Finite Element Analysis of Aluminium Alloy and Carbon-Fibre-Reinforced ABS Conveyor Idler Roller Materials

Abstract

This study presents a finite element analysis of aluminium alloy and carbon-fibre-reinforced Acrylonitrile Butadiene Styrene (CF-ABS) materials for conveyor idler roller applications. A flat type idler roller was designed in accordance with CEMA standards and modelled using SolidWorks, while structural simulations were conducted in ANSYS Workbench under static loading conditions. The performance of aluminium alloy was compared with CF ABS composites containing varying carbon fibre contents (70%, 80%, and 90%). Key response parameters including total deformation, von Mises stress, strain, and bearing reaction forces were evaluated under trough angles ranging from 0° to 60°. Results showed that aluminium alloy exhibited the lowest deformation (8.40 × 10⁻⁵ m), while CF ABS composites recorded higher deformation values between 2.61 × 10⁻³ m and 3.24 × 10⁻³ m depending on fibre content. However, stress levels in CF ABS increased with fibre proportion, reaching up to 8.43 × 106 Pa at 90% carbon fibre content. Bearing reaction forces remained nearly constant at approximately 2538.7 N across all cases, indicating independence from material variation and trough angle. CF-ABS composites therefore demonstrated a favourable balance between lightweight characteristics and acceptable mechanical performance, suggesting their potential as sustainable alternatives to aluminium alloy in conveyor idler roller design.