DESIGN AND ANALYSIS

OF FATIGUE LIFE OF IMPELLER

A THESIS
Presented by:
ANJU.P.P
Reg. No.: 731814410002
II Year / III Sem
M.E. Manufacturing Engineering
Guided by,
T. RAJESH
Assistant Professor/ Mechanical

1
 OBJECTIVE
• This project concern with impeller of centrifugal
pump.
• Material use for impeller productions are Steel,
Plastic, Iron, Aluminium etc.

• These materials have average life span and good

damage resistance

2
 Condt…

• In this project we are using the new material

• Inconel alloy 740, inconel alloy 783 and wrought

aluminum alloy 2219

• The impeller is analyzed under different loading

condition and its corresponding fatigue life is
calculated using different results obtained from the
analysis.

3
 INTRODUCTION

• An impeller is a rotor used to increase the pressure

and flow of a fluid.

• An impeller is a rotating component of a centrifugal

pump, usually made ofiron, steel, bronze, brass,
aluminum or plastic, which transfers energy from the
motor that drives the pump to the fluid being pumped
by accelerating the fluid outwards from the center of
rotation.

4
 Contd….
• If very high mechanical speeds are required
such as for high pressure – ratio wheels in
pump shroud can be eliminated to reduce
centrifugal stresses.
• Single stage open impeller designs can
maintain proper clearance of shroud side blade
tips with nearby cases, whereas multistage
compressor could have large changes in
operating clearance and greater thrust loads.
• Whenever a failure does occur in an impeller,
damage can be extensive, so proper design
parameters to eliminate critical resonances are
necessary.

• The life, damage, safety factor and all other

fatigue parameters are calculated using under
different loading condition.
 LITERATURE REVIEW
YEAR OF OUTCOME
S.NO. TITLE AUTHOR
PUPLICATION (CONTENT)
1 Investigation of Anil Antony The analysis of the result
Tribological Sequeira, indicates that the optimal
Behavior and its Ravikantha combination for low resultant
Relation with Prabhu, 2012 cutting force and good surface
Processing and N.S.Sriram finish are high cutting speed,
Microstructures low feed rate and low depth of
of Al 6061 cut.
Alloys
2 Manufacturing Doddapattar Sand Casting Method approach
of Aluminium N.B,
is involves with mechanical
Alloys Using Lakshmana
Sand Casting swamy 2012 mixing of the preheated a
Process molten metal. This process has
major advantage that the
production cost is very low.
4
 Condt…

S.N YEAR OF OUTCOME

TITLE AUTHOR
O. PUPLICATION (CONTENT)
3 The sliding wear Issac Thamban, This paper presents the
behavior of Al Biju Cherian experimental investigation on
6061 Abraham, Sabu 2013 milling Al 6061 alloys,
Kurian fabricated by sand casting
method
4 Tensile and wear Mohd. Junaid Experiments have been
properties of Mir, Khalid 2012 performed on newly designed
aluminum alloys Sheikh, Balbir experimental setup and the
Singh analysis properties.
5 Behavior of Al Natasa, The article specifically
6063 Alloys Naprstkova 2013 examines the influence of the
fabricated by amount of the substance on
Sand casting the resulting surface
process roughness after machining
alloy
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 PROBLEM IDENTIFICATION

• Work material properties and effects of end milling.

• Tough and work hardened materials, such as stainless

steel, have poor to fair machinability ratings.

• Milling with the end cutter may leave spiral feed marks.

• Various Cutting speed, Feed rate and Depth of cut.

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METHODOLOGY

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 SURFACE ROUGHNESS

• Surface texture is the pattern of the surface which deviates

from a nominal surface.

• The deviations may be repetitive or random and may result

from roughness, waviness and flaws.
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 THEORY OF SPECIMEN

Al 6061 & 6063 Alloy

• It provides good and a high quality surface finish.

• It is a medium to high strength.

• It has very good corrosion resistance

• It has very good weldability

• It reduced strength in the weld zone.

• It has medium fatigue strength.

