In the Flat Switch Project, the objective is to validate the motion of flat switch and find out the problems in the working. The switch was small in dimension and there were many joints in the mechanism so identifying which part is causing failure was critical. eBHARAT developed a 3D model with all required mechanism. Understanding about GD&T and switch working helped eBHARAT team to identify root cause for non-functioning of design. ANSYS Rigid Body Dynamics tool used along CAD tool to simulate the working of switch. Structured approach and software tool expertise helped to complete the motion simulation of the flat electric switch in very less time. Solution to problem is approved & implemented successfully.
Stepped Girder Crane
OEM of overhead crane received requirement of customized overhead beam with handling capacity of 5.8 Tones. End user of crane want to utilize the dead space between girder and roof to increase daylight of 1 m. The challenge for this design, a single girder to be design with two day-light heights. Due to requirements, the conventional design formulas were no longer valid. eBHARAT worked closely with OEM to get the solution. Based FE analysis and Design Iteration, eBHARAT suggested the design change to adopt two level of day lights. The revised design and FE results were accepted by end user. With expertise, OEM converted proposed design in reality, tested and delivered it successfully.
FE Analysis of 12 M Door Assembly
FE analysis is performed to study the effect of bolt pretension and internal pressure on door clamp assembly of spherical pressure vessel as per Section VIII,
Division 3. The clamp assembly is simulated with introducing contacts at required mating surfaces with appropriated mating conditions.
Non-linear contact behavior was the major challenge in clamp assembly analysis.
Seismic Analysis of ITER Pressurizer
Seismic analysis is performed to qualify support assembly of pressurizers as per ASME Section VIII Div II against plastic collapse and local failure.
Pressure, gravity, seismic, sloshing and wind loading are considered for analysis. For evaluation of equivalent acceleration to simulate sloshing and
wind load effect are derived as per Eurocode.
Litter Tiller is suitable for the Poultry farmers. In poultry the health of the chickens is depend on the condition of the litter/Manure which is spread below them in broiler farms. The regular tilling of the manure removes the nitrogen and improves the health of the chickens. But the efforts require for tilling manure is much high and so to reduce that efforts and save the time of the farmer we develop Litter tiller. After few trials with basic design, eBHARAT now developing dual operated, powered & manual, prototype model.
Spacerless Slew-ring Bearing
It is first product project development in alliance with SME executed successfully by eBHARAT. OEM approached for design validation and testing setup for already manufactured various range Spacerless Slew-Ring bearing. Being unique concept, which was patented later, many customers requested for design validation or testing of product for confidence building. eBHARAT performed 3D modeling, engineering, drafting and fatigue evaluation using ANSYS software. Also, eBHARAT played pivotal role for setting up testing facility, conducting test and co relating data with theoretical /CAE results. eBHARAT played facilitator role for technical writing and patent submission process.
General Fatigue Calculation of Valves
The gate valve – NPS 10” is design as per ASME B16.34, ISO 110434 and API 600. The pressure inside valve ranges from 0 MPa (0 Bar) to 3.5 MPa (35 bar). Linear structural and Fatigue calculation performed to evaluate the fatigue life. The fatigue life is evaluated using ASME Section VIII Div.2. The calculated life of gate valve main body is checked against expected design life is 2 millions.
Redesigning of 60 Tons Evener beam to 100 Tons
The evener beam is lifted by assembling D-shackle at two lifting points and rope arrangement using cranes. In simulation, effect of lifting rope and hook are represented by suitable boundary conditions. 3D brick elements are used to mesh the geometry. Static structural analysis is carried out to study deformations and Von-Mises stresses.
FE Analysis of Support of Fluid Bed Reactor
The mechanical design of supports and welds does not meet the criteria of ASME Section VIII Div.1 and Div. 2 Part 4. Therefore, the design is verified by performing FE analysis per rules of ASME Section VIII Div.2 Part 5. During first stage of analysis, local analysis is performed for supports. The regions not considered in analysis are represented using equivalent approach. The severe load combination is considered for second stage analysis i.e. sub-modelling analysis. For evaluation of design against plastic collapse, the stress linearization is performed at critical sections.
