STRUCTURAL AND MODAL ANALYSIS USING

HYPERMESH AND LS-DYNA

A Skill Advance Course

STRUCTURAL AND MODAL ANALYSIS OF HELICAL
GEAR USING HYPERMESH AND LS DYNA
report submitted toJAWAHARLAL NEHRU TECHNOLOGICAL
UNIVERSITY , KAKINADA in partial fulfillment
of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Submitted by
TADI SATYANARAYANA(21761A0356)
Under the Guidance of

Mrs.B.KAMALA PRIYA
ASST. PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING
(AUTONOMOUS)

L.B.Reddy Nagar, Mylavaram – 521 230. NTR Dt

ISO 9001:2015 Certified & Accredited by NAAC and NBA,
(Approved by AICTE , Affiliated to JNTUK, Kakinada)
November – 2024
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 LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE , Affiliated to JNTUK, Accredited by NBA and
ISO 9001:2015 Certified)

L.B.Reddy Nagar, Mylavaram – 521 230. NTR Dist

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the A Skill Advance Course entitled “STRUCTURAL
AND MODAL ANALYSIS OF HELICAL GEAR USING HYPERMESH
AND LS-DYNA” that is being submitted for the partial fulfillment of B.Tech
degree in MECHANICAL ENGINEERING to JNTUK, Kakinada, is a
bonafide work done by TADI SATYANARAYANA (21761A0356).During the
academic year 2024-25 and it has been found worthy of acceptance according to
the requirement of the university.

Staff In-charge Head of the Department

B.Kamala Priya Dr.M.B.S.Sreekara Reddy

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

The Satisfaction that accompanies that the successful completion of any task would be
incomplete without the mention of the people whose cease less co-operation made it possible,
whose constant guidance and encouragement crown all efforts with success.

I humbly express my thanks to our management and Principal Dr. K. Appa Rao sir for
extending their support for providing us with an environment to complete our skill advanced
course successfully.

I indebted to our Head of the Department Dr.M.B.S.Sreekara Reddy sir who modeled us
both technically and morally for achieving greater success in life.

I humbly express my thanks to my guide B.Kamala Priya for giving timely valuable
suggestions and encouragement that make the completion of the skill oriented course
successfully.

I would like to thank all the teaching and non- teaching staff members of Mechanical
Engineering, who have extended their full co-operation during the course of this work.

I am thankful to my friends who helped me sharing knowledge and by providing material to

complete the skill oriented course in time.

TADI SATYANARAYANA

(21761A0356)

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S NO CONTENT Page No

1 Introduction 5-7

2 Review of Literature 8

3 Theoretical Analysis 9-13

4 Clutch 14-15

5 Structural analysis on clutch 16-20

6 Conclusion 21

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 1. INTRODUCTION
1.1 HYPERMESH :-
HyperMesh, developed by Altair Engineering, stands as a versatile and sophisticated pre-
processing software tool at the forefront of the finite element analysis (FEA) and computer-
aided engineering (CAE) landscape. Engineered to address the complexities of modern
engineering simulations, HyperMesh serves as the cornerstone of the FEA workflow, playing
a pivotal role in the creation, modification, and validation of finite element models across
various industries, ranging from automotive and aerospace to civil engineering and beyond. It
is the go-to choice for engineers and analysts who seek to transform intricate three-dimensional
CAD geometries into detailed finite element meshes that can be used for numerical simulations.

HyperMesh also empowers users to assemble multiple components and define connections
between them, fostering a holistic approach to system simulation. This assembly creation
feature is instrumental in understanding how entire mechanical assemblies, structural systems,
or intricate mechanisms behave under various load and boundary condition scenarios.
Engineers and analysts can define loads, constraints, and boundary conditions with precision,
allowing them to investigate how structures or components react to different environmental
forces and operational conditions.

Fig 1.1:-Hypermesh

The model management capabilities of HyperMesh are indispensable when working with
extensive and intricate structures or systems. They ensure that users can efficiently organize
and manage their finite element models, making it easier to navigate and manipulate complex

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data.Additionally, HyperMesh offers compatibility with a wide range of solver interfaces,
enabling users to seamlessly transfer their finite element models to various FEA solvers, such
as LS-DYNA, Abaqus, ANSYS, and others. This flexibility empowers engineers to choose the
solver that best suits their specific analysis requirements, ensuring that simulations are executed
with precision and accuracy.

1.2 LS-DYNA:-

LS-DYNA, developed by Livermore Software Technology Corporation (LSTC), is a high-

performance finite element analysis (FEA) software that stands as a cornerstone in the realm
of complex simulations. Widely regarded as one of the most versatile and powerful FEA
solvers available, LS-DYNA excels in the realm of dynamic and nonlinear analysis, making it
an indispensable tool for engineers and researchers across a broad spectrum of industries.One
of LS-DYNA's primary strengths lies in its unparalleled capacity to simulate dynamic events
and nonlinear structural mechanics. This includes scenarios like automotive crash tests, impact
analysis, and explosions, where rapid and nonlinear deformations are involved.

