CAD/CAE in Mechatronics Engineering

Ph.D. Mai Duc Dai

Faculty of Mechanical Engineering

Ho Chi Minh City University of Technology and Education

7 July 2015

Mai Duc Dai

Background

Bachelors degree in Mechanical Design Engineering

HSPKT

(1995-2000)

Master of Science in Computational Mechanics

University of Liege, Belgium
(2001-2003)

Ph.D in Aerospace Engineering

Konkuk University, Seoul Korea (2008-2012)

7 July 2015

Mai Duc Dai

What are the CAD, CAM and CAE ?

Geometric & Mechanism Simulation

Need
&
Ideas

CAD (Computer Aided Design)

1.
2.

AutoCAD & Mechanical Desktop

Pro/E

3.
4.

Catia
NX

5.
6.
7.
8.
9.

Solid Edge & SolidWorks

Ansys
Samcef
Abaqus
MSC.Nastran

Numerical Simulation (CAE tools)

CAE
1.
2.
3.
4.
5.

Market

ADAM
RecurDyn
Moldex 3D
Moldflow
NX/CAE

Design
&
Simulation

Quality Control

CAM (Computer Aided Manufacturing)

1.
2.
3.

MasterCam
Cimatron
Pro/E (CAM), Catia (CAM), Unigraphics

Manufacture

A mechanical engineer,
Should know how to use at least one of
softwares in each group which previouly
listed

7 July 2015

Mai Duc Dai

CAE analysis
Thc hin cc phn tch k thut (phn tch CAE) cho cc cu kin C kh

Frequency Response Function

120

X_dir

100
d b [g /N ]

Y_dir
80

Z_dir

60
40
20
0
400

800

1200

1600

2000

2400

2800

FREQUENCY [Hz]

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CAE analysis
NASTRAN- NUMERICAL SIMULATION

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CAE analysis

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CAE analysis
Fixed support

Force = 30 N

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The most common CAE analysis

Nhng phn tch k thut thng dng (phn tch CAE) ?

Structural Analysis
Multibody Dynamics (MBD) simulations
Coupled fields analysis
Fluid structure interaction
Thermo-mechanical coupling
Structural-thermoelectric analysis
Electromechanical analysis

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Mai Duc Dai

Structural
Analysis

1
Static
Analysis

2
Modal
Analysis

Nonlinear
analysis

Harmonic
Analysis

Linear
analysis

Transient
Dynamic
Analysis

Spectrum
Analysis

Nonlinear
analysis

Buckling
Analysis

Linear
analysis

Plasticity
Stress stiffening
Large deflection (small strain)
Large strain (finite strain)
Hyper-elasticity
Contact surfaces
Creep.

7
Explicit
Dynamic
Analysis

Nonlinear
analysis

ANSYS
LS-DYNA
only

Structural Analysis-static

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Structural Analysis-static

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Structural Analysis-modal

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Structural Analysis-modal

1rst mode (10.7 Hz)

2nd mode (11.6 Hz)

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Structural Analysis-droptest

Damper part
Weight Balance part

Cover part

Bedplate part
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Structural Analysis-droptest

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Structural Analysis-droptest

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Structural Analysis-droptest

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MBD Analysis

Rigid wall

first-stage
booster

second-stage
booster

Sled

Rocket

Rocket

Sled
railway

Brake mechanism
0.8m

Water/Sand

Ground

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MBD Analysis

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MBD Analysis

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Coupled field Analysis-FSI

Spacer

Hub
Retainer

Inner Plate
Outer Plate

Apply Piston

Apply Piston
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Coupled field Analysis-FSI

Dynamic Test Results
70
Exp. (1 cycles)
Exp. (10 cycles)
Exp. (100 cycles)
Structure model

60
50

Torque (N.m)

40
30
20
10
0
-10
-20
-30

7 July 2015

0.2

0.4

0.6

0.8
1
time (sec)

Mai Duc Dai

1.2

1.4

1.6

1.8

23

Outline

Structural analysis
Static analysis (truss, frame, shell, solid)
Modal analysis
Transient analysis
Coupled-Field analysis
Structural-thermoelectric analysis
Electromechanical analysis
Final project

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Numerical tools in structural analysis

Analytic solutions

Strength of materials

Structural anslysis
Approximate solutions
Finite Element Method (FEM)
Numerical solutions
Boundary Element Method (BEM)

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Common CAE Softwaves

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An Introduction to
FINITE ELEMENT METHOD

