1. Bicycle Wrench Analysis
ME450: Computer-Aided Engineering Analysis
Department of Mechanical Engineering, IUPUI
Instructor: Dr. Koshrow Nematollahi
Bicycle Wrench Analysis
Danny Compton
Adam Douglas
Phil Palmer

2. OBJECTIVES
Perform finite element analysis of a Bicycle Wrench using ANSYS Workbench.
Evaluate stress and deformation resulting from applied loads and constraints.
Evaluate that this design is satisfactory and will not fail during use.

3. The Bicycle Wrench design blueprint
INTRODUCTION
The Bicycle Wrench design blueprint

4. INTRODUCTION CONTINUED…
The Bicycle Wrench design intent is to simplify the model orientation of the wrench using FEA Analysis. To know what the best material for production of wrenches should be used.
Example +
Pro E Model =
FEA Analysis

5. INTRODUCTION CONTINUED…
Normal loading conditions were chosen to be 10N and 100N being applied to the wrench.
Analyzing these forces on the wrench is very beneficial when determining what material to use, and how much force that material will with stand.

6. Theoretical Background
10-node tetrahedral elements were used to mesh the model.
Well suited for modeling models with curved boundaries and are very accurate.

7. BOUNDARIES Use of ANSYS Workbench Maximum number of nodes = 550 nodes
Total number of elements = 54
Use of properties of Aluminum
Use of properties of Steel

8. BOUNDARIES
Properties of Aluminum / Steel
Steel
Aluminum 6061

9. ANALYSIS (Pre-Processing)
The part was modeled in Pro/Engineer and imported into ANSYS Workbench
All parts were assigned properties of Aluminum 6061 / Steel alloy construction
Factor of safety of 3 was applied on the part, telling us our tensile strengths, from which we could determine if the wrench would fail.
Fixed support was assigned at the left edge of the wrench
Design was statically analyzed

10. ANALYSIS (Pre-Processing) Meshing
The imported model was meshed and 550 nodes were obtained
Using ANSYS Workbench, parts were suppressed
550 nodes

11. ANALYSIS - Final Model LOADING MESH
10N & 100N force applied on right edge of wrench
Fixed support applied at left edge
550 Nodes
54 Elements

12. ANALYSIS (Solution Phase)
Principal Stresses
Shear Stresses
Maximum Deformation

13. ANALYSIS (Solution Phase) Principal Stresses Steel – Loading (10N)
Maximum Principal stress of 1.189e6 Pa
Yield stress for Steel alloy is 2.5e8 Pa
Maximum stresses occur where the part potentially failed

14. ANALYSIS (Solution Phase) Shear Stresses Steel – Loading (10N)
Maximum shear stress of 6.180e5 Pa
Passed

15. ANALYSIS (Solution Phase) Maximum Deflection Steel – Loading (10N)
Max. Deflection of 7.296×10-6 m

16. ANALYSIS (Solution Phase) Principal Stresses Steel – Loading (100N)
Maximum Principal stress of 1.189e7 Pa
Yield stress for Steel alloy is 2.5e8 Pa
Maximum stresses occur where the part potentially failed

17. ANALYSIS (Solution Phase) Shear Stresses Steel – Loading (100N)
Maximum shear stress of 6.180e6 Pa
Passed

18. ANALYSIS (Solution Phase) Maximum Deflection Steel – Loading (100N)
Max. Deflection of 7.296×10-5 m

19. ANALYSIS (Solution Phase) Principal Stresses Aluminum 6061 – Loading (10N)
Maximum Principal stress of 1.187e6 Pa
Yield stress for Aluminum alloy is 1.15e8 Pa
Maximum stresses occur where the part potential failed

20. ANALYSIS (Solution Phase) Shear Stresses Aluminum 6061 – Loading (10N)
Maximum shear stress of 6.199e5 Pa
Passed

21. ANALYSIS (Solution Phase) Maximum Deflection Aluminum 6061 – Loading (10N)
Max. Deflection of 2.083×10-5 m

22. ANALYSIS (Solution Phase) Principal Stresses Aluminum 6061 – Loading (100N)
Maximum Principal stress of 1.187e7 Pa
Yield stress for Aluminum alloy is 1.15e8 Pa
Maximum stresses occur where the part potential failed

23. ANALYSIS (Solution Phase) Shear Stresses Aluminum 6061 – Loading (100N)
Maximum shear stress of 6.199e6 Pa
Passed

24. ANALYSIS (Solution Phase) Maximum Deflection Aluminum 6061 – Loading (100N)
Max. Deflection of 2.083×10-4 m

25. Impact Statement
Through the use of finite element analysis on the bicycle wrench, we determined that both the 6061 Aluminum and structural steel propose no risk of structural failure in normal operating conditions.

26. Conclusion - Advantages of Final Iteration
Using the same properties for density and the volume given in ANSYS, we calculated the mass of the wrench for both steel and 6061 aluminum:
Volume
9.22E-05 m3
Mass (steel) kg
Mass (aluminum) kg

27. Conclusion - Advantages of Final Iteration
The cost difference of 6061 aluminum and structural steel can be seen below, which was used to calculate the cost per cubic foot of the material.
$ per ft3
6061 Aluminum
Structural Steel

28. Conclusion - Advantages of Final Iteration
Our final analysis for this wrench is that if the consumer is looking for a lighter weight tool, the aluminum would be the best choice. If strength and cost are more important to the consumer than the structural steel would be the best choice.

29. Bibliography ME 450 Course Text ANSYS Website www.ansys.com