Design And Analysis Of Casting Valve For High Voltage ABC Dead End Clamp By Using Finite Element Analysis.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ANALYSIS OF CASTING VALVE FOR HIGH

VOLTAGE ABC DEAD END CLAMP BY USING FINITE

ELEMENT ANALYSIS

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design)

SITI NUR MADIHAH BT APANDI B050810074

FACULTY OF MANUFACTURING ENGINEERING 2012

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Design and Analysis of Casting Valve for High Voltage ABC Dead End Clamp by

Using Finite Element Analysis SESI PENGAJIAN: 2011/ 12 Semest er 2

Saya SITI NUR MADIHAH BT APANDI

mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk

t uj uan pengaj ian sahaj a dengan izin penulis.

3. Perpust akaan dibenarkan membuat salinan lapor an PSM ini sebagai bahan pert ukaran

ant ara inst it usi pengaj ian t inggi. 4. **Sila t andakan (√)

PENYELIA PSM

Tarikh: _______________________

** Jika Laporan PSM ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyat akan sekali sebab dan t empoh laporan PSM ini perlu dikelaskan sebagai SULIT at au TERHAD.

Alamat Tet ap:

Lot 201, Kg. Kayu Kelat , 22300 Kuala Besut , Terengganu.

Tarikh: _________________________ TIDAK TERHAD

TERHAD SULIT

Disahkan oleh:

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)

(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

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DECLARATION

I hereby, declared this report entitled “Design and Analysis of Casting Valve for ABC Dead End Clamp, HV by using Finite Element Analysis” is the results of my

own research except as cited in references.

Signature : ……….

Author’s Name : ………

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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfilment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design). The member of the supervisory committee is as follow:

……… Principal Supervisor

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ABSTRAK

Kesukaran kecacatan pada struktur produk boleh disebabkan oleh gabungan faktor-faktor yang banyak. Kaedah yang biasa digunakan dalam menganalisis reka bentuk semasa pemutus injap dengan menggunakan kaedah unsur terhingga. Reka bentuk injap pemutus sedia ada dicadangkan oleh syarikat amat sesuai dan terpakai untuk produk ABC Dead Clamp, Voltan Tinggi. Proses yang terlibat dalam injap Pemutus Dai Tekanan Tinggi bahawa tiada apa-apa permohonan terlalu banyak untuk menyebabkan kegagalan struktur yang tidak perlu injap pemutus. Tujuan kajian ini adalah untuk mewujudkan reka bentuk baru pemutus injap dan menentukan sama ada nilai faktor keselamatan adalah lebih besar daripada yang boleh didapati untuk memegang dan genggaman dawai keluli tergalvani standard kuat. Dengan menggunakan Analisis Struktur Statik (ANSYS), hasil daripada analisis bagi reka bentuk baru telah dibandingkan dengan reka bentuk sedia ada mengikut kepada nilai pemalar faktor keselamatan. Dari hasil analisis tersebut, nilai minimum faktor keselamatan yang dikenali adalah rendah dan kurang daipada 1, ianya memberikan kekangan yang lengkap untuk injap pemutus. Secara ringkasnya, reka bentuk baru untuk injap pemutus memberi hasil pegangan yang terbaik dan menggenggam ABC Dead End Clamp bervoltan tinggi dengan kuat berbanding dengan reka bentuk sedia ada.

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ABSTRACT

The difficulty of defects in product structure is caused by a combination of several factors. The most common method that used in analyze the current design of casting valve is using finite element method. The current design of casting valve is proposed by the company that very suitable and applicable for High Voltage ABC Dead End Clamp. The process involved in casting valve is High Pressure Die Casting (HPDC) that is no application too much for the cause of structural failure in unnecessary of casting valve. The aims of this research were to create a new improved design of casting valve and determine whether the value of the safety factor is larger than one that is possible to hold and grip the galvanized standard messenger steel wire strongly. By using Static Structural Analysis (ANSYS), the result of the finite-element analysis for new improved design is compared with current design analysis according to the minimum value of the safety factor. From the result, minimum safety factor was known that is below than 1 and able to provide an improved design for casting valve. Consequently, new improved design of casting valve presents the best holding and gripping for High Voltage ABC Dead End Clamp compared to the current design.

