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Workshop

Table of Contents
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Workshop Table of Contents

1. No Workshop 6.2 Using Joints WS6.2

2.1 ANSYS Mechanical Basics WS2.1 7.1 Remote Boundary Conditions WS7.1

3.1 Gear and Rack Analysis WS3.1 7.2 Constraint Equations WS7.2

3.2 Named Selections WS3.2 8.1 Multistep Analysis WS8.1

3.3 Object Generator WS3.3 9.1 Vibration Analysis WS9.1

4.1 Meshing Control WS4.1 10.1 Steady State Thermal Analysis WS10.1

5.1 Linear Structural Analysis WS5.1 11.1 Mesh Evaluation WS11.1

5.2 Using Beam Connections WS5.2 12.1 Parameter Management WS12.1

6.1 Contact Offset Control WS6.1 Appendix A – Linear Buckling Analysis WSAA.1

Appendix B – Submodeling WSBB.1

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 2.1
ANSYS Mechanical Basics
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Notes on Workshop 2.1
Please Note: The step by step instructions for this workshop do not begin until
slide #6.
The first workshop is extensively documented. As this course progresses,
students will become more familiar with basic Workbench Mechanical
functionality (menu locations etc.), thus subsequent workshops will contain less
details.
Throughout these workshops menu paths are documented as: “First pick >
Second pick > etc.”.
Workshops begin with a goals section followed by an assumptions section.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Goals
Using the Stress Wizard, set up and solve a
structural model for stress, deflection and safety
factor.
Problem statement:
• The model consists of a STEP file representing a control
box cover (see figure). The cover is intended to be used
in an external pressure application (1.0 MPa).
• The cover is to be made from aluminum alloy.
• Our goal is to verify that the part will function in its
intended environment.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
We will represent the constrains on the
counter bores, bottom contact area and
inner sides using frictionless supports.
• Frictionless supports place a normal constraint
on an entire surface. Translational
displacement is allowed in all directions except
into and out of the supported plane. Since we
would expect frictional forces to act in these
areas, this is a conservative approach.

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
Loads: the load consists of a 1 MPa pressure applied to the 17 exterior surfaces of
the cover.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the “Units” menu verify:
• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Toolbox choose create a
Static Structural system (drag/drop
or RMB).

1.

2.
2. RMB in the Geometry cell and
Import Geometry. Browse to the file
“Cap_fillets.stp”.

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Preprocessing
3. Double click the “Model” cell to open the Mechanical
application.
When the Mechanical application opens the model will 3.
display in the graphics window and the Mechanical
Application Wizard displays on the right.

When Mechanical
starts if the Wizard
is not displayed,
use the icon to
open it.

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. . . Preprocessing
4. Set/check the units system:
• From the main menu go to “Units > Metric (mm, kg, N, s,
mV, mA).

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. . . Preprocessing
5. Select a suitable material for the part:
a. From the Mechanical Wizard choose “Verify Material”
b. Notice the callout box indicates Engineering Data is accessible
from the WB2 interface (Project Schematic).

a.
b.

c. Return to the Project schematic window and double click


“Engineering Data” to access the material properties.

c.

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. . . Preprocessing
7. Activate the Data Source toggle and 7.
highlight “General Materials” then click
the ‘+’ next to “Aluminum Alloy”.

8. Return to the Project.

• Notice the Model cell indicates a refresh


is necessary.
8.

9. Refresh the Model cell (RMB), then


return to the Mechanical window.

9.

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. . . Preprocessing
10. Highlight “Part 1” and click the “Material
> Assignment” field to change the
material property to aluminum alloy.

10.

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. . . Preprocessing
11. Insert Loads:
a. Select “Insert Structural Loads” from the Wizard
b. Follow the call out box to insert a “Pressure” load
c. The tree will now include a Pressure load in the “Static
Structural” environment branch

a.
b.

c.

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. . . Preprocessing
12. Apply the load to geometry:
a) Highlight one of the outer faces of the part.
b) Use the “Extend to Limits” icon to select the remaining 16 faces (total 17 faces selected).
c) Click “Apply” to accept the faces.
d) Enter a “Magnitude” of 1MPa.

b.

a.
c.

d.

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. . . Preprocessing
13. Apply supports to constrain the part:
a. Select “Insert Supports” from the Wizard.
b. Follow the callout box to insert a “Frictionless Support”.
c. “Apply” it to the 4 counter bore surfaces of the part.

a.
b.

c.

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. . . Preprocessing
14. Repeat Steps 13.a. and 13.b. to insert a
“Frictionless Support” on the inner surfaces of the
bottom recess (use extend to limits after selecting
one of the inner surfaces.

15. Repeat Steps 13.a. and 13.b. to insert a


“Frictionless Support” on the lip surface at the
bottom of the recess.

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. . . Preprocessing
16. From the Mechanical Wizard request:
a) Insert Structural Results (the call out will point to the Solution
toolbar).
b) Deformation > Total.
c) Stress > Equivalent (von-Mises).
d) Tools > Stress Tool.

b. c. d. a.

Note the Stress Tool detail allows 4 different configurations (explained later).
For this workshop we will leave the tool specified as “Max Equivalent Stress”
theory.

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Solution
17. Solve the model:
a. Select “Solve” from the Wizard.
b. Follow the callout box and click on “Solve”.

b.

a.

• Note how clicking on “Solve” in the Wizard does not automatically start
solving the model but instead, points out the “Solve” icon to the user.
Alternatively, you could right click on any branch in the “outline” and
choose “Solve”
18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Results
18. View the results:
a. Click “View Results” from the Wizard
b. Follow the callout box to where the results are available
under the “Solution” branch

b. a.

