International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 11, November 2018, pp. 1303–1312, Article ID: IJMET_09_11_135 Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=11 ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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DESIGN AND ANALYSIS OF TORSION BAR MADE OF E-GLASS FIBER REINFORCED COMPOSITE

P. Booneshwaran Assistant Professor, Department of Mechanical Engineering, Sri Balaji Chockalingam Engineering College, Arni-632317, Tamilnadu, India

M. Gnanasekaran Assistant Professor, Department of Mechanical Engineering, Sri Balaji Chockalingam Engineering College, Arni-632317, Tamilnadu, India

S. Ayyappan Assistant Professor, Department of Mechanical Engineering, Sri Balaji Chockalingam Engineering College, Arni-632317, Tamilnadu, India

V. Thirunavukkarasu Principal, Department of Mechanical Engineering, Sri Balaji Chockalingam Engineering College, Arni-632317, Tamilnadu, India

C. Arumugam Assistant Professor, Department of Mechanical Engineering, Sri Balaji Chockalingam Engineering College, Arni-632317, Tamilnadu, India

ABSTRACT Automobiles are nowadays a part of day to day life as it accompanies man in various applications. Hence it has a greater significance in its design and modelling especially for Indian road conditions. Many components in the automobiles are being replaced by the composite materials such as propeller shaft, leaf springs, integral , dash boards, bumpers, body, upholsteries, etc. A suspension system called torsion bar suspension system was incorporated in old model and slowly it was field out due to some demerits. Hence a new torsion bar made of composite material need to be indentified which can enhance with the requisites like to allow for ability, to transmit braking force, to supply action and to damp down vibrations. This research aimed at replacing mild steel torsion bar with E Glass fiber reinforced composite material. The torsion bar is designed in CATIA V5 and analyzed in ANSYS software. Different types of results have been taken in this analysis and the stress, deformation and strain values are obtained.

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Keywords: Torsion Bar, Mild Steel, E-Glass Fiber Reinforced, CATIA V5, ANSYS.

Cite this Article: P. Booneshwaran, M. Gnanasekaran, S. Ayyappan, V. Thirunavukkarasu and C. Arumugam, Design and Analysis of Torsion Bar Made of E- Glass Fiber Reinforced Composite, Stress Analysis of Crank Shaft by Using Finite Element Modelling, International Journal of Mechanical Engineering and Technology, 9(11), 2018, pp. 1303-1312 http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=11

1. INTRODUCTION Torsion bars are more familiar in the field of suspension systems made of mild steel and they were used in compact/limited spaces. The structure of a torsion bar looks similar to a cylindrical shaft whenever the vehicle moves along bumpy/jerky roads the torsion bar provides suspension by means of twisting in order to provide comfort to the passenger. Torsion bars are essentially metal bars that functions as a spring Each bar is hex shaped on the anchor end with a replaceable torsion bar to lower bushing on the opposite end and a pivot cushion bushing (permanently attached) midway on the bar creating right and left hand assemblies [1-4]. The hex end of the bar is anchored in the cross member (opposite the affected ) extends parallel to the front cross member, through the pivot cushion bushing (also attached to the cross-member) turns, and attaches to the lower control arm through the torsion bar to lower control arm bushing. The designers seek to reduce weight with every single opportunity. Composite materials, with their high strength/weight ratio are becoming popular with their increasing availability [5-8]. The main design parameter for a torsion bar is torsional rigidity, and as explained above, weight.

Figure 1 Torsion Bar Arrangement in Chassis

2. LITERATURE REVIEW A descriptive outline about the features of torsion bar and damping system as they relate to suspension system is revealed and the performance for armoured and non-armoured military tracked vehicles. It envisages functions of suspension system such as to allow for steering ability, to transmit braking force, to supply spring action and to damp down vibrations [9-12]. The stability behaviour of rotating composite bars under axial compressive loads by using finite element method has been investigated. The laminated composite bar is modelled by applying equivalent beam theory. The stability of the composite laminated shaft is compared

