Evolution of Mathematical Function Based On Statistical Methods for Determination of Geometrical Parameters for Known Natural Frequency of Structural

Elements
S.M Khot1, Nitesh P. Yelve1, Himanshu Paretkar2, Kunjal Kapadia2, Nikhil Sehgal2, Vivek Hariharan2 1 Asst Professor, 2Undergraduate Students Fr. C. Rodrigues Institute of Technology of Technology, Vashi Navi Mumbai 400 703 Email:smkhot66@yahoo.com, niteshpy@yahoo.co.in, himanshu_xaviers@yahoo.co.in, nikhil.sehgal09@gmail.com, kapadia.kunjal@gmail.com, vivekvarun@yahoo.com Avoiding the phenomenon of resonance is the prime objective of any design engineer who is designing a structure that is subjected to substantial vibrations. Most vibration controlling techniques are employed after the structure is designed. However there is still a lot of scope in formulating techniques to predict the design parameters of a system that would lead to resonance. This would provide the user with valuable information regarding certain design parameters. Also elaborate and expensive methods for controlling vibrations in the system, to prevent resonance can be minimized if not completely eradicated. This paper explores the possibility of using statistical methods in order to estimate the values of geometrical parameters, which would give the desired natural frequency of the system so that resonance is avoided. This project analyses a cantilever beam for natural frequencies for different set of geometrical parameters (length and thickness for a given material). These results are used in the statistical method based on Taguchis techniques of Quality Engineering (DOE, Orthogonal Arrays and ANOVA) to determine the major contributing geometrical parameters, to the natural frequency of the beam. The statistical method of Regression Analysis is used to establish a mathematical relationship between the major contributing parameters and the natural frequency of the beam is further explored. Finally the methodology is tested for a Reed Valve used in Hermetic Compressors. 1. Introduction In todays highly competitive world time is equivalent to money. The designing process for a product is constantly under strain to provide the best possible output in least possible time. Continuous changes must be made in the designing procedure to obtain the desirable results. In majority of design processes the dynamic testing of the product is done after the strength design and development of prototypes. However during the dynamic testing if the natural frequency of product if resonance occurs, there is a need to change the geometrical parameters of the product. This leads to wastage of time. Thus if a designer has a tool or a mathematical function to estimate the geometrical parameters of the product for a given natural frequency, he can make changes during the design process itself. One method to obtain this mathematical function is through the use of Statistical Techniques which is discussed in the subsequent sections. 2. FEM Analysis By ANSYS The cantilever beam is analyzed using ANSYS and its natural frequency is determined for the first mode shape for different combinations of length and thickness. The element selected is beam 3.The results obtained from ANSYS are validated with the experimental and analytical results [1] and found to be in close agreement. These results are then used in Taguchis method of orthogonal array. 3. Design Of Experiment (DOE)

The DOE approach is based on the use of orthogonal arrays (Taguchi) to conduct small, highly fractional factorial experiments up to larger, full-factorial experiments. A designed experiment is the simultaneous evaluation of two or more factors (parameters) for their ability to affect the resultant average or variability of particular product or process characteristics. [2]

The natural frequency of a cantilever beam depends upon its length, thickness and material properties. The material for the cantilever beam is fixed as stainless steel (Youngs Modulus=2.11011N/m2, density=7850kg/m3). Hence to vary the natural frequency we vary length and thickness of the beam. The experimentation details are given in table Table 1-Parameters and their levels Control Factors Level 1 Level 2 Level 3 1.Length 2.Thickness 550(L1) 9 (T1) 610(L2) 10(T2) 650(L3) 11(T3)