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 CHEMICAL PROPERTIES OF Al 6061&6063
ALLOY
Al 6061 Al 6063
S.NO MATERIAL WEIGHT S.NO MATERIAL WEIGHT
NAME (kg) NAME (kg)
1 Silicon 0.4 to 0.8 1 Silicon 0.20 to 0.6
2 Iron 0-0 to 7 2 Iron 0.35
3 Copper 0.15 to 0.40 3 Copper 0.10
4 Manganese 0-0 to 15 4 Manganese 0.10
5 Magnesium 0.8 to 1.2 5 Magnesium 0.45 to 0.9
6 Chromium 0.04 to 0.35 6 Chromium 0.10
7 Zinc 0 to 25 7 Zinc 0.10
8 Titanium 0 to 15 8 Titanium 0.10
9 Aluminium Remaining 9 Aluminium Remaining

10
MECHANICAL PROPERTIES OF Al 6061&6063
ALLOY
Al 6061 Al 6063
S. S.
PROPERTIES UNITS PROPERTIES UNITS
N0 NO
310 131
1 Tensile Strength 1 Tensile Strength
Mpa Mpa
276 150
2 Yield Strength 2 Yield Strength
Mpa Mpa

3 Hardness (BHN) 95 3 Hardness (BHN) 96

4 Elongation 16 inch 4 Elongation 18 inch

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 SPECIMEN PREPARATION

The specimen is prepared by various casting method.

• Sand casting method

• Stir casting method

• Vortex casting method

• Die casting method

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 SAND CASTING METHOD
• Al 6061 & 6063 alloys can be cast in metallic moulds or sand
moulds. The most common casting processes used is sand casting.

• Sand Casting is a fast way to produce the desired shape. Casting

Al 6061 & 6063 alloys are produced by pouring molten metal into
moulds.

• After the metal has cooled sufficiently, the casting is separated from
the mould and undergoes cleaning and finishing techniques as
appropriate.

• Three steps are involved in a casting process:

i. Heating metal till it becomes molten
ii. Pouring molten metal into a mould
iii. Allowing the metal to cool and solidify in the shape of the
mould.
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HEATING PROCESS

Electric Furnaces

14
 Condt…

• Electric induction furnaces are the most common type used for
melting of Aluminium alloys.

• This method involves the use of an electrical current

surrounding a Crucible that holds the metal charge.

• Electric heating furnaces offer good melt quality and absence

of products of combustion.

• These furnaces are insulated with ceramic fiber and are of

stationary or tilt types. The aluminium /alloy scrap to be
melted should be clean.

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 MELTING PROCESS

Melting process of Al 6061& 6063 alloys

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 Condt…
• The process of melting consists of - A crucible filled with
metal charge is placed in a furnace and the metal is allowed to
melt.

• The molten metal is removed from the furnace and poured into
a preheated mould.

• Sand mould can be used for collecting the molten metal.

• Aluminium alloys can be melted in direct or indirect fuel fired

furnaces or in electrically heated furnaces like - crucible
furnaces

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 Condt…

The crucibles for collecting the molten Al 6061 & 6063

Crucibles

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CASTING SEPARATION

Sand Casting Tools

19
 Condt…

• Molten metal is poured into moulds using various types of

ladles, automated pouring furnaces.

• Metal is poured into the “runner” until the runner bush is full.
The “riser” provides an additional reservoir of feed metal to
counteract the shrinkage that occurs as the casting begins to
cool.

• It is separated from the mould by mechanical or manual

methods.

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 Condt…

Product of Al 6061 & 6063 alloy

21
 WEAR TEST
The wear testing is most essential for find the
mechanical and chemical properties of the specimen.

TYPES OF WEAR TESTING METHOD

• Pin-on-disc test
• Pin-on-drum abrasive wear test
• Repeated impact wear test
• Rubbing test
• Block on ring test

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PIN-ON-DISC TYPE WEAR TESTING

Wear Testing Machine

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 TESTING PROCESS
• The wear test is performed on all specimens.

• The test is carried out using Pin-on-Disc wear device

• It consists of a rotary horizontal steel disc driven by variable

speed motor.

