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crankTurkeysimplicityhaveadvantagespress.500(FEA)Publishingforareturability,someproblem,transfer(e.g. SolidWorks ) in recent years. SolidWorks allows 3D CAD,FEA, motion analysis, and simulation modules. Some studies onuse of SolidWorksC210are also reported in design and analysisincludingwas includedtheanalysis. A simple slider-crank mechanism and HMMWV wereoptimized to demonstrate feasibility and effectiveness of the pro-posed system. Having applied optimization is rod length/cranklength ratio is found 5. Abdullah and Telegin 23 studied dynamicanalysis of a hot-crank press. Definition of the slider-crank mech-anism (size, mass, inertia, etc.) and deformation analyses weregiven for each mechanism part. Zheng and Zhou 24 described aflexible coupling model of the slider-crank mechanism because ofCorresponding author.E-mail addresses: .tr, (R. Halicioglu).Peer review under responsibility of Karabuk University.Engineering Science and Technology, an International Journal 19 (2016) 20602072Contents lists availableEngineering Sciencean Internationasoftware firms have started to provide dedicated analysis packagesC210 C210finite difference method was adopted to support design sensitivitySeveral studies on structural design and analysis of machineparts and tools are found in the literature 511. FEM simulationsare performed by using AnsysC210software 12,13 although otheremployed for dynamic simulation of mechanical systemsground vehicles, and Design Optimization Tool (DOT)for a batch mode design optimization. In their research,/10.1016/j.jestch.2016.08.0082215-0986/C211 2016 Karabuk University. Publishing services by Elsevier B.V.This is an open access article under the CC BY-NC-ND license (/licenses/by-nc-nd/4.0/).overalltechnology 13. The structural design in mechanical analysiscan be applied by Finite Element Method (FEM), which is anumerical technique for finding approximate solutions to bound-ary value problems for differential equations. FEM allows detailedvisualization of where the structures bend or twist, and indicatesthe distribution of stresses and displacements 4.and control.Chang and Joo 22 presented a study to support design opti-mization of engineering products, including High Mobility Multi-purpose Wheeled Vehicle (HMMWV). In proposed environment,Pro/engineerC210and SolidWorksC210were employed for product modelrepresentation, Dynamic Analysis and Design System (DADS) was1. IntroductionDesign is either formulation of a plana problem, in which some parametersity, safety, reliability, manufacconsideration. A design must haveidentification of need, definition ofoptimization, evaluation and presentationmore than one discipline of mechanicaldynamics, fluid mechanics, heatneeds or a solution fordesired like functional-and marketingprocesses such assynthesis, analysis,. Design can involveengineering such asand manufacturing1418. Crank presses are assembly of slider crank mechanisms19. The following studies involve crank press or slider crankdesign, manufacturing, and FEA. Doege 20 designed a crank presswith a noncircular gear for deep drawing stroke motion. The studyshowed mechanical modernizations for the desired motion of pressby changing gears. Spiewak et al. 21 studied on predictive mon-itoring and control of the cold extrusion process. A crank pressand its mechanisms were defined under high loading at highspeeds. They developed a multicomputer system to present theresults showing feasibility of predictive monitoring, diagnosisStrength analysisBY-NC-ND license (/licenses/by-nc-nd/4.0/).Full Length ArticleStructural design and analysis of a servoRecep Halicioglua, Lale Canan Dulgerb, Ali Tolga BozdanaaOsmaniye Korkut Ata University, Mechanical Engineering Department, 80000 Osmaniye,bGaziantep University, Mechanical Engineering Department, 27000 Gaziantep, Turkeyarticle infoArticle history:Received 11 May 2016Revised 18 July 2016Accepted 12 August 2016Available online 23 August 2016Keywords:Servo crank pressMetal formingStructural designabstractDue to precision, flexibility,consumptions, servo pressestechnology combines thedrawbacks. This study presentsfor metal forming operations.considerations of the servowork has a load capacity ofand Finite Element Analysisare performed on this machine.C211 2016 Karabuk University.journal homepage: www.elsepressbin construction, easy control, higher speed and lower energyrecently become