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Simulation of Flange Modeling by Using Finite
Element Method
K. Shahril, Khairulanwar bin Haris, K. Akmal, M. Sabri, and M. Amzari.
Mechanical Section, Universiti Kuala Lumpur-Malaysian Spanish
Institute,
Kulim Hi-Tech Park, 09000 Kulim, Kedah, Malaysia.
khairuls@unikl.edu.my, khairulakmal@unikl.edu.my, msabri@unikl.edu.my, megatamzari@unikl.edu.my
Abstract — This project focuses on studying the existing
off road buggy component which is flange. The study
includes modeling the flange using solid model as
references to an existing part used for off road buggy
using CATIA software. Stress analysis was conducted
using finite element method in ABAQUS Software.
Performance of proposed design was compared from the
existing part of the flange. A buggy is an automobile
with wheels that project beyond the vehicle body. In
European country, a dune buggy is a recreational vehicle
with large wheels and wide tires, designed for use on
sand dunes or beaches. From the result in running the
first analysis of the design datum analysis found that the
von misses stress had maximum values compared with
new design of flange.
Keywords — Buggy, Stress, Flange, Coordinate
Measurement Machine.
I. INTRODUCTION
This project focuses on studying the existing off road
buggy component which is flanged. Flanged or also
known as Spacer Flanged is a major component for
connect between hubs and wheel. The study includes
modeling the flanged using solid model as references to
an existing part used for off road buggy using CATIA
software. Stress analysis will be conduct using finite
element solver in CATIA or other finite element software
(ANSYS). This analysis is used to determine critical area
of stress distribution on the flanged. The new model
design should have an improvement in term of stress
distribution. The existing flange that installed to the
buggy car is solid surface type. The material of this solid
surface type is carbon steel. For the beginning, the
analysis will be done on the existing component. This
will determine the critical area of stress distribution area
that is needed to be improved.
Load distribution occurs when apply load at the
structure and will influence the dynamic balance of the
vehicle. The good design will increase the toughness of
the flange. The maximum stress occurs at the flanged
during when the vehicle move and apply load.
A. Objectives
The purpose of this analysis is as follows:
1. To develop existing model of flange using CATIA
2. To conduct stress analysis of flange using ABAQUS
solver package
To achieve this objective various parameters will be
observer by using computer simulation. Performance of
propose will compared from the existing part of the
flange. Theoretical of the proposed on its load can be
support by spacer flange will be accomplished by using
theoretical aspects of finite element analysis. The
performance of the load that can carry by the flange will
be observed by using extensive computer simulation that
will performed using ABAQUS and CATIA solver
package subjected to various types of parameter.
B. Buggy
In European country, a dune buggy is a recreational
vehicle with large wheels and wide tires, designed for use
on sand dunes or beaches. That also can move what kind
of surface ground with smoothly movement. The design
is usually a modified vehicle with a modified engine
mounted on an open chassis. The modifications usually
attempt to increase the power to weight ratio by either
lightening the vehicle or increasing engine power or both.
Those with an open frame chassis are called sandrails.
Sandrails are close to dune buggies [1].
More recent generation of off road vehicle, often
similar in appearance to a sand rail but designed for
different use, is the off road go kart. The difference
between a dune buggy or go kart and an off road buggy
or kart is sometimes nothing more than the type of tires
fitted such as sand tires or all terrain tires.
Initially dune buggies were designed for navigating
desert or beaches (hence the word “dune"). However,
dune buggies have become more diversified in terms of
the terrain they can handle and are being built for more
generic off road tasks, indoor track racing. Some are even
built for and used as on-road vehicles. Typically the
function is determined before the buggy is created in
order to maximize the comfort or abilities of the vehicle.
Although dune buggies can be bought (as a kit), many
drivers make their own. This is done by separately buying
chassis, engine, tires, steering wheel, and axles. Some
builders make their own chassis, which creates a special,
customized vehicle.
A 1961 or later Volkswagen sedan is the preferred
donor to create a Dune Buggy. However the engine,
transaxle, wheels, and instruments can be used from these
models. Other parts that can be salvaged from a donor
Volkswagen for use in a Dune Buggy include the front
axle and suspension, frame, pedal assembly, shock
absorbers, seats, battery, fuel tank (1961 or later),
steering column, brakes, instruments and switches,
windshield wiper, horn and emergency flasher unit.
C. Structure of Buggy
For the structure of the buggy it has used tube
framed buggies and fibreglass buggies. Tube frame
buggies have been altered to allow maximum recreational
use. They are now available in varying sizes.
The most common form of non racing buggy
consists of the tube frame which is simple to construct
and sturdy. If the frame bends or breaks it is simple to fix.
Steel tubing is preferred to "pipe" as pipe is rolled and
welded, tubing is mandrel drawn, making it stronger and
with consistent wall thickness.
Engine size varies depending on the suspension,
frame strength and performance needs. Engine size has
varied from 50 cc for small light buggies to 7+ liter
engines designed for professional racing. Dune buggies
use either automatic or manual transmissions, sometimes
based on application and engine power, but often based
simply on personal choice
And for Fibreglass buggies bodies come in many
shapes and sizes. Many companies worldwide have
attempted to copy the original fibreglass dune buggy.