• The test specimen is held in the specimen holder that fastened

to the loading lever against the rough counter-face.

• The load is applied by dead weights (1600 gm) at 3.5 linear

velocity at constant time.

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 Condt…

• An emery paper before the test polished the contact surface of

the test specimens.

• The counter-face is in the form of an emery paper of 80 grad

attached on a steel disc of 50 mm inner diameter.

• Alloys are produced when two materials are joined to give a

combination of properties that cannot be attained in the
original materials.

• Two thin spring steel sheets, where strain gauges are adhered,
friction coefficient can be measured.

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BETTER COMPOSITION OF THE SPECIMEN

S.NO MATERIAL Al 6061 Al 6063 COMBINATION OF

NAME WEIGHT(kg) WEIGHT(kg) Al 6061&6063 (kg)

1 Silicon 0.4 to 0.8 0.2 to 0.6 0.840

2 Iron 0 to 0.7 0.35 0.454
3 Copper 0.15 to 0.40 0.10 0.448
4 Manganese 0 to 0.15 0.10 0.08
5 Magnesium 0.8 to 1.2 0.45 to 0.9 0.620
6 Chromium 0.04 to 0.35 0.10 0.070
7 Zinc 0 to 25 0.10 0.482
8 Titanium 0 to 15 0.10 0.0068
9 Aluminium Remaining Remaining Remaining

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 MACHINING SETUP

Vertical CNC Milling Machine

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 END MILLING
(Using Cutter)

End Mill

Diameter (Ø) = 10 mm
Length (L) = 60 mm
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END MILLING
(Using Inserts)

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 MACHINING PROCESS

• The tool used was a four-flute high speed steel cutter.

• The materials used for the experiments are Al 6061 & 6063
alloy.

• The 10 experiments were randomly run by the CNC milling

machine.

• The measured surface roughness data values is to be collect

after end milling is completed.

• After the data are collect and record in table with the data.

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 MEASURING SURFACE ROUGHNESS
TECHNIQUES

• Tomlinson Roughness Meter

• Electron Microscopy

• Stylus Instruments

• Optical Instruments

• Microscopy Background

• Scanning Tunneling Microscopy

• Atomic Force Microscopy

32
MEASURING INSTRUMENTS

Tomlinson Roughness Meter

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 Condt…

Stylus type instruments

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 Condt…
• Stylus instruments are based on the principle of running a
probe across a surface in order to detect variations in height as
a function of distance.

• One of the early stylus instruments employed a system of

levers to magnify the vertical displacement of the stylus and
recorded the profile on a smoked-glass plate.

• This signal can then be processed by the instrument electronics

to calculate a suitable roughness parameter. The effect which is
a schematic comparison of an actual profile against the traced
profile.

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 ADVANTAGES

• Designer can subsequently select the best combination of

Alloys and design variables for achieving optimum surface
roughness.

• This eventually reduces the machining time.

• Reduces machining cost.

• Save the cutting tools.

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 APPLICATIONS
• Rail coaches