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Basic Steps in the Finite Element Method

2. Select Element Type
(Shape and Approximation)

1. Discretization of analysis domain

v3
v2

u3

v1

2
u1

6. Solve Assembled System of Equations for

Unknown Nodal Displacements,
Secondary Unknowns of Stress and Strain Values

3. Derive Element Equations

(Variational and Energy Methods)

5. Incorporate Boundary
and Initial Conditions

[Ke]{Ue} = {Fe}

4. Assemble Element Equations

to Form Global System

[K]{U} = {F}
21 January 2015

u2

Mai Duc Dai

[Ke] = Stiffness or Property Matrix

{Ue} = Nodal Displacement Vector
{Fe} = Nodal Force Vector
28

Common Types of Elements

Two-Dimensional Elements
Triangular, Quadrilateral
Plates, Shells, 2-D Continua

One-Dimensional Elements
Line
Rods, Beams, Trusses, Frames

Three-Dimensional Elements
Tetrahedral, Rectangular Prism (Brick)
3-D Continua

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Discretization Examples

Three-Dimensional
Brick Elements
One-Dimensional
Frame Elements
21 January 2015

Two-Dimensional
Triangular Elements
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FEM mesh
The number of elements used in a model depends on a number of factors that include
the following
1. Physical geometry of the domain

2. Desired accuracy

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FEM mesh
3. Element formulation

Linear formulation
elements

Higher oder formulation

elements

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FEM mesh
4. Special solution characteristics

5. Available computational resources

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ANSYS Classic Training

basis course

33

General steps in using Ansys classic for solving a structural analysis problems

Pre-Processor
stage

Processor Stage

Post-Processor
Stage

Start-up ANSYS

Define the element types

Define the real constants
Define the material properties
Modeling
create key points, lines, surfaces, volumes
import from CAD files
Meshing
Apply Boundary conditions
geometric BCs
applied load
Solver set-up
modal analysis
static structural analysis
nonlinear structural analysis
Run the job
Visualization of the results
displacements
stress
safety factor

ANSYS GUI

Utility menu

Command line

Working area

Model control
toolbar

Main menu
Current setting

Utility Menu Help

Analysis of truss/frame structures

Truss and frame structures

Element types

LINK180

This element can be used to model trusses,

sagging cables, links, springs, etc.
This 3-D spar element is a uniaxial tensioncompression element with three degrees of
freedom at each node: translations in the nodal x,
y, and z directions.

BEAM188

BEAM188 is suitable for analyzing slender to

moderately stubby/thick beam (or frame)
structures.
BEAM188 has six degrees of freedom at each
node, include translations in the x, y, and z
directions and rotations about the x, y, and z
directions.
This element is well-suited for linear, large
rotation, and/or large strain nonlinear applications.

Trusses

Activity #1: Deflection of a Hinged Support (VM4)

A structure consisting of two equal steel bars, each of length l and cross-sectional
area A, with hinged ends is subjected to the action of a load F. Determine the stress,
, in the bars and the deflection, , of point 2. Neglect the weight of the bars as a
small quantity in comparison with the load F.

a = 2l cos , b = l sin

Material Properties

Geometric Properties

Loading
Reference solution
= 10,000 psi, = - 0.12 in

Change the project title

Utility menu File Change Title

Project Title

Define element type

Main Menu Preprocessor Element Type Add/Edit/Delete

Define material properties

Main Menu Preprocessor Material Props Material Models

Define cross-sectional properties

Main Menu Preprocessor Real Constants Add/Edit/Delete

Modeling-create nodes
Main Menu Preprocessor Modeling Create Nodes In Active CS

Nodes:
1
2
3

x
0
l cos
2l cos

y
0

l sin

z
0
0
0

There is no unit system is defined in Ansys Classic, user have responsibility on using consistent units for
their input parameters.

Consistent system of units

Consistent system of units:

SI

UK

Mass:
Length:
Time:
Force:

kg
m
s
N

Mass:
Length:
Time:
Force:
or

lbf-s2/in (snail)
in
s
lbf (pounds-force)
lb (pound)

g = 9.81m/s2 = 386 in/s2

1ft = 12in = 0.3048m (foot feet)
1in = 0.0254m
21 January 2015

Units for angular functions

Density: kg/m3
Stress: Pa (N/m2)
Gravity: 9.81 m/s2

Density: snail/in3
Stress: Psi (lbf/in2)
Gravity: 386 in/s2

mph (miles per hour), 1mile = 1,6093 km

1lbf = 4.448222 N
1kip (kilopound) = 1000 lbf
Mai Duc Dai

49

Modeling-create elements
Main Menu Preprocessor Modeling Create Elements Auto Numbered
Thru Nodes
Select two nodes to define the element then click OK