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. . . Results
Plotting a model’s deformation often provides a “reality check” in structural
analysis. Verifying the general nature (direction and amount) of deflection can
help avoid obvious mistakes in model setup. Animations are often used as well.

20 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
After reviewing stress results expand the Stress Tool and plot safety factor. Notice
the failure theory selected predicts a minimum safety factor of just over 1.

21 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Report
19. Create an html report:
a. First choose the graphical items you wish to include in your report and insert a figure for each
one (this is your choice).
b. Click the “Report Preview” tab to generate the report.

a.

b.

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. . . Report
Notes on Figures:
Figures are not limited to results items. Adding a plot of the environment branch,
for example, will include an image of model boundary conditions in the Report.
Figures are independent. You may set up individual figures and have their
orientation, zoom level, etc. retained regardless of the active model orientation or
other figures.
Individual branches can have multiple figures associated with them.

23 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 3.1
2D Gear and Rack Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Assumptions
Workshop 3.1 consists of a 2 part assembly representing spur and rack gear
components from a 2500 N hand press.
We will solve it as a 2D plane stress model (thickness = 12 mm).

2D Plane Stress
Full Model Model

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Goals
Analysis Goals:
• We are designing a press that should be capable of delivering 2500 N of force in
the rack.
• In order to design the mechanism for applying the load we need to know the
required torque in the gear to produce the necessary force.
Remote Displacement
• We’ll apply the desired force in the rack and
extract the moment reaction at the gear.
• We will use a “Remote Displacement” to
constrain the gear (instead of a fixed support)
because this type of constraint provides
rotational, as well as translational,
constraints.

Force = 2500 N

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Units
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
1. Double click “Static Structural”
analysis type to add a new system.

2
2. RMB the Geometry cell and request
“Properties”.

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. . . Project Schematic
3. In the “Analysis Type” field specify “2D”.
• Once this setting is made the properties
window may be closed if desired.

Note this setting indicates the model to be


analyzed is not a full 3D model but represents 3.
a symmetry section. It is important that this
is set prior to importing geometry as this
setting cannot be changed after the import.

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Geometry Setup
4. From the “Geometry” cell, RMB >
“Import Geometry” and browse to:
“Gear_Set_2D.stp”.
4.

5. Double click the “Model” cell to start 5.


Mechanical.

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Preprocessing
6. Set the working unit system:
a. “Units > Metric (mm, kg, N, s, mV, mA)”.
6a.

7. Set the Plane Stress options:


a. Highlight the “Geometry” branch. 7a.
b. Verify the “2D Behavior” to be “Plane Stress”
(default).

7b.

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Preprocessing
8. Set the geometry thickness: 8a.
a. Highlight the Gear and Rack parts (use shift or
control for multi-select).
b. Set the thickness field to 12 mm.

8b.

9a.
9. Set the contact options:
a. Highlight the contact branch branch.
b. Change the contact type to “No Separation”.

9b.

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Preprocessing
10. Create a remote point:
10a.
a. Highlight the Model branch.
b. Set the selection filter to “edge select”.
c. Select the circular inner edge of the gear. 10b.
d. RMB > Insert > Remote Point.

10d.
10c.

Note the annotation flag indicating the


remote point location.

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Environment
11. Apply remote displacement on the model:
a. Highlight the Static Structural branch. 11a.
b.“RMB > Insert > Remote Displacement”.
c. Change the scoping method to “Remote Point”.
d.Select “Remote Point” from the RP list
e. Set X, Y and Rotation Z = 0.

11c.

11d.

11b.

11e.

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…Environment
12. Apply frictionless support to the model:
a. Highlight the right edge of the rack.
b.“RMB > Insert > Frictionless Support”.

12a.

12b.

We use a frictionless support along


the edge of the rack to simulate the
guide the part rides in.

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…Environment
13. Apply a force to the model:
a. Select the bottom edge of the Rack.
b.“RMB > Insert > Force”.
c. Change to the component method.
d.Input a Y component = 2500 N.
13c.

13d.

13b.

13a.

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Solution
14. Solve the model. 14.

15. Insert a Total Deformation result:


15a.
a. Highlight the Solution branch.
b. RMB > Insert > Total Deformation.
c. RMB > Evaluate All Results. 15b.

15c.

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…Postprocessing
16. Extract the moment reaction in the gear: 16a.

a. Highlight the Solution branch.


b. From the context menu choose “Probe > Moment
Reaction”.
c. In the probe details choose “Remote Displacement” from
the drop down list.
d. RMB > Evaluate All Results.

16b.
16d.
16c.

Moment reaction about Z axis

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Conclusion
Our stated goal was to determine the required moment that must be applied to
the gear in order to produce a 2500 N force in the rack. We conclude a torque of
approximately 92,000 N*mm will be required.

- 92,000 N*mm

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 3.2
Named Selections
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
The goal of this workshop is to use several techniques to create named selections
that will then be used to set up the boundary conditions shown below.
• Two holes at one end of the model will be used to apply a fixed support.
• On one of the remaining holes we will apply a radial displacement to simulate the
effect of a fastener that has been press fit into it.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Named_Selections.wbpz” and Open (location
provided by instructor).
When prompted, “Save” using the default name in the
same location as the archive file.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double click
(or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units are


2.
set to “Metric (mm, kg, s, mV, mA)”.

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Preprocessing
When Mechanical opens note the model’s orientation with respect to the
global coordinate system:
3. Expand the Coordinate Systems branch and highlight “Global Coordinate
System”.

3.

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. . . Preprocessing
The first named selection will be created so that the
constraints can be added to the geometry and
conveniently modified.
4. Highlight the cylindrical face of the hole nearest
the global coordinate system origin. 4.

