mechanical project list (unigraphics & hepermesh & catia)

HYDERABAD | VIJAYAWADA | GUNTUR

Accords IEEE & International Standards Mobile: 9603150547

Vision Solutions

Uppal, Hyderabad | 4/13 Brodipet, Guntur | Benz Circle, Vijayawada

E-Mail:[email protected], call-9603150547

Web site: www.visiongroups.org

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1. DYNAMIC RESPONSE ANALYSIS OF A CENTRIFUGAL

BLOWER USING FEA

ABSTRACT

Centrifugal blowers are used extensively for on-board naval applications have high noise

levels. The noise produced by a rotating component is mainly due to random loading force on the

blades and periodic iteration of incoming are with the blades of the rotor. The contemporary

blades in naval applications are made up of aluminum or steel and generate noise that causes

disturbance to the people working near the blower.

The present work aims at examining the choice of composites as an alternative to metal

for better vibration control. Composites, known for their superior damping characteristics are

more promising in vibration reduction compared to metals. The modeling of the blower was

done by using solid modeling software, CATIA V5 R19. The blower is meshed with a three

dimensional hex8 mesh is done using HYPERMESH 10.

It is proposed to design a blower with composite material, analyze its strength and

deformation using FEM software. In order to evaluate the effectiveness of composites and metal

blower using FEA packaged (ANSYS). Modal analysis is performed on both Aluminum and

composite blower to find out first 5 natural frequencies.

2.Dynamic analysis of composite propeller of ship using FEA

ABSTRACT

Ships and underwater vehicles like submarine and torpedoes use propeller for propulsion.

In general, propellers are used as propulsors and they are also used to develop significant thrust



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to propel the vehicle at its operational speed and RPM. The blade geometry and design are more

complex involving many controlling parameters. Propeller with conventional isotropic materials

creates more vibration and noise in its rotation. It is undesirable in stealth point of view. In

current years the increased need for light weight structural element with acoustic insulation has

led to use of fiber reinforced multi layered composite propeller. The present work is to carry out

the dynamic analysis of aluminum, composite propeller of CFRP (Carbon Fiber Reinforced

Plastics) materials.

The present thesis deals with modeling and analyzing the propeller blade of a underwater

vehicle for their strength. A propeller is a complex geometry which requires high end modeling

software. The solid model of propeller is developed in CATIA V5 R19. Tetrahedral mesh is

generated for the model using HYPER MESH. Static, Eigen and frequency responses analysis of

both aluminum and composite propeller are carried out in ANSYS. Interlaminar shear stresses

are calculated for composite propeller by varying the number of layers. The stresses obtained are

well within the limit of elastic property of the materials.

3.DESIGN AND ANALYSIS OF A HEAT EXCHANGER

ABSTRACT

The characteristics of heat exchanger design are the procedure of specifying a design,

heat transfer area and pressure drops and checking whether the assumed design satisfies all

requirements or not. The purpose of this thesis work is how to design the oil cooler (heat

exchanger) especially for shell-and-tube heat exchanger which is the majority type of liquid-to-

liquid heat exchanger. General design considerations and design procedure are also illustrated in

this thesis. In design calculation, the HTRI code and Ansys software are used. Heat transfer

concepts and complex relationships involved in such exchanger are also presented. The primary



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aim of this design is to obtain a high heat transfer rate without exceeding the allowable pressure

drop. This HTRI code and computer package is highly useful to design the heat exchanger and to

compare the design. Within the project work , the thermal and pressure drop calculations are

done by using the empirical formula, as per TEMA and verified with HTRI software package

(USA).

The pressure drop values on shell side and tube side at the same time, overall heat

transfer coefficient values are found out and observed that they are with a variation of 0.29%,

1.4% and 1.68% respectively and matching with the HTRI software. From the theoretical

modeling, the convection heat transfer coefficients along with the bulk temperature are found out

and imposed as boundary conditions to predict the temperature distribution in heat transfer

analysis in both the shell and tube.

