STRESS AND DEFORMATION ANALYSIS OF A COMPRESSION SPRING IN A ROTARY TYPE BRIQUETTE PRESS MACHINE USING FEA SIMULATION

Abstract

A comprehensive analysis of a helical compression spring subjected to static loading using two approaches: Finite Element Analysis (FEA) performed with ANSYS and manual calculations based on classical mechanical theory. The objective of this research is to compare and validate the accuracy of simulation results with manual computation, particularly in determining the force and deformation response of the spring.The spring model was first created using Computer-Aided Design (CAD) software and then imported into ANSYS in .STP format. Static structural analysis was selected as the simulation method, with meshing conducted using a body sizing of 1 mm to ensure sufficient detail while maintaining computational efficiency. The spring was modeled using appropriate material properties and subjected to axial forces simulating compression scenarios. Meanwhile, manual calculations were conducted using Hooke’s Law. The comparison between both methods revealed a percentage difference of 4.78%, which falls within the generally accepted engineering tolerance of ±5%. This suggests a strong correlation between the FEA results and manual computations, thereby validating the use of FEA for analyzing spring behavior under static loads. Furthermore, the study highlights the importance of mesh refinement and the impact of geometry setup on the accuracy of simulation outcomes.In conclusion, the findings confirm that ANSYS-based FEA can be effectively used for evaluating the mechanical performance of springs, provided that appropriate modeling, meshing, and material data are used. This approach not only enhances efficiency in analysis but also reduces potential errors associated with manual calculations, especially in complex designs or variable loading conditions.