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ENG581 Modelling and Simulation: Coursework 1 Assessment Answer

Coursework
Coursework 1
ENG581 Modelling and Simulation

TB2 - Coursework 2 (50%) - Structural integrity and safety assessment of the connecting road of an Aero Engine: a FEM analysis with CREO simulate

Learning Outcomes:

  • Apply Structural simulation and analysis to optimise product design.
  • Appraise the use of an integrated 3D CAD/Computer Aided Engineering (CAE) software packages for efficient solutions of real engineering problems.

Student Input:

The connecting road of the assembly finalised in CW 1 should be considered as geometry. Expected loads from the combustion chamber via the cylinder are to be retrieved from table 1 reported at the end of the CW. A complete Finite Element Analysis should be used to assess the structural integrity and the safety of the part.

A typical student should be able to complete this piece of work in 40-50 hours.

Submission:

A ZIP file containing all Creo files/models (3d models) from the working directory and a Report file (Word doc or PDF) to be submitted to Moodle before the date/time specified on the front page.

Late Submission:

Submission and assessment will be in accordance to Academic Regulations, University of Portsmouth, Academic Registry.

Design brief:

Check the structural integrity and assess the safety of the transmission rod of an Aero Engine by using Finite Element modelling integrated on a 3D CAD modelling software

Select the connecting rod of the engine model developed for CW1. Select the assigned combustion pressure from table 1 corresponding to the last digit of your student number. Use the FEM module integrated on the CAD modeller (Creo Simulate) to check the expected distribution of stresses, potential issues with instability and resonance.

In order to fulfil the design brief you need to follow the tasks outlined below and in parallel to present your work in a report/logbook (MS Word then converted in a PDF document for submission) including computer screenshots, relevant comments, results, discussion and evaluation.


Design goals

  • Check the safety of the part with respect to all factors resulting in part failure or structural instability.
  • Try to optimise the part by reducing its weight without compromising the safety.
  • Assess the safety factor of the final design for the part.
  • Check potential issues related to resonance and make some grounded hypothesis to tackle it.

Required tasks: (Write your report/logbook using these headings)

  1. Analyse the Connecting Rod of your engine design from CW1 using FEA Strength in Creo with respect to the expected stresses in a reference vertical position. Identify and apply appropriate constraints to replicate the connection with the crankshaft; identify and apply the expected Load resulting from the pressure on the piston on the combustion chamber (pressure values taken from Table 1 corresponding to your variant).Design If the FEA analysis indicated issues due to unsafe stresses and/or excessive displacements/deformations, revise the design/material in order to get a safe design (e.g. changing material assignment and/or revising some geometrical detail).(up to 30 marks)
  2. Provided a safe solution is identified, try to optimise the design of the connecting road i.e. reducing the weight of the part while maintaining safe mechanical resistance. Discuss these improvements.(up to 20marks)
  3. Identify the maximum load that can be safely applied to the connecting road in its final design, assuming the boundary conditions specified at point 5.(up to 20 marks)
  4. Check whether the final design for the connecting road can be considered suitable to operate at the expected ranges between 1200 and 20000 rpm. If appropriate, suggest and check suitable changes to the design.
  5. Finalise your report (max 2000 words, 10-15 pages) following the above task list. In conclusion critically analyse the use of integrated 3D CAD software in product design and realisation.(up to 20 marks)

Table 1 Combustion pressure values for variants of the course work


Last digit of
Student ID Number
0
1
2
3
4
5
6
7
8
9
Combustion
pressure, psi
500
525
550
575
600
625
650
675
700
725


Answer

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