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Drop Testing Virtually In CAE Using LS-Dyna


Drop test is simulated in a CAE environment for dishwasher with plastic tub. FEA Modelling was carried out in Hyper-mesh and non linear structure analysis of the flat drop test was simulated in LS-Dyna. Mechanical properties of all the components modelled are used to model the mechanical behaviour of the material under load conditions. Impact velocity is given as 6 feet per second as per standards. Load absorbing material like foam used in the analysis are further detailed by adding stress-strain characteristics to properties list.
Total energy absorbed by the packaging, corrugated box, base, wood to the total strain energy is predicted. Energy absorbed by the foam supports to the total strain energy. Maximum Stresses on the tub, Maximum stress of supports is compared with allowable yield stress of the respective material used .

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Virtual Clamp Testing of Dishwasher using CAE Analysis


Project objective was to simulate "Transit Test" of a plastic tub Dishwasher unit in CAE environment for the following test:

  • Full Clamp Test: Apply the clamp force with the 2,200 pounds, measured at the middle of the platens.
  • Platens resting on the floor
  • The front edge of the platens flush with the front of the package.

Important parts which are effected by the clamping force and are prone to failure are modelled. This process is simulated in CAE environment in this project. Analysis model consists of Dishwasher assembly kept on the ground and packaged along with four foam supports using corrugated paper board. Two rigid platens applying a 2200 lbs force on the Dishwasher are modelled Offset Clamp Testing (2x6) : Rigid platens are moved 2 inches up and 6 inches back. Both the horizontal and vertical offset dimensions are measured at the front bottom corner of the platen Maximum Stress on the Tub, on the chassis frame, on the Door components, on EPS Foam supports and on Corrugated box are compared with their respective safe limits of the material used. Failing parts are modified and further analysis Iterations are carried out till all the parts with in the safe limit.

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Modal Analysis Of Dry & Wet Vacuum Cleaner


Modal analysis is a technique used to determine structure's vibration characteristics like Natural frequencies, Mode shapes, Mode participation factors, Most fundamental of all the dynamic analysis types allows the design to avoid resonant vibrations or to vibrate at a specified frequency.
Gives engineers an idea of how the design will respond to different types of dynamic loads. Helps in calculating solution controls (time steps, etc.) for other dynamic analysis. The Motor assembly in the vacuum cleaner is modelled as lumped mass (i.e. a mass element is created at CG of the motor assembly and corresponding weight of the motor is applied to it). Free shapes of vibration are predicted in modal analysis for vacuum cleaner.

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CFD Analysis ,Testing and validation of household convection & microwave oven


CFD Flow Simulation of household bake oven, to study the air flow pattern, temperature distribution and optimize the design to achieve the uniform hot air circulation required for uniform baking.

  • Test setup for validating the result of cfd analysis and the design selected was installed.
  • Test setup constituted of data capturing thermo couples, data logger which converts signal into numerical value, thermal tape for fixing and holding thermo couples and photo colorimeter which captures the image of the cake in the tray, and software to calculate color contour distribution up to 15 scales from the colorimeter image.
  • Good correlation between the testing and the CFD analysis data was found out .Baffle cover and internal configuration leading overall uniformity was selected.

Several changes of the device configurations, such as the location of the heaters, the fan and the fan baffle, have been considered. As a result, the temperature uniformity has been significantly improved, which was also confirmed in the experimental test of the modified prototype.

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