AU-FRG Institute for CAD/CAM

Director : Dr.R.Velraj
Phone : 044-22358051

AU-FRG Institute for CAD/CAM, is offering services to the needs of Indian Industries in CAD/CAM/CAE areas to enable them to become global players and offers a part time PG course on Product Design and Development suited to the needs of the industry. The Institute provides consultancy to industries in large, medium and small scale sectors, besides R&D organization and government sector organizations, to small and medium sector companies like Automobile Manufacturers as well as Automotive ancillary parts manufacturers and consumer product industries etc.

The Institute is equipped with the latest version of CAD/ CAM/CAE Software tools with matching hardware facilities. However, the major unique strength lies in people and experts in every engineering field who are available under this single umbrella, called AU-FRG Institute for CAD/CAM drawn from various departments of the University. The AU-FRG ICC by its sheer strength in hardware and software could handle any industrial projects requiring new product design, product modeling, and optimization in product design, mechanical and thermal stress analysis, NC code generation and CAM. In addition, the institute is having a team of dedicated and experienced project engineers, who can handle the problems requiring CAD/CAM/CAE tools.

In the area of human resource development, the AU-FRG ICC is conducting high quality training programmes for working professionals, engineering graduates and diploma holders and, tailor made Corporate Training programmes for industries according to their need. By virtue of having a Rapid Prototyping Facility, the Institute is in a position to take up projects requiring Rapid Prototyping and Rapid tooling.


Name and highest qualification Designation Phone No. & E Mail Expertise
Dr.R.Velraj Ph.D
Thermal Storage, Energy Management in Buildings, Heat Exchangers and CFD simulation
Dr.K.Srinivasan Ph.D
Tribology, Vibrations, CNC machining.

Mr.K.Malar Mohan
Engineering Mechanics

Completed Projects Ongoing Projects
Value (Rs. Lakhs)
Value (Rs. Lakhs)

Brief Write up on Most Successful Research Projects:

Finite element analysis of optical tracking mount

Optical Tracking Mount (OTM) consists of a pedestal structure and FRP dome. The pedestal structure has freedom for limited angular rotation about two axes and supporting the various electrooptical sensors, of maximum payload weight 100 kg. Both the pedestal and FRP dome are driven by pan cake type Direct drive DC Torque Motors which are co-axially mounted on each axis. Static analysis for various critical components has been carried out for checking of static strength of each part for various loading conditions. The deflections and stresses at the critical locations are found out. The modal analysis has been carried out and find the locked rotor frequency with respect to elevation axis, azimuth axis which are respectively found as 61 Hz and 267 Hz and lie well above the servo bandwidth frequency.

Analysis of Mobile Launch Pedestal (MLP) for GSLV MKIII

MLP is a steel structure made up of thick steel plates and the launch vehicle is assembled in vehicle assembly building (VAB) upon this MLP and then brought to Launch pad through rails. The MLP consists of two strap-on support rings over the deck of the MLP to support the S-200 strap-on motors. During assembly and launch of the vehicle the MLP is fixed to the ground through the Anchor legs. While moving the MLP from the VAB to the launch pad it moves on a bogie system. During the operation of assembly, transportation, launch and post launch, the MLP undergoes various loading conditions. MLP has been modeled using a modeling software I-DEAS and transferred as a Finite Element model into the analysis software ANSYS. The MLP has been checked for stresses and displacements for the various loadings.

Modelling and Finite Element analysis of Tyre Curing Press

The general configuration of Tyre Curing Press consists of Top Dome, Bottom Box, Bayonet ring and Thrust adjusting mechanism. The top dome and bottom box form a steam chamber (with a rubber seal in between) and is locked by a bayonet ring. The bottom box is a stationary unit, which houses a reaction bladder and bolster plate on top of which the bottom half of the tyre mould is placed. The top dome holds the top bolster plate and the top half of the tyre mould. This bolster plate can be adjusted to accommodate moulds of different height. The bladder is inserted inside the green tyre and loaded inside the mould. The steam chamber is closed and the bladder is inflated, the green tyre is pressed against the mould and takes the shape of finished tyre. The chamber and bladder are charged with steam and the tyre will get cured over a period of time. The Tyre curing press components were modeled and assembled using I-DEAS software, from the assembly, components are integrated into a part by Boolean operations. Since the part is symmetrical 1/4th model was taken for FE analysis. The models were meshed with structural solid elements and are switched to appropriate thermal elements for doing thermal analysis. The boundary conditions of temperatures and thermal insulations are applied at different surfaces. In structural analysis, saturated steam pressure is applied as internal pressure in respective locations like reaction bladder, mould and all inside surfaces of tyre curing press. The maximum displacement thrust mechanism is observed. The maximum Von-Mises stress value is found out in thrust mechanism stiffeners, which connects to top dome dished end. The stress distribution is studied and the design was modified for validation.

Design validation of water pump

TVS-Autolec Ltd has designed a Water pump and AU-FRGvalidated their design with respect to the deflection and the stress under the load applied. The individual parts namely shaft, Impeller and cover plate are modeled. The impeller and the cover plate are modeled with shell elements. The shaft is modeled with 10 node Tetrahedron elements. For the studies made on the impeller, the stress values are much closer to the yield stress value. However the induced stresses are highly localized at the edges of the fan blades and the loading is highly severe than operating condition. Hence, a modified design was proposed.