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iii

DEDICATION

For My Industrial Supervisor, Mr. Hirmanto Bin Suib and all my family members that support me physically and mentally, Father & Mother, Apandi Bin Yaa’cob & Ramlah

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ACKNOWLEDGEMENT

In the name of Allah S.W.T, the most gracious and the most merciful, thanks a lot for giving me this strength and opportunity to complete this report. In pursuing this research, I would like to thank several people who have contributed to this effort. The following individuals provided valuable comments on earlier drafts of the work: Engr. Tajul Ariffin Bin Abdullah as my official supervisor, Mr. Taufik as my second reader and others lecturers who have significantly helped, whether directly or not. Special thanks to my industrial supervisor, Mr. Hirmanto Bin Suib and all staff of Jati Beringin Sdn. Bhd. especially to the top management for their permission and support in allowing me to perform my research at the company’s place. A very hue appreciation also would like to be given to all the office staff from the Faculty of Manufacturing Engineering (FKP) and all the office staffs for their courage and support.

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TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables ix

List of Figures x List Abbreviations xii

1. INTRODUCTION 1

1.1 Background of Company 1

1.2 Background of Product 2

1.2.1 Casting Valve 4

1.2.2 Tensile Test 5

1.2.3 Application of Casting Valve 6

1.3 Problem statement 6

1.4 Objectives of research 8

1.5 Scope of research 8

1.6 Structure of research 8

1.7 Gantt Chart 10

2. LITERATURE REVIEW 11

2.1 Finite Element Analysis 11

2.1.1 Matrix Analysis of Trusses 14

2.2 Factor of Safety 15

2.2.1 Mohr Columb 18

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2.4 High Pressure Die Casting (HPDC) 21

