Failure Analysis of Blister Packaging Camshaft - Free Essay Example

Sample details Pages: 8 Words: 2447 Downloads: 5 Date added: 2019/03/18 Category Analytics Essay Level High school Tags: Failure Essay Did you like this example? Project Relevance: Packaging is one of the largest industry sectors in the world, worth $280 billion. Consumer healthcare packaging represents 4% ($11.2 billion) of the packaging industry. As drug manufacturers approach the 21st century, they face a number of challenges that packaging can help them meet. Don’t waste time! Our writers will create an original "Failure Analysis of Blister Packaging Camshaft" essay for you Create order In this work camshaft under consideration operates forming die of a blister forming station at 45 cycles per minute. When forming die is in closed condition, operating load of the assembly is maximum i.e.19828N, and in open condition it takes only dead load i.e. 266N in opposite direction. Thus, camshaft is subjected to alternate tension and compression due to bending loads. The shaft fails after few cycles wherein PLC screen shows the number of cycles completed till failure. The aim of this project is to modify the shaft to withstand such an operational alternating loads which intern provides a high service warranty to the customer. This modification of the shaft done on relaxing the fillet radius. The shaft can be modified with help of changing its filet radius. For that as per reference paper shaft 30 mm diameter and 45 mm diameter with its filet radius is 0.5 mm and 4.5 mm respectively. FEA of that two diameters with changing filet radius . From this comparison best result diamet er shaft manufactured and take experimental test. Before experimental, we analysis a various filet radius with 45 mm diameter for FEA is done. Literature Review: J. D. Chougule1, R. G. Todkar,[1] showed the influence of a cam shaft in the transmission system of a blister packaging machine used for packaging of tablets. It is observed that the cam shaft fails due fatigue loading into two pieces during operation. To find out cause of failure, a finite element analysis was carried out. Results of stress analysis reveal that the highest stressed area coincides with the fractured regions of the failure of the shaft. The theoretical stress fairly matches with the sub-model stress values. The failure analysis shows that the fatigue failure of the shaft is due to weak section at the step provided for cam shaft mount. To enhance service durability of the transmission system of Blister Packing Machine, stress concentration at cam step was modified and material with high service durability, mechanical characteristics such as fatigue strength, ultimate tensile strength, and fracture toughness was selected. The possible reasons concept of the automobile diesel engine crankshaft failure i.e. operating sources, repairing sources and mechanical sources has been presented in detail by F. S. Silva [2] and observed that the crankshaft failure occurs due to small cracks which are developed as an effect of thermal fatigue loading substantial overheating during shaft grinding process. Stuart H. Loewenthal [3] has studied the method of power shaft design which accounts for a variable amplitude loading histories and their effects on limited life design requirements considering the effects of combined bending and torsion loading and a number of service factors. S. Abdullah et al. [4] discussed the technique of analysis is explain to assess a fatigue life of a shell structure under the variable loadings using finite element analysis technique for a simulation works and it is observed that constant amplitude predict a life larger as long as one predicted by variable amplitude tests. To enhance service durability of the transmission system of Blister Packing Machine, stress concentration at cam step was modified and material with high service durability, mechanical characteristics such as fatigue strength, ultimate tensile strength, and fracture toughness was selected. Norman E. Dowling [5] has done comparison of the material test data with various approaches to estimating the effect of mean stress on stress life and strain life behavior is explained and seen that the walkers mean stress equation gives superior results. M. Omid et al. [6] has performed fatigue analysis of the connecting rod to evaluate a critical point calculated stresses and displacements under maximum compression and tension loadings. The caustic method is very powerful method to detect the stress distribution for complicated mechanical elements such as connecting rod. By drilling several distributed small holes on the connecting rod, the caustic method can predict accurately the stress value at each hole position. G. Wang [7] has introduced a crack modeling approach for the prediction of fatigue failure of the camshaft and which allows the calculation of an equivalent stress intensity factor enabling standard fracture mechanics methodology. H. Bayrakceken [8] investigated the reason of failure analysis of a camshaft of an automobile engine is carried out by using scanning electron microscopy and chemical analysis of fractured camshaft material to assess the reasonableness of fracture M. Shabanet. al.,M.I.Mohamed, A.E.Abuelezz, T Khalifa,(2013)[9], studied the