5. RMB > Create Named Selection.

5.
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. . . Preprocessing
6. In the Selection dialog enter the name
“Fixture”. 6.
7.
7. Choose “Apply geometry items of same:”.
8.

8. Check the box “Size”.

9. In the tree, highlight the new named selection 9.


“Fixture” and note the scope of the selection
is 4 faces.
Since our goal is to apply the constraints only to
the 2 holes closest to the origin, we need to add a
location filter the worksheet.

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. . . Preprocessing
In order to proceed we need to first determine the
location of the features to be filtered. While there are
a number of ways we might accomplish this, we’ll use
the “selection information” feature.
10.
10. Highlight the cylindrical face used previously.

11. In the top menu click the box to activate “Selection


Information”.
11.

The summary shows the


face centroid is located at
an X coordinate of 8 mm.
Also note the radius of the
cylinder is 2.5 mm.

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. . . Preprocessing
In the worksheet shows the initial selection (select by size) is represented by
the first row.
12. RMB in the worksheet and “Add Row”.

12.

By inspection we can see that the centroid of both required holes must be at the same X
location. Instead of using that criteria directly we’ll illustrate the use of a “filter”.
13. Configure the row to filter the selection based on X location in a range of 0 to 10 mm.
14. “Generate”.

14.

13.

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. . . Preprocessing
15. With the filter applied verify the scope of the
selection is now 2 faces.
15.
16. In the graphics window review the selection.

16.

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. . . Preprocessing
Again, there are a number of ways we might proceed
with this step, but we’ll create a geometry based
named selection and then convert it to a mesh based
selection.
Create a named selection where the press fit
simulation will be applied:
17. Select the cylindrical face shown here.
17.
18. RMB > Insert > Named Selection.

19. In the tree RMB > Rename the new selection to


“PressFace”.
18.

19.

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. . . Preprocessing
20. Highlight the Named Selections branch, “RMB > Insert > Named Selection”.

20.

21. In the details for the new selection change the scoping method to

21.

22. In the worksheet RMB > Add Row and configure to add a face named
selection, equal to “PressFace”.

22.

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. . . Preprocessing
23. In the worksheet RMB > Add Row and configure to convert to mesh nodes.

24.

23.

24. Generate the named selection.

25. In the tree, rename the selection to “PressNodes”.

25.

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. . . Preprocessing
26. Review the details and the graphics window (using the “Graphics” tab at the
bottom of the worksheet), and note that we now have a named selection
composed of 88 nodes associated with the desired face.

26.

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. . . Preprocessing
As stated earlier we wish to simulate a press fit by displacing the nodes in the
cylinder in a radial direction. We need a local cylindrical coordinate system to use
as a reference.

27. Highlight the same face used to create


the previous named selection, RMB >
Insert > Coordinate System.
27.

28. In the new coordinate system details


change the type to Cylindrical.
29.

29. Rename the new coordinate system 28.


“PressSystem”.

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Environment
30. Highlight the Static Structural branch, RMB > Insert
> Fixed Support.

30.

31. In the details change the scoping method to


“Named Selection”.
32. From the drop down list choose the named 31.
selection “Fixture”. 32.

In the graphics window note the fixed


support is scoped to the 2 holes
closest to the global origin.

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. . . Environment
Before proceeding with the next step (applying the
radial displacement to the nodes) it will be useful to
review the basics of nodal loads (covered in Mechanical
Intro Part 1).
Recall:
• Nodal loads are applied to a nodal named selection.
• The directions in which nodal loads are applied,
unlike their loads, are always with respect to each
node’s individual coordinate system.
Because of this second point nodal orientations must
sometimes be modified so that the correct load
direction can be defined.

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. . . Environment
33. Highlight the Static Structural branch, RMB > Insert > Nodal Orientation.

33.

34. In the nodal orientation details for “Named Selection” choose “PressNodes”
from the drop down list.
35. In the detail for “Coordinate System” choose “PressSystem” (defined earlier).

34.
35.

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. . . Environment
36. Highlight the Static Structural branch, RMB > Insert
> FE Displacement.

36.
37. In the FE Displacement details for “Named
Selection” choose “PressNodes” from the drop
down list.
38. Enter a value of 0.1 mm in the X component field.

Recall that the earlier nodal rotation was done with 37.
respect to a local cylindrical system. For cylindrical
systems the X, Y and Z directions are interpreted as
radial (X), tangential (Y) and axial (Z) directions. 38.

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Postprocessing
Solve the model.

When the solution is complete various displacement plots can be used to verify
the loading. In the figure on the right a directional deformation result is
transformed into the local cylindrical system (PressSystem) defined earlier.

Total Deformation Transformed Deformation

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. . . Postprocessing
A final verification can be done by plotting
the Nodal Triads associated with each node.
To create a clearer display, the coordinate
display was scoped only to the face where
the displacement is applied.

21 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 3.3
Object Generator
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Workshop 3-3 consists of 2 plates separated by 45 mm. Each plate contains 12
holes which are to be connected using beam connections. Instead of creating 12
individual beam connections we’ll create a single beam and use the Object
Generator in Mechanical to create the remainder.

55 mm

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
We’ll assume that one of the plates is fixed around its edges.
The plates will be joined using the Body to Body bolt feature.
A force load (1000 N) will be applied to the top surface of one of the plates.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV)”.
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Toolbox insert a “Static
Structural” system into the Project
Schematic.

1.

2. From the Geometry cell, RMB and


“Import Geometry > Browse”. Import
the file “Bolt_Plates.stp”.
2.

3. Double click the “Model” cell to start


the Mechanical application. 3.

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Preprocessing
4. Set the working unit system:
• “Units > Metric (mm, kg, N, s, mV, mA)”.
4.