http://iaeme.com/Home/journal/IJMET 1304 [email protected] P. Booneshwaran, M. Gnanasekaran, S. Ayyappan, V. Thirunavukkarasu and C. Arumugam with the steel shaft. It was found that the critical speed of the laminated composite bar depends on the stacking sequence, the length to radius ratio (L/R) and the boundary conditions [13-18]. Cross-section deformation of tubular composite bars subjected to static loading conditions was examined. In this study theoretical and experimental studies have been carried out on deflection and cross-section deformation for composite tubular shaft [19-23]. Carbon and aramid reinforced plastic for automotive propeller shaft and found that High strength/stiffness tubes can be produced from carbon fibre reinforced plastics, Aramid fibre reinforced plastics, or hybrid laminates using a filament winding process was analysed. Such tubes are adaptable for the manufacture of power shafts for example automobile propeller with positive advantages over those in metal in terms of weight reduction and assembly [24-28].

3. E-GLASS FIBER REINFORCED COMPOSITE MATERIAL Glass fibers with polymeric matrices have been widely used in various commercial products Glass is by far the most widely used fiber, because of the combination of low cost, corrosion resistance, and in many cases efficient manufacturing potential. It has relatively low stiffness, high elongation, and moderate strength and weight, and generally lower cost relative to other composites. It has been used extensively where corrosion resistance is important, such as in piping for the chemical industry and in marine applications.

3.1. Composition of E-Glass Fiber

• E-Glass is a low alkali glass with a typical nominal composition of SiO2 54wt%, Al2O3 14wt%, CaO + MgO • 22wt%, B2O3 10wt% and Na2O+K2O less then 2wt%. Some other materials may also be present at impurity levels.

3.2. Properties of E-Glass Fiber Properties that have made E-glass so popular in fibreglass and other glass fiber reinforced composite include: • Low cost • High production rates • High strength • High stiffness • Relatively low density • Non-flammable • Resistant to heat • Good chemical resistance • Relatively insensitive to moisture • Able to maintain strength properties over a wide range of conditions • Good electrical insulation

3.3. Selection of Material There are varieties of composite materials which can be used for replacing the engineering components. But the one which should cope up with the basic requirements of the torsion bar need to be un earthed. Study has revealed that E glass Fiber reinforced composite material have properties which can be utilized for replacing steel torsion bar. The very important property required for a torsion bar is the resilience property.

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3.4. Resilience Resilience is the ability of a material to absorb energy when it is deformed elastically, and release that energy upon unloading. The modulus of resilience is defined as the maximum energy that can be absorbed per unit volume without creating a permanent distortion.

3.5. Composition of E-Glass Fiber Reinforced Composite Material • Carbon • Glass • Aramid fiber • Epoxy • Polyester and • Resin bath

3.6. Feasibility of E-Glass Fiber as Torsion Bar The important requirement of a torsion bar is its tensile strength and high resilience. In that manner both the properties are found to be higher than the mild steel. E-Glass fiber Tensile strength - 2000Mpa Resilience - 377 KN/m2 Mild Steel Tensile strength - 500Mpa Resilience - 272 KN/m2

4. BASIC CONCEPTS OF COMPOSITE MATERIALS Composite materials are basically hybrid materials formed of multiple materials in order to utilize their individual structural advantages in a single structural material. Some scientific definitions for composite materials can be expresses as follows. The word composite means made up of two or more parts. A composite material is one made of two other materials. The composite material then has the properties of the two materials that have been combined. The word composite in the term composite material signifies that two or more materials are combined on a macroscopic scale to form a useful third material. The key is the macroscopic examination of a material wherein the components can be identified by the naked eye. Different materials can be combined on a microscopic scale, such as in alloying of metals, but the resulting material is, for all practical purposes, macroscopically homogeneous, i.e., the components cannot be distinguished by the naked eye and essentially act together. A composite is a structural material which consists of combining two or more\ constituents. The constituents are combined at a macroscopic level and are not soluble in each other.