stress pattern of crane hook in its loaded condition, a solid model of crane hook is prepared with the help of ABAQUS software. Real time pattern of stress concentration in 3D model of crane hook is obtained. The stress distribution pattern is verified for its correctness on an acrylic model of crane hook using shadow optical method (Caustic method) set up. By predicting the stress concentration area, the shape of the crane is modified to increase its working life and reduce the failure rates. The complete study is an initiative to establish a FEA procedure, by validating the results, for the measurement of stresses. For reducing the failures of hooks the estimation of stresses, their magnitudes and possible locations are very important. From the stress analysis, they have observed the cross section of max stress area. If the area on the inner side of the hook at the portion of max stress is widened then the stresses will get reduced. The caustic method is very powerful method to detect the stress distribution for complicated mechanical elements such as hooks. By drilling several distributed small holes on the hook, the caustic method can predict accurately the stress value at each hole position. Om Parkash et. al. [10] had studied the Optimizing the Design of Connecting Rod under Static and Fatigue Loading. The main objective of their work was to re-optimize the existing design of connecting rod of universal tractor (U650) by changing some of the design variables. In their work, the model was developed, analyzed and designed using CATIA 19, PRO-E and ANSYS workbench v12. Optimization of connecting rod was done under same boundary and loading conditions for variation in the few stress and fatigue parameters i.e. stresses, weight, life, damage, bi-axiality indication and safety factor. Stress concentration coefficient was varied to obtain the maximum cycles condition. The critical regions under both static and fatigue analysis were identified and improved. The connecting rod was modeled and optimized for the reduced weight, improved life and manufacturability. The results obtained from performed analysis could be used to modify the design of existing connecting rod, so that be tter performance i.e. reduced inertia, fatigue life and manufacturability could be obtained under varying static and fatigue conditions. A. A. Pandharabale, Asst. Prof. A. J. Rajguru,[11] The main objective of their paper was to design a model of dual worm system for optimal load lifting capacity, optimal factor of safety and optimal efficiency for reduced power consumption. They have derived the optimal power for individual motor and select the motor for the application so as to make the device compact. The experimental validation part of the lifting force developed by the dual worm system is validated using test-rig. Various characteristics graph were plotted like Torque Vs. Speed, Power Vs. speed, Power consumption of motor under rated load, Efficiency of system Vs. speed. They concluded that the torque increases with the decrease in the output speed, Graph of power output indicates a rising trend up to certain output speed and then slightly drops indicating that indicating that the device will slow down slightly if the load is increased. A.S.Dhavale , V.R.Muttagi,[12] In four strokes engine one of the most important component is camshaft, such a important part and that over the years subject of extensive research. In this study, causes of fracture of camshaft are discuses. By using scanning electron microscopy and finite element analysis methods are used for fracture analysis of camshaft. It is seen that, The analyzed camshaft is fractured after a very short period of usage of the car. The failure is occurred as a sudden fracture at very close to journal location, where there is a stress concentration. The main reason of the fracture is determined as a casting defect. As the failure was related to a material production problem it is likely to affect more than one vehicle. So, the camshaft of vehicles manufactured from that particular series of camshaft should be replaced. Also, the non destructive testing procedures of the component supplier should also be improved as the defect can easily be detectable by standard n on destructive techniques. Zhiwei Yu, Xiaolei Xu,[13], A failure investigation has been conducted on a diesel-engine crankshaft used in a truck, which is made from 42CrMo forging steel. The crankshaft was nitrided. The fracture occurred in the web between the 2nd journal and 2nd crankpin. The depth of the nitrided layer in various regions of the crankshaft particularly in the fillet region close to the fracture was determined by SEM observation and micro-hardness (HV0.1) measurement, combined with nitrogen content analysis by EDAX. The mechanical properties of the crankshaft including tensile properties, marohardness (HB) and surface hardness (HV1) were evaluated. Fractographic studies indicate that fatigue is the dominant mechanism of failure of the crankshaft. The partial absence of the nitrided layer in the fillet region close to the fracture makes fatigue strength decrease to lead to fatigue initiation and propagation in the weaker region and premature fracture. The partial absence of the nitrided layer ma y result from over-grinding after