4.STRUCTURAL ANALYSIS OF TRANSITION NOZZLE

HEADER

ABSTRACT

Nozzles have significant role in the turbines, heat exchangers, air coolers to control the flow of

fluid and to spry the fluid in fine droplets with high velocity. Nozzle converts the pressure

energy of the fluid in to the kinetic energy. The high pressure fluid is supplied to the nozzle inlet

section as it flows across the nozzle it expands and its pressure decreases with increase in

velocity of fluid. To obtain the specified velocity of the fluid at the exit of the nozzle to suit the

application the fluid has to be supplied at the inlet at predetermined high pressure. In the process

of expansion of fluid nozzle subjected to varying pressure and velocity of fluid. Due to this

stresses are induced in the nozzle. So the nozzle is to be designed such that the induced stresses

should be in the allowable limits of the material used. For this the nozzle is analyzed under

various operating conditions to obtain safer nozzle design. In the present work an attempt is

made to analysis of the nozzle of various cross sections and types using finite element analysis.



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The nozzles are modeled in CATIA imparted HYPER MESH for quality mesh then analysis is

performed in ANSYS.

5.MODELLING AND ANALYSIS OF ENGINE BLOCK

Abstract

The cylinder block forms the basic framework of the engine, it houses the engine

cylinders, which serve as bearings and guides for the pistons reciprocating in them. The analysis

of the engine block is to be carried out to predict its behavior under static and dynamic loading.

The cylinder block has to withstand the stresses and deformations due to loads acting on it. The

solid model of the block is generated in CATIA V5 R19.The nth model is imported to

HYPERMESH 10 through IGES format. The quality mesh is prepared in HYPERMESH for

converged solution and the solver set as ANSYS in which loads and boundary conditions are

applied for analysis. By using different materials Aluminium , Grey cast iron, Steel ,Titanium

and Brass. The static analysis is performed to predict the deformations and stresses. The modal

analysis using lanczo’s algorithm to predict the natural frequencies and corresponding mode

shapes.

6.FINITE ELEMENT ANALYSIS OF A GAS TURBINE ROTOR BLADE

ABSTRACT

In the present work the first stage rotor blade of a two-stage gas turbine has been analyzed for

structural, thermal using ANSYS 12, which is a powerful Finite Element Software. In the

process of getting the thermal stresses, the temperature distribution in the rotor blade has been

evaluated using this software.

In the present work, the first stage rotor blade of the gas turbine has been analyzed using ANSYS

12 for the mechanical and radial elongations resulting from the tangential, axial and centrifugal

forces. The gas forces namely tangential, axial were determined by constructing velocity



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triangles at inlet and exist of rotor blades. The rotor blade was then analyzed using ANSYS 12

for the temperature distribution. For obtaining temperature distribution, the convective heat

transfer coefficients on the blade surface exposed to the gas have to feed to the software. The

convective heat transfer coefficients were calculated using the heat transfer empirical relations

taken from the heat transfer design dada book. After containing the temperature distribution, the

rotor blade was then analyzed using ANSYS 12 for the combined mechanical and thermal

stresses. The radial elongations in the blade were also evaluated.The turbine blade along with the

groove is considered for the static, thermal, modal analysis.

7.DESIGN AND ANALYSIS OF HIGH SPEED HELICAL GEAR .

ABSTRACT

Marine engines are among heavy-duty machineries, which need to be taken care of in the best

way during prototype development stages. These engines are operated at very high speeds which

induce large stresses and deflections in the gears as well as in other rotating components. For the

safe functioning of the engine, these stresses and deflections have to be minimized.

In this project, static-structural analysis on a high speed helical gear used in marine engines,

have been performed. The dimensions of the model have been arrived at by

theoretical methods. The stresses generated and the deflections of the tooth have been

analyzed for different materials. Finally the results obtained by theoretical analysis

and Finite Element Analysis are compared to check the correctness. A conclusion

has been arrived on the material which is best suited for the marine engines based on the results.

8.DESIGN AND ANALYSIS OF PISTON

ABSTRACT

A piston is a disc which reciprocates within a cylinder. It is either moved by the fluid or it moves

the fluid which enters the cylinder. The main function of the piston of an IC engine is to receive

the impulse from the expanding gas and to transmit the energy to the crankshaft through the



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connecting rod. The piston must also disperse a large amount of heat from the combustion

chamber to the cylinder walls.

