New Concept

Status Update
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Sept 2012
2
Objective & Approach
1. Modal analysis

To Perform a Modal analysis to identify the significant modes and natural frequencies in X , Y and Z -directions affecting the
vibrations

2. Random Analysis

To Perform a Random analysis to identify stress and amplitude levels in the geometry when subjected PSD based random
input vibration in X , Y and Z - directions respectively. PSD random vibration input (Based on Danfoss Corporate Guideline
500B0432 curve A) will be provided at this stage.

3. Damage estimation analysis

To study the accumulated fatigue damage during a 2 hour testing in random vibration at the critical failure location. This is
done using Miners three-band technique for cumulative damage.


Objective
Approach

To study stresses under the random vibration profile based on Danfoss Corporate Guideline 500B0432 curve A with base line
design.
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Sept 2012
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Geometry , FE Model & Assumptions
Model is simplified as shown above.
Only structurally important components which contribute to the stiffness of bottom flange is considered.
Motor and all other components are modeled as a point mass.
A damping value of 3% is considered in Random analysis.
Two iterations need to perform with different material.
In new concept design, mold residual stresses are not expected.
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Sept 2012
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Boundary conditions
Fixed in all directions at the following locations(3 screw mountings)

Please confirm the boundary condition.
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Sept 2012
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S.NO. COMPONENT UNIT WEIGHT
1 Aluminum housing Kg 0.368
2 Aluminum ring cast
into the Bottom flange
Kg 0.026
3 Motor cup Kg 0.016
4 Aluminum frame Kg 0.033
5 Bottom flange Kg 0.084
6 Point mass to
represent other
components
Kg 1.373
ICAD TOTAL WEIGHT Kg 1.896
Weight details and material properties
S.NO. COMPONENT MATERIAL DENSITY
Kg/m
YOUNGS MODULUS
Pa
POISSONS
RATIO
1 Aluminum
components
ALUMINUM
ALLOY
2770 7.1E+10 0.33
2 Bottom flange LEXAN-500R
(10% GR PC)
1246 3.45E+09 0.37
Iteration 1
(old Material - LEXAN 500R)
Tensile Strength, yld, Type I, 5mm/min 66 Mpa ASTM D 638
Tensile Strength, brk, Type I, 5mm/min 55 Mpa ASTM D 638
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Sept 2012
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Fatigue data Of lexan-500
Cycles to
failure
Alternating stress
(Mpa)
6.4E+01 67
1.6E+02 62
6.4E+02 56
1.1E+04 42
4.3E+04 35
9.2E+04 32
3.4E+05 25
8.4E+05 21
1.2E+06 19
2.5E+06 16
5.1E+06 12
9.3E+06 10
Source : Sabic innovative plastics : PC resin product brochure

Referance
point(1)
Referance
point(2)
Number of cycles to fail 640 9.3E+06
Alternating Stress 56 10
Slope of fatigue line in log(X)- linear(Y) plot -11.05
Fatigue properties were not available for 20%GF variant of lexan-500.Therefore, properties of Lexan resin 500
is used for these calculations.

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Sept 2012
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Vibration spec used for Random vibration
The flange must pass the following vibration test:
IEC 60068-2-64 and Danfoss Corporate Guideline 500B0432 curve A.
Random vibration (PSD) specification
Frequency range : 18 Hz 1000 Hz.
Vibration level : 7,54g RMS.
Duration time : 3 axes ( X,Y&Z) x 2 hours in each direction,
Frequency
(Hz)
Power spectral
density (g^2/Hz)
18 0.245
150 0.06
1000 0.04
The following points have been extracted from
the graph using digitizer:
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Sept 2012
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PSD Random vibration in X Axis
Results
Notes:-
The RMS (Root Mean Square) stress levels observed from the random vibration analysis is only a statistical measure of the random
stress levels experienced by the assembly.
RMS stress levels are equivalent to 1sigma deviation of stresses following a Gaussian distribution. It means that during 68.27% of the
time, the stress levels seen in the assembly will fall in the range +1sigma to -1sigma.
As a thumb rule, the structure has to be designed to withstand the 3-sigma cyclic stress which is the stress range observed during
99.73% of test duration.


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Sept 2012
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Significant mode in X axis vibration
The most prominent vibration mode in X direction is ~198 Hz
90% mass participation was found @197.896 Hz.
This will be the most excited mode in X-axis vibration.
During 2 hours of testing, it will undergo ~ 1,424,851 cycles
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Sept 2012
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Stress PSD response during X-axis vibration measured near failure location
Random response X direction loading
Frequency
The most damaging vibration during X-axis excitation is occurring at approximately 198 Hz
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Sept 2012
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3-sigma RMS Stress (Mpa) @ X-axis vibration
Notes:-
3-Sigma RMS stress of 36.1 MPa is observed at the failure location. This means that actual stress values observed will not cross this
value during 99.7% of the random vibration duration.
Since this value is less than tensile strength of its material (~55MPa), the component is considered safe against yield failure.
Considering the low stress level, fatigue damage is also less likely to occur.
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Sept 2012
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PSD Random vibration in Y Axis
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Sept 2012
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The most prominent vibration mode in Y direction is ~201 Hz
89% mass participation was found @201.576 Hz.
This will be the most excited mode in y-axis vibration.
During 2 hours of testing, it will undergo ~1,451,347 cycles
Significant mode in Y axis vibration
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Sept 2012
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The most damaging vibration during Y-axis excitation is occurring at approximately 201 Hz
Frequency response Y direction loading
Frequency
Stress PSD response during Y-axis vibration measured near failure location
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Sept 2012
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3-sigma RMS Stress (Mpa) @ Y-axis vibration
Notes:-
3-Sigma RMS stress of 37.85 MPa is observed at the failure location. This means that actual stress values observed will not cross this
value during 99.7% of the random vibration duration.
Since this value is less than tensile strength of its material (~55MPa), the component is considered safe against yield failure.
Considering the low stress level, fatigue damage is also less likely to occur.
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Sept 2012
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PSD Random vibration in Z Axis
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Sept 2012
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The most prominent vibration mode in Z direction is ~765 Hz
94% mass participation was found @765.433 Hz.
This will be the most excited mode in Z-axis vibration.
During 2 hours of testing, it will undergo ~5,511,117cycles
Significant mode in Z axis vibration
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Sept 2012
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Frequency response Z direction loading
Frequency
The most damaging vibration during Z-axis excitation is occurring at approximately 764 Hz
Stress PSD response during Z-axis vibration measured near failure location
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Sept 2012
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3-sigma RMS Stress (Mpa) @ Z-axis vibration
Notes:-
3-Sigma RMS stress of 17.532 MPa is observed at the failure location. This means that actual stress values observed will not cross this
value during 99.7% of the random vibration duration.
Since this value is less than tensile strength of its material (~55MPa), the component is considered safe against yield failure.
Considering the low stress level, fatigue damage is also less likely to occur.
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Sept 2012
21
Action Plan
Maximum stress are seen on single node that calls for mash refinement study.
So next action plan is to perform mesh refinement near pick stresses location.
13
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Sept 2012