Shear pins are generally used as a mechanical safeguard in assembly operations. They are considered sacrificial members which undergo early fracture to safeguard the other components in the assembly. Currently, solid shear pins are used and technically such pins add to the total weight of an assembly. Weight savings is one of the best contributions that can help the design of components to reduce weight and cost wise. In this regard, hollow shear pins can be a suitable alternative. However, there exists a minimum literature on the use of hollow shear pins in assemblies. The current work presents the theoretical and computational analysis of an industrially used solid shear pin that is modified as a hollow pin. Extensive modeling and simulation of the hollow pins are carried out to check the feasibility of replacing the solid shear pins with hollow shear pins. Due to the profound effect of the notch which changes stress concentration, it appears that weight savings using hollow notched pins possibly are not feasible while the hollow un-notched pins are beneficial. The industrial applicability of the hollow pins can be considered as beneficial components primarily towards functionality. In addition to the weight saving, they can also act as channels for passing wires and other similar entities of an assembly.
With the new pollution control rules and surging requirements for the increase in efficiency of the internal combustion engines, designing the exhaust manifold has become a growing area of interest. The present work focuses on modelling the multi-end exhaust manifold and comparing it with the single-end exhaust manifold. Both the structural and thermal analyses are carried out using the finite element method. Along with the modified design, various materials such as mild steel, cast iron, stainless steel and medium carbon steel are also evaluated for their structural and thermal behaviour. It is found that the multi-end exhaust manifold performs better in terms of better stress and temperature distribution in comparison to the single-end exhaust manifold. The magnitude of the stress experienced by multi-end exhaust manifolds is 20 MPa lesser than single-end exhaust manifolds. However, the change in material has a marginal effect in terms of stress and temperature distribution.
The current study compares and analyses the fly-ash–epoxy composite structure with alloys for bracket applications. A dispersed reinforcement composite is created by combining epoxy and fly-ash. Three different prototypical brackets are modelled and analysed using the finite element method, and their results are compared to common alloys used in the manufacture of L-shaped brackets. The mechanical properties of the composite material are calculated using a rule of mixtures, and the properties of the composite material are modified by changing the percentage composition of fly-ash. Based on equivalent stress and total deformation, all geometrical models are analysed and compared. The analysis results appear to be appropriate for broadening the scope of the application of epoxy-based composites for small-scale and large-scale applications. The results also show that the composite material can be used to make a variety of structural elements with high design complexity, such as bulkheads and other structural components.
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