Since only 2 factors are involved a full factorial experiment with 3 levels of these factors can be performed. To conduct a full factorial experiment for two factors and three levels nine experiments have to be conducted. This data is arranged as follows. Table 2-Arrangement for 3 factors and 3 levels Factors l1 l2 l3 lt t1 X1 Y1 Z1 X1+Y1+ Z1 t2 X2 Y2 Z2 X2+Y2 +Z2 t3 X3 Y3 Z3 X3+Y3 +Z3 4. Statistical Analysis By ANOVA The analysis using ANOVA is performed manually and the effect of individual parameters and their interactions is determined. Table 3-Frequencies obtained for different combinations Factors l1 l2 l3 lt t1 24.856 20.209 17.7712 62.386 t2 27.617 22 19.776 69.393 t3 30.379 24.698 21.753 76.830 Total 82.852 66.907 59.3 209.059 From the above table we can hence estimate the following terms using the equations [2] SST = (Yi - Tm)2 SSl = [ (li2/nli)] T2/N SSt = (t1 -t2)2 / N SSlt = [( (lt)i2 / n(lt)i )] T2/N SSl SSt Where Yi Ai Aim T Tm nAi N SSA SST SSAB = ith observation, response, data = sum of observations under Ai level = average of observation under Ai level = Ai/nAi = sum of all observations = average of all observations = T/N = number of observations under Ai level = total number of observations = variation due to any factor A =total sum of squares = total sum of squares due to interaction

(1) (2) (3) (4)

5. Percentage Contribution The portion of the total variation observed in an experiment attributed to each significant factor and/or interaction is reflected in the percent contribution. It indicates the relative power of a factor and/or interaction to cause the variation in the final outcome. If the factor and/or interaction level were

controlled precisely then the desired value of the outcome can be controlled or if we can control the outcome we can have the desired value of the factors or the interactions. The results for percentage contribution of individual parameters and their interaction are given in table 4. Table 4-Percentage contribution of various factors Factors SST %Contribution Length 96.312 74.225 Material 32.682 25.197 Material Length 0.710 0.540 Residual 0.0047 0.008 6. Regression Analysis 6.1 Simple Regression Regression analysis is used to explore the possibility of nature of relationship between two or more variables. The general objective of regression analysis with two numerical variables x and y is to obtain some type of conclusion concerning y using information about x. Here, y is the dependent or response variable and x is the independent variable. The independent variable is often referred to as the predictor variable as in many investigations predicting a y value from a given x value is a primary objective. For the first step in regression analysis a dataset is collected which consists of observations on two variables x and y in the form of a pair of numbers. An unorganized list of such pairs, by itself, yields no information about the relationship of the two variables. This numerical data is assumed to be plotted on a rectangular co-ordinate system with the independent variable on the horizontal axis. The next step is to summarize the relationship between the two variables by finding a line fitting closely to all the points in the plot. The line gives an idea about the approximate linear relation. The line that fits the best is the line closest to the sample data and the deviations from the line are small in magnitude. The value of b, the slope of the line is the amount by which y increases when x increases by 1 unit. The vertical or y intercept a is the height of the line above the value x = 0. Hence, the simple regression model relating y to x is given as y = a + bx The slope b of the least squares line is given by b = Sxy / Sxx The vertical intercept a of the least squares line is a = y bx where Sxx = xi2 ( xi)2 / n Sxy = xiyi ( xi)( yi) / n 6.2 Multiple Regression The natural frequency depends upon two independent predictors length and thickness. This calls for the use of a regression model which makes use of more than one regressor variable called the multiple regression models. Such a model explains more variation and provides better prediction in comparison with the simple regression model. A general additive multiple regression model, which relates a dependent variable y to k predictor variables is given by the model equation y = + 1x1 + 2x2 + + kxk (10) The is are called population regression coefficients. Hence, the regression equation to predict natural frequency with length and thickness as predictors will be modelled as f = + 1l + 2t The coefficient of multiple determinations is defined as R2 = 1 - SSRes / SST (11) (12) (5) (6) (7) (8) (9)