Fig 1.2:-Ls-Dyna Example

LS-DYNA isn't confined to structural analysis alone. It boasts multiphysics capabilities,

allowing for the simulation of coupled physics phenomena, such as fluid-structure interactions,
thermal analysis, and more. This ability makes it a valuable asset in understanding the intricate

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interplay of different physical processes within a single simulation environment. Another
notable feature of LS-DYNA is its scalability, with support for parallel computing. This means
it can efficiently solve large-scale problems by harnessing the power of multiple processors,
making it suitable for simulations of substantial and complex systems.

1.3 HYPERVIEW :-

HyperView, developed by Altair Engineering, is a post-processing and visualization software

tool that plays a vital role in the field of finite element analysis (FEA) and computer-aided
engineering (CAE). As a post-processor, HyperView serves as a bridge between simulation
data and meaningful insights. It enables engineers and analysts to interpret and visualize
simulation results, making complex numerical data accessible and actionable. With its user-
friendly interface and advanced visualization capabilities, HyperView empowers users to gain
a deep understanding of the behavior of structures, components, and systems, allowing them
to make informed design decisions and optimizations. Its versatile tools help in identifying
stress concentrations, deformation patterns, and other critical information, making it an
invaluable part of the CAE workflow, from model setup in HyperMesh to interpreting results
and generating insightful reports in HyperView.

Fig 1.3:-Hyperview

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 2. LITERATURE SURVEY
Zhao Hongxue and Wang Sanxia (2022) at.al, evaluated Optimization for Side Structure of
Vehicle Based on FEA the electric vehicle with HV battery traction which has achieved the
"five-star" result of CNCAP as the research object, and uses HyperMesh and LS-DYNA to
establish a lateral impact finite element model for simulation to verify the performance of this
vehicle in C-IASI.

Rakesh A. Shinde and Ketaki N. Joshi (2016) did the Optimization of Tube Hydroforming
Process by Using FEA Simulations. In this work 3-D Finite Element model for the Tube
Hydroforming (THF) developed using Creo Parametric 2.0, pre-processed using HyperMesh
and solved using LS-DYNA explicit solver.

Dilip S. Chaudhary and Sumit Desai at.al, (2021) stated the Finite Element Analysis and
physical testing to solve bouncing effect during armrest opening FEM model design parameters
are updated using iterative model updating process to give better correlation between the FEM
result and the experimental result. Co-correlation of Physical test with FEA simulation was
done on base model.

K.R. Jagtap and S.Y. Ghorpade at.al, (2017) evaluated the Finite Element Analysis of
Mechanical Clinching Process. The geometry of the clinching tools affects the strength and
quality of the final clinch joint.

Y.H. Yang and T. Huang (2021) did the Numerical simulations of nuclear fuel reprocessing
plant subjected to the free drop impact of spent fuel cask and fuel assembly. The adopted
numerical simulation approach are verified based on the 1/3 scaled SFC model free drop test.

S.S. Godara and Shiv Narayan Nagar (2020) stated Analysis of frontal bumper beam of
automobile vehicle by using carbon fiber composite material the displacement and stress
analysis and design optimization of the automobile vehicle frontal bumper beam is achieved
by designing eight different cross sections with the help of mechanical modeling based
software Creo.

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 3. THEORETICAL ANALYSIS

3.1. THEORITICAL ANALYSIS ON HYPERMESH

Fig3.1 :-Hypermesh
Hypermesh is a widely used software tool in the field of finite element analysis (FEA) and
computer-aided engineering (CAE). It is primarily used for pre-processing tasks, which are
crucial in setting up and preparing the finite element models for analysis. Here's a theoretical
analysis of what Hypermesh is and what it does:

3.1.1 Purpose of Pre-processing

Before performing an FEA simulation, engineers need to create a finite element model. This
process involves defining the geometry, meshing, assigning materials, boundary conditions,
and loads to the model. Hypermesh is a pre-processing tool designed to streamline these task.

3.1.2 Geometry Import and Cleanup:

Hypermesh allows engineers to import CAD (Computer-Aided Design) geometry from
various formats. It often requires cleaning up imported geometry, such as removing gaps,
overlaps, or inconsistencies.

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3.1.3 Meshing
Meshing is the process of dividing the geometry into small elements (e.g., triangles or
quadrilaterals in 2D, and tetrahedra or hexahedra in 3D). The quality of the mesh affects the
accuracy of the FEA results. Hypermesh provides powerful tools for creating high-quality
meshes.

