THERMAL ANALYSIS OF AL6063 & WITH

VARIOUS COMPOSITIONS
PROJECT REPORT 2017-2018
Submitted by
(Team name)

COLLEGE LOGO

Guided by:

Submitted in partial fulfillment of the

requirement for the
Award of engineering in
-----------------------------------------
By the State Board of Technical Education
Government of
Tamilnadu, Chennai.
DEPARTMENT:
COLLEGE NAME:
PLACE:
 COLLEGE NAME

PLACE

DEPARTMENT

PROJECT REPORT-2017-2018

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No. ------------ Of VI Semester

class of this college.

Guide Head of the Department

Submitted for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,

TamilNadu.On -------------- (date) held at the ------------

(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED
PARENTS
 ACKNOWLEDGEMENT

At this pleasing movement of having successfully

completed our project, we wish to convey our sincere thanks
and gratitude to the management of our college and our
beloved chairman------------------------.who provided all the
facilities to us.

We would like to express our sincere thanks to our

principal ------------------for forwarding us to do our project and
offering adequate duration in completing our project.

We are also grateful to the Head of Department

prof., for her/him constructive suggestions
&encouragement during our project.

With deep sense of gratitude, we extend our earnest

&sincere thanks to our guide --------------------, Department of
Mechanical for her/him kind guidance and encouragement
during this project we also express our indebt thanks to our
TEACHING staff of MECHANICAL ENGINEERING DEPARTMENT,
---------- (college Name).
ANALYSIS OF BIKE CLUTCH LEVER
 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
1 INTRODUCTION
2 PRO-E INTRODUCTION AND MODELING
3 ANSYS AND ANALYSIS PROCEDURE
4 MATERIAL PROPERTIES
5 RESULTS
6 CONCLUSION
REFERENCE
 SYNOPSIS

This project deals with design and analysis of clutch lever. The

model of the lever is designed using SolidWorks, and the systematic

analysis of the designed model is done using ANSYS software.

The model selected is clutch lever. The lever that is used is

made of aluminium alloy. As the aluminium has low strength, the

failure due to impact is high. The model is analyzed and the results

are obtained. The material optimization is done. Then the model is

analyzed for the deflection, max stress induced and strain for all the

above materials under same load.

 CHAPTER-I

A clutch is a mechanical device which engages and disengages

power transmission especially from driving shaft to driven shaft.

In the simplest application, clutches connect and disconnect two

rotating shafts (drive shafts or line shafts). In these devices, one shaft

is typically attached to an engine or other power unit (the driving

member) while the other shaft (the driven member) provides output

power for work. While typically the motions involved are rotary, linear

clutches are also possible.

In a torque-controlled drill, for instance, one shaft is driven by a

motor and the other drives a drill chuck. The clutch connects the two

shafts so they may be locked together and spin at the same speed

(engaged), locked together but spinning at different speeds (slipping),

or unlocked and spinning at different speeds (disengaged).

The lever of the clutch in two wheelers fail during impacts

during accidents. The aluminium alloy used has low strength. For

racing in track vehicles need to improve these parts to attain strength.

Here we analyse the model with existing material and then we

find a better material to improve the model.

 Initially the model is designed in solidworks software then it is

converted into IGES (International Graphic Exchange System) file.

The IGES file is opened in a ANSYS software and make the required

analysis.
 CHAPTER-II

SolidWorks (stylized as SOLIDWORKS), is a solid

modeling computer-aided design (CAD) and computer-aided
engineering(CAE) computer program that runs on Microsoft Windows.
SolidWorks is published by Dassault Systmes.

According to the publisher, over 2 million engineers and designers at more

than 165,000 companies used SolidWorks as of 2013. Also according to the
company, fiscal year 201112 revenue for SolidWorks totalled $483 million.

SolidWorks Corporation was founded in December 1993 by Massachusetts

Institute of Technology graduate Jon Hirschtick. Hirschtick used $1 million
he had made while a member of the MIT Blackjack Team to set up the
company.[4] Initially based in Waltham, Massachusetts, USA, Hirschtick
recruited a team of engineers with the goal of building 3D CAD software
that was easy-to-use, affordable, and available on the Windows desktop.
Operating later from Concord, Massachusetts, SolidWorks released its first
product SolidWorks 95, in 1995.[5][6] In 1997 Dassault, best known for
its CATIA CAD software, acquired SolidWorks for $310 million in stock.[5]

SolidWorks currently markets several versions of the SolidWorks CAD

software in addition to eDrawings, a collaboration tool, and DraftSight, a 2D
CAD product.

