BUCKLING AND CRUSHING ANALYSIS OF CYLINDRICAL …€¦ · Courbon studied the mechanical properties of aluminium alloy. [9]used in manufacturing of beverage cans. Xu et al. studied

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 03 Issue: 06 | June-2016 www.irjet.net p-ISSN: 2395-0072

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BUCKLING AND CRUSHING ANALYSIS OF CYLINDRICAL ALUMINIUM

CANS & OPTIMIZING THE PARAMETERS EFFECTING CRUSH STRENGTH

USING FEM

Sawant D. A.1, Dr. Venkatesh M. A.2

1Student, Dept. Of Mechanical Engineering, S.N.D C.O.E & R.C YEOLA, MAHARASHTRA, INDIA 2Principal, S.N.D C.O.E & R.C YEOLA, MAHARASHTRA, INDIA

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Abstract - Beverage industries face a lot of problem of wastage of beverage drinks due to the collapse of aluminium cans which lead to decrease in the profit and disturbance in economical balance of the company. In order to increase the effectiveness of the cans effect of impact loads on the cans is considered in this study. Usually cans are designed as pressure vessels but it leads to failure of cans during impact loads. In this work the impact loads are taken into consideration and crashing analysis of aluminium cans is performed with the aim of finding out the ability of cans to withstand impact loads using FEM. Various factors effecting crushing strength is identified. It is found that thickness of sheet and mass of crusher play a very vital role in crash test

Key Words: Aluminium can, Buckling Load, Crushing, Compression, Loading.

1.INTRODUCTION An Aluminum can is a container for packaging made primarily of aluminum which is commonly used for foods and beverages but also for products such as oil, chemicals, and other liquids. It is used for packaging of food so it is subjected to various external loads while transportation. The major problem associated with aluminium cans is the inability of cans to withstand the impact loads which leads to wastage of lot of beverage drinks and other stuffs. Aluminium cans are designed to withstand the internal pressure exerted by the fluids but the effect of impact which may occur during transportation is considered as a negligible factor.

In this case the effect of impact loads on the cans will be taken into account and various factors involved in effecting crash of cans will be considered.

This study is performed in order to increase the effectiveness of aluminium cans. In this work three piece aluminium can is subjected to both buckling and crashing failure under the applied loads to find the crushing strength of aluminium can.

2. LITERATURE REVIEWS Belblidia et al. presented a simulation study of an aerosol can considering internal pressure and compressive loading to obtain various parameters effecting can’s crushing strength and provided a provided a guidance to improve aerosol can design. [1] Folle et al. studied various parameters affecting the manufacturing process of beverage cans. Parameters such as angle of ironing die, friction coefficient and clearance between punch and ironing die influence the ironing force and consequently the manufacturing process [2] Foster experimentally obtained various radial deformation patterns in thin walled cylinders and further obtained a mathematical relation to obtain radial deformations. [3]

Further Han et al. performed crushing analysis on triangulated aluminium beverage can and optimized the design to obtain best performance using response surface approximation [4] again Han et al. performed crushing analysis but shape of the can was considered to be cylindrical. [5] In the same way Han et al. again perform crushing analysis and optimization but considered aluminum beverage bottle design in place of can. [6] Ceretti et al. studied another manufacturing process of aluminium cans: Hydroforming both experimentally and numerically. Numerical simulations were perfomed to find out various parameters affecting manufacturing process. [7] Furthermore, Abrinia et al. Abrinia studied extrusion as a manufacturing process for aluminium cans.[8] Moreover Courbon studied the mechanical properties of aluminium alloy. used in manufacturing of beverage cans. [9] Xu et al. studied experimentally the crashworthiness performance of thin walled aluminium structures. It was found that functionally graded tubes perform better than uniform thickness counterparts.[10] Mhuruyengwe et al. performed finite element analysis on metal food cans. [11]

3. METHODOLOGY

Methodology usually adopted for the Production of the aluminium cans is that the dimensions of the can are calculated with help of internal pressure of the liquid which it has to withstand and proper factor of safety. After getting the safe dimensions aluminium cans are manufactured using either forming or deep drawing. [2],[7],[8] The crushing analysis in this study is performed on aluminium can made up of aluminium alloy 1100 with three different thickness 0.11,




0.22 and 0.33 mm sheets respectively. Firstly the maximum load under which the aluminium cans buckle is calculated and that buckle load is further used for the explicit dynamic crushing analysis of cans. All the numerical simulations are performed with the help of ABAQUS 14.0.

Table -1: Dimensions of Aluminium Cans Sample Diameter (D0) Thickness Depth

S_11 80 mm 0.11 mm 80 mm S_22 80 mm 0.22 mm 80 mm S_33 80 mm 0.33 mm 80 mm

A thin cylindrical shell is designed with external diameter

80 mm, 80 mm depth and different thicknesses 0.11, 0.22 and 0.33 mm respectively to perform different crush and buckling test for each specimen.

