Strength-based design of a sunflower stalk cutter machine design using finite element analysis and experimental validation

Abstract

In this study, the total algorithm of the strength-based design of the system for mass production has been developed. The proposed algorithm, which includes numerical, analytical, and experimental studies, was implemented through a case study on the strength-based structural design and fatigue analysis of a tractor-mounted sunflower stalk cutting machine (SSCM). The proposed algorithm consists of a systematic engineering approach, material selection and testing, design of the mass criteria suitability, structural stress analysis, computer-aided engineering (CAE), prototype production, experimental validation studies, fatigue calculation based on an FE model and experimental studies (CAE-based fatigue analysis), and an optimization process aimed at minimum weight. Approximately 85% of the system was designed using standard commercially available cross-section beams and elements using the proposed algorithm. The prototype was produced, and an HBM data acquisition system was used to collect the strain gage output. The prototype produced was successful in terms of functionality. Two- and three-dimensional mixed models were used in the structural analysis solution. The structural stress analysis and experimental results with a strain gage were 94.48% compatible in this study. It was determined using nCode DesignLife software that fatigue damage did not occur in the system using the finite element analysis (FEA) and experimental data. The SSCM design adopted a multi-objective genetic algorithm (MOGA) methodology for optimization with ANSYS. With the optimization solved from 422 iterations, a maximum stress value of 57.65 MPa was determined, and a 97.72 kg material was saved compared to the prototype. This study provides a useful methodology for experimental and advanced CAE techniques, especially for further study on complex stress, strain, and fatigue analysis of new systematic designs desired to have an optimum weight to strength ratio.

Design of a precision planter chassis using computer-aided engineering and experimental validation

“…However, FEM is an approach, and it is necessary to compare and verify numerical results with experimental data, especially in systems to be produced in series. 2,17 Thus, the verification of the CAE analysis results, and the fatigue behavior of the system are revealed. The bending strength and fatigue behavior of beams can be calculated using the FE method and experimentally measured stress data.…”

“…The modular designs of the X-section beam and the precision planter chassis, whose geometry was determined (Figure 5), were created using SolidWorks 2017 solid modeling design program by employing the progressive solid design approach. 2,33…”

“…Thin-walled beams are preferred in many engineering applications because of their low weight and reasonable cost. 1,2 Agricultural equipment and transportation vehicles consist of thin-walled structures ∼70% of the chassis of construction machinery. Beams with different geometries and material properties are used in constructive studies.…”

Experimental, analytical, and numerical investigations on the flexural and fatigue behavior of steel thin-walled X-section beam

“…Researchers determined that the CAD models’ prototypes were generated according to the mass criteria. 5,40 The design is suitable according to the mass criterion. Section measurement of X-section beam produced by plastic forming process was performed with Quantum Faroarm and Scanarm laser scanner (Model: LLP SD.…”

“…Thin-walled hollow structures are exposed to a large bending moment when used in industry. 5 Examining this bending mechanism and defining this collapse is very difficult. Although often time-consuming and expensive, accurately determining the bending behavior and mechanical properties of thin-walled hollow beams is possible by numerical simulations and experimental tests.…”