The aim of our project is to design a piston for 150cc engine using theoretical calculations for

Aluminum Alloy A360. 2D drawing is created and a 3D model of piston is designed using Catia

and analysis is done in Ansys .

Coupled field analysis (i.e) structural + thermal is done on the piston to verify the strength. The

analysis is done using two different materials Cast Iron, Aluminum Alloy A360 and Phosphor

Bronze. Comparison is done for the three materials to verify the better material for our designed

piston.

9.MODELLING AND ANALYSIS OF IMPROVED DESIGN OF DISK

BRAKE ROTOR.

The main objective behind undertaking the project “Design and Analysis of Efficient Disc Brake

Rotor” is to study and evaluate the performance of disc brake under severe braking conditions

and thereby assisting in disc brake rotor design and analysis. CATIA is used for modeling and

ANSYS 12.0 is used for Analysis. In this project, an improved design of a disc brake rotor is

considered for analysis. Flange width of 10mm made of Cast Iron, Aluminum and Aluminum

composite is considered. A Steady State Thermal Analysis is performed to obtain the

Temperature Distribution. An attempt is made to improve the heat dissipation for disc brake

rotor, which yields a low temperature variation across the rotor disc and thus increase the

efficiency of a disc brake rotor.

10.DESIGN AND OPTIMIZATION OF DRIVE SHAFT WITH COMPOSITE

MATERIALS

Abstract

Automotive drive Shaft is a very important components of vehicle. The overall objective of this

Project is to design and analyze a composite drive shaft for power transmission. Substituting

composite structures for conventional metallic structures has many advantages because of higher



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specific stiffness and strength of composite materials. This work deals with the replacement of

conventional two-piece steel drive shafts with a Composite material's. In this work Carbon

Epoxy is used as composite material The design parameters were optimized with the objective of

minimizing the weight of composite drive shaft. In this present work an attempt has been to

estimate the deflection, stresses, natural frequencies under subjected loads using FEA. Further

comparison carried out for both steel and composite materials and weight of the shaft is

optimized and stress intensity factor found for both Steel and composite drive shafts.

11.FINITE ELEMENT ANALYSIS OF CONNECTING ROD

Abstract

The main objective of the project is to study the effect of geometric parameters on the stiffness

of the big-end of connecting rod. In operation, the connecting rod is subjected to both gas

pressure and inertia loads, and therefore, it must be adequately strong and rigid and light in

weight as well. Four models of the connecting rod are modeled using Catia with slight variations

in their geometric parameters. A connecting rod with less stresses in big-end is chosen to prevent

the failure of the connecting rod.

12.DESIGN OF VALVE OPERATING SYSTEM FOR INTERNAL COMBUSTION

ENGINES

Abstract

Internal Combustion Engines are the ones that have withstood the test of time and the Poppet

valve system is an indispensable part of the engine. The poppet valve system is found to be

extremely reliable, but the problem associated with this system is the high frictional loss and

large number of components. This is the motivation for the project, i.e., to develop a valve train

having lesser number of components, has reduced friction and wear, consumes least amount of

energy and at the same time is as effective as the poppet valve system from sealing point of view

and has low pumping losses. Various geometric designs of the valve train were developed and



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detailed study of the feasible concept was carried out. Finally a convolution based poppet valve

system, which is free from numerous mechanical elements like the camshaft, cam, pushrod,

rocker arm and rocker bearing is proposed. Finite element analysis is carried out to obtain a

bellow that gives the desired valve lift and the stress levels are within the acceptable limits. The

same is validated experimentally to some extend by fabricating the bellows and taking trials.