2.5 Aluminum Ingot A380 24

2.6 3D Modeling in CAD System 26

2. 6.1 Methods for 3D Solid Modeling 27

2.6.2 Solid Modeling 28

3. METHODOLOGY 29

3.1 Flow Chart 30

3.1.1 Phase 0: Planning 31

3.1.2 Phase 1: Research Establishment 31

3.1.3 Phase 2: Design Development 31

3.1.4 Phase 3: Analysis & Comparison 32

3.1.5 Phase 4: Report Submission & Presentation 32

3.2 Analysis of Casting Valve 32

3.2.1 Finite Element Model 33

3.2.2 Geometrical Modeling 34

3.2.3 Loading 34

3.2.4 Material Properties 35

3.2.5 Static Structural Analysis 36

3.2.6 Finite Element in ANSYS 41

3.2.7 Selection of Safety Factor 41

3.3 Cause & Effect Analysis 43

3.4 Design Parameter 46

4. PROCEDURE FOR ANALYSIS BY USING ANSYS 48

4.1 Create Analysis System 48

4.2 Engineering Data 51

4.3 Geometry 52

4.4 Stiffness Behaviour 53

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vii

4.5.1 Physics Based Meshing 55

4.6 Establish Analysis Setting 57

4.6.1 Fixed support 57

4.6.2 Force 58

4.7 Solve 60

4.7.1 Equivalent (Von-Mises) Stress 60

4.8 Stress Tool 61

4.8.1 Safety Factor 62

4.8.2 Safety Margin 63

4.8.3 Stress ratio 64

4.9 Review result 65

5. RESULT OF ANALYSIS 66

5.1 Results for Current Design Analysis 66

5.1.1 Safety Factor 66

5.2 Results for Improvement Design of Casting Valve 69

5.2.1 Improvement Design 1 69

5.2.1.1 Safety Factor 70

5.2.2 Improvement Design 2 72

5.2.2.1 Safety Factor 73

5.2.3 Improvement Design 3 75

5.2.3.1 Safety Factor 76

6. COMPARISON & DISCUSSION 78

6.1 Comparison 78

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viii

7. CONCLUSION AND RECOMMENDATION 82

7.1 Conclusion 82

7.2 Recommendation 83

REFERENCES 84

APPENDICES

A General Concept Design B Gantt Chart PSM 1 & PSM 2

C Material Properties of Aluminum Ingot A380 D Detail Drawing

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LIST OF TABLES

1.1 The description of HV ABC Dead End Clamp 3

1.2 Result of Sample Test 7

2.1 Description of Shear Strength Reduction Algorithm 16

3.1 Alloy Composition in Aluminum Ingot A380 35

3.2 The mechanical properties of Aluminum Ingot A380 35

3.3 The characteristics of Aluminum Ingot A380 36

3.4 Description of factor of safety 42

5.1 Result of Safety Factor for Current Design Analysis 68

5.2 Result of Safety Factor for Improvement Design 1 71

5.3 Result of Safety Factor for Improvement Design 2 74

5.4 Result of Safety Factor for Improvement Design 3 77

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LIST OF FIGURES

1.1 HV ABC Dead End Clamp 2

1.2 Casting Valve 4

1.3 Tensile Test 5

1.4 Application of casting valve 6

1.5 Sample fracture of Casting Valve during Sample Test 7

2.1 The yield surface of the Deviatoric Plane 18

2.2 Mohr-Coulomb’s failure criterion 19

3.1 Flow Chart for PSM I and PSM II 30

3.2 3D Model of Casting Valve 33

3.3 The illustration of Casting Valve during Sample Test 34

3.4 Cause & Effect Analysis of Casting Valve 45

3.5 Design parameter at front view of casting valve 46

3.6 Design parameter at bottom view of casting valve 47

4.1 New Analysis System was created for Static Structural (ANSYS) 49

4.2 Windows for attaching geometry from SolidWorks 2010 50

4.3 Engineering Data workspace 51

4.4 Length unit option before start DesignModeler workspace 52

4.5 DesignModeler workspace 53

4.6 Details view toolbox for current design 54

4.7 Meshing option in Mechanical application 55

4.8 Meshing result for current design analysis 56

4.9 Fixed Support on Current Design Analysis 58

4.10 Graph Force vs Time 59

4.11 Force Load on Current Design Analysis 59

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4.13 Safety Factor of Current Design Analysis 62

4.14 Safety Margin of Current Design Analysis 63

4.15 Stress Ratio of Current Design Analysis 64

4.16 Solution Information in Worksheet 65

5.1 Minimum Safety Factor 67

5.2 Improvement Design 1 of Casting Valve 69

5.3 Safety factor for Improvement Design 70

5.4 Improvement design 2 of Casting Valve 72

5.5 Safety Factor for Improvement Design 2 73

5.6 Improvement design 3 of Casting Valve 75

5.7 Safety Factor for Improvement Design 3 76

6.1 Design parameter at front view 78

6.2 Design parameter at bottom view 79

6.3 Comparison between current and improvement design 80

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xii

LIST OF ABBREVIATIONS

2D - Second Dimensional

3D - Third Dimensional

ABC - Area Bundle Cable

API - Application Programming Interface

ANSI - American National Standards Institute

ASTM - American Standard Testing Method

CAD - Computer-Aided Design

CFD - Computational Fluid Dynamics

CSG - Constructive Solid Geometry

FEA - Finite Element Analysis

GUI - Graphical User Interface

HV - High Voltage

IGES - Initial Graphics Exchange Specification

JBSB - Jati Beringin Sdn.Bhd.

SPH - Smoothed Particle Hydrodynamics

TM - Telekom Malaysia Berhad

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CHAPTER 1 INTRODUCTION

This first chapter discussed about the introduction of casting valve for ABC Dead End Clamp, HV. Casting valve is a part of ABC Dead End Clamp, HV that is one of pole accessories for TNB’s product. The background, problem statement, objectives and scope of this research are discussed. The expected of this research is briefly discussed in this chapter.

1.1 Background of Company

Jati Beringin Sdn. Bhd. (JBSB) was incorporated on 2 September 1997 and operated at Alor Gajah, Melaka. Established by Mr. Asmadi Bin Wahid and his brother Mr. Daud Bin Wahid whose highly experiences in the engineering field. Owned a factory on the 0.5 acres of land which been equipped with a lot of modern machines and equipments to ensure the smooth operation in order to produce the high standard and quality product. Major in metal fabrication, this company has become a vendor for Tenaga Nasional Berhad (TNB) and Telekom Malaysia Berhad (TMB) to supply pole accessories. Others than that JBSB also involved in furniture manufacturing like to supply steel, lab furniture, office, built-in furniture, interior renovation, custom made steel product for private and government sector (door, grill, drain cover, etc.), and custom made steel work such as turning, milling, grinding and welding.

