Publication: Fatigue life prediction for small component welds
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Date
2023-07-13
Authors
Mohamad Syahir bin Sezale
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Abstract
This report focuses on predicting the fatigue life of small component welds in a moulding frame structure under thermal and vibration loads. Finite element analysis and simulation techniques were employed using ANSYS Mechanical software, considering vibration and thermal fatigue as key parameters. Experimental measurements provided data on motion during the shaking process and temperature variations in the frying oil during honeycomb cookie production using a semi-automatic dipping machine. Transient structural analysis and thermal transient analysis were conducted using ANSYS Mechanical software, with load and boundary conditions derived from the experimental data. The objective was to determine the equivalent stress resulting from the applied loads. The Fatigue tool in ANSYS Mechanical software was utilized to evaluate the stress data and predict fatigue life, considering factors like fatigue analysis type, loading type, and mean stress correction theory. Results showed that thermal fluctuations during the frying process using the semi- automatic honeycomb cookies dipping machine significantly affected the fatigue strength of the moulding frame structure. The minimum estimated fatigue life was 7543 cycles for a moulding frame with three weld joints oerating at 300°C. Contour plots revealed increased thermal stress at the weld joints due to reduced thermal expansion caused by the mould's shape. The number of weld joints influenced stress distribution and fatigue life. Vibration fatigue analysis indicated that the weld component on the moulding frame was not susceptible to fatigue failure, with stress amplitude below the material's endurance limit. This report provides insights into the fatigue life prediction of small component welds under thermal and vibration loads, specifically in the context of a semi-automatic honeycomb cookies dipping machine. The results emphasize the impact of thermal fluctuations on fatigue strength and highlight the resilience of the weld component to vibration loading. These findings contribute to the understanding and optimization of similar structures in various industries, particularly those involving semi-automatic dipping processes in food production.