Fracture Analysis of Exhaust Manifold Stud of Mahindra Tractor through Finite Element Method (fem) – a past Review

The present paper is a review of the past work done in the field of analysis on fracture of various casting components, engine parts and other area of applications using FEM (ANSYS). Failures were observed even after designing the components with maximum stress value well below yield / ultimate stress. Later it was concluded that the failure is because of variation of load with respect to “time” not being taken in to account. Tests were then carried out for time varying loads. Results proved that the component fails at values below yield stress when subjected to time varying load. It was also observed that below a specific stress value components were not failing at all. This stress value was termed as endurance limit. For example yield stress for general steel is around 250 N/mm and endurance limit 160 N/mm.In general while using FEM technique for failure analysis, a finite element routine would be first used to calculate the static and dynamic displacement and stresses under the maximum compression and tension loading, which were then used for critical points evaluation. Calculation based on failure life and accurate loading histories permit components to be optimized for durability without the need for expensive and time-consuming testing of series of prototypes. According to the various literature reviews on failure analysis, FEA based fatigue analysis of metals (iron, steel, aluminium etc.), and mostly the casted components has been well established. But same is not true with non metals (like polymers etc.). The nonlinear fatigue behavior is not yet completely understood and still in research phase. This paper proposes the use of Finite Element Method (FEM) with ANSYS and ABAQUS as one of the helping software for better result analysis in most of the failure applications.