IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 03, 2014 | ISSN (online): 2321-0613

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FINITE ELEMENT ANALYSIS OF BEARING HOUSING USING

ANSYS

Miss. Unnati P. Shah 1 Mr. Jaydeep R. Shah 2

Abstract— In today’s competitive age foundries are required

to be more active and efficient. They need to respond fast.

For that casting simulation has become a powerful tool to

visualize mould filling, solidification and cooling and to

predict the location of the internal defects such as shrinkage,

porosity, sand inclusion and cold shut. It can be used for

existing casting process or for developing new casting

without shop-floor trials. In present finite element analysis is

done for knowing the temperature distribution after material

is poured. This gives information about how the temperature

varies at different portion of the bearing housing

I. INTRODUCTION

Since the evolution of mankind, man has used his

intelligence and creative instinct to develop things that will

reduce his labor. He shaped bowls, tools and weapons out of

stones and wood which was naturally found in nature. With

the passage of time he discovered other element in nature

like gold, silver and copper which were readily available in

nature in the form of nuggets. He melted and shaped this

metal according to his desires. He probably discovered gold

pebbles with stone and copper from the copper bearing ores

that line the fire pits. He found it easy to melt the iron,

copper and gold using the fire woods and charcoal, and

hence in different ages cast-iron and copper became the

most profusely used natural materials.

A metal casting can be defined as a metal object

formed when molten metal is poured into a mold which

contains a cavity of the desired shape and is allowed to

solidify.

The casting process is used most often to create complex

shapes that would otherwise be difficult or impossible to

make using conventional manufacturing practices. Casing

has certain characteristic metallurgical, physical and

economical advantages over other methods of metal

processing. It is by far the cheapest method to produce

different shapes in metals. The size of the casting may vary

from a few grams to several tones. They may also vary in

composition and properties depending upon the material of

the mold, type of metal charged, alloying elements added in

the charge or in laddel and the rate and method of cooling.

Casting can be divided into six general classes commercially

known as plain gray cast iron, alloy cast iron, malleable

iron, steel, alloy steel and nonferrous casting. It is rare that a

foundry attempts at making all the six types. Castability of

metals depend on many factors and castability index is high

if the material has high fluidity, low shrinkage, low affinity

for absorbing gas, low stress and uniform strength. Material

which are considered exceptionally good for casting include

casting iron, copper base alloy zinc, aluminum, nickel and

magnesium. Some of typical casting includes pulleys,

flywheel, engine and machine blocks, machine tool beds,

gear blank turbine, blades, C.I pipes etc.

A. Classification of casting process

Die casting

Continuous casting

Sand casting

Centrifugal casting

Investment casting

B. Casting Defects

Cold Shuts and Misruns

Porosity

Pipe shrinkage

Hot Tearing and Cracks

Open Blows and Blow holes

Hot spots

II. MODELLING AND FINITE ELEMENT ANALYSIS

A. Details of bearing housing

Name of the Product: Bearing Hosing

Material: A216WCB

Unit weight: 133.5 kg

Size of the casting box:

Cope: 609.5mm × 609.5mm × 355.6mm

Drag: 609.5mm × 609.5mm × 355.6mm

Cheek: 609.5mm × 609.5mm × 355.6mm

Shape of the Casting box: rectangular

Type of the gating system used: pressurized gating system

used

Pattern material: wooden

Type of pattern: multi piece pattern

Type of moulding: Hand moulding

Moulding sand: silica sand

No. of cores used: 1

Pouring temperature: 1610 0 C \

B. Material Properties of A216WCB

Table. 1: Material Properties of A216WCB

C. Properties of sand

Conductivity 0.519 W/m K

Specific Heat 1172.304 J/kg K

FINITE ELEMENT ANALYSIS OF BEARING HOUSING USING ANSYS

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Density 1495 kg/m3

Table. 2: properties of sand

III. MODELING OF BEARING HOUSING IN PRO E

Fig. 1: wire frame model of bearing housing

Fig. 2: solid model of bearing housing

IV. THERMAL ANALYSIS OF BEARING HOUSING IN ANSYS

This is a transient heat transfer analysis of a casting

process.The objective is to track the temprature distribution

in the steel casting and mold during solidification process.

Steps involve in this software as given below.

A. creating 2d elemnt of bearing housing with mould

Fig. 3: 2D element of bearing housing with mould

B. Assign material and give different material properties to

mold & cast product

Material properties (like specific heat, enthalpy, and thermal

conductivity)

Fig. 4: Temp Vs enthalpy

Fig. 5: Temp Vs thermal conductivity

C. Meshing the mold & cast product

Meshing size fine course= 1is used for cast product

&meshing size fine course=6 for mould

Fig. 6: Meshing of mould

Fig. 7: selection of material

FINITE ELEMENT ANALYSIS OF BEARING HOUSING USING ANSYS

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Fig 8 Meshing of bearing housing

D. Click on node numbers button which separate nodes of

mold & cast product

Fig. 9: Meshing with node number

E. Apply convection loads on the exposed boundary lines.

Apply the convection to the lines of the model. Loads

applied to solid modeling entities are automatically

transferred to the finite element model during solidification.

Fig. 10: Apply loading condition

F. Find out nodal solution

Stepped boundary condition simulates the sudden contact of

molten metal at definite temperature with the mould at

ambient temperature. The program will choose automatic

time stepping that will enable the time step size to be

modified depending on the severity of nonlinearities in the

system.

Fig. 11: Nodal solution

Fig. 12: Time Vs. Temp. Graph

G. Find out simulation result

It gives the temperature distribution in bearing housing

under loading condition.

Fig. 13: Simulation result

V. CONCLUSION

Based on the above result we come to know about

temperature distribution in bearing housing using sand

casting process. Temperature at the middle portion of the

model is very high and get reduce at the outer portion.

REFERENCES

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Websites

[1] www.wikipedia.com

[2] www.efoundary.iitb.ac.in