SolidWorks was headed by John McEleney from 2001 to July 2007 and Jeff
Ray from 2007 to January 2011. The current CEO is Gian Paolo Bassi from
Jan 2015. Gian Paolo Bassi replaces Bertrand Sicot, who is promoted Vice
President Sales of Dassault Systmes Value Solutions sales channel.
 SolidWorks is a solid modeler, and utilizes a parametric feature-
based approach to create models and assemblies. The software is written
on Parasolid-kernel.

Parameters refer to constraints whose values determine the shape or

geometry of the model or assembly. Parameters can be either numeric
parameters, such as line lengths or circle diameters, or geometric parameters,
such as tangent, parallel, concentric, horizontal or vertical, etc. Numeric
parameters can be associated with each other through the use of relations,
which allows them to capture design intent.

Design intent is how the creator of the part wants it to respond to changes
and updates. For example, you would want the hole at the top of a beverage
can to stay at the top surface, regardless of the height or size of the can.
SolidWorks allows the user to specify that the hole is a feature on the top
surface, and will then honor their design intent no matter what height they
later assign to the can.

Features refer to the building blocks of the part. They are the shapes and
operations that construct the part. Shape-based features typically begin with
a 2D or 3D sketch of shapes such as bosses, holes, slots, etc. This shape is
then extruded or cut to add or remove material from the part. Operation-
based features are not sketch-based, and include features such as fillets,
chamfers, shells, applying draft to the faces of a part, etc.
MODELING THE CLUTCH LEVER

CREATE THE WORKING DIRECTORY-First create the working

directory to save the all model in one folder

File set working directory select the required folder ok.

SKETCH- This command is used to create the new sketch like circle,

line, rectangle, ellipse, etc,..

The pro-e window select the sketch icon and select the plane or

surface want to sketch.

CIRCLE- This command is used to create the circle. Create circle by

picking the center point and a point on the circle from Right Tool

chest.

Pick the origin for the circles center - pick a point on the circles

edge- click the middle mouse button ok

ELLIPSE- This command is used to create the ellipse. Create ellipse

by picking the center point and a minor radius point and major radius
point, the minor and major radius of the ellipse is vertical and

horizontal direction depend upon the shape of ellipse we want.

Select the ellipse icon from right toolchest- Pick the center for

the ellipse pick the minor radius of ellipse point and pick the major

radius of the ellipse- click the middle mouse button ok

LINE- This command is used to create the line. Create the line by

start point and end point.

Select the line icon from the right Toolchest click the start point of

the line click the end point of the circle enter

ARC- This command is used to create the arc. Create the arc by

using three points. The three points are start point, end point and

center point of the arc.

Select the arc icon from the right Toolchest click the start point of

the arc click the end point of the arc and click the middle point of

the arc enter.

 The dimension of the arc is modified by double click on the arc

then the dimension will appear in the pop up box, then provide the

value of the arc.

CREATE THE HEXAGON The hexagon is created by insert foreign

data icon in the Right Toolchest.

Insert foreign data from Palette into active object - scroll down

to see the hexagon - double-click hexagon- Place the hexagon on

the sketch by picking a position - with the left mouse button, drag and

drop the center of the hexagon at the origin - modify Scale value to

the required size click enter

RECTANGLE- This command is used to create the rectangle and

square.

Click the rectangle icon in the right Toolchest click the lower

left point of the rectangle and higher right corner of the rectangle we

want to draw.
 After drawing the rectangle the dimension of the rectangle is

provided by the pick the dimension command from the dimension

icon in the right toolchest of the pro-e software.

DIMENSION- This command is used to provide the dimension of the

sketched entities the entities may be circle, line, rectangle, ellipse,

etc,..

The dimension is provide to the sketch by select the dimension

icon from the right tool chest then select the sketched entities and

press the middle mouse button to finish the dimensioning.

To change the dimension of the sketched entities by just double

click the dimension line of created sketch.

EXTRUDE This command is used to create the material (to make

3D object from 2D sketch) from the sketched entities. The entities

may be circle, line or rectangle, etc,...

 Select the extrude icon from the right toolchest then select the

sketched part in the window, enter the extrude length and press the

middle mouse button to finish the extrude command.

REVOLVE- This command is used to create the material from taking

the one axis and sketched entities. The axis is the center of the

revolved part. The revolve angle should between 0 degree to 360

degree.

Select the revolve icon from the right toolchest then select the

sketched part and axis of the object in the graphical window, enter the

revolve angle and press the middle mouse button to finish the extrude

command.

