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EML 4500 Finite Element Analysis & Design PROJECT II Analysis and Design of Torque Arm

RAMIN SHAMSHIRI Fall 2009

Due Dec 14th, 2009

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

Problem statement Give a 2D Torque Arm model

Figure 1. Torque Arm

Material properties: E = 206.8 GPa Poissons ratio = 0.29 thickness =1.0 cm mass density = 7850 kg/m3 a. b. c. d. Conduct a FEA Analysis to determine stress acting on the model. Determine displacement Conduct convergence study varying mesh size in determining both stress and displacement Bonus: Minimize the weight for max. allowable stress<= 240 MPa

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

1.

Preliminary analysis

The torque arm has an extruded thickness of 1 cm, which is very small compared to the other dimensions. Therefore, this part can be analyzed using the plane stress assumption. In the middle of the torque arm is a cutout, which is created to save mass. The left-hand circle is pinned, while the right-hand circle has two loads applied: 2,789 N in the x-direction and 5,066 N in the y direction. In the preliminary analysis stage, we should idealize the problem and use analytical methods to obtain an approximate solution. This includes drawing free body diagrams of different components and analyzing force equilibrium and applying simplified, strain-displacement relations, and stress-strain relations. Since this is a combined loading problem, we will use principle of superposition of the loads. According to the Figure 1, the locations of maximum stresses are at the top and bottom of the cross-section, the shear stress is zero at those locations. The axial and bending stresses should add or subtract, depending on the location. In order to approximate stress level at the top and bottom of this structure, we need to consider it as a combination of axial stress and pure bending problem. The rod structure was assumed as a cantilever beam with a rectangular shape cross section. The effects of stress concentration on cut-outs sections were also considered by utilizing the coefficients factors from the available charts given in Figure 3 and 4. Details of the Preliminary analysis are illustrated below: 1.1. Pure bending and Basic assumption: The first assumption to use pure bending is that only straight beams having constant cross sectional areas with an axis of symmetry are to be included for utilizing equation 1. It is also assumed that the applied bending moments lie in a place containing this axis of symmetry and the beam axis. For bending stresses, the flexure formula for beams is given by:

where

Figure 2. Pure bending

Eq.1

= . (N.m) : the internal or resisting bending moment (m) : distance from the neutral axis of the beam to the point on a section where the normal stress is measured = 3 (m ) : moment of inertia of the whole cross sectional area of the cantilever beam about its neutral axis. 1.2. Axial stress Using the above assumption that the stress is constant in the cross-section, the nominal axial stress can be calculated using equation 2; = = 2 Eq.2
8 3
4

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

1.3. Stress concentrations for axial stress and bending moment The equation for pure bending applies only to beams of constant cross sectional area, usually called prismatic beams. Since we do not have a constant cross sectional area, we should consider the arising of high local stresses. This case makes it very difficult to obtain analytical expression for the actual stress. Since the interest is in the maximum stress, the idea of the stress consideration factor may be used to advantage. The ration K of the actual maximum stress to the nominal maximum stress in the minimum section given by Equation (2) is defined as the stress-concentration factor in bending. Using the chart in Figure 3 for stress concentration factors in pure bending for grooved flat bars, we have: = Eq.3

To calculate the stress concentration factor at the hole, we need to calculate the geometric factor which is the ration between the diameter of the hole and the width of the plate. From Figure 3, the geometric factor for each part of the rod structure was found. The stress concentration factor corresponding to this geometric factor can obtain from the graph in figure 3 which is K. Then, the maximum stress occurs at the top part of the hole and its value becomes: = Eq.4

Figure 3. Theoretical stress-concentration factor Kt: A-for a flat bar loaded in tension by a pin through the transverse hole; B-for a flat bar with a transverse hole in axial tension.

Figure 4. Theoretical stress concentration factor Kt for a notched bar in bending

1.4. Idealizing the rod structure The rod structure was idealized by modeling it with a simple cantilever beam with an axial force, Fx and a vertical force Fy=. The cut-out section in the middle was also modeled with two circle shape holes each with diameter of 2 centimeter.The idealized model of the rod is shwon in Figure 5 and 6.

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

Figure 5. Idealized model of the rod structure

In order to anlyctically analyse the stress level through out the entire cantilever beam, we should consider four different sections, as shown in Figure 6. These sections are each shown in Figure 7 throuh 10 with nominal and maximum stresses calculated for each. Obviusly these results are approximate. It is obvious that the maximum bending stress happens at the largest disstance from the neutral axis (we have torsion stress on the bottom and compresion stress on the top of the beam) and the maximum axial stress happens the corners of the cut-out sections.

Figure 6.

2789 = = 3.48 10 2 1 2 = = 0.2 => = 2.31 10 max = = 2.31 3.48 = . . 5066 15 1 = = = = . 8 3 /3 8 (1) (53 /3)

Figure 8

2789 = = 5.578 10 5 1 5 = = 0.5 => = 2.12 10 max = = 2.12 5.578 = . 5066 = = 14.9 (8.4 5) 1 5 = 8.4 = 0.6 => = 2.1 max = = 2.1 14.9 = .

Figure 7

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

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Figure 10

2789 = = 13.94 10 8 1 8 = 10 = 0.8=> = 2.07 max = = 2.07 13.94 = . . 5066 42 4 () = = = 8 3 /3 8 (1) (53 /3) = .

2789 = = 3.48 10 2 1 2 = 10 = 0.2 => = 2.31 max = = 2.31 3.48 = . . 5066 30 1 () = = = 8 3 /3 8 (1) (53 /3) = .

Figure 9

So the maximum compression stress level at the top of the beam using principle of superposition is: = + = 25.53 + 28.86 = 54.39

It should be noted that this is a very approximate solution and may not be correct. 1.5. Maximum displacement calculation Maximum stress occurs at the bottom and top of the left side of the rod. Using = 42 the following equation, we have: 12 6 12 6 6 42 6 22 3 12 6 12 6 6 22 6 42 206.8 109 (102 0.42
3

1 1 1 1 2 = 2 0 1 1 1 1 2 = 5066 2 0

12 6(0.42) 12 6(0.42) 10 102 3 ) 6(0.42) 4(0.42)2 6(0.42) 2 0.42 2 3 12 6(0.42) 12 6(0.42) 2 6(0.42) 2 0.42 6(0.42) 4 0.42 2

Applying boundary conditions: 12 6(0.42) 2 5066 9.304 106 = 6(0.42) 4 0.42 2 2 0 2 0.1815 3 2 = 0.6482 10

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

2.

Formulation

Using finite element analysis, the rod was divided into a set of contiguous rectangular elements. Each element is connected to other elements by sharing nodes. The unknowns for each element are the displacements at the nodes, called degrees of freedom. Displacement boundary conditions and applied loads are then specified. The element level matrix equations are assembled to form global equations. The global matrix equations are solved for the unknown displacement, given the force and boundary conditions. From the displacement at the nodes, strains and then stress in each element are calculated. 2.1. Pane stress problem In two-dimensional problem, the stress and strains are independent of the coordinate in the thickness direction. The governing equations for place problems are: + + = 0 + + = 0

Since the thickness of the given rod structure is much smaller than its length and width dimensions, we can consider it as a place stress problem. Therefore we would model this structure in two dimensions. For linear isotropic materials, the stress-strain relation can be written as: 1 = 2 1 1 0 0 0 0
2

Eq.5

Using Equation above and the material property of the rod, the stress-strain matrix for this problem is calculated as: 1 0 1 0.29 0 206.8 109 0.29 1 0 1 0 = = 1 0.29 1 2 0 0 1 1 0.292 0 0 2 2 2.1542 0.4308 0 = 1011 0.4308 2.1542 0 0 0 0.8617

2.2. Four-node rectangular element The rod structure was modeled in finite element using rectangular element. Each element is composed of four nodes and eight DOFs. Each element shares its edge and two corner nodes with an adjacent element, except for those on the boundary. The four vertices of a rectangle are the nodes of that element. Each node has two displacement, u and v, respectively in x- and y-directions. A Matlab program was provided for this project to design element module and topology for generating finite element meshes. This program divides the rod structure into 12 major elements as shown in Figure 11. Using mesh_density variable in the Matlab program, the number of sub elements are defined. The outputs of rodDesign.m file for mesh density of 10 and 20 are shown in Figure 12 and 12 respectively.

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

Figure 11. Mesh density 10

Figure 12. Mesh density 20

Figure 13. Mesh density 20, zoomed

2.3. Lagrange interpolation and displacement vector In four node-rectangular element, since all edges are parallel to the coordinate directions, shape functions can be calculated using a polynomial in x and y as the interpolation function. Since there are four nodes, we can apply four conditions and hence the polynomials should have four terms, as follows: = 1 + 2 + 3 + 4 = 1 + 2 + 3 + 4 The shape functions for rectangular elements are then defined as: 1 1 = 3 3 1 2 = 1 3 1 3 = 1 1 1 4 = 3 1 The displacement vector at any point (x,y) is given by the following equation: 1 1 2 2 3 3 4 4

= 1 0

0 1

2 0

0 2

3 0

0 3

4 0

0 4

2.4. Strain displacement relations: Since the shape functions are given as function of x- and y- coordinates, the strain can be calculated by differentiating the shape function with respect to the coordinates as follow:

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

= = = =

=1 4

=1

= + =

=1

=1

Writing the above equation in matrix form, we have: 1 1 2 2 3 3 4 4

1 3 0 3

0 3 3

3 0 1

0 1 3

1 0 1

0 1 1

1 0 0 3 3 1

2.5. Iso-parametric mapping The physical elements in Figure 11 and 12 has quadrilateral shape, however all interior angles should be less than 180 degrees. Each node has two DOFs, u and v. Thus each of the elements has a total of eight DOFs. The physical element in Figure 11 and 12 should be mapped into the reference element coordinate. The physical element is defined in x-y coordinates, while the reference element is defined in s-t coordinates. The reference element is a square element and has the center at the origin. Although the physical element can have the first node at any corner, the reference element always has the first node at the lower left corner (-1,-1). The interpolation functions are defined n the reference element so those different elements have the same interpolation function. Since the reference element is of square shape, the Lagrange interpolation for rectangular element can be used. The interpolation or shape functions can be written in s-t coordinates as; 1 1 (1 ) 4 1 2 , = 1 + (1 ) 4 1 3 , = 1 + (1 + ) 4 1 4 , = 1 (1 + ) 4 2.6. Assembly procedure and description of Matlab code 1 , = Plane solid element have two DOFs at each node, ux and uy. The coordinates of nodes and element conductivity are produced by rodDesign2.m file. For material property, we need to build the stress-strain matrix given in Equation 5 for plane stress problem. This equation is written in Matlab using the following code:
ep=[1 0.01 2];

The first column of ep specifies problem type; 1= Plane stress, 2= Plane strain, 3= axismetric, 4= 3D. The 2 nd column stands for the thickness of the plane solid element. The hook function calculates the stress-strain (elasticity matrix) matrix . %Material Matrix

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

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E=260e9; nu=0.29; D=hooke(1,E,nu); The axial and vertical forces are input as Fx and Fy in Matlab code and divided by the number of elements at the right hole.
Fx = -2789; Fy = 5066; len = numel(frc); %Number of elements at the right hole fx = Fx/len; %X force at the right hole fy = Fy/len; %Y force at the right hole

The forces are assigned to elements using the frc matrix provided by the rodDesign2.m file. F= zeros(2*numfenod,1); %Generates force matrix F F(frc*2-1) = fx; F(frc*2) = fy;

In order to construct the element stiffness matrix for the i-th element, the plani4e function is called with the i-th row of Ex and Ey array along with thickness in ep and stress-strain matrix D: K=zeros(2*numfenod); for i=1:numfele ke=plani4e(Ex(i,:),Ey(i,:),ep,D); K=assem(Edof(i,:),K,ke); end Applying boundary conditions and solving the matrix equation are done using the following code: U=solveq(K,F,bc); After solving for the nodal DOFs, the element stress can be calculated using plani4s function: ed=extract(Edof,U); for i=1:numfele es(i,:,:)=plani4s(Ex(i,:),Ey(i,:),ep,D,ed(i,:)); end Arrays es contain element stresses and is 3 dimensional. The first index of es is the element number and the second index is the integration point, and the third index is the stress component. Since the stress is not constant within an element, different stress values are calculated at the integration points. The element stress contour can be plotted by calling the following program: plcontour2(Ex,Ey,es(:,1),ed,10);

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

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3.

Numerical Results and its comparison with analytical solution

Results are shown for different mesh density in Figure 14 through 17 . 3.1. Stress Calculation and Plot

Figure 14. Mesh 3

Figure 15. Mesh5

Figure 16. Mesh 7

Figure 7. Mesh 12

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

12

3.2. Convergence study based on displacement The convergence study is a powerful tool when there is not analytical solution available. Since we dont know the exact solution in this cases, it is impossible to know how accurate the current analysis result is. After a convergence study we can have a confidence in the analysis results. The convergence study consists of two sets of meshes, the original mesh and the other is the mesh with twice as many elements in critical regions. If the two meshes yield nearly the same results, then the mesh is probably adequate. Based on Figure 18 through 21, we can see that mesh density equal to 6 or 7 is adequate enough to give a good analysis results.

Figure 8. Plot of Displacement vs. elements number for Mesh density =3

Figure 9. Plot of Displacement vs. elements number for Mesh density =5

Figure 20. Plot of Displacement vs. elements number for Mesh density =7

Figure 21. Plot of Displacement vs. elements number for Mesh density =9

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th

13

Mesh density 3 5 7 9

0.0769 0.0916 0.0972 0.1000

0.6999 0.7822 0.8153 0.8327

0.0769 0.0916 0.0972 0.1000

0.6999 0.7822 0.8153 0.8327

0.0913 0.1013 0.1044 0.1057

0.7122 0.7902 0.8212 0.8373

0.0913 0.1013 0.1044 0.1057

0.7122 0.7902 0.8212 0.8373

Table 1. peak values of displacement

Figure 22. Plot of peak values of displacement for four mesh density

4.

Conclusion

4.1. Summary of Findings The rod structure was first analyzed using conventional beam theories. In order to do that, the rod was idealized to a cantilever beam and preliminary analysis were done. The maximum compression and tension stress was found using several simplified assumptions. The rod structure was then analyses using finite element method. A rodDesign.m MATLAB file was used to generate the topology and elements for the rod as well as generating boundary condition, Ex and Ey arrays. Another Matlab file was written to solve the rod structure for stress and displacement. 4.2. Comparison with Preliminary Analysis The results from Finite elemenet are somewhat different from the preliminary analysis. In the case of pure bending problem, the axial stress/strain is constant. Since the rod was idealized with a cantilever beam, this stress/strain was found to be constant along the same y-location. The finite element analysis provides different values which are smaller or larger than the theoretical values. These results indicate the finite element analysis is stiffer than exact solution. In addition, the beam theory says that the shear strain for the pure bending problem is zero; however, the finite element analysis yields a varying shear strain.

Ramin Shamshiri

EML 4500, Finite Element Analysis & Design

Due Oct 30 2009

th