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. . . Preprocessing
5. Create 2 Named Selections: 5a.
a. Select a face on one of the holes in either plate
(which hole or plate is arbitrary).
b. RMB > Create Named Selection.
c. In the dialog box enter the name “TopHoles”
d. Set “Apply geometry items of same: Size”.
e. OK

5c.
5b.
5d.

5e.
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. . . Preprocessing
6. Modify the Named Selection:
a. Highlight the “TopHoles” named selection branch.
6a.
b. In the worksheet RMB > Add Row.

6b.

c. Configure the new row as shown below.


d. Generate
6d.

6c.
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. . . Preprocessing
The result of the configuration can be seen in the
figure on the right. We chose to remove the faces
located less than zero which resulted in the holes in
the bottom plate being removed from the NS (note
the global coordinate system).

7. Create a second Named Selection:


a. Highlight the “TopHole” NS.
7a.
b. RMB > Duplicate.
c. Rename the new NS “BottomHoles”.

7c.
7b.
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. . . Preprocessing
8. Modify the “BottomHole” NS:
a. Change the operator field from “Less Than” to “Greater Than”.
b. Generate.

8b.

8a.

As shown here, this single modification


reverses the selection set to only those
faces in the bottom plate.

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Environment
9. Create a Beam Connection:
a. Highlight the Connections branch.
b. Hold the CTRL key and select 2 opposing 9a.
holes, one from each plate.
Again the actual pair of holes selected is
arbitrary. 9b.
c. RMB > Insert > Beam.
d. In the beam details enter a radius of 2 mm.

9d.
9c.

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. . . Environment
10. Apply the fixed support to the mount:
a. Highlight the beam branch under Connections.
10a.
b. Toggle on the Object Generator icon.
10b.

Configure the Object Generator as shown here:


The “Reference” and “Mobile” fields allow access
to the Named Selections created earlier.
Since we know the outer distance between the
plates is 55 mm, we enter 45 and 55 for min/max
distances.
Since our named selections are defined between
all 12 holes we leave “Ignore Original” checked so
the existing beam is not duplicated.
11. Generate. 11.
12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Solution
Graphically all 12 beam connections can be seen. A
check of the connections branch verifies this.

Next we’ll apply some simple boundary conditions,


solve the model and see how the beam probe can be
used to extract the reactions seen by the beams.

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Postprocessing
12. Add a fixed constraint to the bottom plate:
12a.
a. Highlight the Static Structural branch:
b. Select one of the side faces on the bottom plate.
c. Choose “Extend to Limits” (status bar should
indicate 4 faces selected).
d. RMB > Insert > Fixed Support. 12b.

12c.

12d.

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Postprocessing
13. Add a pressure load to the top plate:
13a.
a. Highlight the top face of the top plate.
b. RMB > Insert > Force.
c. Change “Define By” to “Components.
d. Enter 1000 N for the Z component in the
force details.

13b.

14. Solve
14.

13c.

13d.
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. . . Postprocessing
Insert Total Deformation and Equivalent Stress results and evaluate. The plots
would indicate that the solution progressed as expected and we can now look
more closely at the beam connections.

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
14. Verify the overall reaction force in the model:
a. Drag & Drop the “Fixed Support” in the tree 14a.
onto the Solution branch.
b. RMB > Evaluate All Results to calculate the
“Force Reaction” result object.

14b.
A check of the details
for the force reaction
indicates we have a
force balance in the
solution.

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. . . Postprocessing
15. Retrieve beam probe results:
a. Drag & Drop the 12 branches representing the
circular beams (use Shift key to multi-select).
b.RMB > Evaluate All Results. 15a.

15b.

As the details from one of the beam probes


shows there are a number of quantities returned
for each beam. Our goal is to verify the axial
forces in the beams so we’ll reconfigure the
probes.
18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Postprocessing
16. Modify the beam probes to retrieve only axial
results:
a. Highlight all the beam probes in the Solution branch
(use Shift key to multi-select).
16a.
b. In the details set the “Result Selection” field to “Axial
Force”.
c. “Evaluate All Results”.

Results now show only 16b.


the axial forces are
returned to the beam
probes.

16c.

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
• A convenient way to combine all the probe results
in one location is to use the chart/table feature and
export the data to a spreadsheet.
• Since not all training machines may have Microsoft
Excel installed we’ll simply describe the procedure
here.

• First highlight all the beam probes in the tree. Then


select the Chart/Table icon from the toolbar.
• A new chart object is displayed in the tree. Notice
the details in this case, indicate the chart relates to
12 objects.

20 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
• A closer look at the table area shows each of the axial force values from the
beam probes is shown in individual columns.

• Clicking in the “Steps” column selects the


entire row of data and a RMB will allow an
“Export” of the data (*.xls or *.txt formats).

21 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
• As shown below a simple summation formula in Excel verifies the combined
values for all beam connections.

• This workshop has shown how the object generator can be used to create
multiple beam connections. The object generator can be used for
essentially any object in the tree that allows duplication (e.g. RMB >
Duplicate).

22 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 4.2
Meshing Control
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Use the various ANSYS Mechanical mesh controls to enhance the mesh for the
model below.
Problem statement:
• The model consists of a CAD file representing a solenoid.
• Our goal is to mesh the model using all defaults and inspect the result. Next we will add
mesh controls to modify the mesh in various regions of the model.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
Since this is a meshing exercise we will not be applying loads or solving the model.
Instead we will assume a linear static structural analysis is to follow the meshing
operation.

Note, due to a certain randomness in the nature of meshing, the actual number of
elements generated during the workshop may vary from machine to machine. This
is normal.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Units
Open the Project page.
From the “Units” menu verify:
• Project units are set to “US Customary (lbm, in, s, F, A, lbf, V).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
1. In the Toolbox, double click “Static
Structural” to create a new analysis
system.

1.

2.

2. RMB on the “Geometry” cell and


“Import Geometry”. Browse to
“Solenoid_Body.stp”.

3.
3. Double click the “Model” cell to start
the Mechanical application.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Basic Meshing
Start by meshing the model using all defaults. This
will establish a “base line” from which we can
compare changes.

4. Highlight the mesh branch, “RMB > Generate 4.


Mesh”.

When mesh generation


completes we can view the
mesh and inspect the
statistics in the details for the
mesh branch.
Note: node/element count
may vary slightly across
machines/platforms.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Basic Meshing
5. View the mesh metrics:
a. Highlight the mesh branch. 5a.
b. In the details under “Statistics >
Mesh Metric” specify “Element
Quality”.
5b.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Mesh Size Control
Based on our inspection we may decide a more refined
mesh is necessary for our analysis.
6. In the mesh branch details expand the “sizing”
section and set the “Relevance Center” to
“Medium.
6.
7. RMB the mesh branch and Generate Mesh.

7.
The finer mesh is visually
obvious. The details show an
increase in the number of
elements as expected.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Mesh Shape Control
A closer look at the mesh shows some anomalies where certain faces meet.
By zooming to the area in question we can see several small “sliver” surfaces are
forcing a fine mesh locally.
We’ll attempt to clean this up using virtual topology.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Virtual Topology
8. Highlight the Model branch > RMB > Insert
> Virtual Topology.

8.
Since it appears that the sliver area is closer to
being tangent to the sides, we will combine
these into virtual cells.

Sliver

Side In order to preserve the basic


topology we will join pairs of
surfaces into virtual cells rather
than trying to combine all surfaces
together. The result will be 3 cells
per side, 6 in total.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Virtual Topology
9. Create Virtual Cells: 9b. 9a.
a. Select one of the sliver surfaces.
b. Hold the CTRL key and select the
adjacent surface (as shown at right).
c. RMB > Insert > Virtual Cell.
9c.

The resulting virtual cell is displayed in red.


Although underlying surfaces still exist,
this is the surface the mesher will use.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Virtual Topology
Continue by creating the remaining 5 virtual
cells (select in pairs as before). When complete
you will have a total of 6 virtual faces and 4
virtual edges.

Remesh the model:


10.Highlight the Mesh branch, RMB > Generate
Mesh.
10.

The resulting mesh shows


a much more uniform
mesh with a significant
reduction in element
count.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Mapped Face Meshing
11. Map mesh several faces (highlight Mesh
branch):
a. Select the 3 planar faces shown here.
b. RMB > Insert > Mapped Face Meshing.
c. RMB > Generate Mesh.
11a.

As shown map
meshing results is
elements on the
11b.
selected faces which
share very regular
shapes.

11c.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Face Size Control
12. Specify face sizing on selected face:
a. Select the face of the gusset section shown
here.
b. RMB > Insert > Sizing. 12a.

c. Set Element Size = 0.03.


d. Set Behavior = “Hard”. 12b.
13. Remesh the model (highlight the mesh branch):
• RMB > Generate Mesh.

13.

12c.
12d.

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Edge Size Control
14. Specify edge sizing on selected edges:
14a.
a. Select the 4 edges of the gusset shown here.
b. RMB > Insert > Sizing.
c. Change “Type” to “Number of Divisions”.
d. Set Number of Divisions = 25.
e. Set Behavior = “Hard”.
15. Remesh the model (highlight the mesh branch): 14b.
• RMB > Generate Mesh.

15.

14c.
14d.
14e.

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Edge Size Control
Review the mesh metric as compared to the original mesh. With just a few
refinements overall mesh quality has improved.

Original Mesh Metric

Final Mesh Metric

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 5.1
Linear Structural Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Workshop 4 consists of a 5 part assembly representing an impeller type pump.
Our primary goals are to analyze the assembly with a preload on the belt of 100N
to test:
• That the impeller will not deflect more than 0.075mm with the applied load.
• That the use of a plastic pump housing will not exceed the material’s elastic limits around
the shaft bore.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
We’ll assume the pump housing is rigidly mounted to the rest of the pump
assembly. To simulate this, a frictionless support is applied to the mounting face.
Similarly, frictionless surfaces on the mounting hole counter bores will be used to
simulate the mounting bolt contacts. (Note if accurate stresses were desired at the
mounting holes, a “compression only” support would be a better choice).
Finally, a bearing load (X = 100 N) is used on the pulley to simulate the load from
the drive belt. The bearing load will distribute the force over the face of the pulley
only where the belt contact occurs.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV)”.
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Toolbox insert a “Static
Structural” system into the Project
Schematic.

1.

2. From the Geometry cell, RMB and


“Import Geometry > Browse”. Import
the file “Pump_assy_3.stp”.
2.

3. Double click the “Model” cell to start


the Mechanical application. 3.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
4. Set the working unit system:
• “Units > Metric (mm, kg, N, s, mV, mA)”.
4.
5. Add “Polyethylene” the Engineering Data (return to
Workbench window):
a. Double click the Engineering Data cell.
b. Activate the Data Source toggle and highlight General
Materials and click the + sign next to “Polyethylene”.
c. Return to Project.

5a.

5c.
5b.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
6. Refresh the Model cell:
a. RMB > Refresh.

6a.

Return to the Mechanical window.