Fig -1: Aluminium Can Table -1: Properties Of AL1100

Properties Values

Density 2710 kg/m3

Poisson’s ratio 0.33

Tensile Strength 110 MPa

Yield Strength 105 MPa

Shear Strength 69 MPa

Percentage Elongation 12%

The material used in this analysis is Al 1100 alloy with

properties as given in the above table. The aluminium can analysis is carried out in two phases: In the first phase buckling analysis of each sample of can is carried out to find the maximum load under which a structure fails and in second phase can samples are subjected to explicit dynamic

loading to attain crushing strength of each can. In this phase the maximum load obtained in the first phase is used as an input along with time increment of 1 Second.

4. EXPERIMENTAL SETUP & ANALYSIS

After the samples were fabricated, they were subjected to static load in Compression Testing Machine. This Compression Testing Machine is a hydraulic, electrically operated unit, designed for conducting compression tests on concrete specimens up to 20 cm. Diameter (or width and depth) and 30 cm, in height and also rocks and various other materials. Cold Crushing Strength (CCS) test is also possible in this Compression Testing Machine.

The Compression Testing Machine consists of a steel cross head and cast iron base with two pillars connecting the base and cross head by means of nuts. The hydraulic jack of this Electric Compression Tester is fixed to the base. The upper platen has got a self-aligning action and is attached to a screw which passes through the cross head and can be raised or lowered for initial clearance adjustment. The lower platen rests on the jack ram and is positioned with the help of a centre pin.

Loading is accomplished by the upward movement with the help of a centre pin. Loading of Compression Testing Machine is accomplished by the upward movement of the motorized pumping unit is of plunger type and is connected to the jack by means of a steel connecting tube. A maximum red pointer is provided to facilitate taking of the readings after failure of specimens. The pressure gauges of 20 cm diameter with isolating valves are fixed on the pumping unit at an angle for easy readability.

Fig -2: Crush Strength Of Can Sample




Fig -3: Compression Testing machine

Aluminium cans with 80 mm diameter and depth 80 mm are prepared with different thickness 0.11 mm, 0.22 mm and 0.33 mm respectively. After preparing the samples are subjected to compression tests with the help of compression testing machine. The samples are crushed till the maximum displacement of the sample is reached and the maximum or peak load is noted.

5. RESULT & DISCUSSSION

The results and discussion in this study is divided in two different sections- Buckling analysis of can and Crushing analysis of can.

5.1 Buckling Analysis

It is a simple static analysis performed in ABAQUS 14.0 to find out the maximum load which a structure can withstand without failure. In this analysis meshing is performed with the help of S4R elements. Initially 1 kN load is applied at the centre by creating it as a control point with MPC constraint so that the load is distributed equally to all nodes with which it is connected.

Fig -4: Buckled Aluminium can

Fig -5: Maximum Load On Each Sample

The maximum buckling load carried by the aluminium can

of 0.33 mm thickness sheet is 850 N. The maximum load

carried by 0.22 mm thickness aluminium can is 586 N while

load carried by 0.11 mm thickness aluminium can is 427 N.

The above graph represents that as the thickness of the sheet increases with which can is manufactured the maximum load carrying capacity of a structure without failure also increases. 0.33 mm sample aluminium can withstands the maximum load out of three samples tested.

5.2 Crushing Analysis

Each sample of aluminium can has specific maximum load

which is used as input for further analysis. Maximum load is

applied as an input parameter for each case separately to

perform its crush test. Crushing is a time dependant

phenomena thus the loading conditions become more

complex as compared to static analysis. In crashing a crasher

or moving wall is created which is used to crush the can. In

this case a square shell with 100 mm X 100 mm and 1 kg

mass is crusher or moving wall. The square crusher is

chosen with a rigid plastic model for analysis.




Fig -6: Crushing of Sample S_33 having [80, 80] Co-ordinate

System.

The load is applied in time step incremental form to perform explicit dynamic analysis. The crusher wall is restricted to move in any direction other than downward with a velocity of 1 m/s.

5.3 Effect of Thickness Of Sheet

Crushing analysis is performed in three different samples of aluminium cans with three different thickness 0.11, 0.22 and 0.33 mm respectively. It is found that the crushing strength of aluminium can with maximum thickness of aluminium can is maximum.

Fig -7: Crushing strength variation of each sample

It is also quite evident from the figure that as the thickness of the sheet increases the crushing strength of aluminium cans also increases. In this analysis mass and velocity of the crusher is kept constant and equal to 1 kg and 1 m/s respectively.

5.4 Effect of Mass Of Crusher

Crushing analysis is also performed on 0.33 mm aluminium can with varying masses of the crusher as 1 kg, 2 kg and 3 kg respectively in order to observe the effect of mass of crusher on performance and crushing strength of cans.

Fig -8: Crushing strength variation with mass of Crusher

It is quite evident from the analysis that as the mass of the crusher increases the crushing strength of the aluminium can decreases that is the load required to totally crush the sample of 0.33 mm decreases drastically. This is mainly because of the effect of inertia of crusher in dynamic loading. In crush test kinetic energy also becomes very important parameter thus effect of mass is quite evident.

