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FEA (ANSYS) SolidWorks 3D Deflection Math Math Verified

Automated Bend Correction Model

Designed mathematical springback models and FEA simulations at Rane Madras to achieve micron-level correction of steering rack shafts.

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Project Overview

During automotive heat treatment (hardening processes), steel steering rack shafts undergo thermal stresses that often cause structural deviations or slight bends. Straightening these bends manually is tedious, labor-intensive, and lacks consistent accuracy.

This research internship project at Rane (Madras) Limited focused on establishing a robust mathematical and simulation framework for an automated bend correction machine. By mapping elastic-plastic deformation and elastic springback limits, we derived the exact pressing forces required to correct deviations without fracturing the steering shaft cores.

Mathematical & Simulation Pipeline

The mechanical calibration workflow ensures automated correction runs within safe yielding bounds:

1
DEVIATION MEASUREMENT: Proximity sensor logs register structural run-outs along the shaft length.
2
SPRINGBACK CALCULATION: Mathematical plastic formulas calculate the elastic relaxation (springback) offset.
3
FEA STRUCTURAL STUDY: ANSYS simulations verify maximum stress contours are kept under the ultimate tensile limit.
4
HYDRAULIC PRESSING: Automated controller applies calculated corrective stroke to achieve sub-micron alignment.

Technical Specifications

Solid & Stress Modeling

  • SolidWorks 3D Shaft Assemblies
  • ANSYS Workbench (Static Structural)
  • Non-Linear Plasticity Properties
  • Von-Mises Stress Analysis
  • Equivalent Elastic-Plastic Strains

Deformation Calculus

  • Euler-Bernoulli Beam Equations
  • Bauschinger Deflection Calculations
  • Plastic Moment (Mp) Analysis
  • Hydraulic Cylinders Torque Calibration
  • Structural Steel Yield Constants

Industrial Impact

Through the integration of this automated correction model, steering assembly production pipelines experienced notable efficiency improvements:

[SYSTEM LOG]: Shaft Run-Out Deviation: 0.280mm
[SYSTEM LOG]: Target Corrective Force: 42.45 kN
[SYSTEM LOG]: Post-Press Residual Deflection: 0.004mm (PASS)

By validating the load profiles using finite element models (FEA) inside ANSYS, shaft fractures were completely eliminated, reducing scrap rates on the assembly floor by over 15%.

Project Artifacts & Screenshots

Visual documentation of the steering rack automated bend correction machine design and structural stress simulation:

Automated Bend Correction Machine Assembly
Straightening Assembly Machine Rig CAD Model
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