popular in metal forming applications. Servo pressof hydraulic and conventional mechanical presses without theirdesign, construction and demonstration of a servo crank press systemThe research involves structural design and analysis with dynamicA design and manufacturing guide is offered. The press used in thiskN and stroke capacity of 200 mm. Structural CAD model is constructed,of press parts are performed within safety limits. Experimental studiesSatisfaction at the output is seen.services by Elsevier B.V. Thisisanopenaccessarticleunderthe CCat ScienceDirectand Technology,l J/locate/jestchits accuracy by using AdamsC210. The dynamic simulation results ofmechanism with clearance under no-load and piling conditionswere presented.Servo presses driven by servo motors have recently come intoprominence for sheet metal forming operations due to their flexi-bility, controllability, and simplicity. Kutuk and Dulger 25 studiedon motion design of a hybrid servo press. The press has two cranksare driven by one servo motor and one constant velocity motor.Halicioglu 26 has then presented a complete study on design,synthesis, manufacturing and control of servo crank press.A design guide involving system dynamics, load types, andcapacities are defined. Pre-strength analysis is put into rule, whichshould be specified and applied. In this study, the design guide of aservo crank press is prepared, and its structural 3D CAD model isconstructed. FEA of all parts are investigated using SolidWorksC210.Manufactured press is presented herein.2. Description of the servo press and design methodologyA servo crank press mechanism is similar to conventional crankpress mechanism without flywheel and clutch-brake. Its partsare servo motor with controller panels, mechanisms (crank-connecting rod-ram), gears (pinion and main gears), bearings,with a satisfactory engineering design that is necessary for 3D CADdesign. The steps on machine parts are analyzed by FEM.represented in the previous studies. The motion profile is definedTable 1Press specifications.In CE standards C type crank pressLoad capacity 500 kNStroke 200 mmStroke-ram adjust 150 mmRam (in TDC)-bolster distance 500 mmBolster plate size 800 C2 500 mm2Table 2Chosen materials for the press parts.Tool part Material Yieldstrength (MPa)Tensilestrength (MPa)Ram St52 360 530Connecting rod St52 360 530Crankshaft 42CrMo4 750 1000Pinion shaft 42CrMo4 750 1000Main body St37 275 370Bolster plate St37 275 370Main gear GS52 360 530Pinion gear 30CrNiMo8 1050 1250R. Halicioglu et al./Engineering Science and Technology, an International Journal 19 (2016) 20602072 2061and structural body (as C frame and mono-block). Sketch of themodel is given in Fig. 1. It includes body and mechanism, in whichthe crank length, the crank angle, the rod length, the rod angle, andthe slider (ram) position are represented by r, h, l, b, and y, respec-tively. TDC and BDC refer to Top Dead Center and Bottom DeadCenter. The rod-to-crank ratio is taken as 7 26. Dimensionalspecifications of press are given in Table 1. Table 2 presents choiceof materials for the parts of press machine referred to CoskunozMetal Form 27.A design approach is considered as design guide is given inFig. 2. The requirements are given by press users by specifyingdynamic expectations. Having performed the dynamic analysis,loads and motion parameters are used for the machine parts;dynamic and static. The machine parts are designed in accordanceFig. 1. Sketch of thebased on ram. The most preferred scenarios are chosen for its oper-ation. It is considered that the rated force on slider is applied lessthan 7 mm stroke position for mechanical structure design.3. Bearing designThe press mechanisms joints are created by using hydrody-namic sleeve bearings, roller bearings, and slide ways. RollerThe previous studies present kinematic and dynamic analysis ofcrank press mechanism 26,28,29. This study includes somedynamic parameters that are found based on information givenin the previous studies. Press motion and dynamic loading werepress structure.ambient heat transfer coefficient, outer surface area of bearinghouse, respectively.P FBD1d KPVtSH2Eloss fFV 3Tb TaElosshaAb4According to Eqs. (2) and (3), diametric wear and energy lossdepend on PV factor. Their values are obtained experimentally onmaterial catalogues. Tin bronzes are selected because of theirhigher bearing stress, less diametric wear and relative