Reg. No.

M.E. DEGREE EXAMINATION, JUNE 2010 First Semester CAD/CAM

CC9212 FINITE ELEMENT ANALYSIS IN MANUFACTURING ENGINEERING (Regulation 2009) Time : Three hours Answer ALL Questions

PART A (10 2 = 20 arks) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Give one example for boundary value and initial value problems. State the principle of variational formulation. Differentiate between natural and essential boundary conditions.

State the benefits of natural coordinate system.

Express the Jacobian matrix of a linear triangular element. What are uses of gap element?

What is meant by chip separation criterion?

Name different methods of generation of mesh. What is solution phase in ANSYS?

11.

(a)

A steel rod of diameter d = 2 cm, length L = 25 cm, and thermal conductivity k = 50 W/m. C is exposed to ambient air T = 20 C with a heat-transfer coefficient = 64 W/m2 C. Given that the left end of the rod is maintained at a temperature of T0 = 120 C and the other end is exposed to the ambient temperature, determine the temperature distribution in the rod using a two-parameter Ritz approximation with polynomial approximation functions. The equation governing the problem is given by
d 2 dx 2 + c = 0 for 0 < x < 25 cm

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where = T T , T is the temperature, and c is given by

C = (P / Ak ) = ( D/ (1/4 )D 2 k = (4 / kD ) = 256 / m3

P being the perimeter and A the cross sectional area of the rod. The boundary conditions are :

(0 ) = T (0 ) T = 100 C . { k(d / dx ) + } / x = L = 0 .
Or

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{ }

PART B (5 16 = 80 Marks)

State any four types of presenting results from post processing.

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Maximum : 100 Marks

Question Paper Code: J7624

(b)

12.

(a)

(i) (ii)

Derive the stiffness matrix for a linear bar element.

The stepped bar shown in Fig.12 (a) is subjected to an increase in temperature, T = 80 C. Determine the nodal displacements and elemental stresses. (10)

(b)

Rectangular fins are used to remove heat from the surface of a body by conduction along the fins and convection from the surface of the fins into the surroundings. The fins are 100 mm long, 5 mm wide, and 1 mm thick, and made of aluminium with thermal conductivity k = 170 W/m C. The natural convection heat transfer coefficient associated with the surrounding air is ( = 35 W/m2 C) and the ambient temperature is

T = 20 C. Assuming that the heat transfer is one dimensional along the

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13.

(a)

length of the fins and that heat transfer in each fin is independent of the others; determine the temperature distribution along the fins and the heat removed from each fin by convection. Use two quadratic elements.

The Cartesian (global) coordinates of the corners of a triangular element are given by (6, 4), (12, 6) and (8, 12). The element is subjected to a temperature change 100 C. Assuming plane stress condition finds the load due to temperature change. Take E = 200 GPa, Poissons ratio = 0.3, thickness of the element = 2 mm and coefficient of thermal expansion of the element material = 7 10 6 / C .

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Stepper Bar Fig. 12(a) Or 2

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(6)

The deflection of a beam on an elastic foundation is governed by the equation d 4w / d 4 x + w = 1 , where x and w are dimensionless quantities. The boundary conditions for a simply supported beam are given by transverse deflection = w = 0 and bending moment = d 2w / dx 2 = 0. By taking a two-term trial solution as w(x ) = C1 f1 (x ) + C2 f2 (x ) with f1 (x ) = sin x and f2 (x ) = sin 3 x , find the solution of the problem using the (i) Galerkin method and (ii) the least squares method.

Or (b) The Cartesian (global) coordinates of the corner nodes of a quadrilateral element are given by (1, 1), (5, 1), (6, 6) and (1, 4). The element
Find the elemental strains. 14. (a) (i)

Explain the following with suitable examples: (1)

Incorporation of latent heat in finite element analysis of castings. Crank-Nicholson algorithm.

(2) (ii)

Discuss the prediction of grain structure in normalized carbon steel plates using FEA in detail. (8) Or

(b)

(i)

(ii)

15.

(a)

(i)

Explain with suitable example the three phases of FEA using a commercial FEA software. (10) How are material and processing characteristics given as input in ANSYS and DEFORM? (6) Or

(ii)

(b)

(i)

Discuss the advantages and limitations of ANSYS and DEFORM packages. (8) Write down a computer program to find the displacements and stresses in a stepped bar subjected to an axial load. (8)

(ii)

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Discuss briefly FEA of metal cutting of carbon steels including the chip separation criteria. (8)

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3

Explain the basic concepts of plasticity. How is plasticity concepts incorporated in finite element analysis of metal forming processes? (8)

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T

displacement vector q is given as q = [0, 0, 0.20, 0.15, 0.10, 0, 0.05] .

(8)

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