• Truck frames

• Ship building

• Bridges

• Aerospace applications including Helicopter rotor skins

• Towers

• Transport

• Boiler making

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 RESULTS
COMBINATION TEST – I (Al 6061 50% & Al 6063 50%)
Exp Cutting speed Feed rate Depth of Ra
No. (rpm) (mm/min) cut (mm) (µm)
1 2000 80 2 0.89
2 2000 120 2 0.73
3 2000 100 1.5 0.69
4 1500 100 1 0.58
5 2000 100 1.5 0.69
6 2500 120 1.5 0.57
7 2500 100 2 0.91
8 1500 100 2 0.91
9 2000 120 1 0.41
10 1500 80
38 1.5 0.62
 Condt…
COMBINATION TEST – II (Al 6061 40% & Al 6063 60%)
Exp Cutting speed Feed rate Depth of Ra
No (rpm) (mm/min) cut (mm) (µm)
1 2000 80 2 0.9
2 2000 120 2 0.78
3 2000 100 1.5 0.67
4 1500 100 1 0.5
5 2000 100 1.5 0.66
6 2500 120 1.5 0.62
7 2500 100 2 0.83
8 1500 100 2 0.8
9 2000 120 1 0.43
10 1500 80
39 1.5 0.7
 Condt…
COMBINATION TEST – III (Al 6061 60% & Al 6063 40%)
Exp Cutting speed Feed rate Depth of Ra
No (rpm) (mm/min) cut (mm) (µm)
1 2000 80 2 0.85
2 2000 120 2 0.69
3 2000 100 1.5 0.63
4 1500 100 1 0.55
5 2000 100 1.5 0.76
6 2500 120 1.5 0.68
7 2500 100 2 0.7
8 1500 100 2 0.58
9 2000 120 1 0.6
10 1500 80
40 1.5 0.45
 Condt…

VARIATION CHART - I (AL 6061 50% & AL 6063 50%)

Ra(µm)
1
0.9
Measured 'Ra' values

0.8
0.7
0.6
0.5
0.4
0.3
0.2 Ra

0.1
0
1 2 3 4 5 6 7 8 9 10

No. of Experiments

41
 Condt…

VARIATION CHART - II (AL 6061 40% & AL 6063 60%)

0.9
Ra(µm)
0.8

0.7

0.6

0.5

0.4

0.3
Ra
0.2

0.1

0
1 2 3 4 5 6 7 8 9 10
No. of Experiments

42
 Condt…

VARIATION CHART - III (AL 6061 60% & AL 6063 40%)

Ra(µm)
0.9

0.8
Measured 'Ra values

0.7

0.6

0.5

0.4

0.3
Ra
0.2

0.1

0
1 2 3 4 5 6 7 8 9 10

No. of Experiments

43
 Condt…

COMPARISON OF VARIATION IN CHARTS

1
Ra(µm)
0.9

0.8
Measured 'Ra' values

0.7

0.6

0.5

0.4

0.3
TEST 1 - (Al 6061 50% & 6063 50%)
0.2
TEST 2 - (Al 6061 40% & 6063 60%)
0.1
TEST 3 - (Al 6061 60% & 6063 40%)
0
1 2 3 4 5 6 7 8 9 10

No. of Experiments

44
BEST PARAMETERS FOR MACHINING

BEST PARAMETERS FOR MACHINING

TEST NO
Cutting Feed rate Depth of Ra (µm)
speed (rpm) (mm/min) cut (mm) measured

I 2000 120 1 0.41

II 2000 120 1 0.43
III 1500 80 1.5 0.45

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 Condt…

COMPARISON CHART OF BEST “Ra” VALUES

"Ra" (µm)
0.46
MEASURED "Ra" VALUE

0.45

0.44

0.43

0.42

0.41

0.4

0.39
I II III

NO. OF TESTS

46
 CONCLUSION
• The suitable specimens of Al 6061 & 6063 Alloy were
prepared by Sand Casting Method.

• Using pin–on–disc method, the components were induced

various testing to find mechanical and chemical properties.

• Variable parameters were used to machine the Al 6061 & 6063

Alloys to experimentally investigate and improved good
surface finish of product using end milling machine.

• Tomlinson Roughness meter were used to ensure the surface

roughness of Al 6061 & 6063 Alloy.

• The preferred “Ra” values are found by comparison chart.

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 REFERENCE

• Anil Antony Sequeira, Ravikantha Prabhu, N.S.Sriram,

“Effect of Cutting Parameters on Cutting Force and Surface
Roughness of Aluminium Components using End Milling
Process” Issue 4 (2012)

• Doddapattar.N.B, Lakshmanaswamy.N “An optimization of

machinability of Aluminium Alloy 6063 and cutting tool
parameters” Volume 3, Issue 2, May-August (2012)

• Muhammed Hayat Jokhio, Muhammed Ibrahim Panhsher and

Mukthiar Ali Unar “Manufacturing of Aluminum Alloys
Material Using Sand Casting Process” Vol.30, 2010.

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