nitriding. In order to prevent fatigue initiation in the fillet the final grinding has to be done carefully and the grinding amount controlled to avoid grinding down the nitrided layer. Aim of Project: The aim of this project is to modify the shaft to withstand such an operational alternating loads which intern provides a high service warranty to the customer. This modification of the shaft done on relaxing the fillet radius Objectives of Dissertation: To modify the shaft to withstand such an operational alternating loads which intern provides a high service warranty to the customer. For validation with finite element analysis (FEA) it is found that the stress is higher at the step, where failure was found in field. To overcome problem of sub-modelling technique, in CREO-PARAMETRIC 2.0 is used. Sub-modeling is the technique of studying a local part of a model with a refined mesh, based on interpolation of the solution from an initial, global model onto appropriate parts of the boundary of the sub-model. The method is most useful when it is necessary To obtain an accurate, detailed solution in the local region and the detailed modelling of that local region has negligible effect on the overall solution. Research Methodology: Literature Review Study of Blister machine and its techniques. Modeling of Camshaft FEA of selected materials cross-sections for particular load Selection of best material cross-section from FEA results Manufacturing of camshaft from FEA result Experimental testing Comparison of experimental result with FEA results for given load Conclusions Experimental Setup: Fig. 1: Experimental testing of camshaft on UTM Results: FEA results Results can be obtained by FEA as well as Experiment. Table 1 : Results of FEA Diameter 30 mm 45 mm Fillet Radius 0.5 mm 4.5 mm Von-mises stress 120.27 Mpa 100.23 Mpa Deformation 0.0070434 0.005869 After that, by FEA best result obtained, by taking fillet radius 4.5 mm. As the comparison of above result von-mises stresses is high at 30 mm diameter as compared to 45 mm diameter. This is also same as deformation, that means deformation is less at 45 mm diameter and it is more 30 mm diameter. Next step we want to check at 45 mm diameter, changing fillet radius and check out the results. And then this result compare to above table. Before that best result obtained at 45 mm diameter , so taking the dimensions and shaft is made on workshop. After the manufacturing of shaft experimental analysis is done on UTM. By using the strain gauge strain also calculated. In experimental analysis we can get the values of von-mises stress and deformation. After th values whuch are coming from the experiment , FEA is done . but in fea total load applied on shaft is 10 % reduced, because in real there is no possible to applied a load. So external weight is applied. Then the result comparison of expe rimental and FEA are given below, Table 2 :Results of FEA Optimised FEA Diameter 45 45 Filet radius 4.5 4.5 Von-mises stress 103.87 100.23 Deformation 00020 000569 So, we take as 45 mm diameter and fillet radius takes 3 mm , 3.5 mm and 4 mm. and that obtained result by FEA is below table. Table 3 : Results of FEA (with different filet radius) Diameter 45 mm 45 mm 45 mm Fillet Radius 3 mm 3.5 mm 4 mm Von-mises stress 112.07 Mpa 107.52 Mpa 104.78 Mpa Deformation 0.00656 0.006296 0.006136 After studying of all result, best result given by 45 mm diameter and its fillet radius 4.5 mm, so using this dimension camshaft is made. And this shaft using UTM stresses and deformation is calculated. After that calculating the life cycle for 45 mm diameter and its different filet radius. Also comparing all result diameter 45 mm and its filet radius 4.5 mm gives good result as compare to all. Table 4 : Results of FEA life cycle (with different filet radius) Diameter 45 mm 45 mm 45 mm 45 mm Fillet Radius 3 mm 3.5 mm 4 mm 4.5 mm Life cycle 2.106e5 2.802e5 3.2499e5 4.1978e5 As the above result shows the, number of cycles increases, with decreasing the stress. Conclusion: This chapter consist the concluding remarks on current research work. The experimentation performed on Universal testing machine. The analysis result was also done in previous chapter result and discussion. The concluding remarks on experimentation and its results are covered and also necessary outcomes are represented in this chapter. The future scope for this project is also stated at the end of this chapter. The outcomes from the current research work are as follows; From results of finite element analysis it is observed that the maximum stress value is within the safety limit. There is a great potential to optimize, this safety limit which can be done by removing material from low stressed region thus optimizing its weight without affecting its structural behavior. The maximum displacement value is also very less. So, the material from low stressed region is can be removed without affecting its strength and is within the yield strength. Von-mises stress found on existing (120.27 MPa) and optimized (100.23 MPa) components are within the material yield strength. Deflection measured and found on existing (0.0070434mm) and optimized (0.00569mm) model is very less. Project Expenditure: Sr. No. Name of Equipment Qty. Approx. Cost (INR) Material for Specimen 01 2000 = 00 Raw Material Cutting and machining 01 5800 = 00 Bracket Joining 04 1000 = 00 Experimentation and Lab charges - 8000 = 00 Miscellaneous Expenses 4000 = 00 Total Expenditure: Rs. 20800 = 00