7a.
7. Change the material on the pump housing:
a. Highlight “PumpHousing” under geometry.
b. From details change the material assignment to 7b.
“Polyethylene”.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
8. Change the contact region behavior for the first 4
contact regions (shown below):
a. Hold the shift key and highlight the first 4 contact 8a.
branches.
b. From the detail window change the contact type to
“no separation”.
• The remainder of the contacts will be left as
“bonded”.

8b.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
9. Apply the bearing load to the pulley:
a. Highlight the “Static Structural” branch.
b. Highlight the pulley’s groove surface.
c. RMB > Insert > Bearing Load”.
d. From the detail window change to “Components” and “X =
100 N” 9a.

9b.

9c.

9d.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
10. Apply supports to the assembly:
a. Highlight the mating face on the pump housing (part 1).
b.“RMB > Insert > Frictionless Support”.

10a.

10b.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
Now we will add the frictionless supports to the 8 countersink portions of the
mounting holes (shown here).
Each of the required surfaces could be selected individually while holding the CTRL
key however we will use a macro (select by size) provided with Mechanical. After
selecting the initial surface, running the macro finds and selects all surfaces of the
same size (area). Note, this macro also works with edges or bodies.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
11. Select the countersunk holes (select by size macro):
a. Highlight 1 of the countersink surfaces (arbitrary).
b. Choose “Tools > Run Macro . . .” and browse to: 11a.

C:\Program Files\ANSYSInc\v140\AISOL\DesignSpace\DSPages\macros

c. In the browser choose “selectBySize.js”


d. Click “Open”

11c.
11b.

11d.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
Constrain the countersunk hole surfaces:
12. From the context menu, click on “Supports” and
choose “Frictionless Support” or “RMB > Insert > 12.
Frictionless Support”

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
13. Highlight the “Analysis Settings” and from the details
window change “Weak Springs” from “Program
Controlled” to “Off”.
13.

Note : Because of the presence of frictionless supports


and non bonded contact, Workbench-Mechanical will
trigger the use of weak springs during the solution. If
we know the model is fully constrained we can turn off
this function.

14. Solve the model:


• Choose solve from the tool bar or RMB Solution branch 14.
and choose “Solve”.

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
15. Add results to solution:
a. Highlight the solution branch:
b. From the context menu, choose Stresses > Equivalent (von-Mises) or RMB > Insert >
Stress > Equivalent (von-Mises)
c. Repeat the step above, choose Deformation > “Total Deformation”

• Solve again.
• Note: adding results and re-solving the model will not cause a complete solution to take place.
Requesting new results requires only a re-read of the results file.

15b. 15c.

15a.

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
While the overall plots can be used as a reality check to verify our loads, the plots
are less than ideal since much of the model is displayed in few colors. (your results
may vary slightly due to meshing differences).

To improve the quality of results available we will “scope” results to individual


parts”.

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
16. Scope the results to individual bodies/surfaces:
a. Highlight the “Solution” branch and switch the 16a.
selection filter to “Body” select mode.
b. Select the impeller (part 2)
c. “RMB > Insert > Stress > equivalent (von- Mises)” 16b.

• Notice the detail for the new result indicates a


scope of 1 Body.

17. Repeat the procedure above to insert “Total


Deformation” results for the impeller part. 16c.
18. Repeat to add individually scoped stress and total
deformation results to the pump housing (part 1).

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
19. Rename the new results:
a. RMB on the result > Rename
b. Rename the results as shown here to simplify postprocessing

19b.

19a.

20. Solve

18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
By checking the impeller deformation we can verify that one of our goals is met.
The maximum deformation is approximately 0.024mm (goal < 0.075mm).

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
Inspection of the housing stress shows that, overall, the stress levels are below the
material’s elastic limit (tensile yield = 25 MPa). We could again use scoping to
isolate the results in the area of interest.

20 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 5.2
Beam Connections
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Workshop 5-2 consists of a flange containing 2 parts. The fasteners holding the
flange together are not modeled. Instead we’ll use Mechanical’s beam feature to
simulate them. We’ll then use a remote force to represent a structural load whose
line of action is located some distance from the flange.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
We’ll assume the mount is fixed to some larger assembly.
As noted, we’ll use the Body to Body bolt feature to simulate the fasteners.
Finally, a remote load (X = 1000 N) scoped to the flange face and located at Z =
100 mm..

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV)”.
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Toolbox insert a “Static
Structural” system into the Project
Schematic.

1.

2. From the Geometry cell, RMB and


“Import Geometry > Browse”. Import
the file “Flange Mount.stp”.
2.

3. Double click the “Model” cell to start


the Mechanical application. 3.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
4. Set the working unit system:
• “Units > Metric (mm, kg, N, s, mV, mA)”.
4.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
5. Change the contact region behavior:
a. Highlight the contact branches.
b. From the detail window change the contact type
to “frictionless”. 5a.

Note: frictionless contact is nonlinear. We are using


frictionless contact because this behavior allows
separation.

5b.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
6. Add beams to model fasteners:
a. Highlight the connections branches.

b. From the connections context menu choose 6a.


“Body-Body > Beam”.

Mobile

The scope of the bolted


connections is shown
here for clarity. The next
several slides describe the
procedure.

Reference 6b.
8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
7. Add beam details:
a. Enter “5” mm for beam radius.
– Note, structural steel is the assumed material
7a.
b. Scope the Reference side of the beam as shown.

7b.

c. Scope the Mobile side of the beam as shown.

7c.

Note: the designation of which


face is to be reference or mobile
is arbitrary in this case.
9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
8. Change beam behavior:

a. Change the reference behavior to “Deformable”.

8a.

b. Change the mobile behavior to “Deformable”.

8b.
Repeat steps 6 through 8 for the remaining three
holes.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment 9b.
9. Add a remote force:
a. Highlight “Static Structural” in
the tree. 9a.
b. Select the flange face shown.
c. RMB > Insert > Remote Force.