Thermal-Structural Analysis of Manifold By Nonlinear Elastic-Plastic Material model
The analysis of this component poses challenge as the complex geometry is subjected to pressure and temperature transients along with loadings due to pipes. The analysis is carried out in a step by step approach wherein first the temperature distribution is obtained from thermal transient analysis. This temperature distribution is used as thermal load in static structural analysis which is performed at critical thermal gradients. As the manifold is classified as thick cylinder according to ASME Code based on thickness to diameter ratio, elastic-plastic analysis approach is selected to qualify code requirement. Local analysis approach is used which reduces computational time drastically. Multilinear Elastic-Plastic Material Model with Kinematic Hardening is used for analysis. By the use of ANSYS Workbench, thermal-structural elastic-plastic analysis is performed to qualify a critical component with complex loading according to code ASME BPVC Section II Part B, Part D & ASME Section VIII, Division 2.
RCA of Agitator Shaft
The 50KL blending tanks are installed for mixing of products like Maaza, MMPO, etc. The agitator shaft installed in such vessel, which is driven by motor gear box arraignment, has a primary function of homogenous mixing. The agitator shaft used in the present vessels consist of 3 nos. of 3 bladed hydrofoil impeller spaced and mounted on 100NB SCH 80 pipe. We perform the failure mode analysis of agitator shaft as failures are observed during operation. The failures are mainly observed at the shaft mounting location where shaft is vertically suspended using a bolting arrangement. Also, failures are observed at the connection of upper solid shaft to lower hollow shaft. To address issues of failure, few modifications are carried in shaft mounting design. The Stud mounting arrangement is replaced by shaft groove & split washer arrangement. The detail comparative study is carried out between the original design and improved design to understand the effect of improvement and reliability of modified design.
Shipping Frame Calculation
Design from manufacturer was to be analysis for various shipping loads. Testing cases of lifting and jacking along with longitudinal and lateral loadings were analyzed. In addition to these load cases, shipping loads like roll, pitch, heave were analyzed considering gravity effect. Modifications in design were carried out based on the results, to optimize the design with respect to weight of the frame. unique design by combining two C-channels to obtain required dimensional configuration using standard components was achieved. Weight of frame was reduced considerably and the resulting frame was fit for actual physical testing.
Analyze Thermo-electric system
Thermoelectric systems are used for measurement techniques (such as thermocouples etc.), for Peltier-cooling (such as CPU-Cooling, refrigeration, temperature stabilization etc.) and direct energy conversion of heat (such as TEGs, driven by waste heat, radioactive decay, combustion etc.). Performance of T-E material mainly depends on Seeback coefficient, thermal and electric conductivities. In heating/cooling applications of TE systems, temperature control is very crucial since we need to balance Peltier and Joules effects. By varying various parameters such as thermoelectric properties, input current, convection etc. we can optimize our system very effectively using finite element package like ANSYS. eBHARAT's innovative approach towards problem coupled with engineering excellence will definitely help to solve problems in this industry.
Even though transient analysis gives accurate results, they are computationally expensive and highly non-convergent. Hence it is not always feasible to use transient analysis for large problems such as shock, seismic analysis. Time response analysis can give results in reasonable limits of the transient results in very less time as compared to transient analysis. The time advantage is even more for large problems with complicated load histories. Shock analysis for shell component is shown in figure using transient and response spectra analysis. As you can see deformation and equivalent stress obtained from response spectra differs by 0.5% and 3.5% only as compared to transient.
Seismic Qualification of Rectifier Unit
In today’s world, seismic analysis of a component or structure has gained a major importance because of the damage done by the earthquake in recent incidents. Qualifying the Rectifier unit under seismic zone 4 was a real challenge. The entire frame consisted of C or L channels and different thicknesses of sheet metals. Due to uniform thickness of the component with high thickness to length ratio, shell modeling approach was adopted. Higher order shell elements are used for meshing. In the first stage of analysis, the design shear load calculations is calculated using National Structural Code of Philippines 2010 Section 208 as the unit was going to be installed in the Philippines. Modal Analysis was performed in pre-stressed condition to check the parameter T as per the NSCP. In the second Stage 5 analysis cases were carried out separately for individual 9 load cases as covered in the NSCP code. For seismic analysis the Stress and Deflection were considered to qualify the component. Based on the results suitable modifications were suggested and the component was certified for the seismic zone 4. The FE Report prepared was well accepted and got approved by the Philippines approving body in first the attempt.