Literature Review - How to Do It - 1653 Words

Writing A Literature Review and Using a Synthesis Matrix My professor says I have to write a literature review, what do I do? Well, to begin, you have to know that when writing a literature review, the goal of the researcher is to determine the current state of knowledge about a particular topic by asking, â€Å"What do we know or not know about this issue?† In conducting this type of research, it is imperative to examine several different sources to determine where the knowledge overlaps and where it falls short. A literature review requires a synthesis of different subtopics to come to a greater understanding of the state of knowledge on a larger issue. It works very much like a jigsaw puzzle. The individual pieces (arguments) must be put†¦show more content†¦116) - WASP created opportunities for women that had never previously existed (p. 112) - Women’s success at flying aircrafts â€Å"marked a pivotal step towards breaking the existing gender barrier† (p. 112) - â€Å"From the outset male pilots resented women’s presence in a traditionally male military setting† (p. 1113-4) - â€Å"The WASP were routinely assigned inferior planes that were later found to have been improperly maintained† (p. 114) - discrimination against WASP at every level of military service, women were only paid 2/3 of what men were for doing identical tasks (p. 114) Stewart - WAAC (Women’s Army Auxiliary Corp) was 1st chance for women to serve in army, given full army status in 1943 as WAC (p. 28) - Needs of the war were so great that women’s traditional social roles were ignored (p. 30) - Military women paid well for the time period and given benefits if they became pregnant (p. 32) - The 1940’s brought more opportunities to women than ever before (p. 26) Bruley -Women given equal opportunities (p. 223) - Women joined workforce as a break from the ordinary to help the war (p. 220) - Unconscious decision to cross into male-dominated roles (p. 221) - Seized these new oppor tunities to bring about change (p. 230) Scott - Women born in the 1920’s found new doors open to them where they once would have encountered brick walls (p. 526) -Even women not directly involved in the war were changing mentally by being challenged toShow MoreRelatedliterature review1550 Words   |  7 PagesWriting a Literature Review A literature review†¦ †¢ Provides an overview and a critical evaluation of a body of literature relating to a research topic or a research problem. †¢ Analyzes a body of literature in order to classify it by themes or categories, rather than simply discussing individual works one after another. †¢ Presents the research and ideas of the field rather than each individual work or author by itself. 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The Honor Code - 1348 Words

2. A large subsection of cosmopolitanism is the power of external public shaming, and the power of shame to shape the behaviors of cultures. This is also the part of cosmopolitanism which can be applied more broadly to societies than to individuals. In his book, The Honor Code, Appiah offers various examples about the connected roles which shame and honor have respectively in guiding the morality of different cultures, and how these influences change over time through external forces which evaluate and judge the practices of that particular society. The reason he gives for honor having enough weight to influence behavior to such an extent is â€Å"our deep and persistent concern with status and respect, our human need for what Georg Wilhelm Friedrich Hegel called Anerkennung ¬Ã¢â‚¬â€Ã‚ ¬recognition† (Honor xiii). This theory about honor connects to a psychological notion that human beings are social creatures and depend on social connections and interactions for a large par t of our own self worth. Appiah goes on to say that â€Å"we human beings need others to respond appropriately to who we are and to what we do. We need others to recognize us as conscious and to acknowledge that we recognize them† (Honor xiii). Not only do humans need to be recognized, but we must also have our actions affirmed, a theory which Appiah applies not only to individuals, but to collective honor as well. a. This idea of honor is not entirely removed from his cosmopolitan standards concerning morals, and AppiahShow MoreRelatedThe Code Of The Honor Code1303 Words   |  6 Pagesethically better the students. 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Michelle Had Duty Of Care Towards Rebecca â€Myassignmenthelp.Com