4.1. Fibers Fibers are the principal constituent in a fiber-reinforced composite material. They occupy the largest volume fraction in a composite laminate and share the major portion of the load acting on a composite structure. It influences the following characteristics of a composite laminate. • Specific gravity • Tensile strength and modulus • Compressive strength and modulus • Fatigue strength and fatigue failure mechanisms

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• Electric and thermal conductivities • Cost

Figure 2 Specific Modulus and Specific Strength for Various Engineering Materials and Fibers

4.2. Glass Fibers Glass fibers with polymeric matrices have been widely used in various commercial products such as piping, , boats and sporting goods. Glass is by far the most widely used fiber, because of the combination of low cost, corrosion resistance, and in many cases efficient manufacturing potential. It has relatively low stiffness, high elongation, and moderate strength and weight, and generally lower cost relative to other composites. Glass fibers are strong as any of the newer inorganic fibers but they lack rigidity of on account of their molecular structure. The properties of glasses can be modified to limited extent by changing the chemical composition of the glass, but the only glass used to any great extent in composite materials is ordinary borosilicate glass, known as E-glass. (Harris. B; 1999; 7).E glass is available as continuous filament, chopped stable and random fiber mats suitable for most methods of resin impregnation and composite fabrication.

5. CONVENTIONAL MATERIALS AND THEIR LIMITATIONS It is difficult to draw up a table of materials characteristics in order to assess the relative strengths and weaknesses of metals, plastics and ceramics because of each these terms covers whole families of materials within which the range of properties is often as broad as the differences between the tree classes. Plastics are of low density. They have poor mechanical properties, but are easily fabricated and joined. Ceramics may be of low density .They have great thermal stability and are resistant to forms of abrasion, wear, corrosion are mostly of medium to high density- only magnesium, aluminum and beryllium can compete with plastics in this respect. They have useful mechanical properties and high toughness, and they are easier to shape and join.

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Figure 3 Torsion Bar

5.1. Overview of CATIA v5 CATIA v5 is a designing computer-aided design/computer-assisted manufacturing/computer- aided engineering (CAD/CAM/CAE) system that fully use to create the model, it also consist of simulation, analysis. CATIA V5 builds on powerful smart modelling and morphing concepts to enable the capture and reuse of process specifications and intelligence. This capability allows optimization of the entire product development process while controlling change propagation. The below shown diagrams has modelled by using CATIA V5 modelling software.

Figure 4 CAD Model for Torsion Bar

6. STRESS AND DEFORMATION ANALYSIS BY FEM PACKAGE ANSYS Mechanical provides solutions for many types of analyses including structural, thermal, modal, linear buckling and shape optimization studies. ANSYS Mechanical is an intuitive mechanical analysis tool that allows geometry to be imported from a number of different CAD systems. It can be used to verify product performance and integrity from the

http://iaeme.com/Home/journal/IJMET 1308 [email protected] P. Booneshwaran, M. Gnanasekaran, S. Ayyappan, V. Thirunavukkarasu and C. Arumugam concept phase through the various product design and development phases. The use of ANSYS Mechanical accelerates product development by providing rapid feedback on multiple design scenarios, which reduces the need for multiple prototypes and product testing iterations. The ANSYS Workbench environment is an intuitive up-front finite element analysis tool that is used in conjunction with CAD systems and/or Design Modeller. ANSYS Workbench is a software environment for performing structural, thermal, and electromagnetic analyses. The class focuses on attaching existing geometry, setting up the finite element model, solving, and reviewing results.

Figure 5 Total Deformation

Figure 6 Equivalent Elastic Strain

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Figure 7 Equivalent Stress

Figure 8 Shear Stress

7. CONCLUSION Design and analysis of torsion bar made of e-glass fiber reinforced composite using CATIA and ANSYS software was carried out. From the obtained results the following conclusions were made. • Both of the study was carried out and the results were verified with the help of ANSYS software. • The result reveals that the e-glass fiber reinforced composite material is best suited for a torsion bar. • Thus we have concluded that torsion bar made of e glass fiber reinforced composite material will be more advantageous, comfortable and consistent when compared to torsion bar made of mild steel.

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