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1.2 Background of Product

The HV ABC Dead End Clamp is used as an accessory for High Voltage (HV) ABC System and suitably designed to hold and grip the 11kV and 33kV HV ABC 50 mm2 _{galvanized standard messenger steel wire to support it on to 10m-19-5kN spun}

concrete poles via HV Dead End Clamp Brackets (Single or Double). The HV ABC Dead End Clamp capable to withstand a minimum breaking load of 65 kN or 6630 kg-force or 7.3 ton kg-force for 60 seconds. The general concept design of High Voltage ABC Dead End Clamp is shown in Appendix A. Meanwhile, figure 1.1 shows High Voltage ABC Dead End Clamp for current use.

Figure 1.1: HV ABC Dead End Clamp (Source: Jati Beringin Sdn. Bhd., 2011)

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The description of High Voltage ABC Dead End Clamp is shown in the table 1.1. Table 1.1: The description of HV ABC Dead End Clamp

Item

No. Part Number Description Qty.

1 Shackle 16mm Finish Hot-Dip Galvanizing 1

2 Shaft For Shackle 16mm Finish Hot-Dip Galvanizing 1

3 Casting Valve High Pressure Aluminum Die _Casting 1

4 U-Bolt 1/2” For Dead End _Clamp Finish Hot-Dip Galvanizing 1

5 Pin Clip 1

6 Spring 20 mm x 40 mm _{Length x 2 mm} 1

7 Casting Valve Taper Lock _Holder ABS Plastic 1

8 Casting Valve Taper Lock 4

9 Casting Valve Washer High Pressure Aluminum Die _Casting 1

10 Stainless Steel Pipe 1

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1.2.1 Casting Valve

Casting valve is one of the parts in the HV ABC Dead End Clamp. The function of the casting valve is to hold and grip the galvanized standard messenger steel wire to support it on the spun concrete poles via HV Dead End Clamp Brackets (Single or Double). Figure 1.2 shows casting valve before make the Sample Test.

Figure 1.2: Casting valve (Source: Jati Beringin Sdn. Bhd., 2011)

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1.2.2 Tensile Test

In mechanical testing, tensile test is used as the testing to test the structural failure of casting valve. Basically, there are two classes of testing machines; electromechanical and hydraulic. Tensile test that is provided by this company is hydraulic machine. A hydraulic testing machine uses either a single- or dual-acting piston to move the crosshead up or down. (Richard Gedney, 2005)

Mechanical properties are an important measure of product quality in production line and tensile testing is a way to certify the product included to test the structure of casting valve for High Voltage ABC Dead End Clamp. Figure 1.3 shows the tensile test that used during Sample Test for Casting Valve and other product in this company.

Figure 1.3: Tensile test (Source: Jati Beringin Sdn. Bhd., 2011)

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1.2.3 Application of Casting Valve

Casting valve is one of the important parts of High Voltage ABC Dead End Clamp. Figure 1.4 shows one of the applications for High Voltage TNB distribution that is held and grip the galvanized standard messenger steel wire to support it on the spun concrete poles via HV Dead End Clamp Brackets (Single or Double).

Figure 1.4: Application of Casting Valve (Source: Jati Beringin Sdn. Bhd., 2011)

1.3 Problem statement

The Casting Valve is important and critical part of HV Dead End Clamp Bracket. In this case, the current design of the Casting Valve is failing to maintain 10% and below of the rejection rate during the Sample Test. Therefore, the product has fractured below 62kN for 60 seconds. Besides, the other problem that occurs on Casting Valve for HV ABC Dead End Clamp is not following Product Design and Development with a proper method. As a result, we need to redesign and develop new mould to make the modification for casting valve by using Finite Element Analysis (FEA).