Stress Analysis of Transition Piece & Load Transfer Attachment in a Once through 500 MW Boiler.

There is a need for higher capacity boilers (600MW and above) of once through super critical type. In a once through super critical boiler, the lower part of the furnace is spiral wall construction, which is not self-supporting by itself and which calls for load transfer attachments and transition from spiral to vertical wall. The analysis of piping junction arrangement used for spiral to vertical wall transition and load transfer plate arrangement attached to the tubes are important for design of such boilers. The 3D model is created using CAD software and is imported to FEA software for analysis. The analysis of the Transition piece is done by using a three dimensional model. The area of interest is the behavior of one single transition piece. In order to avoid the localized effects due to the application of boundary conditions, the pipe connecting the spiral tube to header is modeled such that the length is not less than that of attenuation length. Thermal analysis carried out to find the temperature distribution in the transition piece. Onto this temperature distribution the mechanical load was mapped and the thermo mechanical cum structural analysis are carried out. The maximum temperatures, displacement, Von Mises stress in the transition piece were found out. The safe thickness of the plate of the transition piece is optimized.

Flow & Stress analysis of a cooling fan

It is defined that cooling fan, which is used to transfer the amount of heat produced, should be analyzed for stress developed also. The fan is rotating with very high speed in the order of 5500 rpm.CFD analysis was carried out to arrive at the mass flow rate for various rotational speeds. The computational domain of the cooling fan consisted of eight big blades with eight splitter blades. The turbulence flow is simulated with the high Reynolds number. Pro Engineer was used to extract the computational domain and CFX-Turbogrid was used for structured grid generation of complex bladed geometries. CFX5 solves the three dimensional Reynolds averaged, Navier–stokes equation of flow. The results from the numerical simulation are in terms of pressure distribution, velocity distribution and temperature distribution. The mass flow rate was found using CFX 5 for three different rotational speeds of the fan and their effect was studied. The effect of suction was also analyzed. The maximum amount of pressure created by the fan at the given rotating speed is given as an input and the stress analysis of the fan is carried out. From the CAD model the finite element model of the cooling fan was discretized using IDEAS software. The FEM model was built with higher order tetrahedral elements and the above said boundary and loading conditions are applied. It is observed that the displacement is maximum in the shroud region and maximum stress is developed in the hub region and the design is validated

Design optimization of Shoe Brake

M/s. Sundaram Brake Linings Ltd is interested in optimizing their design of 130mm diameter and 110mm diameter aluminium brake shoe castings. The brake shoes are used in two wheelers and as the brake is applied to the vehicle the shoe which is hinged on the one end is expanding at the other end by means of a cam. As it is expanded by cam, it is butting against the drum. The drum in turn applies the frictional torque, which stops the vehicle. Simulation studies have to be made so as to understand the physics of the problem and to validate its design.

Two type of loading conditions viz; 3 point & 2 point loading to validate the design and also to simulate the optimization for the weight of the brake shoes.

Solid Modeling in 3D is done by I-DEAS as software for both 130mm diameter & 110mm diameter X 30mm width brake shoes The brake shoe CAD model was meshed with higher order elements and quality checks were made by I-DEAS simulation module. Based on the stress developed on the component, the weight optimization was applied to redesign and hence to remove /scoop the materials for weight reduction. The optimized model was taken for stress analysis to check for the strength and significant weight reduction was obtained.

Design and analysis of Launcher Platform & Articulation Mechanism for project NAMICA

The NAMICA system is made up of three main sub-structures. These are turret roof, hull roof and launcher platform and casing for the articulation mechanism. The hull roof plate holds turret roof plate through slewing ring at the periphery. Turret roof plate is connected to the casing of articulation mechanism, which in turn supports the missile platform. The launcher platform consists of base plate platform which sighting and other equipments. The complete structure includes the turret roof, articulation mechanism and the launcher (missile) platform, made of different materials and hence the structure was considered as an assembly of these three substructures. AU-FRG Institute for CAD/CAM, carried out the work to develop the articulation mechanism required for elevation/depression of launcher Platform of NAMICA and also to carry out the Finite Element Analysis of the complete structure of Turret and launcher platform integrated with NAMICA for the specified orientations and under the prescribed loading conditions.

The salient features of the project are
(i) complete design and engineering calculations for Launcher Platform Articulation mechanism.
(ii) 3D modeling of Turret, Launcher (missile) Platform and Articulation mechanisms.
(iii) Static analysis of individual structure as turret, platform and independent components of articulation mechanism.
(iv) Finite Element Analysis of turret structure and Launcher platform structure integrated as NAMICA is required to be carried out for different loading conditions.
(v) Free vibration analysis of the complete structure for different orientations.
(vi) Simulation of the Articulation mechanisms.

A numerical model was made for each of them and also for the integrated assembly. Individual static analysis was carried out for turret, platform and articulation mechanism components. These components are modeled and simulated using I-DEAS. An integrated assembly model was also analyzed and the results are reported. The vibration analysis of integrated assembly has been done. The fundamental frequency is evaluated and the relevant modes up to 40 Hz are obtained. The equivalent static analysis for the validation of impact loading is made. The deflections of the launcher platform in the raised position and in the home position are evaluated for different loading cases. Thus the proposed configuration and the design are validated.