3.1.4 Materials Assignment:

Engineers specify the material properties of the components in the model. This includes
defining material types (e.g., steel, aluminum), elastic properties, thermal properties, and
more. Hypermesh allows for efficient assignment of materials.

3.1.5 Boundary Conditions:

Boundary conditions define how a structure is constrained or supported. This includes fixing
certain nodes or applying loads or displacements to specific parts of the model. Hypermesh
facilitates this by providing a user-friendly interface for defining these conditions.

3.1.6 Load Application

Engineers apply loads to simulate real-world conditions. These loads can be forces, pressures,
thermal loads, etc. Hypermesh assists in specifying these loads accurately.

3.1.7 Model Visualization and Verification

Hypermesh provides tools to visualize the finite element model, inspect the mesh quality, and
ensure that boundary conditions and loads are correctly applied.

3.1.8 Solver Compatibility

Once the pre-processing tasks are complete, the finite element model can be exported to various
solver formats. Hypermesh supports multiple solver formats, making it compatible with a wide
range of FEA software.

3.1.9 Automated Processes:

Hypermesh often includes automation features, such as templates and scripts, to expedite the
modeling process and ensure consistency across different projects.

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3.1.10 Optimization and Analysis:

Some versions of Hypermesh also include optimization tools that allow for the design and
analysis of structures with the goal of minimizing weight, maximizing strength, or achieving
other performance targets.

3.2 BENEFITS OF USING HYPERMESH

Hypermesh have many benefits, including:-

 User-Friendly Preprocessing

 Versatility

 Meshing Capabilities

 Geometry Cleanup

 Automation and Customization

 Quality Assurance

 Material Database

3.3 LIMITATIONS OF HYPERMESH

 Steep learning curve for new users.

 Resource-intensive, demanding hardware

 High licensing costs.
 Challenges with complex and poorly structured CAD geometries.
 No built-in solvers; reliance on external solvers.
 Limited post-processing capabilities.

3.4 THEORITICAL ANALYSIS ON LS-DYNA

LS-DYNA is a versatile and powerful finite element analysis (FEA) software tool primarily
designed for simulating complex and dynamic events. Here's a theoretical analysis of LS-
DYNA:

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3.4.1 Versatility:
LS-DYNA is renowned for its versatility and wide range of applications. It can simulate various
engineering scenarios, including automotive crash tests, structural analyses, material forming
processes, fluid-structure interactions, and more.

3.4.2 Nonlinear and Transient Analysis:

LS-DYNA excels in solving problems that involve significant nonlinearities, including large
deformations, contact, and material nonlinearity. It can handle transient dynamic events,
making it ideal for simulating events like vehicle crashes, explosions, and impact analyses.

3.4.3 Material Models:

LS-DYNA offers an extensive library of material models, allowing users to accurately simulate
the behavior of different materials under various loading conditions. This is essential for
representing real-world materials and their responses in simulations

3.4.4 Element Types:

The software supports various advanced element types, such as shell elements for thin
structures and solid elements for 3D analysis. This enables users to model complex geometries
with precision.

3.4.5 Parallel Processing:

LS-DYNA is designed to take advantage of parallel processing, leveraging multiple CPU cores
and high-performance computing clusters. This parallel computing capability significantly
reduces simulation time, making it suitable for large-scale and computationally demanding
simulations.

3.4.6 Scalability:

The software is scalable, making it compatible with both desktop computers and high-
performance computing environments. Users can adapt their computational resources to the
complexity of the problem they are solving.

3.4.7 Contact Modeling:

LS-DYNA provides robust contact modeling capabilities, allowing for the accurate simulation
of interaction and contact between components in a model. This is crucial for applications
involving assemblies or complex structures.

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3.4.8 Advanced Load Capabilities:
LS-DYNA allows users to apply a wide range of loads, including forces, pressures,
accelerations, and thermal loads, making it suitable for simulating complex physical
phenomena.

3.5 BENEFITS OF LS-DYNA

 Versatility: LS-DYNA can simulate a wide range of dynamic and complex
engineering scenarios.
 Nonlinear Analysis: It handles large deformations, material nonlinearity, and contact
modeling effectively
 Material Models: LS-DYNA provides an extensive library for accurate material
behavior representation.
 Element Types: It supports advanced element types for precise geometry
representation.
 Parallel Processing: The software leverages parallel computing for faster simulations.
 Scalability: It can run on both desktops and high-performance clusters, adapting to
different project sizes.
 Contact Modeling: LS-DYNA excels in modeling complex interactions and contact
between components.
 Broad Industry Applications: Used in automotive, aerospace, civil engineering,
manufacturing, and defense for product safety and performance analysis.

3.6 LIMITATIONS OF LS-DYNA

 Steep learning curve for new users.