SWEEP FEATURES

The Sweep option extrudes a section along a defined trajectory.

The order of operation is to first create a trajectory and then a

section. A trajectory is a path along which a section is swept. The

trajectory for a sweep feature can be sketched or selected. The

Sweep option of protrusion is similar to the Extrude option. The only

difference is that in the case of the Extrude option, the feature is

extruded in a direction normal to the sketching plane, but in the case

of the Sweep option, the section is swept along the sketched or

selected trajectory. The trajectory can be open or closed. Normal

sketching tools are used for sketching the trajectory. The cross-

section of the swept feature remains constant throughout the sweep.

SWEEP CUT

To create a Sweep Cut feature, the procedure to be followed is

the same as that in Sweep Protrusion. The only difference is that in

case of cut features, the material is removed from an existing feature.

The Cut option can be invoked by choosing Insert > Sweep >

Cut from the menu bar. A cut can be a solid swept cut or a thin

swept cut.
 CHAPTER-III

ANSYS

ANSYS is an engineering simulation software provider founded

by software engineer John Swanson. It develops general-purpose

finite element analysis and computational fluid dynamics software.

While ANSYS has developed a range of computer-aided engineering

(CAE) products, it is perhaps best known for its ANSYS Mechanical

and ANSYS Multiphysics products.

ANSYS Mechanical and ANSYS Multiphysics software are non

exportable analysis tools incorporating pre-processing (geometry

creation, meshing), solver and post-processing modules in a

graphical user interface. These are general-purpose finite element

modeling packages for numerically solving mechanical problems,

including static/dynamic structural analysis (both linear and non-

linear), heat transfer and fluid problems, as well as acoustic and

electro-magnetic problems.

ANSYS Mechanical technology incorporates both structural and

material non-linearities. ANSYS Multiphysics software includes

solvers for thermal, structural, CFD, electromagnetics, and acoustics

and can sometimes couple these separate physics together in order

to address multidisciplinary applications. ANSYS software can also

be used in civil engineering, electrical engineering, physics and

chemistry.

ANSYS, Inc. acquired the CFX computational fluid dynamics

code in 2003 and Fluent, Inc. in 2006. The CFD packages from

ANSYS are used for engineering simulations. In 2008, ANSYS

acquired Ansoft Corporation, a leading developer of high-

performance electronic design automation (EDA) software, and

added a suite of products designed to simulate high-performance

electronics designs found in mobile communication and Internet

devices, broadband networking components and systems, integrated

circuits, printed circuit boards, and electromechanical systems. The

acquisition allowed ANSYS to address the continuing convergence of

the mechanical and electrical worlds across a whole range of industry

sectors.
 ANALYZING PROCEDURE

ANALYZING THE CLUTCH LEVER STEP BY STEP

PROCEDURE

The 3D model of the LEVER 3D model is converted as iges

format through the solidworks software

The IGES (Initial Graphics Exchange Specification) format is

suitable to import in the ANSYS Workbench for analyzing

open the ANSYS workbench

Create static structural analysis

Import the required materials in engineering data tab

Create new geometry

File import external geometry file generate

Close the window

setup mesh

Defaults physical preference mechanical

Advanced relevance center fine

 Right click the mesh in tree view generate mesh

Select the all solid in geometry tree

Select material choose aluminium alloy

Solution

Static structural right click insert fixed support

Choose the required face

Geometry apply

Static structural insert force select the Geometry apply

Magnitude 1000 N

Solution insert the total deformation, directional deformation,

equivalent elastic strain, equivalent stress, strain.

Right click the solution icon in the tree solve

After solve the analysis take the reading of above mentioned

items (i.e. total deformation, directional deformation, etc,)

The all results are taken in a picture and save it to the

required folder in the system

GEOMENTRY OF CLUTCH LEVER IN ANSYS

WORKBENCH
MESH OF LEAF SPRING IN ANSYS WORKBENCH
BOUNDARY CONDITIONS OF LEAF SPRING IN ANSYS

WORKBENCH

CHAPTER-V
 MATERIAL PROPERTIES

ALUMINIUM ALLOY:

PROPERTIES VALUES

DENSITY (Kg/m3) 2770

YOUNGS MODULOUS (MPa) 7.1 E4

POISSIONS RATIO 0.33

THERMAL CONDUCTIVITY (W/mC) 175

 CHAPTER-VI

RESULTS
FORCE APPLY ON THE CLUTCH LEVER IS 1000N

RESULTS FOR ALUMINIUM

TOTAL DEFORMATION
EQUIVALENT ELASTIC STRAIN
EQUIVALENT STRESS