13.STATIC AND MODAL ANALYSIS OF LEAF SPRING USING FEA

Abstract

The objective of this present work is to estimate the deflection, stress and mode

frequency induced in the leaf spring of an army jeep design by the ordinance factory. The

emphasis in this project is on the application of computer aided analysis using finite element

concept. The component chosen for analysis is a leaf spring which is an automotive component

used to absorb vibrations induced during the motion of vehicle. It also acts as a structure to

support vertical loading due to the weight of the vehicle and payload. Under operating

conditions, the behavior of the leaf spring is complicated due to its clamping effects and interleaf

contact, hence its analysis is essential to predict the displacement, mode frequency and stresses.

The leaf spring, which we are analyzing, is a specially designed leaf spring used in military

jeeps. This spring is intended to bare heavy jerks and vibrations reduced during military

operations. A model of such jeep has been shown in this project report. In analysis part the finite

element of leaf spring is created using solid tetrahedron elements, appropriate boundary

conditions are applied, material properties are given and loads are applied as per its design, the

resultant deformation, mode frequencies and stresses obtained are reported and discussed.

14.ANALSYSIS OF BALL ROLL MILL USING FEM

Abstract

The raw mill separator unit is an integral part of modern cement manufacturing

industries. The unit consists of main and auxiliary fan assemblies along with many other

accessories. The purpose of the raw mill separator is to create suction pressure and provide the



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means to separate the fine cement particles from coarse cement particles. The fine particles are

collected separately while the coarse particles are again sent back to crushing units and the cycle

goes on. The cement comprises of two main erodent in form of alumina and silica which causes

wear loss of fan blade in raw mill separator unit. Since this wear loss is non uniform in nature, it

causes the development of eccentricity in the rotating fan assemblies of separator. This rotating

un balance causes the whole structure to vibrate. The foundation and other installed units this

raw mill separator unit get thus vibrating. Therefore it becomes important to analyze the

vibration characteristics of separator unit for different cases of unbalance and to find out suitable

means to minimize the vibration. In this report, the computer aided solid model generation of the

separator fan assemblies has been done based on the drawings. The modal analysis of the fan

assembly attached with housing and supporting frame has been done using finite element

analysis software. To see the effect of unbalance on supporting structure one simplified approach

has been used and vibration response for unbalanced rotation has been analyzed. The root cause

of unbalance in separator fan assembly is non uniform wear loss of fan blade material. To control

this erosive wear loss from fan blade, one experiment has been performed to compare the wear

loss from mild steel substrate plate coated with suitable hard material. Good wear resistance

result has been found for coated material which can be used for fan blade to control the quick

wear loss.

15.STRESS AND ANALYSIS OF CRANKSHAFTS SUBJECT TO DYNAMIC LOADING

Abstract

The main objective of this project was to investigate weight and cost reduction opportunities for

a forged steel crankshaft. The need of load history in the FEM analysis necessitates performing a

detailed dynamic load analysis. Therefore, this study consists of dynamic load analysis and

stress analysis. In this project a dynamic simulation was conducted on crankshafts cast iron from

similar single cylinder four stroke engines. Finite element analysis was performed to obtain the

variation of stress magnitude at critical locations. The pressure-volume diagram was used to



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calculate the load boundary condition in dynamic simulation model, and other simulation inputs

were taken from the engine specification chart. The analysis was done for different engine

speeds and as a result, critical engine speed and critical region on the crankshafts were obtained.

Stress variation over the engine cycle and the effect of torsional load in the analysis were

investigated.

16.“STATIC AND DYNAMIC ANALYSIS OF AIRCRAFT STIFFENED

PANEL”.

Abstract

The title entitled to our major project is “STATIC AND DYNAMIC ANALYSIS OF

AIRCRAFT STIFFENED PANEL”. Stiffened panel is a component in aircraft that is used to

fasten the stiffener and the skin. These are the components that carry and allocate the loads

throughout the surface of the fuselage or the wing. These panels are present in both fuselage and

wings. Stiffener or longeron or stringer is a thin metal strip that is used as a supporting member

in fuselage and wing. When we consider the issue i.e. resistance of the aircraft’s skin towards the

loads applied on it, due to frailty the aircraft skin is easily deformed. In order to solve this

problem we designed a stiffened panel which can endure to deflection and stress levels.