Residual sum of squares, denoted by SSRes, is given by SSRes = (yi yi)2 = (y1 y1)2 + + (yn yn)2 And total sum of squares, denoted by SST, is defined as SST = (yi yi)2 = (y1 y1)2 + + (yn yn)2

(13) (14)

where the ^ above y denotes that y is a prediction of y that results from the substitution of any particular x value into the approximate regression equation. The R2 value is the portion of y variation that can be explained by an approximate linear equation. The closer the value of R2 is to 1 the better the explanation of the model of the variation of the predictors with the response variables. 6.3 Creating New Predictors From Existing Ones The natural frequency equation for a cantilever beam known to us isnt a linear relation. Therefore, the regression model for predicting natural frequency with two predictors gave R2 value not close to 1. Thus, making it incapable explaining the variation effectively. The possible explanations to this can be the failure to take into account the interaction between the variables. Another reason could be the need of a quadratic predictor to explain the variation effectively. The ability of the predictors to explain the variation in the response variable can be enhanced by using additional predictors that are mathematical functions of the original predictors. If the change in the mean y value associated with a 1-unit increase in one independent variable depends on the value of a second independent variable, there is interaction between these two variables. Denoting the two independent variables by x1 and x2, we can model this interaction by including an additional predictor x3 = x1x2, the product of the two independent variables. As the natural frequency depends simultaneously on thickness and length an additional interaction predictor is incorporated which is the product of the length and thickness, thus, making the model f = + 1l + 2t + 3(lxt) (15) This regression model, though, increasing the R2 value considerably, still falls short in the effective explanation of variation. Next, additional predictors, the quadratic predictors, which are squares of the length and thickness variables, are included. Quadratic predictors are often included to model a curved relationship between the response variable and several other independent variables. Now the full quadratic or complete second order model which includes both, the interaction predictors as well as the quadratic predictors is developed. f = + 1l + 2t + 3(lt) + 4l2 + 5t2 6.4 Calculations Initially with a database of 30 values a regression equation was obtained with the help of MINITAB software which yielded the model f = 41.8 - 0.0618 (l) + 1.88(t) (17) A sample calculation from within the database was checked for the above equation and was compared with the frequency obtained from ANSYS l = 500mm, t = 15mm Expected frequency Calculated frequency Error : 50.106 Hz : 39.1 Hz : 21.96% (16)

As we see, the error in calculating the given frequency was above 20% the database was expanded to 85 values. Also, the interaction predictor which is the product of length and thickness as the third parameter was included. f = 7.25 - 0.0986(l) + 4.48(t) - 0.00375(lxt) Again calculating for a given frequency from the dataset l = 702.9mm, t = 9.82mm (18)

Expected frequency Calculated frequency Error

: 16.604 Hz : 18.428 Hz : 10.9%

Again the error is much more than the acceptable limit of 5%. Next, the database is increased to 174 values and is also incorporated with the quadratic predictors which are squares of the length and thickness variables. f = 76.2 - 0.236(l) + 6.17(t) - 0.00621(lxt) + 0.000178(l)2 - 0.00088(t)2 Calculating for a given frequency from the database, we see that l =690mm, t = 13.4mm Expected frequency : 23.513 Hz Calculated frequency : 23.2081 Hz Error : 1.3% Thus after incorporating the full quadratic model the error is considerably reduced and fall within the acceptable range of 5%. 7. Case Study- Reed Valve 7.1 Introduction The hermetically sealed reciprocating compressors are widely used in the refrigeration and air conditioning applications. The noise levels in the compressor have to be maintained in the audible range i.e. less noise and compact size. One of the significant sources of higher frequency noises are the suction or discharge cantilever reed valves which control the refrigerant gas flow from the suction or discharge port. A reed valve is actuated by pressure difference across it. The preliminary design of these reed valves depends on the shapes of valve ports and cylinder block. Under these confined geometries, the reed valve is to be properly designed to perform continuous operation satisfactorily. So it is important to predict the dynamic characteristic of the reed valve. The natural frequency of such a system is significantly dependent on length, thickness, and material properties. However for a particular make of the reed valve there will be a constant material. So the natural frequency of the system is dependent on the length and thickness. To perform regression analysis there must be an agreement upon a particular range of length and thickness for a given material. The reed valve under consideration is the one used in Hermetic compressor model KC-3, manufactured by the KIRLOSKAR COPELAND LTD., KARAD. A. Material properties: 1. E = 2.068428 * 1011 2. Density= 7800 Kg/m3 B. Range of thickness: Thickness varies from 0.2mm to 0.7mm C. Range of Length Length of reed valve varies from 40mm to 70mm 7.2 Regression Analysis Step1: A database for reed valve is created. The data base contains information about the natural frequencies of reed valve at different combination of length and thickness. It is seen that the value of natural frequency for the given make of reed valve for the first mode, when calculated through analytical method and through FEM analysis in ANSYS is equal within permissible error limits [6]. Hence the relation obtained from the analytical methods is used to determine the natural frequency of the given reed valve. A part of the entire database is shown in Table 5 Table 5-Sample of database created LENGTH (l) THICKNESS (t) NATURAL FREQUENCY (f) (19)