9c.
9d.

d. Set the location to 0, 0, 100 as shown.


9e.
e. Switch to the component method and
enter X component = 1000 N.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
10. Apply the fixed support to the mount:
a. Highlight the “Static Structural” branch. 10a.
b. Highlight the mount surface shown.
c. RMB > Insert > Fixed Support.

10b.
10c.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
11. Highlight the “Analysis Settings” and from the details
window change “Weak Springs” from “Program
Controlled” to “Off”.
11.

Note : Because of the presence of frictionless contact


Workbench-Mechanical will trigger the use of weak
springs during the solution. If we know the model is
fully constrained we can turn off this function.

12. Solve the model:


• Choose solve from the tool bar or RMB in the tree and
choose “Solve”.
12.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
13. Add results to solution:
a. Highlight the solution branch:
b. From the context menu, choose Stresses > Equivalent (von-Mises) or RMB > Insert >
Stress > Equivalent (von-Mises)
c. Repeat the step above, choose Deformation > “Total Deformation”

14. Solve again.


• Note: adding results and re-solving the model will not cause a complete solution to take place.
Requesting new results requires only a re-read of the results file.

13b. 13c.

13a.

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
For beam connections, no contours are displayed however results can be
obtained using a Beam Probe (see step 15).

Beam
Connections

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
By turning on Auto Scale from the context menu (magnifying displacements) you
can see the tendency for the flange to separate due to the remote force.

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
15. Retrieve results for beams:
a. Highlight the 4 branches representing the circular 15a.
beams.
b. Drag and drop the beams on to the Solution branch.
c. RMB > Evaluate All Results.

15b.
A sample of one of the
details windows for
the beam sections
shown here displays
the various results
15c.
available

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
16. Review FE Connections:
a. Highlight the Solution Information Branch.
b. In the “FE Connection Visibility” section set “Display” 16a.
to “All FE Connectors”.
c. At the bottom of the graphics window change to the
Graphics tab.

16c.
16b.

18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
• The figure on the left shows all constraint equations written as a result of
the remote force and the beam connections.
• On the right the beam connections are shown.

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 6.1
Contact Offset Control
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Problem statement:
• The model consists of a workbench archive file representing a valve and piston
assembly with loads applied (see figure on left).
• As the figure on the right shows, a gap exists between the piston and bore (0.39 mm).
• Our goal is to:
– Solve the model as is with no interface treatment (results will be non physical).
– Solve the model a second time using an appropriate initial contact offset to close the
gap.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Contact_Interface.wbpz” and Open (location
provided by instructor).
When prompted, “Save” using the default name and the
same location.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double
click (or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units


are set to “Metric (mm, kg, s, mV, mA)”.
2.

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
3. Verify the boundary conditions are set as described
here:
• Force (20N in +Y) applied to the end of the piston shaft.
• Fixed supports applied to the 4 holes in the valve.
• Remote displacement applied to the inside face of the
piston:
– X=0
– Y = Free
– Z=0
– RotX = 0
– RotY = 0 3.
– RotZ = Free

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
4. Check the current contact settings:
• Notice the contact type is frictionless and that no
offset has been specified in the form of an interface
treatment.
• All other settings are left as default.

4.
• Recall that a 0.39 mm gap exists between the piston
and valve. With the boundary conditions as set, we
should expect the piston to be initially free as the
force is applied.

0.39 mm Gap

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
5. Solve the model: 5.

• When the solution completes a message should indicate possible


rigid body motion has occurred.
• A quick check of the magnitude of total deformation should
confirm the message.
• A magnified deformation shows the 2 parts have separated as
expected.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Background
• Background: how would we find the size of the gap?
• One method is to select the circular lines for the piston and the bore and request the
“Selection Information”.

• From the information panel we can see 8.89 – 8.5 = 0.39 mm gap.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Background
• Background: how would we find the size of the gap?
• A second method is to insert the Contact Tool at the Connections branch and
“Generate Initial Contact Results”.

• The initial information shows a Gap of 0.3851 mm.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
To address the gap in the contact return to the
contact details:
6. In the “Offset” field enter 0.39.
• Verify the Interface Treatment is set to “Add Offset,
No Ramping”.
7. Re-solve the model.
• The model should solve in several iterations.

7.
6.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
8. The deformation and stress results now appear to be reasonable.

Total Deformation Equivalent Stress on the


valve

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
9. Insert the Contact Tool into the Solution branch.
• Check the Contact Status to verify contact has been maintained.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Conclusions
Notes:
• The initial solution verified that rigid body motion was occurring when we
tried to apply a force to parts which were separated by an initial gap.
• We were able to determine the gap size using 2 different methods in order to
determine how to address the contact problem.
• With the gap size verified, we input an initial offset at the contact, effectively
closing the gap.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 6.2
Using Joints
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
The goal of this workshop is to use joints to connect some parts in an assembly
instead of contact. Joints can provide a convenient alternative to contact.

The 4 part assembly shown here would normally be


connected using contact definitions. In this
workshop the model contains a single contact region.
We’ll use the automatic joint feature to setup the
remainder of the connections and make several
modifications before solving.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Joint_Connection.wbpz” and Open (location
provided by instructor).
When prompted, “Save” using the default name in the
same location as the archive file.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double click
(or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units are


2.
set to “Metric (mm, kg, s, mV, mA)”.

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
3. Highlight the Connections branch. Notice that
currently there is a bonded contact region between 3.
the Piston and Pin parts.

4. From the Connections branch, RMB > Insert >


Connection Group.

4.

5. In the connection group details change the


connection type to “Joint”.
5.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
6. Highlight the “Joints” branch, RMB > Create
Automatic Connections”.