By changing the stiffened panel sections and by changing the material of the skin, the

aircraft skin can withstand the deformation. Generally T-section stiffened panel is used but there

is a disadvantage of using T-section, it can’t resist to deformation. So we designed an I-section

stiffened panel (because I-section is more resistant to deformation) in CATIA and Meshing in

Hypermesh and Analysis is done in ANSYS. We considered three types of analysis in ANSYS,

Modal analysis, Static analysis, Harmonic analysis respectively and also we considered two

materials, one is aluminum and the other is carbon fiber. Aluminum is the common element used

in the design of aircraft, but Carbon fiber is recently being used in aircrafts.



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17.DYNAMIC ANANYLIS OF SPINDLE IN CNC HORIZONTAL

BORING MACHINE

ABSTRACT

The structure of machine tool forms the vital link between the cutting tool and the work

piece. The machine tool accuracy mostly depends upon the structural design of the various

components of the machine tool. To maintain the accuracy under the influence of cutting forces

and the moving weight of machine tool elements, the structure, particularly spindle must poses

high dynamic stiffness. The spindle should be rigid enough to with stand the various forces

acting on it. Therefore, the extent to which the behavior of the various elements of a machine

tool contributed to its overall performance is by no means fully understood.

The objective of the present project work is to design the machine tool spindle (CNC

Horizontal Boring machine) for dynamic stiffness by considering the above influencing

parameters.

For this purpose Finite Element Method is being implemented to analyze the spindle

behavior in CNC Horizontal Boring machine. FEM package like ANSYS 12 is used in this

project.

FEM methods are widely used in industry for analyzing various mechanical parts. It has

also found its use in Civil Engineering (for structural analysis), Aeronautics etc., It has a broad

spectrum of uses than they appear to be.

18.BUCKLING ANALYSIS OF ORTHOTROPIC SANDWICH PANELS

Abstract



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A three dimensional sandwich panel, which is characterized by two thin flat sheets and a core

sandwiched between them is relatively a complex structure. After study of the previous data, the

assumptions required for analysis of orthotropic sandwich panels with corrugated core are

finalized. The analysis of orthotropic sandwich panels are complex and the number of variables

involved is high. A description is given for predicting buckling stresses of rectangular sandwich

panels with corrugated core. Mathematical formulations are made for finding elastic contants of

orthotropic sandwich panels and for their buckling coefficients/loads. Finite element method is

used for finding the buckling stresses of rectangular sandwich panels with different types of

corrugated core.

The purpose of the present work is to determine the buckling stresses induced in

orthotropic sandwich panels with the newly developed “Top hat core” and compare with the

buckling stresses obtained with the earlier available types of corrugated core(Continuous

corrugated core, Top hat core, Zed core and channel core) and to summarise the benefits of top

hat core.Accordingly buckling stresses were calculated using the powerful finite element analysis

tool “ANSYS” .

19.FINITE ELEMENT ANALYSIS OF LPG CYLINDER

ABSTRACT

This project aims at reduction of weight of Liquid petroleum gas(LPG). So, the finite

element analysis of Liquefied Petroleum Gas (LPG) cylinders made of Steel and Fiber

Reinforced Plastic (FRP) composites has been carried out. Finite element analysis of composite

cylinder subjected to internal pressure is performed. Layered shell element of a versatile FE

analysis package ANSYS (version 12.0) has been used to model the shell with FRP composites.



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A number of cases are considered to study the stresses and deformations due to pressure

loading inside the cylinder. First, the results of stresses and deformation for steel cylinders are

compared with the analytical solution available in literature in order to validate the model and

the software. The weight savings are also presented for steel, Glass Fiber Reinforced Plastic

(GFRP) composites and Carbon Fiber Reinforced Plastic (CFRP) composite LPG cylinders.

Variations of stresses and deformations throughout the cylinder made of steel, GFRP and CFRP

are studied.

A complex orthotropic mechanics of FRP composites has been studied and discussed in

brief to have some understanding of behavior of FRP composites. In addition to that an

introductory Finite Element Method has also been presented on the basis of which the cylinder

has been analyzed.

