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Presentation on�EXPERIMENTAL AND FEA ANALYSIS OF COMPOSITE MUDGUARD WITH EXISTING 2-WHEELER MUDGUARD

By: Mr. Yashodhan.H.Awchar B150360823

Mr. Prathamesh.R.Lohakare B150361029

Mr. Rohit.S.Mali B150361037

Mr. Amit.B.Jharia B150360817

GUIDE : Prof.V.H.Waghmare

SMT.KASHIBAI NAVALE COLLEGE OF ENGINEERING

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OVERVIEW

ABSTRACT
INTRODUCTION
RESEARCH & LITRATURE SURVEY
PROBLEM STATEMENT
OBJECTIVES & LEARNING GOALS
WORK METHODOLOGY
DESIGN
DRAFTING
FINITE ELEMENT ANALYSIS
MATERIAL PROPERTIES
BOUNDARY CONDITION OF 2 WHEELER MUDGUARD
PROPOSED OUTCOME
REFERENCES

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ABSTRACT

Two wheelers are becoming increasingly popular in India. Competition in this segment has made the product developers to develop the vehicles with short time without compromising durability.
Vibration Analysis is an advanced technique to evaluate the life of components undergoing vibration, thereby the drastic reduction in durability evaluation time.
Modal analysis using Finite Element Analysis Method (FEA) is used to ensure the durability in design stage itself. Various customer usage modes of the vehicle are considered.
In this project conventional front mudguard of Royal Enfield Classic 500 was taken for FEA and experimental purpose. Static analysis will be performed for understand exist mudguard strength.
In this project front mudguard was replace with glass fiber for improve the static and vibration characteristic of front fender. static and modal analysis of glass fiber mudguard will be perform using ANSYS 19 software.
Experimental validation of mudguard will be completed using FFT and impact hammer test.

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INTRODUCTION

The automotive industry is poised to make the lightweight designs to get the cost and weight benefit along with customer delight. So main emphasis is given on the thickness reduction of frame/body panels and use of alternative materials.
The use of simulation software in metal forming process has increased significantly in recent years as the benefit of troubleshooting and optimizing process on the computer rather than through extensive shop floor trials have been realized.
The rapid development of software technology, together with faster and lower cost computer hardware, have recently enabled many manufacturing operations to be modeled cost-effectively that only a few years ago would have been considered impractical.

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RESEARCH & LITRATURE SURVEY

TOPIC NAME	AUTHOR NAME	DESCRIPTION
[1]" Simulation Analysis of Dynamic Dent Resistance On Auto Body Panel."	S.M.Chavan, Dr.R.B.Hiremath	In automotive industry there is increasing demand for higher quality exterior panels. Better functional properties and lower weight. The demand for weight reduction has led to thinner sheets, greater use of high strength steels and a change from steel to aluminum grades.
[2]" FEA of Superplastically formed Front Fender Car Panel ."	by Pankaj K. Bhoyar, C.M. Sedani , Monika S. Agrawal	Super plastic forming (SPF) is a near net-shape forming process which offers many advantages over conventional forming operations including low forming pressure under low flow stress, low die cost, more design flexibility, and the ability to shape hard metals to form complex shapes.

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[3]"Structural optimization with CADO method for a three-dimensional sheet-metal vehicle body."	Mehmet C¸alis¸ kan, Vahdet Uc	The aim of this study is to increase power/weight ratio of a steel-alloyed vehicle body without any structural weakness and to use an integrated engineering solution of ‘‘computer-aided design, engineering and optimization (CADO)’’.
[4]"Energy assessment and optimization of perforated metal sheet double skin through Design Builder; a case study in Spain	Jesús M. Blanco, Aiert Buruaga, Eduardo Rojí, Jesús Cuadrado, Belinda Pelaz	Double-skin perforated sheet fac¸ ades, are enclosures composed of a perforated metallic sheet, air chamber and carbon, is showing an increasing tendency in modern building design.
[5]"Design and Fabrication of Two-Wheeler Mudguard using Sisal Natural Fiber."		In the current scenario automobile industries focuses on enhancing the strength and reducing the weight of body parts. In two wheelers mudguard is provided to prevent the dirt’s and sand particles in tire from entering and damaging other parts.

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PROBLEM STATEMENT

Two-wheeler mudguards are subjected to harmonic and random vibration due to various road conditions. They undergo structural failures due to vibration excitations.
So we need to increase the natural frequency of the mudguard to increase the stiffness of component.

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OBJECTIVES

To enhance dynamic characteristics of existing mudguard by composite reinforcement.
To develop optimized Royal Enfield Classic 500 front mudguard by using glass fiber composite material
To perform modal analysis of existing Royal Enfield Classic 500 front mudguard and composite front mudguard.
To perform experimental testing of existing Royal Enfield Classic 500 front mudguard and composite front mudguard using FFT analyzer and impact hammer.
To validate results and propose further future scope.

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WORK METHODOLOGY

purchase of existing two wheeler mudguard

Making of 3D model of existing Mudguard

FEA and modal analysis of existing

model

Manufacturing of Epoxy Carbon mudguard

Manufacturing Process used for project was hand lay -up method

Experimental testing will be perform on both mudguard using FFT and Impact hammer test

FLOW OF PROJECT

Find the literature survey, problem statement and objective of our project

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FINITE ELEMENT ANALYSIS

User interface of ANSYS software

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MATERIAL PROPERTIES �(OF EXISTING MUDGAURD)

Meshing and details

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BOUNDARY CONDITION OF 2 WHEELER MUDGUARD

Mode shape 1

Mode shape 5

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MATERIAL PROPERTIES�(OF E-EPOXY GLASS)

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BOUNDARY CONDITION OF COMPOSITE MUDGUARD �(E-EPOXY GLASS)

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RESULT

STRUCTURAL STEEL

E-EPOXY GLASS

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CONCLUSION

From above graph it is clear that Natural frequency is higher at initial model for Epoxy mudguard and slightly less at higher order frequencies.
The Natural Frequencies obtained in the Analysis & Testing results are almost same so, the validation of the result is done.
Steel Mudguard has mass of 1.45 kg and Epoxy glass fibre Mudguard mass is 0.25 kg.,
Hence 82 % reduction in mass is achieved which finally helps in increasing mechanical efficiency of vehicle as its controlled by mass of components.
Due to use of Epoxy glass fibre material natural frequency increase than existing Royal Enfield Classic 500 front mudguard. so it conclude that epoxy glass fiber material is most suitable for replacing existing front mudguard of Royal Enfield Classic 500

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REFERENCES

1]" Simulation Analysis of Dynamic Dent Resistance On Auto Body Panel." by S.M.Chavan, Dr.R.B.Hiremath

2]" FEA of Superplastically formed Front Fender Car Panel." by Pankaj K. Bhoyar, C.M. Sedani, Monika S. Agrawal

3]"Structural optimization with CADO method for a three-dimensional sheet-metal vehicle body." by Mehmet C¸alis¸ kan, Vahdet Uc

4]"Energy assessment and optimization of perforated metal sheet double skin through Design Builder; a case study in Spain by Jesús M. Blanco, Aiert Buruaga, Eduardo Rojí, Jesús Cuadrado, Belinda Pelaz

5]"Design and Fabrication of Two-Wheeler Mudguard using Sisal Natural Fiber." by Baskaran, Justin Dhiraviyam., Sathish.K