 Resource-intensive, demanding hardware.
 Complex setup and model preparation.
 Licensing costs can be high.
 Limited built-in post-processing capabilities.
 May require specialized training for advanced simulations.
 Nonlinear simulations can be time-consuming.
 Complex models may require significant computational resources.

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 4. HELICAL GEAR

4.1 Introduction to HELICAL GEAR:

Helical gears are a type of mechanical transmission mechanism that plays a fundamental role
in the world of machinery and engineering. They consist of cylindrical gear teeth that are cut
at an angle to the gear's axis, forming a helix shape. This helical design allows for smoother
and more gradual engagement of the teeth compared to spur gears, which have straight teeth
and tend to produce abrupt, noisy motion and high contact stresses. The helix angle, which
defines the degree of inclination of the teeth, is a crucial parameter in helical gear design, as it
influences the gear's ability to transmit power efficiently. Helical gears are widely utilized in a
diverse range of applications, such as automotive transmissions, industrial machinery, and even
in everyday consumer products like washing machines and power tools. Their superior
performance characteristics, including reduced noise, increased load-bearing capacity, and
higher efficiency, make them a preferred choice in many situations where precise and reliable
power transmission is essential. Whether in high-speed or high-torque applications, helical
gears are a key element in the machinery that drives our modern world.

Fig 4.1.1:-Helical gear

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4.2 Purpose of HELICAL GEAR:
Helical gears serve several important purposes in various mechanical systems and applications:

Smooth Power Transmission: Helical gears are designed with angled teeth that engage
gradually, resulting in a smoother and quieter transfer of power compared to spur gears with
straight teeth. This characteristic is crucial in applications where noise reduction and minimal
vibration are essential.

High Load-Carrying Capacity: The inclined teeth of helical gears allow for a larger contact
area between the teeth, which increases the gear's load-bearing capacity. This makes them
suitable for applications that require the transmission of high torque or heavy loads.

Efficient Power Transfer: Helical gears have a higher contact ratio, which means that multiple
teeth are in contact at the same time. This results in improved power transmission efficiency,
making helical gears efficient for a wide range of applications, including industrial machinery
and automotive transmissions.

Reduction of Axial Loads: Helical gears help in reducing axial thrust or axial loads on the
gear shafts. This is particularly important in applications where minimizing thrust forces is
essential to prevent excessive wear and tear on bearings and other components.

Versatility: Helical gears can be designed with various helix angles and tooth profiles to suit
specific requirements, such as speed reduction, speed increase, or even changing the direction
of rotation. This versatility allows them to be used in a wide array of applications across
different industries.

High Precision: Helical gears provide precise motion control, making them suitable for
applications where accuracy and synchronization are critical, such as in CNC machines,
robotics, and precision instruments.

Durability: Their ability to distribute loads evenly across the gear teeth and reduce wear and
stress concentration points contributes to the overall durability and longevity of helical gear
systems.

Wide Range of Applications: Helical gears find application in various industries, including
automotive, aerospace, construction, manufacturing, and more. They are used in gearboxes,
driveshafts, winches, conveyors, and many other mechanical systems.

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 5. STRUCTURAL ANALYSIS ON HELICAL GEAR
This structural analysis consists of three steps:

1.Pre-processing

2.Solving

3.Post-processing

Pre-processing:-

Preprocessing consists of 11 steps:

1.Meshing

2.Properties

3.Material

4.Assembly

5.Intersections and penetrations

6.Connections

7.Loads

8.Boundry conditions

9.Contacts

10.Control cards

11.Data base cards

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HELICAL GEAR:

STEP-1: Import the geometry in hypermesh

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STEP-2: Delete the solids if any present by clicking (f2) and delete the entities.

STEP-3: Generate the 2D mesh

2D - auto mesh - select all surfaces - set the element size – mesh

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STEP-4: Create material cards (steel) and assign to component

STEP-5: Create properties and assign property to component

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 6 . CONCLUSION
The use of the import function in HYPER MESH AND LS-DYNA definitely has
some advantages. It can help to reduce the time it takes to produce the drawings
needed in the work environment.The use of the import function may also be relied
on heavily in order to create efficiencies within the industry .This could possibly
lead to a decrease in the rate of innovation .It's obvious that the import function
has a place in the building industry ,but its use will have to be regulated in order
to create a balance between the negative and the positive effects it creates .

Mesh generation is the premise of finite element analysis, Hyper Mesh as a high
performance finite element preprocessor, by analyzing the clutch, the key
problems of geometry cleaning and mesh generation in the process of finite
element preprocessing are studied. The influence of different modeling methods
on mesh generation is analyzed. According to the basic principle of finite element
mesh division, through the good interface between HyperMesh and CAD and
CAE software, the geometric model import and modal analysis are realized, and
the quality and efficiency of finite element analysis are improved

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