Question: Discuss About The Michelle Had Duty Of Care Towards Rebecca? Answer: Introducation The duty of care is related with the circumstances and the relationships in which it has recognized by the law as resulting in a legal duty to take care. On the other hand, if such care is not taken, it may result in the liability of the defendant to pay damages to the other party, to whom injury or loss has been caused as a result of such breach of duty (Topp v London Country Bus, 1993). Hence, in such cases, the claimant is under a legal obligation to establish that the defendant had a duty of care. To find out the presence of duty of care in cases involving personal injury or damage to property, the neighbor test is used. This test was originally provided by Lord Atkins in Donahue v Stevenson (1932). Application: In the present case, it can be said that it was reasonably foreseeable for Michelle that her actions may result in causing injury to Rebecca. Any driver would have known that in case of an accident, the passenger may suffer serious injuries. According to this test, there should be reasonable foresight of harm, and a relationship of proximity should also be present between the parties (Overseas Tankship Ltd. v Morts Dock Engineering Company Ltd., 1961). While deciding if the defendant had a duty of care towards the plaintiff, there are a number of legal principles that considered by the court (Bourhill v Young, 1943). For this purpose, the plaintiff is required to establish that the:- Defendant had a duty of care to the plaintiff There has been a breach of such duty by the defendant; and The plaintiff had suffered an injury or a loss due to the actions of the plaintiff which resulted in the breach of such duty. Application: The standard of care that can be applied in this case required Michelle to be careful while driving the car. But Michelle was quite drunk when she was driving the car. She had taken a lot of wine before the show. Hence, the standard was not met and as a result, there was a breach of the duty of care. The issue in this question is related with causation. The law provides that there should be a connection present between the alleged negligence on the part of the defendant and the hound that has been suffered by the plaintiff. However, this is a question of fact. A particular articulation related with causation is the "but for" test. It has to be seen if but for the actions of the defendant, the harm suffered by the building would not have taken place. Application: In this case, Rebecca has suffered serious injuries and broken her leg when the car being given by Michelle met with an accident. In this case, Michelle was driving the car under the influence of liquor. Hence it can be said that Michelle was negligent while driving the car. Similarly, the injuries suffered by Rebecca can be described as the direct result of the negligence of Michelle in driving the car under the influence of liquor. Hence, the injuries suffered by Rebecca were the direct result of the Michelles negligence. Rule: The law of tort provides that contributory negligence can be described as such behavior of the claimant as a result of which, it can be said that the claimant had also contributed to some extent in the injuries suffered by him or her. As a result of the fact that the claimant had also failed in meeting the standard of care that would have been made by any other reasonable person under the circumstances, for the purpose of avoiding the loss of the injury that has been suffered by the claimant. Hence, when such circumstances are present and the claimant had also contributed in the loss on the injury, the defendant can rely on the defense of contributory negligence. Therefore in such cases, the defense of contributory negligence is available to the defendant only if the defendant is in a position to establish that there was some fault present on part of the claimant also. The defendant has to establish that there was some fault of the defendant, which had contributed in causing th e injury or the loss suffered by the claimant. Application: in the present case, when Rebecca and Michelle went to see the Oprah Winfrey show, there was a delay in starting the show as there was a ticketing issue. In order to parse time, both of them had consumed wine while waiting for the show to start. Rebecca was well aware of the fact that on their way back home, Michelle would be driving the car. Still, Rebecca decided to drink wine with Michelle and she also decided to ride in the car being driven by Michelle. Although she was aware of the fact that Michelle had drank wine. Rule: The defense of volenti non fit injuria has limited application under the tort law. The translation of this latter phrase means that when a person has volunteered, no harm is done (Nettleship v Weston, 1971). This defense is applicable as a complete defense and absorbs the defendant of all liability (White v Blackmore, 1972). The requirements of voluntary assumption of risk that it should be voluntary, and exhibited the present and it should be made after having complete knowledge regarding the nature and extent of the risk (Morris v Murray, 1991). Application: In Dann v Hamilton (1939) the court had stated that the defense of volenti non fit injuria is available in such cases when the drunkenness of the driver is obvious and as a result, it can be concluded that an obvious and evident risk existed and satirist has been accepted by the defendant, knowingly. In this case, the defense of volenti non fit injuria is not available to Michelle. References Bourhill v Young [1943] AC 92 Donahue v Stevenson (1932) AC 562 Morris v Murray [1991] 2 QB 6 Nettleship v Weston [1971] 3 WLR 370 Overseas Tankship (U.K.) Limited v Morts Dock Engineering Company Limited (New South Wales) [1961] UKPC 2 Topp v London Country Bus [1993] 1 WLR 976 White v Blackmore [1972] 3 WLR 296