5. CONCLUSIONS

Various parameters affecting the crush strength of the aluminium can is evaluated using ABAQUS 14.0. It is found that the thickness of sheet effect in direct proportion with the buckling strength or maximum load carrying capacity. In the same way crushing strength of the aluminium can also increases with increase in the thickness of sheet. But it is well known fact that with the increase in thickness material required and cost incurred also increases so the designer has to basically decide a thickness keeping this in mind. The effect of mass of crusher on crushing strength is also evaluated. It is found that with increase in mass the crushing strength of the aluminium can reduces.

REFERENCES [1] F. Belblidia ,T.N. Croft, S.J. Hardy, V. Shakespeare, R.

Chambers, “Simulation based aerosol can design under




pressure and buckling loads and comparison with experimental trials”, Materials and Design , 2013, pp. 214–224.

[2] Luis Fernando Folle, Sergio Eglan Silveira Netto, Lirio Schaeffer, “Analysis of the manufacturing process of beverage cans using aluminum alloy”, Journal of materials processing technology 2 0 5, 2 0 0 8, pp. 347–352.

[3] C.G. Foster, “Measurement of Radial Deformations in Thin-walled Cylinders:, Experimental Mechanics, 1977, pp. 238-244.

[4] J. Han, K. Yamazaki and S. Nishiyama, “Optimization of the crushing characteristics of triangulated aluminum beverage cans”, Structural Multi-disc Optimum 28, 2004, pp. 47–54.

[5] J. Han, K. Yamazaki and S. Nishiyama, R Itoh, “Application of structure optimization technique to aluminum beverage bottle design Structural Multi-disc Optimum 29”, 2005, pp. 304–311.

[6] J. Han, K. Yamazaki and S. Nishiyama, R Itoh, “Multi-objective optimization of a two-piece aluminum beverage bottle considering tactile sensation of heat and embossing formability”, Structural Multidisc Optimum 32, 2006, pp. 141–151.

[7] E. Ceretti, A. Attanasio, A. Fiorentino, L. Giorleo, C. Giardini, “Aluminium can shaping by hydroforming: simulative feasibility study and prototype production”, Int J Adv Manuf Technol (2013) 68:1797–1807

[8] Joel Courbon, “Mechanical metallurgy of aluminium alloys for the beverage cans”, Materials Science Forum vols. 331-337, pp 17-30, Dec. 2000.

[9] F. Xu, X. Tian, G. Li, “Experimental Study on Crashworthiness of Functionally Graded Thickness Thin-Walled Tubular Structures”, Experimental Mechanics (2015) 55:1339–1352.

[10] F. Xu, X. Tian, G. Li, “Experimental Study on Crashworthiness of Functionally Graded Thickness Thin-Walled Tubular Structures”, Experimental Mechanics (2015) 55:1339–1352.

[11] Ngonidzashe Mhuruyengwe, Tawanda Mushiri, Talon Garikayi, “Finite element analysis of metal food cans under axial loads and sealing pressure”, Global J. of Mech., Engg. & Comp. Sciences, 2013: 3 (2), PP No. 58-61.

[12] M.R. Hackworth, J.M. Henshaw, “A pressure vessel fracture mechanics study of the aluminum beverage can”, Engineering Fracture Mechanics 65, 2000, pp. 525-539.

[13] S J Hardy, R Abdusslam, “Finite element modelling of the manufacturing process for aluminium aerosol cans”, Proc. IMechE Vol. 221 Part L: J. Materials: Design and Applications 265-274.

BIOGRAPHIES

Sawant D. A. borned in Pachora,

situated in Maharashtra India in year

1990. He completed his high school

education from St. Xavier's English

Medium School in Manmad. He is

graduated in mechanical Engineering

from S.N.D.C.O.Engineering and

Research Center Yeola. Now persuing

Master degree in Design branch from S.N.D.C.O. Engineering

and Research Center yeola.

As his interest is towards design and development, He had

shown his Skill in design field. He had done two project in

Design field. The First project is "Multiutility unit for Micro-

finishing, Filter Cleaning, Ceiving and Grinding by Forced

Vibration Effect”. This project was showcased in DIPEX-

2013. It was well appreciated by all. Second Project is

"Vibratory Super Finishing unit". This project also Displayed

in DIPEX 2014.

Deepak Has also Presented Paper on the topic" Structural

Analysis and Design Optimization of Handle Bar Assembly of

motor" in year 2016, are organized by International

conference on immerging trends and research in

engineering.

Dr. Venkatesh M. A. received B.E in

Mechanical. and M.Tech. in production,

& Ph.D. in Mechanical.

He has been working asPrincipal of

S.N.D.C.O.E &R.C, Yeola, Maharashtra. He

has 30 years of teaching experience. He

has published 10 national papers and 5 international paper.

BUCKLING AND CRUSHING ANALYSIS OF CYLINDRICAL …€¦ · Courbon studied the mechanical properties of aluminium alloy. [9]used in manufacturing of beverage cans. Xu et al. studied

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