Finite Element Analysis of thermal fatigue loading of Nanomaterials coated turbine blade for Critical Applications
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Turbine blades when operated at high temperatures for a high number of cycles succumb to wear and tear and collapse before fulfilling their lifecycle
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To overcome this problem, Thermal Barrier Coating (TBC) is applied over the turbine
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The TBC coating has 3 layers- Top Coat (Ceramic), Thermally Grown Oxide Layer, and Bond Coat followed by the substrate material (Turbine blade)
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The traditional TBC has its limitations and lets heat flow to the substrate material causing damage
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This was confirmed by Finite Element Method by Solid Modelling the entire setup and computing the interfacial temperatures and residual stress on ABAQUS
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The entire process was repeated by replacing the traditional Top Coat with a Top Coat of Nano-material properties and performing FEA
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It was concluded that the Nano-material property TBC is more efficient than the traditional TBC in keeping large portion of heat from dissipating to the substrate material
Fig.1 Schematic of the setup
Fig.2 Cyclic loading schematic
Fig.3 Contour produced on ABAQUS
Design of shaft and ball bearings
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The following problem statement is given to design a chop saw shaft with loads being applied to it at the locations as shown
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For the given problem, Bending Moment, Torque, Shaft diameter, Maximum deflection, and Critical speed of the shaft are to be analytically calculated
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The material of the shaft was chosen to be Alloy Steel EN4140 which is widely used for Shafts in Automotive industry
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PHP 6SPZ125TB type pulley is chosen
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A 1.5 HP motor that will drive the pulley is chosen which furthermore drives the shaft. This assumption is based on the various forums and websites that use a motor for a saw that requires an rpm between the range of 2500-400.
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A square key was selected as they are preferred up to a shaft diameter of 6 1⁄2”. The key material is selected same as that of the shaft as it prevents key failures. The dimensions of the key-seat were determined by using ASME B17.1-1967 code on “KEYS AND KEYSEATS”
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Free body diagrams were plotted giving a clear and concise idea about the problem leading to the Shear force and bending moment diagrams
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Calculations were made to simplify the Force components to Horizontal and Vertical components
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Maximum shear stress theory is used to calculate the maximum Torque and thus the diameter
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Von Mises stress is applied to calculate the diameter for fluctuating stresses and fatigue
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From the two values obtained for diameters, the largest value of diameter is taken into consideration
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Using Dunkley's equation, maximum deflection and critical speed of the shaft is analyzed analytically
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CAD model of the setup is prepared on SolidWorks and simulated on Ansys for finding the stress, strain and deflection to verify the analytical result through Simulation
Fig.1 Schematic of the setup
