DESIGN & DEVELOPMENT OF AIR
INTAKE MANIFOLD THROUGH
CONVERSION OF PLASTIC MATERIAL
1) Rashmin Kukde.
2) Ankur Koul.
3) Ashutosh Nandkeolyar.
4) Soumya Kumar.
5) Neha Gawkar
OUT LINE
INTRODUCTION
METAL TO PLASTIC CONVERSION
MATERIAL SELECTION
MODELING
ANALYSIS
RESULT AND DISCUSSION
MOLD FLOW ANALYSIS
CONCLUSION
REFRENACE
FUNCTION OF INLET
MANIFOLD
Why metal to plastic conversion
1. Decrease Piece Part Prices
2. Eliminate Time-Consuming and Costly
Secondary Operations
3. Reduce Product Weight and Improve User
Ease
4. Gain Greater Product Structural Strength
5. Increase Your Product Design Options
Selected Material classification
Thermoplastics
Recyclable
Engineering plastics
Meet the engineering &
structural requirements
Nylon
for better strength &
temperature stabilities
Nylon 6,6 with Glass filled
Why 20% Glass filled Nylon
6,6?
Thermoplastics shows up to a disadvantage
when compare with metals. This are include:
1) Low rigidity and tensile strength,
2) Dimensional instability due to a high temperature
coefficient of expansion and higher water absorption.
3) Low impact strength to fracture.
4) Low maximum service temperature.
5) Low creep resistance.
6) Low hardness and scratch resistance.
Properties of Nylon 6,6 with 20%
glass fiber
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Melting point = 252-265°C
Maximum service temperature = 227-254°C
Thermal conductivity = 0.42 W/ mK
Co efficient of thermal expansion (at 100°C) = 336um/m°C
Specific heat = 1.8J/g°C
Density = 1.25 g/cc
Modulus of elasticity = 4.5-7.2 Gpa
Ultimate tensile strength = 120 Mpa
Yield tensile strength = 130 Mpa
Poison’s ratio = 0.33
Hardness = R 110
Cost = Rs180/ kg
Properties of Aluminum casting alloy
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Melting point = 557- 596°C
Thermal conductivity = 113W/mK
Co efficient of thermal expansion (at 100°C) = 22.9µm/m°C
Specific heat =0.963 J/g°C
Density = 2.68g/ CC
Modulus of elasticity = 71MPa
Ultimate tensile strength = 317MPa
Yield tensile strength = 165MPa
Poison’s ratio = 0.33
Hardness, BHN = 75
Cost = Rs135/ kg
Modeling
For modeling a model of
Inlet manifold, manufactured
by Tata indica and is used by
V2
diesel
engine
with
turbocharger was taken as
reference.
When I begin to create model, I
went for manual measurement. In
my component some holes and,
some angular profiles, fillet profiles
& totally the component body is like
a shell like structure with taper and
fillet radius and with a base part.
After taking the dimensions properly a 3D
graphical model is created by the use of software
PRO-ENGINEER.
Picture after modeling
Views of Inlet Manifold
Section Views of Inlet manifold
Procedure of analysis
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For analysis of the product, the analysis software, HYPERMESH &
ANSYS has used.
The model is imported into HYPERMESH as an IGES file format.
Then midsurface for the component is created by using midsurface
command.
Again for the midsurface geometry cleanup option is used to make
it ideal one for meshing and analysis.
Then 2D mesh for that midsurface prepared using automesh
command by applying Manual creation and tria type mesh
After finished these procedure in the HYPERMESH I try to
applying the boundary conditions for the meshed midsurface at that
time, but in my component to various temperature in outside and
inside so I can’t apply various temperature in single surface. So I
planned to create solid mesh (3D) in the HYPERMESH.
CAD MODEL IN
HYPERMESH PLATFORM
Midsurface created in
HYPERMESH
Mes
MESH IN HYPERMESH
Total Nodes 69651
10-Node Quadratic
Total Elements 38034
Tetrahedron
Solid187
Total Body Elements 38034
Boundary conditions applied:
(Environments)in HYPERWORKS
WORKBENCH
• Static:
Fixed support
- Base of the Manifold which is fitted
with Engine.
Pressure - 0.138 Mpa constant pressures inside the
shell.
• Temperature:
Convection 1
Convection 2
Conduction
- 120°C outside the component.
- 30°C Inside the shell.
- 150°C base which is fitted with the
Engine.
ALUMINIUM & NYLON properties given for
analysis:
AFTER GIVING BOUNDRY
CONDITION
Results of 20% Glass filled Nylon 6,6
(Vonmises Stress Plot)
Results of 20% Glass filled
Nylon 6,6
(Total deformation)
Results of aluminum alloy
(Total deformation)
Results of 20% Glass filled
Nylon 6,6
(Temperature distribution)
Results of aluminum inlet
manifold
(Temperature distribution)
Results of Equivalent Stress and Total
Deformation in Aluminum Alloy.