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Figure 1.5: Sample fracture of casting valve during sample test (Source: Jati Beringin Sdn. Bhd., 2011)

Figure 1.5 shows a few samples of casting valve during sample test by using tensile test. Meanwhile, table 1.2 shows the summary of the result for the sample test. From the table 1.2, the fracture of casting valve happened five times during 10 samples of casting valve is tested. It shows that the design of casting valve is failing to maintain 10% and it will be improved.

Table 1.2: Result of sample test Sample

No.

Load 62 kN Time (60 second)

Result

Pass Fail Pass Fail

1 √ √

2 61kN √ Casting valve fracture at the U -

bolt

3 √ √

4 60kN √ Casting valve fracture

5 58kN √ Casting valve fracture

6 60kN √ Casting valve fracture

7 √ √

8 58kN √ Casting valve fracture

9 √ √

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1.4 Objectives of research

The objectives of this research are:

a) To investigate design parameter of casting valve for ABC Dead End Clamp, HV. b) To analyze the current design of casting valve for ABC Dead End Clamp, HV by

using Finite Element Analysis (FEA) software.

c) To propose new design of casting valve for ABC Dead End Clamp, HV.

1.5 Scope of research

This research investigates the current design of casting valve for ABC Dead End Clamp, High Voltage weakness, strength, and fracture or structure failure of this part. ANSYS software will be used to carry out this analysis and improvement on existing design based on the founding. The cover topic for this research is use design parameter and factor of safety for design improvement by using finite element analysis (FEA). It is used to study on current design by comparing actual experimental data from sample test. Then, new design of casting valve is drawn by using SolidWorks software.

1.6 Structure of research

Chapter 1 is covers the introduction by looking at problem statement, objective and scope of the research. The method of this research also explains briefly from the beginning of the PSM 1 in semester 1 until the finishing point of the PSM 2 in semester 2. Besides, the importance of the finding project and report structure also discussed properly in this research.

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The description of High Voltage ABC Dead End Clamp is shown in the table 1.1.

Table 1.1: The description of HV ABC Dead End Clamp Item

No. Part Number Description Qty.

1 Shackle 16mm Finish Hot-Dip Galvanizing 1

2 Shaft For Shackle 16mm Finish Hot-Dip Galvanizing 1

3 Casting Valve High Pressure Aluminum Die _Casting 1

4 U-Bolt 1/2” For Dead End _Clamp Finish Hot-Dip Galvanizing 1

5 Pin Clip 1

6 Spring 20 mm x 40 mm _{Length x 2 mm} 1

7 Casting Valve Taper Lock _Holder ABS Plastic 1

8 Casting Valve Taper Lock 4

9 Casting Valve Washer High Pressure Aluminum Die _Casting 1

10 Stainless Steel Pipe 1

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4 1.2.1 Casting Valve

Figure 1.2: Casting valve (Source: Jati Beringin Sdn. Bhd., 2011)

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5 1.2.2 Tensile Test

Figure 1.3: Tensile test (Source: Jati Beringin Sdn. Bhd., 2011)

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6 1.2.3 Application of Casting Valve

Figure 1.4: Application of Casting Valve (Source: Jati Beringin Sdn. Bhd., 2011)

1.3 Problem statement

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7 Figure 1.5: Sample fracture of casting valve during sample test

(Source: Jati Beringin Sdn. Bhd., 2011)

Table 1.2: Result of sample test Sample

No.

Load 62 kN Time (60 second)

Result

Pass Fail Pass Fail

1 √ √

2 61kN √ Casting valve fracture at the U -

bolt

3 √ √

4 60kN √ Casting valve fracture

5 58kN √ Casting valve fracture

6 60kN √ Casting valve fracture

7 √ √

8 58kN √ Casting valve fracture

9 √ √

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8 1.4 Objectives of research

The objectives of this research are:

a) To investigate design parameter of casting valve for ABC Dead End Clamp, HV. b) To analyze the current design of casting valve for ABC Dead End Clamp, HV by

using Finite Element Analysis (FEA) software.

c) To propose new design of casting valve for ABC Dead End Clamp, HV.

1.5 Scope of research

1.6 Structure of research

Design And Analysis Of Casting Valve For High Voltage ABC Dead End Clamp By Using Finite Element Analysis.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA