expert expert expert expertfea.com fea.com fea.com fea.com catalog catalog catalog catalog with with with with 21 FEA tutorials 21 FEA tutorials 21 FEA tutorials 21 FEA tutorials available in available in available in available in June June June June 2014 2014 2014 2014 2 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural FEA of Static Structural FEA of Static Structural FEA of Static Structural FEA of meshing spur gears meshing spur gears meshing spur gears meshing spur gears
1. Introduction....................................................................... page 3 2. Advice and good practices for a future FEA engineer......... page 4 3. What we learn in this tutorial.............................................. page 16 4. Static Structural FEA of meshing spur gears...................... page 17 5. The end............................................................................. page 29
- how to define and edit non-linear Contacts - how to define and edit Joints - how to define the Mesh - how to define proper Output (including basic Fatigue Tool) - how to read the Solver
1. Open Ansys Workbench; drag Static Structural into the Project Schematic area 2. Right click Geometry, Replace Geometry, Browse for 2013_05_14_gears2_asm.STEP, OK 3. Right click on the gear on the left and Rename it to "gear +Z"; Rename the other gear " gear - Z" 6 expert expert expert expertfea.com fea.com fea.com fea.com
1. In Solution Output, select Time Increment to see its values, getting a hint on the trend of the solving process; after a bisection, these values will suddenly decrease 2. Check the values for the Contact Pressure as seen here; click on Probe than on the desired spots on the needed surfaces in contact 7 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural FEA of a sphere Static Structural FEA of a sphere Static Structural FEA of a sphere Static Structural FEA of a sphere pressing with plasticity pressing with plasticity pressing with plasticity pressing with plasticity onto a plate onto a plate onto a plate onto a plate (double symmetry) (double symmetry) (double symmetry) (double symmetry) 8 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of sphere-plate plasticity............... page 17 5. The end.......................................................................... page 45
- how to define Materials - how to define and edit Contacts - how to create the Mesh - how to insert Supports - how to define Symmetry Regions - how to define proper Output - how to read the Solver
4. Static Structural FEA of sphere-plate plasticity
1. Open Ansys Workbench; drag the geometry file from your computer into the Project Schematic area 2. Drag the Static Structural analysis on the Geometry tab and release it will share its geometry file 3. Your Static Structural analysis should look like this 11 expert expert expert expertfea.com fea.com fea.com fea.com
1. Double click Model in Static Structural and the Mechanical window will open like here 2. Expand the Geometry tree and rename the parts with more relevant names 12 expert expert expert expertfea.com fea.com fea.com fea.com
1. The default contact is Bonded; we will select for Contact face the spherical face (green here), than hit Apply 2. For Target face we will select the flat face of the plate (green here), than hit Apply 13 expert expert expert expertfea.com fea.com fea.com fea.com
1. We will let Ansys WB create the mesh automatically by right clicking on Mesh, Generate Mesh 2. The Default mesh should look like this; we will modify the parameters later, on the next, more advanced tutorials; for now it is helpful to account for the small number of nodes and elements, which means less time consumed with solving 14 expert expert expert expertfea.com fea.com fea.com fea.com
1. During solving, click on Solution Information, Solution output, Solver output to see what the solver is doing; these messages will be important later, when we will need to improve or debug more complex analyses 2. Change from Solver Output to Force Convergence to see a graphical plot of how the solution will converge; as seen in the Legend, the Force Convergence curve should intersect with the Force Criterion curve in order to achieve convergence 15 expert expert expert expertfea.com fea.com fea.com fea.com
2. Because the steps can become very crowded, you can "rarify them" by in 25 Display Points 3. This is how the analysis looks at the end of the solving time; the messages are not to worry in this case 1. In this case, for faster solving time, you can press Stop Solution than click on Analysis Settings, Solver Controls, Solver Type and change from Program Controlled to Direct, then hit Solve again 16 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the Equivalent Stress plot 2. This is the vertical Directional Deformation plot 3. To see the elements, we can press Show Elements on this top bar 17 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the Equivalent Stress plot where we can see the element edges 2. Plasticity means that we should have remanent deformations; we can clearly see this only if we apply the load than release it, to see if the plate comes to its initial shape; to do this, on Analysis Settings we change in Step Controls the Number of Steps to 4 18 expert expert expert expertfea.com fea.com fea.com fea.com
1. The Prescribed Displacement was initially -2 mm 2. We insert these values to apply than release the load that the quarter sphere exerts on the plate 19 expert expert expert expertfea.com fea.com fea.com fea.com
1. During solving time, we can change the Solution Output to Time Increment to see how the solver automatically adjusts the time steps to achieve convergence 2. The solved analysis should look like here when it reaches time step 4 20 expert expert expert expertfea.com fea.com fea.com fea.com
1. Looking for the Stress plot, we can see that, after the sphere has risen to its initial position, the plate remains deformed; we can animate the results by clicking the play button 21 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural FEA Static Structural FEA Static Structural FEA Static Structural FEA of meshing bevel gears of meshing bevel gears of meshing bevel gears of meshing bevel gears (debugging (debugging (debugging (debugging solution to achieve convergence) solution to achieve convergence) solution to achieve convergence) solution to achieve convergence)
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of meshing bevel gears.................. page 17 5. The end........................................................................... page 51
- how to work with Contacts - how to work with Joints, parameterize the Joints - how to create, simplify and refine the Mesh, parameterize the Mesh - how to simplify the 3D model in Ansys Workbench Geometry module - how to define proper Solution output, parameterize the output - how to debug the Solution if it does not converge, apply suitable measures to achieve convergence - how to use the parameters in defining Design Points, run multiple consecutive scenarios without interfering in Ansys Workbench
4. FEA of a Static Structural case of meshing bevel gears
1. Open Ansys Workbench; drag Static Structural into the Project Schematic area 2. Right click Geometry, Replace Geometry, Browse for Bevel Gear T24-T16-M3.IGS, OK 3. Right click on the gear highlighted in green and Rename it to "big_gear"; Rename the other gear " small_gear" 25 expert expert expert expertfea.com fea.com fea.com fea.com
1. To find out the expected life-time of the small gear, on Fatigue Tool we will select Life for the small gear; notice the fatigue criteria Ansys uses by default 2. Right click on Contact Tool, Insert, Gap 26 expert expert expert expertfea.com fea.com fea.com fea.com
1. For computation, right click on Solution, Solve 2. When the solution is running, this is how Solver Output looks like, obtaining a real- time log with the solver's processes 27 expert expert expert expertfea.com fea.com fea.com fea.com
2. Extending the mesh refinement leads to convergence on several steps; to rarify the seen steps, select Solution Information, Display Points: 25 1. Being an important solver parameter, you can see the Time Increment as here 28 expert expert expert expertfea.com fea.com fea.com fea.com
1. We still have no convergence; it is time to refine once more the gears, but because the number of nodes and elements is high, let us cut the model on the regions not FEA relevant: on their centers 2. We go to Project Schematic, right click on Geometry, Edit Geometry 3. To import the gears, right click on Import1, Generate 29 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select this face of the small gear and click on New Sketch button 2. To have a view normal to sketch, select the Look at Face/Plane/Sketch button; instead Modeling, go to Sketching tab, select Circle and snap to the center of the small gear 30 expert expert expert expertfea.com fea.com fea.com fea.com
1. To cut the material on the big gear, select the details seen here, than right click on Extrude2, Generate 2. We will suppress the resulting cut cylinders; Ctrl select the last 2 solids, right click, Suppress Solid Bodies 31 expert expert expert expertfea.com fea.com fea.com fea.com
1. Re-run the analysis with high hopes this time :) 2. Our hopes were met, because the analysis successfully converged! 32 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is how the stress looks at the last time step; notice the peaks caused by the teeth collisions 33 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is how the gaps in contact look like 2. To easily make multiple consecutive runs, we can change the parameters values for the items we chose before; go to Project Schematic, right click on Parameter Set, Edit 34 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Explicit Dynamics Explicit Dynamics Explicit Dynamics Explicit Dynamics FEA of a car body FEA of a car body FEA of a car body FEA of a car body crashing into a wall and a wedge crashing into a wall and a wedge crashing into a wall and a wedge crashing into a wall and a wedge 35 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Explicit Dyanmics FEA of a car body crashing................. page 17 5. The end.......................................................................... page 46
- how to work with Dynamics, analyses that occur in time - how to use Symmetry conditions for 3D bodies - how to refine the Mesh or make it coarse, parameterize the mesh - how to define proper Solution output and re-define it, parameterize the output - how to duplicate and re-use analyses - how to use the parameters in defining Design Points, run multiple consecutive scenarios without interfering in Ansys Workbench
1. Open Ansys Workbench; drag Explicit Dynamics into the Project Schematic 2. Right click Geometry, Replace Geometry, Browse for carbody_wall.STEP, Open 3. Open Mechanical window, and selecting the bodies in the tree we see that only the highlighted ones are relevant for our analysis Wall-Carbody FEA 38 expert expert expert expertfea.com fea.com fea.com fea.com
1. Right click on the highlighted unnecessary bodies and suppress them 2. Select the last surface body and insert 0.3 mm for the Thickness; tick the Thickness box to parameterize it for later usage 3. To achieve deformations past the Yield Point of the material, change it to nonlinear: Assignment, Import 39 expert expert expert expertfea.com fea.com fea.com fea.com
1. We can see that the mesh is with TET elements on the wall (as we requested before) and quadrilateral elements on the carbody; also, for Explicit Dynamics, the number of nodes and elements is too high, leading to 6-10 hours of solving time 2. Click on Mesh and make Sizing, Smoothing, Low; right click on Mesh, Update 3. Now the number of nodes and elements is 2.5 times smaller, which will lead to less than 30 min solving time 40 expert expert expert expertfea.com fea.com fea.com fea.com
1. Clicking on Solution Information, Solution Output , Energy Conservation will give us this windows; even though the amount of work done fluctuates, it is most important for the Energy Error not to increase (the default is set to 10%=0.1), or else will lead to stopping the solving 2. Clicking on Solution Information, Solution Output , Energy Summary will give us this window; it is most important for the Hourglass Energy not to increase, as seen here 41 expert expert expert expertfea.com fea.com fea.com fea.com
1. As the solving continues, we can see that the fluctuations of Work Done subside, which is a very good sign and the value for Energy Error is constant and low 2. Also, we can see that the fluctuations of the Kinetic Energy subside, which is a very good sign and there is no sign of the Hourglass Energy 42 expert expert expert expertfea.com fea.com fea.com fea.com
1. After ~24 min of solving, the solution is done, as seen here 2. Here is the Displacement plot of the wall: ~500mm as we imposed 3. Here we see the overall Stress plot, with some high values given by the coarse mesh we used in the wall; let us scope only the carbody to see its stress plot 43 expert expert expert expertfea.com fea.com fea.com fea.com
Carbody-Wedge FEA 1. To realize the second analysis, with the carbody colliding with a wedge block, right click on Explicit Dynamics, Duplicate 2. Both analyses should look like here; rename the items as seen here, for better visualization 3. Right click Geometry, Replace Geometry, Browse for carbody_wedge.STEP, Open 44 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the stress plot for the carbody, with a maximum on the impact region; let us parameterize Maximum Value Over Time, Maximum 2. This is the displacement plot for the front of the carbody; the value is true, because if the carbody travels with 50 m/s, than in 0.02 s it will travel with 1 m/s; let us parameterize it by ticking on Maximum Value Over Time, Minimum 45 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of a a a a copper sheet stamping copper sheet stamping copper sheet stamping copper sheet stamping (double symmetry) (double symmetry) (double symmetry) (double symmetry) 46 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of a copper sheet stamping.......... page 17 5. The end.......................................................................... page 54
- how to assign non-linear materials - how to use Symmetry conditions on 2 axes for 3D bodies - how to properly assign different elements and refine the Mesh - how to edit the geometry in Ansys Workbench - how to define complex Analysis Settings and stabilize the solving - how to define proper Solution output; how to investigate the output of the Contacts (Pressure, Status, Stress etc.)
4. Static Structural FEA of a copper sheet stamping (double symmetry)
1. This is the geometry setup in Solidworks, before it was simplified, for easier meshing and solving time 49 expert expert expert expertfea.com fea.com fea.com fea.com
1. We have cut half of the assembly longitudinally and transversally 50 expert expert expert expertfea.com fea.com fea.com fea.com
1. Open Ansys Workbench; drag Static Structural into the Project Schematic area 2. Right click Geometry, Import Geometry, Browse for narrow_stamp.x_t, Open 51 expert expert expert expertfea.com fea.com fea.com fea.com
1. In Mechanical it will open the 3D model ready for pre-processing 2. Let us change the material of the plate to a nonlinear one. After we rename the parts as here, click on plate, Material, Assignment, Import 52 expert expert expert expertfea.com fea.com fea.com fea.com
1. Create also a Symmetry Region for the die faces, as seen here in green 2. After having finished defining the symmetry conditions for X axis, you can rename them, than select all 3 Symmetry Regions to check if they are properly defined, as seen here in red 53 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the plate, Apply than choose Method, Tetrahedrons 2. Let us refine the mesh on the multiple rounds of the die; right click on Mesh, Sizing, select the rounds shown green here, Element Size 0.1 mm, Apply 54 expert expert expert expertfea.com fea.com fea.com fea.com
2. Because we need to round the outer edge of the plate, we will go to project Schematic window, right click on Geometry, Edit Geometry 3. In the DesignModeler window, to import the geometry, right click on Import1, Generate 1. Click on Model, Show All Bodies; let us refine the surface mesh of the underside of the plate seen here in green: right click on Mesh, Sizing, 1 mm, Apply 55 expert expert expert expertfea.com fea.com fea.com fea.com
1. We will insert a downwards displacement on the punch: right click on Static Structural, Insert, Displacement, Apply 2. We select from the punch these 3 faces in green 56 expert expert expert expertfea.com fea.com fea.com fea.com
1. To find out the stress in all bodies: right click on Solution, Insert, Stress, Equivalent von-Mises 2. To find out the stress only in the plate, let us duplicate the previous one: right click on Equivalent Stress, Duplicate 3. With Body filter pressed, select the plate than Apply 57 expert expert expert expertfea.com fea.com fea.com fea.com
1. To find out how much plasticity we will have in the plate, right click on Solution, Insert, Strain, Equivalent Plastic 2. We will scope only the plate, Apply 3. To find out how the contacts behave, right click on Solution, Insert, Contact Tool, Contact Tool 58 expert expert expert expertfea.com fea.com fea.com fea.com
1. We are interested in the Contact Pressure: click on Status and change Type to Pressure 2. Before solving this analysis, let us see the Mesh: right click on it, Generate Mesh 3. The mesh should look like here; right click on Solution, Solve 59 expert expert expert expertfea.com fea.com fea.com fea.com
1. The Directional Deformation on Z axis looks like this 2. The Stress in all bodies looks like this 3. The Stress only in the plate looks like this 60 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of rolling of a copper plate rolling of a copper plate rolling of a copper plate rolling of a copper plate 61 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of rolling of a copper plate............ page 17 5. The end.......................................................................... page 51
2. Advice and good practices for a future FEA engineer a) Where do I find info and docs? b) Where do I find 3D models for FEA practice? c) Where do I find databases with materials? d) What should I know about the meshing procedures? e) How can I validate my FEA results/analyses? f) Advice for future eastern and mid-eastern FEA engineers. g) What should I do to become an FEA expert, with strong knowledge and experience?
- how to assign non-linear materials - how to edit the geometry in Ansys Workbench - how to resize the Mesh - how to define Joints - how to define complex Contacts - how to define complex Analysis Settings and stabilize the solving - how to define proper Solution output: Force and Moment Reactions, Contact Pressure, Plastic Strain etc.
4. Static Structural FEA of rolling of a copper plate
1. Start a Static Structural analysis, right click on Geometry and Insert 2013_07_21_rolling.stp 2. Because the plate is too wide and too short, we will optimize it: Right click on Geometry, Edit Geometry in Design Modeler 65 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is how to initial geometry looks in Design Modeler 2. With Selection filter on Faces (Ctrl+F), click on one of the lateral sides of the plate 66 expert expert expert expertfea.com fea.com fea.com fea.com
1. To look normally at the sketch, press Look At Face/Plane/Sketch 2. Select Sketching tab and press Rectangle 67 expert expert expert expertfea.com fea.com fea.com fea.com
1. Draw a free-style rectangle that will contain the plate 2. Return to Modeling tab than click Extrude 68 expert expert expert expertfea.com fea.com fea.com fea.com
1. To extend the plate, select its end, than click New Sketch 2. Look at Face / Plane; switch to Sketching tab, Modify 69 expert expert expert expertfea.com fea.com fea.com fea.com
1. Press Duplicate and select the lines of the rectangle 2. Right click, Duplicate Selection 3. Back to Modeling tab, press Extrude 70 expert expert expert expertfea.com fea.com fea.com fea.com
1. The new Extrude should have these details 2. Having obtained the optimized geometry, Close Design Modeler 71 expert expert expert expertfea.com fea.com fea.com fea.com
1. Back to Project Schematic, right click on Model, Edit 2. Mechanical window will show us this initial setup; right click on the parts, Rename, if you are more into English 72 expert expert expert expertfea.com fea.com fea.com fea.com
1. To assign the material to the piece, select it and go to Import 2. Select the first Bonded contact, click on Target and select both external faces of the wheel, Apply 73 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the first Bonded contact, click on Contact and select all 3 underside faces that will touch the Target, Apply 74 expert expert expert expertfea.com fea.com fea.com fea.com
1. Solution, Strain, Equivalent Plastic 2. To see the values only in the piece, select it, Apply 3. Solution, Stress, Equivalent (von-Mises) 75 expert expert expert expertfea.com fea.com fea.com fea.com
1. Solution, Probe, Force Reaction 2. Solution Output, Force Convergence will give a similar plot; some bisections can be seen because the high plasticity that appears due to increased thickness of the piece 76 expert expert expert expertfea.com fea.com fea.com fea.com
1. Solution Output, Time Increment will show how the solver automatically varies the time steps, in order to achieve convergence; usually, the time increments decrease after a bisection, trying to rise again 2. Right click on Directional Deformation, Clear Generated Data 77 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the faces on the tip of the piece, Apply 2. Right click on Directional Deformation, Evaluate All Results 78 expert expert expert expertfea.com fea.com fea.com fea.com
1. The result makes more sense now, showing clearly that the front of the piece advanced with ~85mm 2. The Equivalent Plastic Strain looks like this; because copper alloys generally break at 30 %, the values we obtained are for a thicker than normal plate; to avoid these high strains, in a factory, the thinning is done in multiple stages / passes 79 expert expert expert expertfea.com fea.com fea.com fea.com
2. Right click on Directional Deformation 2, Evaluate All Results 1. Very interesting would be to find out the lateral deformation of the piece, how much its width is increased due to rolling? Solution, Directional Deformation, select both lateral faces, Orientation, Z Axis, Apply 80 expert expert expert expertfea.com fea.com fea.com fea.com
1. The Directional Deformation of piece on Z axis look like here, showing clearly that each face widened with ~7.8 mm; congratulations, you have successfully finished this nice FEA tutorial! 81 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Transient Structural Transient Structural Transient Structural Transient Structural FEA of FEA of FEA of FEA of heat generated between heat generated between heat generated between heat generated between a piston and a cylinder a piston and a cylinder a piston and a cylinder a piston and a cylinder 82 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Transient Structural FEA of heat generated between a piston and a cylinder...................................................... page 17 5. The end.......................................................................... page 57
- how to simplify a complex model - how to assign a complex Contact - how to insert Joints, with the ground and between bodies - how to resize the Mesh - how to prescribe APDL commands - how to define complex Analysis Settings and stabilize the solving - how to define proper Solution output: User Defined Result (Temperature), Force Reaction, Contact Pressure, Plastic Strain, Velocity etc.
4. Transient Structural FEA of heat generated between a piston and a cylinder
1. Start a Transient Structural analysis, right click on Geometry, Import Geometry, Browse: piston2_tutorial7.x_t 2. Right click on Model, Refresh, than Edit... 85 expert expert expert expertfea.com fea.com fea.com fea.com
1. When Mechanical window opens, this is how the imported model looks like; we will simplify it for faster solving time 2. Select with Ctrl pressed the shown parts, right click, Suppress Body 86 expert expert expert expertfea.com fea.com fea.com fea.com
1. With the unnecessary parts removed, we should see this from under the cylinder 2. Go to Connections, Contacts and observe that the contacts for the suppressed parts automatically became suppressed; select the only valid contact, right click on it than Rename Based on Definition 87 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the hole on the crank, seen here in green, than go to Reference, Scope, Apply 2. Select the corresponding hole on the connecting rod, seen here in green, than go to Mobile, Scope, Apply 88 expert expert expert expertfea.com fea.com fea.com fea.com
1. With the selection filter on Body, select the piston, Apply, Orientation, Y Axis 2. Solution, Deformation, Directional Velocity 89 expert expert expert expertfea.com fea.com fea.com fea.com
1. Again, we select only the piston, as we did before: select the piston, Apply, Orientation, Y Axis 2. Solution, Stress, Equivalent (von Mises) 3. Solution, Contact Tool 90 expert expert expert expertfea.com fea.com fea.com fea.com
1. For Contact Tool, because the default is Status, change Type to Pressure 2. Solution, Probe, Joint 3. Boundary Condition, Revolute - ConnectingRod; To PistonHead; 91 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the vertical displacement of the piston, with a sinusoidal shape, as we would expect it 92 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the Temperature plot inside the cylinder 2. This is the Temperature plot outside the piston 93 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Modal analysis and random vibrations Modal analysis and random vibrations Modal analysis and random vibrations Modal analysis and random vibrations using PSD on a PCB using PSD on a PCB using PSD on a PCB using PSD on a PCB
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Modal analysis and random vibrations using PSD on a PCB........................................................ page 17 5. The end.......................................................................... page 63
- how to assign new materials - how to edit the Contacts - how to define a Modal analysis and ask for natural frequencies - how to understand an interpret Random vibration analyses - how to define Random vibrations analyses on all 3 axes - how to check the strength of parts using Equivalent Stress and Response PSD results etc.
4. Modal analysis and random vibrations using PSD on a PCB
1. Drag a Modal analysis in Project Schematic window, right click on Geometry, Import Geometry, Browse: 2013_07_26_PCB.step 2. Double click on Model and the Mechanical window will open showing the imported geometry; we can see some support bushings underneath the PCB 97 expert expert expert expertfea.com fea.com fea.com fea.com
1. We will remove these bushings: select with Ctrl pressed all 4 bushings, right click, Suppress Body 2. Because it's not default in Ansys library, we will create the material for the PCB, which is a layered epoxy composite called FR4; select the last part, Material, New material 98 expert expert expert expertfea.com fea.com fea.com fea.com
1. Having the materials that we need, click Refresh Project, Return to Project 2. Back to mechanical window, select with Shift pressed, from the tree all the parts, green intense here, except the last one (the PCB), Material, Assignment, Aluminum Alloy 99 expert expert expert expertfea.com fea.com fea.com fea.com
1. No interference now 2. This is the 2nd mode 3. This is the 3rd mode 100 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the 4th mode 2. This is the 5th mode 3. This is the 10th mode 101 expert expert expert expertfea.com fea.com fea.com fea.com
As a reminder, we will quote the basics of Random analysis from: http://www.sharcnet.ca/Software/Fluent13/help/wb_sim/ds_spectral_analysis_type.html Random Vibration Analysis Introduction This analysis enables you to determine the response of structures to vibration loads that are random in nature. An example would be the response of a sensitive electronic component mounted in a car subjected to the vibration from the engine, pavement roughness, and acoustic pressure. Loads such as the acceleration caused by the pavement roughness are not deterministic, that is, the time history of the load is unique every time the car runs over the same stretch of road. Hence it is not possible to predict precisely the value of the load at a point in its time history. Such load histories, however, can be characterized statistically (mean, root mean square, standard deviation). Also random loads are non-periodic and contain a multitude of frequencies. The frequency content of the time history (spectrum) is captured along with the statistics and used as the load in the random vibration analysis. This spectrum, for historical reasons, is called Power Spectral Density or PSD. In a random vibration analysis since the input excitations are statistical in nature, so are the output responses such as displacements, stresses, and so on. Typical applications include aerospace and electronic packaging components subject to engine vibration, turbulence and acoustic pressures, tall buildings under wind load, structures subject to earthquakes, and ocean wave loading on offshore structures. 102 expert expert expert expertfea.com fea.com fea.com fea.com
2. The result should look like this 3. Opening the Mechanical window we see that Ansys "forgets" the Modal solution, so we need to Solve it again 1. In Project Schematic, drag Random Vibration to the Solution of our Modal analysis, than drop 103 expert expert expert expertfea.com fea.com fea.com fea.com
1. Right click, Clear Generated Data 2. Having active the Body selection filter, click the capacitors, green here, Apply 104 expert expert expert expertfea.com fea.com fea.com fea.com
1. Because we let 1 Sigma for the Scale Factor, in 68.269% of the time, the stress will be under this value shown here; nevertheless, the stress values exceeds the Ultimate Tensile Stress for Aluminum alloys, meaning that these legs will break under the imposed PSD for X axis 105 expert expert expert expertfea.com fea.com fea.com fea.com
1. The Response PSD plot looks like here; close Mechanical window 2. Drag Random Vibration on Modal Solution; name it Random Vibration Z axis 106 expert expert expert expertfea.com fea.com fea.com fea.com
1. To obtain plots for Y axis with Response PSD vs. PSD G Acceleration, select them both with Ctrl pressed and click New Chart and Table; Rename to Chart Z axis 2. This is the resulting chart, with overimposed values for both curves; notice that we obtain peaks in Response PSD at the first and second natural frequencies, which are 228.3 and 500.98 Hz (see Total Deformations in Modal analysis) 107 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing under load under load under load under load 108 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of a roller bearing under load......... page 17 5. The end.......................................................................... page 41
- to define complex multiple Contacts - to define multiple Joints - to modify the Mesh to suit analysis' needs - to define proper Analysis Settings and stabilize the solving - to define proper output for forces, moments, rotations, contact behavior etc.
4. Static Structural FEA of a roller bearing under load
1. Drag a Static Structural analysis in Project Schematic window, right click on Geometry, Import Geometry, Browse: 2013_08_01_roller_bearing1.x_t 2. After import, right click Model, Edit... 111 expert expert expert expertfea.com fea.com fea.com fea.com
1. To ignore the roller cage, in Mechanical window, right click on cage;CirPattern1, Suppress Body 2. Right click on Contacts, Delete 3. Right click on Contacts, Insert, manual Contact Region 112 expert expert expert expertfea.com fea.com fea.com fea.com
1. Right click on Contacts, Insert, Joint 2. Connection Type, Body-Ground 113 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the outer face of the bearing, green, here, Mobile, Scope, Apply 2. From Connections toolbar, select Body- Ground, Revolute 114 expert expert expert expertfea.com fea.com fea.com fea.com
1. Select the inner face of the bearing, green here, Mobile, Scope, Apply 2. Drag a window as shown here, to include all bodies 115 expert expert expert expertfea.com fea.com fea.com fea.com
1. Method, Tetrahedrons 2. Right click on Mesh, Insert, Sizing 3. Select the inner and outer faces of the bearing, green here, Apply, Element Size = 35 mm 116 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the Stress plot 2. This is the Contact Status plot 117 expert expert expert expertfea.com fea.com fea.com fea.com
1. This is the Joint Probe showing Total Moment 2. This is the Joint Probe showing the Relative Rotation; feel free to modify the friction coefficient, the rotational velocity and the bearing load and compare the results; congratulations, you have successfully finished this nice FEA 118 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF MACHINING MACHINING MACHINING MACHINING WITH A WITH A WITH A WITH A PLANER PLANER PLANER PLANER 119 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Explicit Dynamics FEA of machining with a planer........... page 17 5. The end........................................................................... page 30
- to assign Explicit Materials - to define various body loads - to mesh in a simplified manner, for faster solving time - to define proper Analysis Settings for split second event - to define proper output for velocity, stress, strain etc. - to interpret the behavior of the solver
To take into account our new materials, exit by clicking Refresh project, than Return to Project Back to project Schematic, right click on Geometry, Import Geometry, Browse for 2013_09_11_machining3.x_t As an easier reminder, you can rename the Geometry: right click, Rename to 2013_09_11_machining3.x_t 122 expert expert expert expertfea.com fea.com fea.com fea.com
Let us define the pre- processing conditions: right click on Model, Edit... In Mechanical window, right click on first body from the tree, Rename it to "piece" Right click on the second body from the tree, Rename it to "tool" 123 expert expert expert expertfea.com fea.com fea.com fea.com
After Apply, select Type, Number of Divisions, 10 124 expert expert expert expertfea.com fea.com fea.com fea.com
Go to Analysis Settings and insert End Time, 0.00075 From Environment toolbar select Velocity To define the needed output, select Solution, Deformation, Directional 125 expert expert expert expertfea.com fea.com fea.com fea.com
Select only the piece, green here, Apply Preparing of the model is done, let us proceed to the solving stage: right click on Solution, Solve 127 expert expert expert expertfea.com fea.com fea.com fea.com
If you click immediately on Solution Information you will see how a log with a pre- solver setup, as shown here If you click on Solver Output you will see that, initially, Ansys Workbench predicts that the analysis will be done in 9.9 minutes; but this is done prior having the collision and the large deformations 128 expert expert expert expertfea.com fea.com fea.com fea.com
Click on Solution Output, Time Increment, we see that it fluctuated initially, but it's stabilized afterwards As we said, the solver was wrong to assume 9.9 minutes of solving and, after collision is established, we see that it takes almost double 129 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Total Velocity plot This is the Stress plot This is the Strain plot only in piece. Congratulations, you have successfully finished this simple Explicit Dynamics analysis! 130 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A THREADED BOLT THREADED BOLT THREADED BOLT THREADED BOLT- -- -WASHER WASHER WASHER WASHER- -- -NUT NUT NUT NUT CONNECTION CONNECTION CONNECTION CONNECTION 131 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of a threaded bolt-washer-nut connection......................................................................... page 17 5. The end........................................................................... page 54
- to assign solvable Contacts, and Joints that mimic the real load - to mesh in a simplified manner, for faster solving time - to define proper Analysis Settings and stabilize the solving - to define proper output for deformation, stress, strain, reactions etc. - to customize the solver's response - to create full and section views for better handling and result probing
4. Static Structural FEA of a threaded bolt-washer-nut connection
Drag and drop Static Structural from left column called Analysis Systems; right click on Geometry, Import Geometry, Browse: 2013_09_30_bolt_washer4.x_t After the import is done, right click on Model, Edit... 134 expert expert expert expertfea.com fea.com fea.com fea.com
This is the 3D model; for easier handling, right click on each part from the Model tree, Rename: washer (than nut, than bolt) as seen here 135 expert expert expert expertfea.com fea.com fea.com fea.com
With Ctrl key pressed, click Scope, Target, 4 Faces and deselect the top and the bottom of the thread The result should look like this; Apply 136 expert expert expert expertfea.com fea.com fea.com fea.com
From tree click on Solution, than go to the upper toolbar, Deformation, Total Deformation, Directional With selection filter on Body, click the bolt, Apply 137 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Stress, Equivalent (von-Mises) Scope only the washer, Apply Right click on the previously created Equivalent Stress, Duplicate 138 expert expert expert expertfea.com fea.com fea.com fea.com
Scope only the bolt, Apply Solution, Strain, Equivalent (von-Mises) Scope only the nut, Apply 139 expert expert expert expertfea.com fea.com fea.com fea.com
To proceed to the solving part, right click on Solution, Solve Firstly, the mesh is created and this is how it looks like 140 expert expert expert expertfea.com fea.com fea.com fea.com
To obtain an easier readable graphical representation of this log, select Solution Output, Force Convergence This is how the Force Convergence plot looks like; observe that the analysis performs well, the bisections being expected due to the high contact forces 142 expert expert expert expertfea.com fea.com fea.com fea.com
As the solving continues, the spikes may get pretty crowded, as seen here This is the Directional Deformation plot in bolt and washer 143 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Stress plot in washer; the extremely high values appear because we exaggerated with the pressing of the bolt and the materials we used do not suffer plasticity; assign non-linear materials to all parts, re-solve and see the difference This is the contact Pressure for the Frictional contact 144 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS PINS PINS PINS PINS 145 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Explicit Dynamics FEA of the impact between a bowling ball and its pins............................................................................... page 17 5. The end........................................................................... page 53
- to edit the 3D model to obtain shell elements - to mesh in a simplified manner, for faster solving time - to define proper Analysis Settings correlated with the nodes and elements number - to define proper output for deformation, stress, velocity etc. - to properly observe the solver's response - to parameterize the input data for automatic solving of multiple FEA scenarios in the same file
4. Explicit Dynamics FEA of the impact between a bowling ball and its pins
Drag and drop Explicit Dynamics from left column called Analysis Systems; right click on Geometry, Import Geometry, Browse: 2013_10_01_bowling1.x_t Right click on Geometry, Edit Geometry in DesignModeler 148 expert expert expert expertfea.com fea.com fea.com fea.com
In DesignModeler window, right click on Import1, Generate This is the result of the import: the walls are solid and we will make them thin, to have shell elements 149 expert expert expert expertfea.com fea.com fea.com fea.com
In the main window, right click Model, Edit... This is how the geometry looks like; because we have question mark in front of Geometry, we need to define the thickness of the surfaces/shells we crated in DesignModeler 150 expert expert expert expertfea.com fea.com fea.com fea.com
Select the last 2 parts and assign them 5mm thickness (the lateral walls were united into one surface) With the Face filter active, click the ball, Apply 151 expert expert expert expertfea.com fea.com fea.com fea.com
For the ball to run into the pins, select X Component, Tabular 152 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Energy Conservation plot before any collision 153 expert expert expert expertfea.com fea.com fea.com fea.com
For easier reading, insert 100 Display Points (instead of 0) and we will obtain a better resolution 154 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Total Deformation plot in all bodies; ~8 meters is the height that a pin reached because it fell off the "bowling alley" and is headed to the abyss 155 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Directional Velocity plot on X axis for the ball; its fluctuation can be seen in the bottom graph If, for instance, you need the investigate the trajectory of any pin, you can create a Directional Deformation plot (vertical here), select the pin, Apply 156 expert expert expert expertfea.com fea.com fea.com fea.com
Right click on the newly created Directional Deformation, Evaluate All Results 157 expert expert expert expertfea.com fea.com fea.com fea.com
The needed variation in time, of the pin's height, looks like here 158 expert expert expert expertfea.com fea.com fea.com fea.com
Let us parameterize the extreme values for later solving; check the boxes in front, as seen here marked with blue P letters 159 expert expert expert expertfea.com fea.com fea.com fea.com
To find out if we will have other parts that will eventually fall into the abyss, let us parameterize the maximum displacement, as seen here 160 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING WITH HALF SYMMETRY WITH HALF SYMMETRY WITH HALF SYMMETRY WITH HALF SYMMETRY 161 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of stamping with half symmetry..... page 17 5. The end........................................................................... page 52
- to assign non-linear materials - to simplify the 3D model and apply symmetries - to assign complex contacts suitable to large strains - to define proper Analysis Settings to ensure smooth solving - to define proper output for stress, strain, tools, probes etc. - to properly observe the solver's response - to re-evaluate the output data according to most important steps
4. Static Structural FEA of stamping with half symmetry
First, make sure that you have a proper geometry, like the one we provide, shown here Drag and drop Static Structural from left column called Analysis Systems; to insert the material for the copper plate, right click on Engineering Data, Edit... 164 expert expert expert expertfea.com fea.com fea.com fea.com
Once the model is imported, select XYPlane, than press New Sketch button, as seen here To normally look at the sketch, press Look at Face/Plane/Sketch button 165 expert expert expert expertfea.com fea.com fea.com fea.com
If at first the zoom level doesn't reveal the entire model, use Box zoom and drag several windows with it in the center of the coordinate system we see Box zoom several times in the center, as seen here Then the model starts to appear; repeat the zooming 166 expert expert expert expertfea.com fea.com fea.com fea.com
When we have this magnitude of zoom, we can stop zooming Select the cut surface of the die (green here, Apply) 167 expert expert expert expertfea.com fea.com fea.com fea.com
Observe that our symmetries are as default, about X axis which is normal to the cut surfaces, red axis here Right click on Connections, Contacts, Rename based on Definition Select with Ctrl pressed both contacts, Flip Contact/Target 168 expert expert expert expertfea.com fea.com fea.com fea.com
With Ctrl pressed, click the lateral surface to unselect it (blue here), than click the spherical surface, (green here); Apply 169 expert expert expert expertfea.com fea.com fea.com fea.com
This is how the Target part of the first contact should look like (green here); right click anywhere, Show All Bodies Select the touching surfaces, Apply, Element Size = 1 170 expert expert expert expertfea.com fea.com fea.com fea.com
This is the result Environment, Fixed Support Select the outer faces of the die (green here), Apply 171 expert expert expert expertfea.com fea.com fea.com fea.com
With selection filter on Body, select the piece (green here, Apply) Solution, Tools, Contact Tool Uncheck the second contact, to have this result 172 expert expert expert expertfea.com fea.com fea.com fea.com
Select Status and replace with Pressure, as seen here It's very useful to hit Interrupt Solution after some solving was done, to check if the analysis performs as desired; notice the Pause symbol near Solution, which means that the analysis can be continued 173 expert expert expert expertfea.com fea.com fea.com fea.com
This is the max. pressure plot in first Contact Tool 174 expert expert expert expertfea.com fea.com fea.com fea.com
For Contact Tool 2, retrieve also the value from second 6 175 expert expert expert expertfea.com fea.com fea.com fea.com
The Reaction Force plot gives us the value required to stamp the sheet- metal; max. value at second 6, where we have the max. depth of the punch; congratulations, you have successfully finished this nice FEA! 176 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
Seismic Random Vibration analysis using Seismic Random Vibration analysis using Seismic Random Vibration analysis using Seismic Random Vibration analysis using PSD on a real size skyscraper PSD on a real size skyscraper PSD on a real size skyscraper PSD on a real size skyscraper 177 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Seismic Random Vibration analysis using PSD on a real size skyscraper......................................................................... page 17 5. The end.......................................................................... page 68
- how to assign new materials - how to manage only important parts - how to define a Modal analysis and ask for natural frequencies - how to understand and interpret Random Vibration analyses - how to define Random Vibrations analyses on all 3 axes - how to check the strength of parts using Equivalent Stress and Response PSD results etc.
4. Seismic Random Vibration analysis using PSD on a real size skyscraper
Drag a Modal analysis in Project Schematic window, right click on Engineering Data, Edit... Click the button Engineering Data Sources to reveal all material libraries 180 expert expert expert expertfea.com fea.com fea.com fea.com
From General Materials tab, choose Concrete by clicking the yellow plus sign For the new material to be taken into account by Ansys, click Refresh Project, Return to Project 181 expert expert expert expertfea.com fea.com fea.com fea.com
Right click on Mesh, Insert, Sizing With selection filter on Body, click the 6 columns (green here), Geometry, Apply 182 expert expert expert expertfea.com fea.com fea.com fea.com
Assign them Element Size, 1000 mm To see the mesh, right click on it, Generate Mesh 183 expert expert expert expertfea.com fea.com fea.com fea.com
After the solving is finished, here is the Total Deformation plot for the 1st vibration mode; the magnitude of the deformation is not realistic in any modal analysis, only the tendency of the deformation is; most important here are the natural frequencies found by FEA 184 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Total Deformation plot for the 5th vibration mode Because we have finished with the Modal analysis, which is the basis of every vibration simulation, Let us leave this window; File, Close Mechanical 185 expert expert expert expertfea.com fea.com fea.com fea.com
Back to project Schematic, drag and drop Random Vibration from the left toolbox onto the Solution of the Modal analysis Right click on Equivalent Stress, Duplicate Select only the concrete part, Apply 186 expert expert expert expertfea.com fea.com fea.com fea.com
Once the analysis is solved, let us change the orientation to Y Axis, which is the vertical one Right click on Directional Deformation, Evaluate All Results 188 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE CLAMP WITH PLASTICITY CLAMP WITH PLASTICITY CLAMP WITH PLASTICITY CLAMP WITH PLASTICITY
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural FEA of toggle clamp with plasticity....... page 17 5. The end........................................................................... page 47
3. What we learn in this tutorial 190 expert expert expert expertfea.com fea.com fea.com fea.com
- to assign non-linear materials, that allow plasticity - to properly mesh the contacts - to assign many types of Joints - to define proper Analysis Settings to stabilize the solving - to define proper output for stress, strain, tools, probes etc.
4. Static Structural FEA of toggle clamp with plasticity
Firstly, make sure that you have a proper geometry, like the one we provide, shown here 192 expert expert expert expertfea.com fea.com fea.com fea.com
Select Contacts, right click, Rename Based on Definition; select each contact and look at the mating parts; we will suppress the contacrts that are not of interest in this FEA Select the shown contacts with Ctrl pressed, right click, Suppress 193 expert expert expert expertfea.com fea.com fea.com fea.com
Select 4th contact, which is very important; observe that it is incomplete, because it does not contain all the surfaces that will later touch the handle, red here Click Contact, 3 Faces and, with Ctrl pressed add these 3 surfaces, green here, to obtain 6 faces for the Contact, Apply 194 expert expert expert expertfea.com fea.com fea.com fea.com
Select both bolt holes, Scope, Apply Connections, Body-Ground, Fixed, select the underside of the base plate, Scope, Apply 195 expert expert expert expertfea.com fea.com fea.com fea.com
Connections, Body-Body, Revolute Select the outer surface, green here, Reference Scope, Apply 196 expert expert expert expertfea.com fea.com fea.com fea.com
Selecting Static Structural will activate the Environment upper toolbar; Loads, Joint Select the first Revolute joint Insert these Details; observe that the arrow shows a proper rotation Insert these values in the table 197 expert expert expert expertfea.com fea.com fea.com fea.com
Select Directional Deformation, than click on the surface of the washer that touches the spring, green here, Apply Select the Coordinate System we just created 198 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Strain, Equivalent Total With selection filter on Body, select this green part, Apply 199 expert expert expert expertfea.com fea.com fea.com fea.com
If at Solution Output you choose Force Convergence you will see this window 200 expert expert expert expertfea.com fea.com fea.com fea.com
After 10-15 minutes, the analysis is solved; this is the Total Deformation plot This is the Directional Deformation plot, where we see the washer (hence this side of the spring), which is displaced with ~34 mm 201 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Equivalent Total Strain plot 202 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
TRANSIENT STRUCTURAL FEA OF BENDING A LAMELLA WITH PLASTICITY AND SPRING BACK EFFECT
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Transient Structural FEA of bending a lamella with plasticity and spring back effect....................................................... page 17 5. The end........................................................................... page 48
- to assign non-linear materials, that allow plasticity and spring back - to properly mesh the contacts - to assign many types of restraints, to achieve convergence - to define proper Analysis Settings to stabilize the solving - to define proper output for stress, strain, tools, probes and results depending on time
4. 4. 4. 4. Transient Structural Transient Structural Transient Structural Transient Structural FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and spring back effect spring back effect spring back effect spring back effect
Firstly, make sure that you have a proper geometry, like the one we provide, shown here 206 expert expert expert expertfea.com fea.com fea.com fea.com
Drag Transient Structural from Toolbox. To allow plasticity in the parts, let us define the non-linear material: right click Engineering Data, Edit... Back to Project Schematic, right click on Geometry, Import Geometry, Browse... "2013_11_13_bending_lamella1.x_t" 207 expert expert expert expertfea.com fea.com fea.com fea.com
Right click on Model, Edit... This is the 3D model; if you like English names, let us change the default ones; right click each part, Rename and assign different names Rename the parts as here 208 expert expert expert expertfea.com fea.com fea.com fea.com
The mesh looks like here, with an optimum number of nodes and elements, to ensure short solving time Analysis Settings, Number of Steps = 30 209 expert expert expert expertfea.com fea.com fea.com fea.com
Select the external faces of the die, green here, Apply Right click Transient (A5), Insert, Displacement 210 expert expert expert expertfea.com fea.com fea.com fea.com
Select all lateral faces, green here, Apply; Z Component = 0 mm Solution, Deformation, Directional 211 expert expert expert expertfea.com fea.com fea.com fea.com
With selection filter on Body, click the punch and the lamella, Apply; orientation, Y Axis With selection filter on Face, click the top face of the lamella, Apply; orientation, Y Axis Solution, Stress, Equivalent (von-Mises) 212 expert expert expert expertfea.com fea.com fea.com fea.com
With selection filter on Body, click the lamella, Apply Solution, Strain, Equivalent Total; with selection filter on Body, click the lamella, Apply 213 expert expert expert expertfea.com fea.com fea.com fea.com
Making Display Points = 35 will give you a rarified plot, with last 35 substeps/increments After ~1 hour solving time, the analysis is done; this is the Total Deformation plot in all parts 214 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Directional Deformation plot on Y axis, vertically; observe a remanent deformation of 0.626 mm, due to the spring back effect 215 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Directional Deformation plot on Y axis, vertically, on the upper face of the lamella; the spring back effect is seen more clear on both green and red line, in the lower Graph tab 216 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
TRANSIENT STRUCTURAL FEA OF A GRIPPER WITH GEARS AND JAWS
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Transient Structural FEA of a gripper with gears and jaws.................................................................................... page 17 5. The end........................................................................... page 50
- to take advantage of rigid bodies - to properly set-up the contacts in moving gears - to assign many types of joints (12 different ones) - to define proper Analysis Settings to stabilize the solving - to define proper output for stress, strain, tools, lots of probes and results depending on time
4. 4. 4. 4. Transient Structural FEA of a gripper with gears and jaws
Firstly, make sure that you have a proper geometry, like the one we provide, shown here Double click Transient Structural from Toolbox. Right click Geometry, Import Geometry, Browse... "2013_12_08_claw_gears1.x_t" 220 expert expert expert expertfea.com fea.com fea.com fea.com
Right click Model, Edit... With Shift or Ctrl pressed, select all the parts named "Claw- Bolt1", right click, Suppress 221 expert expert expert expertfea.com fea.com fea.com fea.com
For easier handling, right click on the active parts and Rename them as seen here Select first 3 parts, green here, and make their Stiffness Behavior, Rigid 222 expert expert expert expertfea.com fea.com fea.com fea.com
Right click on Contacts, Rename Based on Definition With Shift pressed select all contacts, than with Ctrl unselect the ones marked with green check (as seen here), right click on the inactive selected contacts, Suppress 223 expert expert expert expertfea.com fea.com fea.com fea.com
Properly suppressed, the unnecessary contacts receive an X sign in front As an exercise, do a similar Revolute Joint for the other gear, transparent here 224 expert expert expert expertfea.com fea.com fea.com fea.com
Connections, Body-Body, Revolute For Reference, Scope, select this cylindrical surface of the Housing plate, green here, Apply For Mobile, Scope, select the corresponding surface of the Link, green here, Apply 225 expert expert expert expertfea.com fea.com fea.com fea.com
For Reference, Scope, select this cylindrical surface of the Jaw, green here, Apply For Mobile, Scope, select the corresponding surface of the Link, green here, Apply 226 expert expert expert expertfea.com fea.com fea.com fea.com
This is the resulting Spring joint For verification, select with Shift pressed all 12 joints and they should look like here 227 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Deformation, Directional Right click anywhere, Show All Bodies; Orientation, Z Axis, select with Ctrl pressed these green surfaces, Apply 228 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Tools, Contact Tool Right click Status, Duplicate Change Status 2's Type to Pressure Solution, Probe, Force Reaction 229 expert expert expert expertfea.com fea.com fea.com fea.com
Click on Solution Information to see what the solver is doing 231 expert expert expert expertfea.com fea.com fea.com fea.com
For a graphical representation of the solver's activity, change Solver Output to Force Convergence; for a rarified plot, make Display Points = 35 232 expert expert expert expertfea.com fea.com fea.com fea.com
After ~25 min, the solve is finished; this is the Total Deformation plot 233 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Strain plot 234 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Stress plot This is the Directional Deformation plot showing the displacement/ the stroke of the jaws 235 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
TRANSIENT STRUCTURAL FEA OF A MISALIGNED 4-CYLINDER ENGINE
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Transient Structural FEA of a misaligned 4-cylinder engine................................................................................ page 17 5. The end........................................................................... page 56
- to properly set-up the contacts in moving parts - to pre-investigate the contact behavior, for a proper definition - to assign many types of joints (14 different ones) - to define proper Analysis Settings to stabilize the solving - to define proper output for stress, strain, tools, lots of probes and results depending on time
4. 4. 4. 4. Transient Structural FEA of a misaligned 4-cylinder engine
Firstly, make sure that you have a proper geometry, like the one we provide, shown here 239 expert expert expert expertfea.com fea.com fea.com fea.com
Double click Transient Structural from Toolbox. Right click Geometry, Import Geometry, Browse... " 2013_12_09_engine1.x_t" Right click Model, Edit... 240 expert expert expert expertfea.com fea.com fea.com fea.com
In Mechanical window, expand Connections and right click on Contacts, Rename Based on Definition To check for interferences in contact areas, right click on Contact Tool, Insert, Penetration Right click, Generate Initial Contact Results 241 expert expert expert expertfea.com fea.com fea.com fea.com
Initial Information shows, in orange, 2 contacts that are to worry The max. penetration value helps us define the Pinball Radius, for the contact to work without interference; this is why we used 0.05 mm, bigger than the max. penetration 242 expert expert expert expertfea.com fea.com fea.com fea.com
For an easier view on the piston, select any face of the block, right click, Hide Body 243 expert expert expert expertfea.com fea.com fea.com fea.com
For Mobile, Scope, select the 4 outer faces of the corresponding piston (green here), Apply 244 expert expert expert expertfea.com fea.com fea.com fea.com
Right click any where, Show All Bodies; for verification, this is how the Translational joint looks like, when it's finished Solution, Stress, Equivalent (von-Mises) 245 expert expert expert expertfea.com fea.com fea.com fea.com
Select all the pistons, Apply Select the crankshaft, Apply 246 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Probe, Force Reaction Location Method, Contact Region, select the last contact from the drop down list Duplicate the Force Reaction 247 expert expert expert expertfea.com fea.com fea.com fea.com
Change the Contact Region, as seen here Solution, Tools, Contact Tool Uncheck the last 4 contacts, to have only the first ones active, as seen here 248 expert expert expert expertfea.com fea.com fea.com fea.com
Selecting Solution, Information, this is the log of the solver, called Solver Output 250 expert expert expert expertfea.com fea.com fea.com fea.com
Change Solver Output to Force Convergence to obtain a graphical representation of the solver's activity; we observe that the analysis converges nicely Choosing Force Convergence instead of Solver Output you will obtain such a plot that shows a nice convergence trend 251 expert expert expert expertfea.com fea.com fea.com fea.com
After ~1 hour of solving time, this is the Total Deformation plot 252 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Directional Deformation plot in pistons 253 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
STATIC STRUCTURAL DETAILED FEA OF VERIFICATION OF M10 SCREWS USING BOLT PRETENSION
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static Structural detailed FEA of verification of M10 screws using Bolt Pretension................................................................... page 17 5. The end........................................................................... page 54
- to properly set-up the Contacts , Named Selections, Object Generator - to investigate the validity of the results with Structural Error tool - to optimize the geometry and the mesh where needed - to define proper output for stress, strain, tools etc. - to re-run the FEA with non-linear materials
4. 4. 4. 4. Static Structural FEA of verification of M10 screws using Bolt Pretension
Firstly, make sure that you have a proper geometry, like the one we provide, shown here Double click Static Structural from Toolbox. Right click Geometry, Import Geometry, Browse... " 2013_12_20_flanges_bolts1.x_t" 257 expert expert expert expertfea.com fea.com fea.com fea.com
For last 4 features, let us change the measurement unit to MPa, as seen here For the very common bolt steel with 8.8 grade, insert these values 258 expert expert expert expertfea.com fea.com fea.com fea.com
Refresh Project, Return to Project Right click Model, Edit... Right click Component2, Rename to: "nut M10"; right click Component1, Rename to: "bolt M10" 259 expert expert expert expertfea.com fea.com fea.com fea.com
To set the mesh size for the rest of the parts, right click on Body Sizing, Duplicate Click Geometry, 8 Bodies, zoom with middle mouse to properly select the flanges and the spacer between them, Apply, Element Size = 4 mm 260 expert expert expert expertfea.com fea.com fea.com fea.com
Make sure you have checked Named Selections toolbar from View menu 261 expert expert expert expertfea.com fea.com fea.com fea.com
With selection filter on Face, select with Ctrl pressed the 4 cylinders of the bolts (green here), than press Create Named Selection button 262 expert expert expert expertfea.com fea.com fea.com fea.com
Uncheck the contact from the ring and the bonded ones, as seen here Right click Status, Duplicate Change Type of Status 2 to Pressure Right click Pressure, Duplicate 263 expert expert expert expertfea.com fea.com fea.com fea.com
Change Type of Pressure to Penetration Right click Solution Information, Solve 264 expert expert expert expertfea.com fea.com fea.com fea.com
This is how Solver Output shows the activity of the solver Change Solver Output to Force Convergence for a graphical representation of the solver's activity 265 expert expert expert expertfea.com fea.com fea.com fea.com
This is the force Convergence plot where we will see when the solver converges After the successful finish of the solving, make sure that the results scale is 1 and check the axial Directional Deformation 266 expert expert expert expertfea.com fea.com fea.com fea.com
This is the stress only in the bolts; click on the upper Probe button than on different points to find out the stress where needed; compared to the Yield Stress of 640 MPa, we are exactly fine 267 expert expert expert expertfea.com fea.com fea.com fea.com
After we have adjusted the legend to visible, this is the Safety Factor plot in the M10 screws, related to Yield Stress 268 expert expert expert expertfea.com fea.com fea.com fea.com
To illustrate the Contact Tool, use 4 viewports pressing the respective button in the upper toolbar 269 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
STATIC STRUCTURAL FEA OF A PIN LARGELY DEFORMING A RUBBER SEALING 270 expert expert expert expertfea.com fea.com fea.com fea.com
CONTENT:
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Static structural FEA of a pin largely deforming a rubber sealing................................................................... page 17 5. The end........................................................................... page 35
- to assign hyperelastic and plastic materials - to set-up a proper mesh with dropped midside nodes - to correctly assign contacts between distinct parts and between features of the same part - to set-up a multi-step Static Structural FEA - to define proper output for stress, strain, tools etc.
4. Static structural FEA of a pin largely deforming a rubber sealing
Firstly, make sure that you have a proper geometry, like the one we provide, shown here Drag Static Structural from Toolbox to Project Schematic. Right click Geometry, Import Geometry, Browse... " 2014_01_29_sealing_1lip4.x_t " 273 expert expert expert expertfea.com fea.com fea.com fea.com
On the Environment toolbar, choose Supports, Displacement Select the outer face of the pin, Apply. X and Z Component = 0 mm and for Y Component choose Tabular Data. 274 expert expert expert expertfea.com fea.com fea.com fea.com
Insert these values in Y column. On the Environment toolbar, choose Supports, Fixed Support. 275 expert expert expert expertfea.com fea.com fea.com fea.com
Click the green face, than propagate the selection with Extend to Limits, Apply. Click the green face, than propagate the selection with Extend to Limits, Apply. On the Solution toolbar, choose Deformation, Total. Solution toolbar, Deformation, Directional. Orientation = Y Axis 276 expert expert expert expertfea.com fea.com fea.com fea.com
Solution, Stress, Equivalent (von-Mises). Solution, Strain, Equivalent (von-Mises). Select the sealing, Apply. Solution, Tools, Contact Tool. We are not interested of what happens between the polyethylene reinforcement and the surrounding rubber, so uncheck the Bonded contact, as seen here 277 expert expert expert expertfea.com fea.com fea.com fea.com
Right click Contact Tool, Insert, Pressure Solution, Probe, Force Reaction. Location Method = Contact Region. Contact Region = Frictionless - pin To sealing. Right click Solution (A6), Solve. 278 expert expert expert expertfea.com fea.com fea.com fea.com
During solving, if you select Solution Information = Force Convergence, you will get a similar plot, very helpful on judging the tendency of the solution computation. Right click Equivalent Stress, Evaluate All Results. Scope only for the reinforcement, Apply. 279 expert expert expert expertfea.com fea.com fea.com fea.com
This is the Stress plot only in the reinforcement. This is the Status of the Contact Tool. 280 expert expert expert expertfea.com fea.com fea.com fea.com
Finite Element Analysis Hints and Ansys Workbench Tutorial
TRANSIENT STRUCTURAL FEA OF A SMALL SKID STEER LOADER
1. Introduction.................................................................... page 3 2. Advice and good practices for a future FEA engineer...... page 4 3. What we learn in this tutorial........................................... page 16 4. Transient structural FEA of a small skid steer loader....... page 17 5. The end........................................................................... page 49
- to work with both rigid and flexible bodies - to correctly assign many different joints (23) - to set-up a multi-step Transient Structural FEA - to define proper output for stress, deformation, velocity, probes etc.
4. Transient structural FEA of a small skid steer loader
Firstly, make sure that you have a proper geometry, like the one we provide, shown here. Drag Transient Structural from Toolbox to Project Schematic. Right click Geometry, Import Geometry, Browse... " 2013_10_18_loader_asm.x_t ". 284 expert expert expert expertfea.com fea.com fea.com fea.com
Right click Model, Edit... Right click Contacts, Delete. Select first 9 components (green here), with Shift pressed and make Stiffness Behavior, Rigid. 285 expert expert expert expertfea.com fea.com fea.com fea.com
From the upper Connections toolbar, choose Body-Ground, Fixed. Let us fix the loader body: select the underside, green here, Apply. From the Connections toolbar, choose Body-Ground, Revolute. 286 expert expert expert expertfea.com fea.com fea.com fea.com
Select the green surface from Component10, Apply. Repeat the Revolute Joint for the Component15 on the other side. Selecting with Shift pressed all 23 joints, they should look like here. 11 pairs of mirrored joints and 1 joint fixes the excavator body. 287 expert expert expert expertfea.com fea.com fea.com fea.com
To simulate a load in the hoe, right click Transient (A5), Insert, Pressure Click Analysis Settings and make Number of Steps = 10. Select with Shift pressed all 10 steps from the lower right Graph tab and insert these values for Initial, Minimum and Maximum Time Step 288 expert expert expert expertfea.com fea.com fea.com fea.com
Click inside of the hoe, Apply. Magnitude = 0.07 MPa Choose from Solution toolbar, Stress, Equivalent (von-Mises) 289 expert expert expert expertfea.com fea.com fea.com fea.com
With selection filter on Body, click the 5 parts, green here, Apply Choose from Solution toolbar, Deformation, Directional Select only the hoe, Apply. Orientation, Y Axis. 290 expert expert expert expertfea.com fea.com fea.com fea.com
To see how the FEA evolves, make Solution Output, Force Convergence. Display Points, 35 291 expert expert expert expertfea.com fea.com fea.com fea.com