40 44 48 62 72

0.62768 0.3221 0.29282 0.5192 0.354

296.8112 138.4646 105.7716 112.4093 56.8315

Step 2: A full quadratic regression model is created. This includes additional parameters like thickness2, length2, length x thickness (interaction). Step 3: The entire database is then analyzed in the statistical software MINITAB The regression equation is obtained as follows. Frequency = 328 - 12.3 (length) + 922.0 (thickness) 11.0 (length x thickness) + 0.11 (length) 2 11.2 (thickness) 2

(20)

Step 4: Random entries are then chosen from the database and the values of natural frequency from the database are compared with the frequency values obtained from the above frequency equation. Finally the error percent is calculated. Table 6-Sample Calculations FREQUENCY OBTAINED NATURAL FREQUENCY (f) FROM REGRESSION 296.8112 138.4646 105.7716 112.4093 56.8315 310.785 141.2356 105.52 109.882 57.256 % ERROR 4.99 2.005 0.31 2.24 0.747

LENGTH (l) 40 44 48 62 72

THICKNESS (t) 0.62768 0.3221 0.29282 0.5192 0.354

8. Conclusion and Future Scope The procedure involves a path wherein one needs to determine the significant parameters affecting the natural frequency of a structure and obtain a mathematical relationship for it. The technique of ANOVA and Regression Analysis makes this possible. This methodology will help designers to alter their design right at the initial stages to counter resonance which otherwise would have been predicted only after the designing stage, during the dynamic testing. The future scope of this work might involve evolution of similar mathematical functions for other more complicated geometries to obtain a mathematical relationship between the significant geometrical parameters and the natural frequency of the system. 9. References 1. Phillip J. Ross (Edition 4), Taguchi Techniques for Quality Engineering Tata McGraw Hill Publication 2. Madhav S. Phadke (Edition 2), Quality Engineering and Robust Design, Tata McGraw Hill Publications. 3. Douglas C. Montgomery and George C. Runger (Edition 4), Applied Statistics and Probability for Engineers, Prentice Hall India Publications. 4. S. P. Gupta (Edition 7), Statistical Methods, Dhanpat Rai Publications. 5. S.M. Khot, C.M. Choudhri, Nitesh P. Yelve and Jitendra K. Sardar, 2006, An Investigation of Effect of System Parameters on Natural Frequency of Beams by Using Statistical Methods, Proceedings of the Second International Conference on Computational Mechanics and Simulations. 6. A Project Report on Design Analysis of Discharge Valve Thickness of a Hermetic Compressor by Using Technique by Somesh J. Ghunkikar under the guidance of Professor S. M Khot. Department of Mechanical Engineering , Rajarambapu Institute of Technology, Rajaramangar.