20.DYNAMIC ANALYSIS OF THIN -WALLED

COMPOSITE I- BEAMS

ABSTRACT

In an effort to save weight while still remaining high strength, many contemporary structural

systems are designed with lower margins of safety than predecessors. The criterion of minimum

weight design is particularly prevalent in the design of aircraft, missile, and spacecraft vehicles.

One obvious means of obtaining a high strength, minimum weight design is the use of light, thin-

walled structural members of high strength alloys. Thin- walled beams of open sections such as

I, Z, Channel and angle sections are frequently used for intricate structures in spacecrafts. Due to

low torsional rigidity thin-walled beams of open sections, the problem of torsional vibrations and

stability is of prime interest. For the last three to four decades mechanical vibrations have been

recognized as a major factor in the design. Mechanical vibrations produce increased stress,



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energy loss and noise that should be considered in the design stages if these undesirable effects

are to be avoided, or to be kept minimum.

The present work particularly deals with dynamic analysis of lengthy uniform thin-

walled uniform I-beams and tapered I-beams of open sections, particularly composite beams.

Fiber-reinforced plastics (FRP) have been increasingly used over the past few decades in a

variety of structures that require high ratio of stiffness and strength to weight. A

displacement-based one-dimensional finite element model is developed to predict natural

frequencies and corresponding vibration modes for a thin-walled composite beam. Numerical

results are obtained for thin-walled composite beams addressing the effects of fiber angle,

modulus ratio, height-to-thickness ratio, and boundary conditions on the vibration frequencies

and mode shapes of the composites. Using ANSYS 12, the modal and harmonic analysis are

carried out and presented in graphical form.

21.FRACTURE ANALYSIS OF FRP COMPOSITES SUBJECTED TO STATIC

AND DYNAMIC LOADING

ABSTRACT

Analytical solution exists for relatively simple cases. Due to complicated boundary conditions

associated with the governing equations analytical approaches are used. Over the last decade or

so finite element method has been firmly established as a standard procedure for the solution of

practical fracture problems.

The usefulness of stress intensity factors (SIF’s) in the analysis of the problems of residual

strength, fracture and fatigue crack growth rate has resulted in effort being expanded on the

determination of SIF.A number of techniques have been suggested for the validation of SIF from

the finite element results but adequate representation of crack tip singularity remains a common

problem to most of these method.



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The objective of the present work is to investigate the Stress Intensity Factor (SIF) for

benchmark problems for static and dynamic loading in composite plates having center, edge.

Further the analysis is extended to CT specimen, plate with 3-point bend, v-notch and double

edge notch.

In the static analysis SIF’s are found for an isotropic material using singular and j-integral

approach and it is inferred that the deviation is minimal. For the orthotropic material SIF is found

out for the above specimens with Carbon UD/Epoxy, R Glass roving UD/epoxy, S2 glass

fabric/epoxy material properties.

22.BUCKLING ANALYSIS OF COMPRESSION LOADED

COMPOSITE CYLINDRICAL SHELLS

ABSTRACT

Composite thin cylindrical shells are most widely used structural forms in Aerospace and

Missile applications. In designing efficient and optimized shell structure, they become

increasingly sensitive to buckling. It is well known that the experimental display is mainly

attributed to geometrical imperfection like damage in the structure, or local thinning of material

etc.

In Missile and Airframe, the composite cylindrical shell structure is generally provided

with cutouts for accessing internal components during integration. The cutouts invariably reduce

the strength of the composite cylindrical shell and more specifically the buckling load. It has

been a design practice to improve strength by addition of Reinforcement around cutout. The

cutout not only introduces stress concentration but also significantly reduce buckling load.

Results from a numerical study of the response of thin-walled compression-

loaded laminated composite cylindrical shells with unreinforced and reinforced square

cutouts are presented. The results indicate that a local buckling and deformation occurs in



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the shell near the cutouts are described when subjected to compression load. Interlaminar

shear stress occurs on the near the free edge of the cutouts.

In general, reinforcement around a cutout in a compression-loaded composite

cylindrical shells is shown to retard or eliminate the local buckling response, Interlaminr

shear stress near the cutout and increase the buckling load and decrease the deformation of

the shell.