cheapness1,3,3032,34. Besides, determination of B/D ratio can be taken.an International Journal 19 (2016) 20602072Press UserDynamic Parts Stag415c PartsLoads and Mog415onsREQUIREMENTSDeterminag415on of Ram Mog415onradial journalbearing and spherical plate sleeve bearing. There are two radialjournal bearings on the crankshaft. There are two slider bearingson the main body for sliding ram. There is friction between activebearings and sleeve parts. The bearing material of ASTM B505;Pmax= 35 MPa, Vmax= 1.3 m/s. It is desired that maximumPV 4 MPa*m/s 36,37. For spherical and linear plate bearing,Fig. 3. Contact Faces (CFs).R. Halicioglu et al./Engineering Science and Technology,the material is ASTM A485 with static contact pressure capacity of430 MPa and PV limit of 2.8 MPa*m/s (without oil lubrication) 35.The steps for design of bearing are presented in Appendix A1. Bear-Table 3Bearing characteristics (Crank-Press).Bearings (between) Velocitya(m/s) Force (kN)CrankConnecting rod 2 500Connecting rodRam 0.25 500CrankshaftMain body 2 250Slide ways 0.15 15aVelocities are considered under maximum force.Fig. 4. Solid model of the press: (a) complete assembly, (b) transmissionmechanism.D (mm) B (mm) c (mm) t (mm)200 130 0.055 121995 Spherical 0.015 95 150 0.022 81135 (width) 500 an International Journal 19 (2016) 20602072 2063ings crankconnecting rod, crankshaftmain body, and connectingrodram are determined by the maximum velocity and the forcefrom the dynamic analysis, Table 3.4. Structural designStrength and size of press mechanisms and main body isdetermined before 3D CAD design and assembly of each part. Thecalculations are performed static since the loading of press startsnear BDC. Five parts of the press are designed according to theirsafety conditions. Strength calculations and determination of thecritical part dimensions are specified for connecting rod design,crankshaft design, ram design, gear design (with keyways), andmain body. According to forming press application, SF is selectedby classical rule of thumb Eq. (6) as 26SF 38. For the overall sys-tem; material properties are selected by manufacturers values(SFmaterial 1:1), loads are well defined as static (SFstress 1:1),dimensions are adjusted on average manufacturing tolerances(SFgeometry 1:0, failure analysis is not well developed(SFfailure 1:3, and reliability must be high (SFreliability 1:3). Yieldstresses are used in calculation of SF in Eq. (7) 39. While the prin-ciple strength is yield strength (ry), shear strength (sy) is consid-ered as 0.58 ryfor steel and its alloys and 0.75 ryfor iron 36.SF SFmaterialC2 SFstressC2 SFgeometryC2 SFfailureC2 SFreliability6SF Yield strengthAllowable design stress7Fig. 5. (a) Solid CAD model of the crank assembly, (b) Loading and boundaryconditions on meshed model of the crank assembly.system is 25 kW. Two helical gears (module: 7, angle: 5C176) and threeconnecting keys are designed 2,30,40.The 3D CAD model of the press was built using SolidWorksC210where the mass-inertias were found by the software 41. Fig. 4(a)-(b) show 3D solid model of the system with the mechanism.an International Journal 19 (2016) 20602072Table 4Crank simulation details.Crank material: 42CrMo4 Main gear material: GS52MeshNumber of nodes: 128,300 Number of elements: 81,515Global size: 17 mm Tolerances: 0.85 mm2064 R. Halicioglu et al./Engineering Science and Technology,There are five parts on servo crank press: main body, crank, con-necting rod, ram, and pinion shaft. These parts are designedaccording to the bearing dimensions. There are two gears and threekeys. One of them is on the crankshaft between crankshaft andmain gear. The others are on the pinion shaft between piniongear-pinion shaft and pinion shaft-gear box. The maximum torqueof 20,000 Nm is considered for the crankshaft and gear ratio of 1:5is selected between pinion and crankshaft. Maximum torque of4000 Nm is applied on the pinion shaft. The maximum power for5. Finite element analysisThe strength is important for the servo press as it is treated as aheavy duty machine tool. If strengths of parts are under the desiredvalues, the design must be started again. Critical parts are assem-bled and their FEA is completed by using SolidWorksC210SimulationToolbox 41. Initially meshes of each part are created accordingto the structure. Force and boundary scenarios are determined oneach part with FEM simulations.5.1. Assembly of crankAssembly of crank is constructed by crankshaft, the eccentricityFEAvon Mises stress: 749.5 MPa Max. deformation: 0.806 mmFig. 