EGH414 - Simple Crank Problem - Engineering Assignment Help

Assignment Task

Problem Statement
This submission requires you to develop, verify and validate a FEA model against both analytical and experimental data. This task will require you to demonstrate that an FEA model in ANSYSAPDL is a valid representation of the real system and analyse that components are “fit-for-purpose”.
This task requires you to analyse a simplified version of a bicycle crank which is stylised in Figure 1. The crank has been manufactured from 6000 series aluminium alloy with the following properties: E = 70 GPa, v = 0.3, ultimate tensile strength of 280 MPa, and a yield stress of 140 MPa.The dimensions for the crank are outlined in Figure 2, The bolt is 12.48 mm in diameter and made from steel with the properties: E = 200 GPa, v = 0.33.

Figure 1: Schematic of Crank and Strain Gauge Layout

Assignment Tasks:
For this assignment, you must:
1. Experimental:You will need to carefully watch the demonstration of the experiment using the apparatus which would normally be undertaken in your workshop. The results of this experiment are given in the Experimental section. This will give you information for your validation step.
a. The strain rosette results need to be converted into an appropriate form for comparison with analytical and FEA model results.
2. Analytical: Produce an analytical solution for the model. This includes:
a. Develop appropriate load diagrams
b. Determine the stresses/strains at points coincident with the strain rosettes in the experimental apparatus.
3. FEA Model: Develop a model of the bike crank in ANSYS APDL. You must:
a. Submit a working APDL simulation file with appropriate boundary conditions, element choice and mesh.
b. Justify your boundary conditions, element choice and meshing approach in your report.
4. Model Verification/Validation: Compare your APDL model to your calculated and experimental models by:
a. Perform a convergence study, or studies on your model. These must be performed at appropriate points on the model and use appropriate convergence metrics/criteria. Discuss (comment on and justify any differences between the results of the models).
b. Compare your FEA Model to analytical and experimental data using appropriate metrics.
c. Discuss the Verification and Validation of your model
i. Does the model behave how we expect it to?
ii. Is your FEA Model an appropriate representation of the real system?
iii. Are there any areas of your model which do not represent the behaviour of the real system? Identify them and comment on their effect on the usefulness of your model.
5. Fit-for-Purpose: What is the current safety factor of the crank?
a. The crank should be designed with a safety factor of 4 under a load of 50 kg.  What changes would you make to the design of the crank to achieve this?
b. Confirm that your updated design satisfies a safety factor of 4 using your FEA model and appropriately show the results. 
Submission
Your submission should take the form of a report.
• You should include all the basic elements of a report.
• A page limit is set at 15 pages (this is more than sufficient to complete the assignment).
• Ensure you appropriately explain the problem/focus of the report.  Ensure you justify and explain all modelling decisions.  Ensure your report is well written and concise.

Your submission should consist of a .PDF file of your report and a .APDL file containing your simulation.
• Your report file must be labelled as follows: PartB_<student number>.PDF.  For example, if your student number is n9111111, label your file PartB_n9111111.PDF.
• Your simulation file must be labelled as follows: PartB_<student number>.APDL.  For example, if your student number is n9111111, label your file PartB_n9111111.APDL.
• You may draw your geometry in Solidworks (or other software).  If you do so, you must attach your geometry file with the naming convention PartB_<student number>.<file extension>.  Your simulation file should have the relevant commands to import the geometry file.

In your PDF submission:
• Include response to the assignment tasks.
• Ensure the tasks are complete in order and each task is clearly identified.
• Ensure any mathematical working is sufficiently explained (equations and working can be included as an appendix).
• Ensure all diagrams are labels and referred to in text.
• Ensure all screenshots are labelled and referred to in text.
• All parts of the submission must be neat and legible.
• Ensure your name and student number is clearly identified on your submission.

Group submissions:
• If you are submitting as a group, only one member should submit the assignment.
• In you file labelling, use the student number of the group member who will submit the assignment.
• Ensure the names and student numbers are clearly identified on your submission.

If you are unable to submit correctly, email a copy of your assignment (all files) to s2.bell@qut.edu.au before the due date. 
Experimental
Procedure: 
1. Remove the weight from the crank and place on the shelf of the trolley (do not remove the wire from the bolt).
2. Clamp the crank at an appropriate orientation to represent the critical case.
3. Carefully record the orientation of the gauges on each rosette and their values in the unloaded condition.Transience due to noise in the instrument of around 5 - 10 is acceptable.
4. Carefully hang the weight from the bolt ensuring that the hanging wire is snug against the bolt head (i.e. 60mm from the crank).
5. Once the load has reached stability, record the values off the software for each channel of the strain gauge. These values are set to strain (mm/mm).
6. Remove the weight from the crank and place on the shelf of the trolley.
Note: if the software throws and error, accept and restart the program. A black arrow in the top right hand corner means that the program in running.
 

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