

GRAPHS

Fig.10 Displacement graph for the Boundary

Condition 1

The displacement values of the composite

at different orientation while considering te



condition 1 displacement value is maximum at the

fiber orientation of 0 and is very low at 90 degrees

orientation. It is observed that the lamina which is

have 0 degree orientation have more displacement

and it able to withstand more time compared to

other orientations.


at different orientation while considering the boundary condition 2 is shown in figure 11. It is



fiber orientation of 60 degree and is very low at 0

degree orientations. It is observed that the lamina

which is have 60 degree orientation have more

displacement and it able to withstand more time

compared to other orientations.

Figure.11 Displacement graph for the Boundary

Condition 2

Fig. 12 Displacement graph for the Boundary

Condition 3






fiber orientation of zero degrees and is very low at

45 degree orientation. It is observed that the lamina

which is have zero degree orientation have more

displacement and it able to withstand more time

compared to other orientations.

380400420440460480

STR

ESS

N/m

m2

B4

B4

0

0.02

0.04

0.06

0.08

0.1

DIS

PLA

CEM

ENT

mm

B1

B1

0

5

10

15

20

DIS

PLA

CEM

ENT

mm

B2

B2

0

0.02

0.04

0.06

0.08

DIS

PLA

CEM

ENT

mm

B3

B3

00.005

0.010.015

0.020.025

DIS

PLA

CEM

ENT

mm

B4

B4




Fig.13 Displacement graph for the Boundary

Condition 4



boundary condition 4 is shown in figure 13. It is observed that the while considering boundary


fiber orientation of 0 and gradually decreased to 30

degree and in other degree orientations it is

gradually decreased as shown above. It is observed

that the lamina which is have 0 degree orientation

have more displacement and it able to withstand

more t4ime compared to other orientations.

SAFE MATERIAL TABULATION

Table. Safe Material Tabulation for

Boron/Aluminium

The analysis results are discussed below.

SAFE MATERIAL FOR BORON AND

ALUMINIUM

Fig. 14 Safe Material for Boundary Condition 1 at zero

Degree

The safe material limit while considering

boundary condition 1 at zero degree is shown in

figure 14. While all the load is applied at all the

directions equally, the material is getting weak at

the center of the lamina and also at the corner of the

lamina as shown in figure 14. The maximum stress

value obtained is 534 N/mm2.

Fig.15 Safe Materials for Boundary Condition 2

at 90 Degree


boundary condition 2 at 90 degree is shown in

figure 15. While the load is applied at only one

direction equal, the material is getting weaker at the

point of the lamina where it is fixed as shown in

figure 15. The maximum stress value obtained is

11680 N/mm2.

Fig. 16 Safe Material for Boundary Condition 3 at 60 Degree



figure 16. While the load is applied at two opposite

directions equally, the material is getting weaker at

the point of the lamina where the load is applied

and also at the center of the lamina as shown in

figure 16. The maximum stress value obtained is

544 N/mm2.




Fig. 17 Safe Material for Boundary Condition 4 at 30 Degree



figure 17. While the load is applied at all directions

equally and all degrees of freedom are constrained,

the material is getting weaker at the point of the

lamina where the load is applied as shown in figure

17. The maximum stress value obtained is 422

N/mm2.

SAFE MATERIAL FOR BORON AND

ALUMINIUM GRAPH

Fig.18 Safe Material Graph for Boundary

Condition 1 at zero Degree

The displacement value when considering

boundary condition 1 at zero degree is shown in

figure 18. From the figure it is observed that the

displacement value is maximum and it is observed

that the lamina can withstand up to stress value of

534 N/mm2.

Fig. 19 Safe Material Graph for Boundary

Condition 2 at 60 Degree



figure 19. From the figure it is observed that the displacement value is maximum at 0 degree and it

is observed that the stress value of the lamina is

reduced while the displacement is increased and it

can be seen in figure 19.





figure 20. From the figure it is observed that as the

displacement value increases it leads to reduction of

stress value. After some time the stress value

increases gradually up to particular point and then

again it decreases. Finally, when the displacement

value increases the stress value is also increased as

shown above.








figure 21. From the figure it is observed that as the

displacement value increases it leads to reduction of

stress value. After some time the stress value

increases gradually upto to particular point and then

again it decreases. Finally, when the displacement

value increases the stress value is also increased as

shown above.

VI CONCLUSION

This experimental analysis of boron/aluminium

based composites using ANSYS leads to the

following conclusions:

Modeling of the composite structure in

ANSYS is possible.

Analysis of the composite at different orientations is possible using ANSYS.

The stress and displacement curves are

obtained are analysed using ANSYS.

It is observed that the stress value is

maximum 15188 N/mm2 while considered

the boundary condition 2 at 30 degree.

Also the stress value is minimum 422

N/mm2 while considered boundary

condition 4 at 30 degree.

It is also observed that displacement value

is maximum 17.525 mm while considered boundary condition 2 at 60 degree.

From the result it is observed that

the orientation at 30 degree with boundary

condition 4 is safe while comparing other

boundary conditions. From this it is

concluded that we can use the safe

orientation for better performance. The

default orientation of material is replaced

by safe orientation are show above results

REFERENCE

[1] Ahmed Oumer and Othman Mamat, (2012) ―A study of fiber orientation in short fiber-reinforced composites with simultaneous mold filling and phase change effects‖, Composite structures, Vol.43, pp. 1087–1094,.

[2] Bernasconi, Cosmi and Hine, (2012) ―Analysis of fibre orientation distribution in short fibre reinforced polymers: A comparison between optical and tomographic methods‖, Aerospace science and technology, Vol.431, pp. 104–113,.

[3] Blanc, (2006) ―Fiber orientation measurements in composite materials‖, Composite Structures, Vol. 37, pp. 197–206

[4] Colin Eberhardt, (2015) ―Fibre-orientation measurements in short-glass-fibre composites—II:a quantitative error estimate of the 2D image analysis technique‖. International Journal of Mechanical Engineering, Vol. 4, Issue 5, pp. 9-16,

[5] Du Jun, Liu Yaohui, Yu Sirong and Dai Handa, (2003) ―Effect of fibre-orientation on friction and wear properties of Al2O3 and carbon short fibres reinforced AlSi12CuMgNi hybrid composite‖, Composite Material and Application, Vol.254, pp. 164–172,.

[6] Gregorio M. Velez-Garcia, (2012) ―Unambiguous orientation in short fiber

composites over small sampling area in a center-gated disk‖, Aerospace science and technology, Vol.431, pp. 104–113.

[7] Laspalas,(2008). ―Application of micromechanical models for elasticity and failure to short fibre reinforced composites. Numerical implementation and experimental validation‖, Vol.86, pp. 977–987

[8] Mittal and Jain,(2008). ―Effect of fiber orientation on stress concentration factor in a laminate with central circular hole under transverse static loading‖, Design and application of composite, Vol. 15, pp. 452-458.

[9] Papanicolaou, Zaoutsos and Kontou,(2004).‖Fiber orientation dependence of continuous carbon/epoxy composites

nonlinear viscoelastic behavior‖, International Journal of Advanced Mechanical Engineering, Vol 64, No 5, pp. 2535-2545.

[10] Su-Tae Kang and Jin-Keun Kim,(2014).―Measurements of Fiber orientation and elastic-modulus analysis in short-fiber-reinforced composites Composite Structures‖, Vol. 109, pp 167-199.

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