Today’s Demanding Manufacturing Environments - Management Assignment Help

Assignment Task

Outline
Today’s demanding manufacturing environments require greater amounts of data to be collected at each stage of the
process;throughthedesignphase,manufacturingandlogistics–totheproductslifecycle.Logisticoperationsintodays internationalmarketsarecomplex,andtrackingpartsisessential.Sensorsandotherdatacollectiondevicesarekeyin adaptingtoIndustry4.0requirementssetoutbymanycompanies.Thesensorcomponentsthemselvesarenotableto operateincertainharshmanufacturingenvironmentsand,therefore,requireprotectivecasestominimisedamageand maximise their uptime.
Many factors need to be considered when designing components with such complex requirements. These include; cost, design life, loads, deflections, dynamic behaviour, material etc. – all of which must be analysed to ensure the safety and reliability butalsoensure.Moreover,asthesensortechnologydrivensectorisrapidlychanging,sotooaretheneedsforthe requiredprotectiveequipment;whichhighlightstheneedtohaveeficientdesignandanalysistoolinplacetoshortenproduction times.

Objectives andSpecifications
The aim of this project is to conduct a finite element based structural analysis of a sensor cover (Figure 1) to ensure it
conformstoasetofspecifications.Thesensorcasewillhousetwoopticaldevices,thatrequiresapphirelensestoallowfor hightransmissionofawiderangeofwavelengths.Astheelectronicscontainedwithinthecaseareisolatedandsensitiveto dimensionalchange(suchasdeformations),themaximumdeformationofthecasecannotexceed1.00mmandalthougha degreeofplasticitycanbeaccepted,thefinaldeformationafterelasticrecoverycannotexceed0.2mm.Asthesapphirelens
cannotwithstandexcessivedeformationwithoutfracturing,thedeformationatthelocationwherethelensismounted(Figure
2)cannotexceed0.1mm.Therefore,somemodificationstotheinternalcasedesignandmaterialselectionwillneedtobe made. The external shape of the case must remain as-is, and no external dimensional changes are allowed. Tip: supress everythingexceptthecasebeforerunningananalysis.Wearenotconcernedaboutthesensorsthemselvesorthelenses– theyarejustthereforyourguidanceintheredesign.
The sensor cover is floor mounted, therefore, you will need to analyse for a worst-case scenario of the cover being run over by a fork-lift of other heavy loading device. The loads will be applied to the top surface only. The current design of the cover has it mounted via 4 countersunk holes at the edges. In addition, the bottom flanged surface and overlapped edge that runs around theoutsidearerestingagainstasolidrigidsurface.Basedonthisinformation,youwillneedtoset-upappropriateboundary
conditions within ANSYS and describe in your technical report how these represent the physical setup.
Figure4toFigure6providehintsonthelocationsboundaryconditions.However,youwillneedtosettheseupyourselfin ANSYS.Makesureyoudescribeeachboundaryconditionandhowitrelatestothephysicalsetupinyourreport,i.e.,why certainsettingsareusedwithineachboundarycondition.

Yourinitialanalysiswillneedtobedonewith“StructuralSteelNL”.Youwillalsoneedtoexploreatleastthree(3)different materialsintotal,i.e.,StructuralSteelNLplus2others.Asyouwillneedtoanalyseforplasticdeformations,makesureyou useNon-Linear(NL)materials.Alsodiscussthetypeofnon-linearityyouareusinginyourmodel.Asthecomponentisina
harshoperatingenvironment,youwillneedtousemetalalloys.Justifythematerialsyouareselecting,discusstheminterms oftheirproperties,cost,manufacturabilityandanythingelseyoumaydeemrelevant.
Youwillneedtoshowtheeffectofmeshsizes.Thismeansyoumustapplyatleasttwo(2)meshingtoolsofyourchoiceto improvethemeshqualityaswellasperformingameshconvergencestudythatplotsthemax.principlestressasafunction ofelementsizeinaregionofinterest.Hint:youmaylooktosimplifyyourdesigninSpaceClaim(andjustifythissimplification) andrefinethemeshincertainareasonlytocreateamoreeficientanalysis.Thisonlyneedstobedoneonthefirstmaterials, asonewouldexpectthatthemeshyouhavedefinedcanbeusedfortheproceedinganalyses.
Theloadingconditionsaresuchthatonlyaquarterportionofthecoverwouldbeloadedatonetime.Therefore,youwillneed tosplitthesurfacetoapplytheloads,Figure5.Thereare2forcesgeneratedbyavehicletyrepressingonthesurface.The
highestloadneedstobeappliedintheYdirection(3250N)andthesmallerloadintheX(1750N)direction(makesurethe loadsareinthecorrectdirection!).Becauseyouwillbelookingattheplasticdeformationsofthecover,makesureyouapply theloadoverthreesteps.Withthefirststephavingzeroloads,thesecondstepwiththeloadsapplied,andthethirdandfinal step zero loads. Use the analysis settings shown in Figure 7 . Include and describe your force convergence plot – use the lecturenotesandworkshopmaterialsasareference.

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