Modeling- Controls entity numbering/coloring on plots

Utility Menu PlotCtrls Numbering

Utility Menu Plot Keypoints Keypoints

Lines
Areas
Volumes
Elements

Isometric view
Front view

Fit view

Apply BCs & Load

Main Menu Preprocessor Load Define Loads Apply Structural Displacement
On Nodes

Main Menu Preprocessor Load Define Loads Apply Structural Force/Moment

On Nodes

Set up solver, save & solve the problem

Main Menu Solution New Analysis

ANSYS Toolbar Save_DB

Main Menu Solution Solve Current LS

Post-processing, show deformed shape

Main Menu General Postproc Plot Results Deformed Shape

Post-processing, Printout nodal solution per nodes

Main Menu General Postproc List Results Nodal Solution Displacement vector sum

Post-processing, Printout nodal forces

Main Menu General Postproc List Results Element Solution Structural forces

Post-processing, Printout element axial stress

Main Menu General Postproc Element Table Define Table Add Button

Main Menu General Postproc Element Table List Elem Table OK Button

Post-processing, Plot axial stress

Create one more element table, axial stress at node J

Main Menu General Postproc Element Table Define Table Add Button

Post-processing, Plot axial stress

Plot axial stress diagram
Main Menu General Postproc Plot Results Contour Plot Line Elem Res

Frame structures

Activity #2: Beam Stresses and Deflections (VN2)

A standard 30" WF beam, with a cross-sectional area A, is supported as shown below
and loaded on the overhangs by a uniformly distributed load w. Determine the
maximum bending stress in the middle portion of the beam and the deflection at
the middle of the beam.
Material Properties
Geometric Properties
l = 240 in
a = 120 in
w1 = w2 = 15 in
w3 = 30.0968 in
t1 = t2 = 1.0484
t3 = 0.6856 in

Loading

Reference solution
= -11400 psi, = 0.182 in

Define element type

Main Menu Preprocessor Element Type Add/Edit/Delete

Define material properties

Main Menu Preprocessor Material Props Material Models

Define sectional properties

Main Menu Preprocessor Sections Beam Common Section

Modeling-create key points

Main Menu Preprocessor Modeling Create Keypoints In Active CS

Keypoints:
1.
0
2. 240
3. -120
4. 360
10. 0

0
0
0
0
120 (orientation)

Modeling-create lines
Main Menu Preprocessor Modeling Create Lines Lines / Straight Line
Select two keypoints to define the line then click OK

Meshing Associates element attributes with the selected, unmeshed lines.

Main Menu Preprocessor Meshing Mesh Attributes Picked Lines
1. Select lines then click OK
2. Pick Orientation Keypoint(s) Yes OK
3. Specifying the keypoint 10 OK

Meshing setting element size & meshing.

Main Menu Preprocessor Meshing Size Cntrls ManualSize
Lines All Lines

Main Menu Preprocessor Meshing MeshTool

1. Click Mesh button
2. Select lines OK close MeshTool Dialog

Display elements with shapes determined from the real constants or section definition.
Utility Menu PlotCtrls Style Size and Shape

Utility Menu Plot Elements

Apply BCs
Main Menu Preprocessor Load Define Loads Apply Structural Displacement
On Lines (or On Keypoints)

BCs on Lines:
1, 2, 3
BCs on Keypoints:
1
2

Uz=Roty=Rotx=0
Ux=Uy=0
Uy=0

Apply load
Main Menu Preprocessor Load Define Loads Apply Structural Pressure
On Beams

Set up solver, save & solve the problem

Main Menu Solution New Analysis

ANSYS Toolbar Save_DB

Main Menu Solution Solve Current LS

Post-processing, show deformed shape

Main Menu General Postproc Plot Results Deformed Shape

Post-processing, Printout nodal solution per nodes

Main Menu General Postproc List Results Nodal Solution Displacement vector sum

the deflection at the

middle of the beam

Post-processing, plot bending stress diagram

Main Menu General Postproc Element Table Define Table Add Button

Comp: 2, 15 for bending moment

Post-processing, Plot bending stress

Plot bending stress diagram
Main Menu General Postproc Plot Results Contour Plot Line Elem Res

2-Dimensional Elastic Problems