These types of buggies are known as clones.
II. METHODOLOGY
In the beginning, there have two tasks that need to be
done simultaneously. Besides doing literature review,
exercise and tutorial need to be done for mastering the
simulations tools and some preliminary simulation need
to be carried out to be as well.
Then, the problem of this research will be stressed on
a buggy and the main task is find the type of flange that
suitable for this vehicle .It’s very important because this
will be consider dynamic balance of the buggy and
motion make vehicle unstable. Various parameters will
be observed such as relationship between load of the
buggy and load that can be support by spacer flange.
After preliminary research, the existing part will be
sketch and calibrate by using coordinate measuring
machine (CMM). After that the datum will be develop by
using CATIA and will be import to ABAQUS to analysis.
After the analysis is done, the existing part was optimized
into new design and analysis by using ABAQUS [2].
From the result analysis the comparison between the
existing and optimization part then the two parts will be
evaluate, if yes proceed to next step and if no back to
design and analysis.
III. FLANGE DESIGN
D. Design of Buggy
Before determining the appropriate design for the
space flange there are several studies have been done to
obtain a suitable design of the space flanged. From the
previous study, Diploma student at University Kuala
Lumpur, Malaysian Spanish Institute (2009) has
developed a vehicle called as Buggy military (Figure 1).
The model was built with good design and follows the
required specification. But it still has some weaknesses at
certain part such as the size of the spacer flanged not
same. Besides, the design still not undergoes any analysis
test for the load of the buggy.
Figure 1: Design Model at UNIKL MSI
E. Design of the flanged (Datum)
For the size of the spacer flanged the problem are it
have a different size between hub and rim (Figure 2).
From that it will be effect the dynamic balance for this
vehicle and also the size of rib and hollow tube of the
part.
Figure 2: The existing part (Datum) of flange.
Figure 3: CAD Model of existing flange.
From the picture above (Figure 3) the part was
developing by using CATIA, the small diameter
connects to the hub and the larger diameter connects
to the wheel.
Figure 4: The rib of the existing flange.
Rib is parts to support the other part and reduce
the stress, as shown in Figure 4 the size of rib very
thin around 2mm and the angle of rib not suitable.
F. New Design of the flanged
Figure 5: New flange design.
After make observation from the existing part, the
design optimization for the flange has produce, as
shown in Figure 5. The rib size has be increase from
5mm to 10mm and at certain angle the fillet be
placed because stress concentration will reduce if we
put the fillet at the angle, as shown in Figure 6.
Figure 6: Rib and fillet of new flange design.
IV. ANALYSIS
The first analysis was carried out is design datum
analysis. This analysis was conducted to compare
between the datum design and the new design. The new
design that was developing will also do some analysis.
Analysis that will conduct for this part is stress analysis,
for the space flange. The purpose of carrying out the
analysis this component is to identify the maximum stress
for both designs [3].
G. Datum Analysis
The datum space flange for off road buggy was
selected and study at University Kuala Lumpur
Malaysian Spanish Institute. Material for this datum
component is carbon steel as shown in Table 1, and the
force exerted at this part will refer to the component that
available at the buggy. Refer to the Figure 7 and Table 2,
the maximum stress obtained from datum design was 250
Mpa.
Rib
Rib and
Fillet
Table 1: Material properties of the flange [4].
Figure 7: Maximum stress of datum design.
Table 2: Von misses stress of datum design.
NODE LABEL S.Mises
Minimum 6.97504
At Node 540
Maximum 250
At Node 6724
Total 1.04457E+06
H. New Design Analysis
Maximum stress in Figure 8 and Table 2, for the new
design was reduced to 200 Mpa. It was reduced due to the
effect of dimensions changed for this new design.
Figure 8: Maximum stress of new design.
Table 3: Von misses stress of new design.
From Table 3, found that the stress at the minimum
for the optimization part is 4.62 Mpa and for the
maximum stress has reduced from 250 Mpa to 200 Mpa
or 20% reduction.
V. CONCLUSION
The analysis was made to compare the design and the
datum. From the result in the first analysis of the datum
design found that the von misses stress and displacement
was very high. While the von misses stress and
displacement for new design was decreased. These result
influences by parameters diameter tube hollow and
thickness for both design which is datum and new design.
The objective of the project is achieved and the new
flange designs outclass the datum.
VI. REFERENCES
[1] Saeed Information on
http://en.wikipedia.org/wiki/Buggy_(automobile),
accessed on 8/3/2012.
[2] Ahmad Shazwan Mohd & K. Shahril,
Fundamental Analysis of Bracket Modeling for
Proton Wira Bumper, Proceedings for 3rd
International Conference on Engineering Technology
(ICET) at Renaissance Hotel, Kuala Lumpur, 6-8
December 2011.
NODE LABEL S.Mises
Minimum 4.62
At Node 1934
Maximum 200
At Node 9225
Total 576.524E+03
Material Properties Carbon Steel
Density 7850 kg/m3
Young`s Modulus 207 Gpa
Poisson`s Ratio 0.3
Yield Stress 220-250 Mpa