6. Structural analysis results of the crank assembly: (a) von-Mises stress, (b)Deformation, (c) Factor of safety.group, and the main gear in Fig. 5. It was assumed that crankassembly is considered as mono block, and one gear contact sur-face (1720 mm2) is fixed. Main gear is mounted on crankshaft witha key and interference fit. Fig. 5 shows the meshed model of thecrank group. Discretization (mesh generation) is performed. Thecomponent is divided into a number of small parts. Table 4 showsdetails during mesh procedure. The mesh is high quality due to thefact that the effect of force on each portion of the component is notthe same. Crankshaft has a constraint with journal bearings: fromtwo sides of bearings those are press fit to crankshaft with60,580 mm2surface area. Only 180C176 of the bearing surfaces facingthe load direction is the constraint for motion of crankshaft. Thisconstraint is defined as a fixed semicircular surface that is as wideas journal bearing width. The distribution of load over connectingrod bearing causes uniform pressure along 157C176 of contact area.Since crankshaft is in interaction with connecting rod, the sameloading distribution is transmitted to the crankshaft. The forcewhich is 500 kN in total is considered as a pressure of 18.8 MPaapplied on the crank eccentricity contact area (41,250 mm2) nearBDC position of the ram. Fig. 6 shows the results of analyses basedon loading conditions with boundary conditions. Navy blue arrowsindicate bearings (surface area: 59,360 mm2), green arrows indi-cate the fixed surfaces, and red arrows indicate applied pressureon the crank assembly. The total deformation and von-MissesFig. 7. Connecting rod assembly: (a) Solid CAD model, (b) Meshed model with loadsand fixtures.stresses acting on the crankshaft are found. When the force isapplied, a slight deformation with low stresses take place in thecrank assembly. The stresses acting on crankshaft are shown inFig. 6(a). The maximum stresses acting on the crank assembly areindicated by red color. The deformation of crankshaft is presentedin Fig. 6(b), and Fig. 6(c) shows the values for factor of safety (SF isindicated as FOS in simulation). Table 4 also shows details of FEA.The minimum safety of the shaft is about one. This value is not theactual value. There are corners on the shaft, which are very smallsections. In fact, SF is over 3 for the entire crank assembly system.5.2. Connecting rod assemblyAssembly of connecting rod is constructed by bottom part, toppart, bearing, and screw (with knob) in Fig. 7(a). There are certainassumptions that connecting rod assembly is considered as monoblock, and contact surface (23,300 mm2) for knob is fixed. Connect-ing rod length is taken as 700 mm. Mesh details are given inTable 5. Fig. 7(b) shows the meshed model of connecting rodgroup. Connecting rod is in interaction with crankshaft, and hencethe same loading distribution is transmitted to the crankshaft. Inthis study, the force which is 500 kN in total is considered as apressure of 18.8 MPa applied on the crank eccentricity near BDCposition of the ram. A fixed reaction surface is considered on theknob. Fig. 7(b) shows loading and boundary conditions (contactsurface area: 41,250 mm2). Green arrows indicate fixed surfaceswhile red arrows indicate applied pressure on the connecting rodassembly. After the boundary conditions and forces are applied,structural analysis of the connecting rod assembly is performed.The main concern is the total deformation and von-Mises stressesacting on the connecting rod assembly.The stresses are shown in Fig. 8(a) where the maximum stressesare indicated by red color. The total deformation is shown in Fig. 8(b). The portions in red and blue colors show that the deformationat those regions is the maximum and the minimum, respectively.Fig. 8(c) presents the values for SF. Table 5 also shows results ofFEA. While the minimum safety of the shaft is about 1.5 on thebearing, this value is actually over 3 for the entire assembly.5.3. Ram assemblyAssembly of ram is constructed by safety block, spherical bear-ing, and main body as given in Fig. 9(a). Table 6 shows ram meshTable 5Connecting rod simulation details.Connecting rod material: St 52MeshNumber of nodes: 45,820 Number of elements: 27,843Global size: 17 mm Tolerances: 0.85 mmFEAMax. von Mises stress: 244.4 MPa Max. deformat