ISO tank Container
The concept design required an extensive brainstorming session along with the client to meet the design requirements of ISO standards. Preliminary calculations were performed based on which we arrived at a design, meeting all the manufacturing constraints and the standard. The design is unique in its own way compromising of all I-sections except the vertical box sections. In-depth understanding of the overall structure behavior under stringent loading and testing conditions was the key to optimize the design. Re-engineering the existing concept design to meet the ISO standard, weight requirement and client’s acceptance was crucial which we have achieved. The FE report was approved in one go by the International Approving Agency, Lloyds UK.
Threaded Connection Analysis
Performing threaded connection analysis is always a challenge. Based on the literature study, linear 3D FE analysis and theoretical calculation, a whole new 2D axisymmetric analysis methodology was developed to calculate the stress distribution and connection behavior. The methodology helping in simplified FE domain, in turns makes it possible to capture the stress distribution over the entire part. An APDL program was developed for estimation of torque based on results and shown in a graph of Torque range vs Stresses (non-linear). This approach towards the problem lead us to complete the 9 connection FE Analysis in record time. Also, the FE report was approved in first go which resulted in a new challenge to execute 21 joints with the similar design.
N/NS Stamp Analysis
Core team members of eBHARAT have personal service experience to perform calculation to meet the requirements of N and NS stamp. The vessel was analyzed for internal pressure, transient, gravity and seismic loadings. Also, challenge was to design and analyse the vessel with ASME ‘N’ code stamping. The stress intensities in each loading condition for vessel as per ASME Section III, Div. 1, NB-3200 - Design by Analysis and NF-3220 Design by Analysis for Class1 were evaluated .The mechanical design was validated for code requirements and as per customer design specification by using design by analysis approach. The RP Certification for the vessel was achieved which was a great achievement for the organization.
The need for raking machine evolved considering the problems faced while poultry farmer was raking in poultry shed. The challenges encountered during a conventional raking process is to break the thick and compact layer of the litter in a proper way, this in turn requires more operational time and efforts. So, to conquer the challenges, a concept of special purpose Power Operated Raking Machine, PakshiMitra was developed which significantly reduced the time, efforts and helped to improve an effective raking process. We achieved a revolutionary reduction in time as compared to the conventional raking process/methods. We have also filed Patent of this unique design and product.
RCA of Hydro Cyclone Leakage
A root cause analysis for an observed leakage failure of Hydro Cyclone which was optimized for weight was done. It was a problem in the realm of multi-physics including pressure-velocity variations affecting its strength. The fluid structural interaction further complicates by constraints like application in food industry, use of stainless steel and light weight design. The cause of failure was identified using one way FSI simulation. Design was verified and modified using code based design, linear structural analysis and fatigue calculation to mitigate the leakage problem. It was particularly challenging as a small change in design affects the efficiency in terms of particulate separation.
3D Modelling of Complex Assemblies
The criticality of this project was considerable as it incorporated 7 assemblies, 14 sub-assemblies and 3200 parts which needed to be modeled. The challenges involved in 3D modeling using NX 6.0 were understanding the 2D drawings thoroughly, identifying the conflicts in assemblies and sub –assemblies and delivering on time. The project was executed swiftly with our software expertise overcoming the challenges by precisely modeling and generating simplified BOM by using proper parent-child relationship. Also, we received the appreciation from the client for good understanding of the 2D drawings and by delivering on time.
Frugal Innovation - Tube Punching
The need for a punch evolved considering the problems faced while cutting slots in the aluminum window frame. The challenges encountered during conventional cutting of the slots for lock fitting were scrap generation which also caused damaging of tubes. This in turn increased the operational time. So, to conquer the challenges, a concept of special purpose tooling was developed which significantly reduced the scrap, damaging of tubes and the operation time. The tooling helped in reducing the manual efforts, eliminated the requirement of skilled labor and ease in punching the slots. We achieved a revolutionary reduction in cost to time ratio as compared to the conventional cutting process/methods. We have also applied for Patent of this design.