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In the inlet nylon manifold the temperature distribution is very equal through out
the body of the component and the rises in boss and fillet areas, but in the
aluminum material the temperature distribution is not good, so the stress
developed is more in aluminum. The stress developed in the nylon material is
with in factor of safety 3.
NYLON RESULTS:
0. m
3.2621e-004 m
minimum
maximum
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TOTAL DEFORMATION:
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EQUIVALENT VON-MISES STRESS:
7.6319e-004 Pa
4.9191e+007 Pa
minimum
maximum
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MAXIMUM PRINCIPAL STRESS:
-1.3982e+007 Pa
2.9388e+007 Pa
minimum
maximum
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TOTAL HEAT FLUX:
2.6606e-005 W/m²
minimum
43.529 °C
120. ° C
minimum
maximum
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TEMPERATURE:
MANUFACTURING OF
PART
• The part can manufactured in two halves and
then with the help of ultrasonic welding we can
join two parts.
• The part can also be manufactured by another
process that is called lost core injection molding
process.
• I have here shows the process of manufacturing
it with two halves and then ultra sonic welding
it.
MOLD FLOW ANALYSIS
Material used
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FAMILY NAME: POLYAMIDE
TRADE NAME: XYTEL
MANUFACTURER: DU POINT
FILLER: GLASS
MESHED MODEL
MESHED WITH COOLING
CIRCUIT
PROCESS SETTING
PROCESS SETTING
PROCESS SETTING
FILL TIME PLOT
TEMPERATURE AT FLOW
FRONT
BULK TEMPERATURE
MAXIMUM PART
TEMPERATURE
FROZEN LAYER
FRACTION
PRESSURE PLOT
SHEAR RATE
VOLUMETRIC
SHRINKAGE
TIME TO FREEZ
SHEAR STRESS
WELD LINE
OVERALL DEFLECTION
SHOT WEIGHT
AIR TRAP
CLAMPING FORCE
CLAMPING FORCE AT
CENTROID
CIRCUIT COOLANT
TEMPERATURE
COMPARISON OF COST & WEIGHT
EFFECTIVE RESULTS:
• Thus from the above results and their comparisons it
can be concluded that though the nylon with 20%
material can replace well Aluminum, then the
comparison of the cost with aluminum is calculated.
First we should consider the material costs of both
materials:
• Cost of Al casting alloy = Rs135/kg
• Cost of Nylon 66 with 20% glass fiber = Rs180/kg
• But it is Rs45 higher than that of Al casting alloy. But
we think the density of them it is found that,
– Density of Al casting alloy (2.68gm/cc)
– Density of Nylon6,6 with 30% glass fiber (1.35gm/cc)
Conclusion
The entire project on “DESIGN & DEVELOPMENT OF
AIR INTAKE MANIFOLD THROUGH
CONVERSIONOF PLASTIC MATERIAL” in the sense of
metal to plastic conversion has been completed with full
concentration as far as possible regarding the modeling and
analysis.
Thus after the project is over, it can be concluded that by a
slight modification of the design and through a proper process
design the material of the Inlet Manifold can be converted into
Nylon 6,6 with 20% glass fiber successfully with a reduced cost
for the same or better performance.
REFERANCE
• Modern Plastics Encyclopedia handbook (1994) New
York, McGraw-hill.
• Smith, M.A(1986) in the Wiley encyclopedia of packaging
technology, M. Bakker (Ed),New York, John Wiley &
Sons.
• Susan E.M. Selke “Understanding Plastics Packaging
Technology” Hanser publisher, Munich.
• Michel L.Berins, “Plastics Engineering Handbook of the
society of plastics industry, inc. fifth edition.
• P.Radhakrishnan, C.P.Kothandaraman, “Computer
graphics & design”, Danpat rai publications , New Delhi,
2000.
REFERANCE
• Sidney Levy, J.Harry Dubois, “Plastics Product Design
Engineering Handbook”, Van Nostrand Reinhold
Company, Sidney.
• Ronald D. Beck, “Plastics Product design”, Yan
Noastrand Reinhold Company, London.
• R.G.W. Pye, “Injection mould design for thermoplastics,
Affiliater east-west Press P.Ltd, New Delhi, 1989.
• Irvin Rubin, Injection Molding Thery and practice,
A.Wiley Interscience Publications, 1972.
• Donald V. Rosato, Injection molding handbook,
International Thomsan Publishing company, 1985.