Mechanical Strength of Mild Steel

Mechanical Strength of Mild Steel aditCE 2.1 One day on National Geographic melodic phrase I was watching a program in which they were experimenting with the finite section analysis softwargon to observe structure and thermal load personal effects on the wing of Boeing 747s wing. Luckily, during the same time, in my 8th semester back in 2013 we were taught the introduction to limited subdivision Methods by our professor, Dr. Ijaz Ahmed Chaudhary in University of Engineering and Technology, Lahore. The specialness in that subject laid the initial foundations of my inte equalisering project named as Drop Test Calculations for Mild Steel where I run awayed as a Team Leader. This experience paved my way to two more leaders roles.BackgroundCE 2.2 It was almost four years in UET Lahore. And macrocosm a student of engineering I almost had the fundamental noesis of the field by that point. I wanted to lend unityself my theoretical experience in some practical way. I had already st udied the chemical mechanism of visibles 1 and 2. And performed various experiments in lab to find out the material properties such as ductility, malleability, brittleness and toughness. In 8th semester ANSYS was being utilise as external load analysis softw ar in Finite Element Analysis course. I was assigned a project to set apart a topic and perform it in the lab and as closely as analyze it using ANSYS. That was a good opportunity to tally practical experience and integrate the knowledge of Mechanics of Materials and Finite Element Analysis.Nature of ProjectCE 2.3 This project included the tally for unload mental testing of mild steel. In industry and real world contrastive keepsakes and object face different kind of environmental conditions. Drop testing was employ for electrical shock loading effects. First of all, theoretical modeling was through with(p) for sack add-in to check either items stack survive shock or not. Then commercial finite element softw be was employ to investigate the response of pearl get across.Objective of the ProjectCE 2.4 The butt of the report was to determine mechanical strength of mild steel. I had to use brush aside testing method therefore I investigated its behavior on finite element software.Nature of My Particular Work AreaCE 2.5 In this project, I had to perform calculations for upchuck table by taking it as a fixed beam at both ends and applying a sinusoidal shock load of deoxycytidine monophosphate gram. Then calculations were made to bode the uttermost binding straining produced in drop table.CE 2.6 organisational StructureCE 2.7 Statement of DutiesBeing leader of the group my cathode-ray oscilloscope of duties includedTo plan the project for well-timed(a) completion.To clear up work packs to chink health and safety.Conduct meeting with members and supervisor for mutual feedback.Theoretical calculation of drop test mechanism on mild steel.Report piece of writing and technical prese ntation.Personal Engineering ActivityCE 2.8 I started with lit review about drop testing and FEA on internet and library. ulterior discussions with my professor led me up to kick off my calculations. The second clapperclaw of course was to select certain parameters and their dimensions for drop testing. These parameters are given in the table below.The drop table material and the shock load survey was assigned to us by our professor. I chose the dimensions of the table and mass of test item carefully. If the mass of the table is too slight it wont be able to bear the shock itself let alone the test item. To make things more clear, test item is always on the top of table when shock is being applied on it.Now the next clapperclaw was to front the weight of the table.Table thickness = d = 0.0125mTable length = l = 0.3mTable comprehensiveness = b = 0.3mWeight of the table =W1 = density * volume*gW1 = 86.75 NWeight of the test item = W2= 20KG = 196 NTotal Weight = W = W1+W2 = 282. 75 N scrap of Inertia = I = 4.88 * 10-8 m-4The rest of the calculations are shown belowTo calculate shock factor, F, I needed to calculate . dishonour duration, , is 0.01 s and the natural time period, , is given as belowWhere ,, is the placid deflection and is calculated as followsWhere,W = Weight per unit length, N/m = E = Youngs modulus of Elasticity of Mild Steel = 210 x 109 N/m2So, after substituting the values in the above equationHence,As a result,CE 2.9 By using the graph below in encipher 1, we deduce that F factor comes out to be 1.2. witness 1 Calculation of Factor FMoreover, some of the basic calculations are done belowDynamic load is calculated as Pd = F * M * AA= Applied Shock = 100gM= Total Weight/gravitational force (g)Therefore ,Pd = 33930 NewtonNow, I have to calculate maximum bending stressMax Bending Stress =(Bending Moment * Distance from axis)/ InertiaMax Bending Stress = 48.88 MPaI support the bending moment calculations as they were performed by my team mate and it is beyond the scope of this report to discuss it fully here.CE 2.9 According to the formula of mechanics, if the maximum bending stress produced by the applied load is less than the crowning(prenominal) tensile strength of the material then the material can withstand the applied load without harm and vice versa. In this encase, since the ultimate tensile strength of mild steel is 165 MPa which is greater than the maximum bending stress of 48.88 MPa produced by the applied load, drop table go out easily sustain the 100 g shock loading.CE 2.10 computational dynamics came into play in the form of FEA as I used ANSYS to simulate static deflection of the drop table subjected to 100 g shock loading. The load is applied on the top surface of drop table in form of pres positive(predicate) and both ends of the table are fixed by using fixed support. Material properties used for the drop table are shown in the bet 2 below.Figure 2 Material properties of the test pieceCE 2.11 I still echo that there came a point where my team was very much unhappy out because of the criticality of the extensive calculations involved. In fact, my team failed in orthodontic braces of iterative processes and they wanted to give up on this project. I summoned a meeting where I emphasized on the fact that all failure is itself a step towards success. By omitting those factors which are causing us letdown should be identified and removed. My team appreciated the gesture and went on to get along the project with more enthusiasm and that is when we finally got the 3D mesh of the work piece as shown below in variant 3Figure 3 3D meshing of the drop tableThe parameters for meshing exposit are show in figure 4 below.Figure 4 Meshing parameters obtained during FEACE 2.11 After the meshing, the sinusoidal shock load of 100 g, shown in figure below, depicts that the maximum Von Mises stress produced in drop table amounts to be 50.23 MPa. Our theoretical calculated maximum str ess comes out to be 48.88 MPa. Again, I can surely say that this stress is within the supportable load limits of the table load and hence wont fracture. The stress patterns are shown in figure 5 below.Figure 5 Static structural analysis of drop tableCE 2.12 Mild steel is a very stiff material so a very high-pitched shock wave is generated when drop table hits the mild steel. On the new(prenominal) hand, due to its stiffness the duration of the shock is very low. In case of mild steel peak shock value calculated was 55.84 g when a drop table is dropped from a height of 330 m. Below figure 6 depicts this behavior in the form of a graph.Figure 6 Shock loading VS Time GraphCE 2.13 Von Mises stress contours produced when drop table strikes with mild steel attached sensors are shown in the figure below. Stress contours clearly shows that high stresses are produced in region where drop table makes contact with the object. Highest stress produced is 49.9 MPa as shown in figure 7.Figure7 Von Mises stress contours produced in case of mild steel programmers contactCE 2.14 As we had to use Lab with heavy machinery and metal pieces, I made sure that every used proper safety procedure such as wearing PPE. Toolbox talks and near miss discussions were conducted before every session. That was the reason project was completed without any accidents.SummaryCE 2.15 The timely completion of this project boosted up my technical knowledge and had an ever unyielding impact on my people and time management skills. Later on, during one of my internships I realized that my quality check department was facing a material failure issue. Keeping in view this project I performed the drop testing and deduced that the material wasnt strong enough to resist the stresses and buckled in extreme loading conditions. My study was well praised and they switched from Steel to Aluminum and since then have got fewer failures.