6.
You should see 4 new joints have been created.
Before inspecting the joints, we’ll rename them to
make the process easier.

7.
7. Highlight the Joints branch, RMB > Rename
Based on Definition.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
8. Highlight the “Crank To Con_Rod” joint. 8.
– A revolute joint has been defined between the crank
and the connecting rod. We’ll keep this as it is.

9. Highlight the “Con_Rod To Pin” joint. 9.


– A revolute joint has been defined here which we will
also keep.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
Highlight the “Pin To Piston” joint.
– Notice in the Contacts branch there is a contact region
already defined between these parts (“Bonded – Pin 10.
to Piston”). This joint can be deleted.
10. Highlight the joint “Revolute – Pint To Piston” >
RMB > Delete.

11. Highlight the “Fixed - Con_Rod To Piston” joint,


11.
RMB > Delete the fixed joint.
– A fixed joint has been defined between 2 adjacent
faces. This joint is not only unnecessary, it will
prevent proper motions in the assembly.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
12. Highlight the Static Structural branch. 12.

13. Highlight the tapered cylindrical face on the crank


shown here.

14. RMB > Insert > Fixed Support. 13.

14.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
15. Highlight the cylindrical face on the crank shown
here.

15.

16. RMB > Insert > Cylindrical Support. 16.

17. In the details configure:


• Radial = Fixed
• Axial = Free
• Tangential = Free
17.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
18. Highlight the cylindrical face on the piston shown
here.
18.
19. RMB > Insert > Frictionless Support.

20. Highlight the circular top face on the piston shown 19.
here.
21. RMB > Insert > Pressure.
20.

22. In the details enter a


Magnitude = 0.5 MPa.

21.
22.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
23. Solve the model. 23.

When the solution completes plot displacement and stress to review.


Drag and drop the “Cylindrical Support” and “Fixed Support” onto the Solution
branch to obtain the reaction forces.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
Let’s review the loading to determine if the forces balance:
• Highlighting the top face of the piston shows (in the status
bar), the approximate surface area is 9740 mm^2.
• Applying a 0.5 Mpa pressure should result in an approximate
applied force of 4870 N in the –Y direction.

Reviewing the details for the reactions we see:


• Y reaction at the fixed support = 4004 N
• Y reaction at the cylindrical support = 922 N
• Total Y reaction (4004 + 922) = 4926

Note, using a default mesh may result in slight differences in your


results compared to those here. The difference here, (~56 N)
represents approximately a 1% difference.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 7.1
Remote Boundary Conditions
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
The goal of this workshop is to analyze the base of the jack assembly shown here.
Our assumption is the mechanism has been proven already so we choose to not
include the additional parts and model only the base.
• The weight of a vehicle will be simulated using a point mass.
• We’ll assume there are lateral loads acting on the jack as well which will be
applied using a remote force.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Goals
Since we won’t be modeling the entire assembly, we need to know the location
where the jack will be contacting the vehicle. We assume this to be the centroid
of the top member of the jack assembly.
Centroid = (-2, 247, 0)

247 mm
Analysis Model

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Remote_BC.wbpz” and Open (location provided by
instructor).
When prompted, “Save” using the default name in the
same location as the archive file.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double click
(or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units are


2.
set to “Metric (mm, kg, s, mV, mA)”.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
When Mechanical opens we will have only the base part. Since we’ll be using
remote conditions as well as a point mass all at the same location, it makes
sense to use a remote point as a reference.
– Note, the use of a remote point means multiple conditions at the same loction
(like point masses, remote loads, etc.), can all reference that location without
duplicating the constraint equations used to apply them.

3. Highlight the Model branch in the tree.


4. Select the 8 split faces shown here, RMB > Insert > Remote Point.

3.

4.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
5. Highlight the remote point, RMB > Rename: “Load
5.
Point”.
6. In the Remote Point details enter the location:
– X=-2
– Y = 247
– Z=0 6.

As said earlier, this location represents the centroid of


the top pad of the jack where the vehicle will make
contact when it is lifted.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
7. Highlight the Geometry branch.
7.
8.
8. RMB > Insert > Point Mass.

9. In the point mass details change the Scoping


Method to “Remote Point”.
9.
10. In the Remote Points field choose “Load 10.
Point” from the list.

11. Enter a mass of 350 kg in the details. 11.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
12. Highlight the Static Structural branch, RMB > Insert
> Remote Force.
12.

13. In the details change the Scoping Method to


“Remote Point”.
14. Select “Load Point” from the drop down list of
remote points. 13.
14.

15. In the details enter the following loads:


• X Component = 2
• Y Component = 0 15.
• Z Component = 4

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
16. Highlight the bottom face of the part, RMB
> Insert > Fixed Support. 16.

17. Highlight the Static Structural branch,


RMB > Insert > Standard Earth Gravity.

17.

18. Specify –Y direction for gravity.

18.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
Solve the model.

When the solution is complete various displacement plots can be used to verify
the loading.

In this workshop we’ve shown how remote boundary conditions can be used to
simplify the geometry model making for a more efficient solution.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 7.2
Constraint Equations
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
The model shown represents a hook fastener often used to snap components
together in an assembly. The goal of this workshop is construct a constraint
equation that will simulate the Y displacements in the hook’s tip as it is pressed
into place in the X direction. Only the hook section is modeled.
Note, although there are a number of ways this simulation could be set up, the
purpose of this workshop is to gain practice with constraint equations.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Background
Using the dimensions shown here we can readily see that a simple relationship
exists between the X and Y directions. Specifically, the –Y displacements will be
1/5 of the – X displacements. In other words, when the part has displaced 25
mm in the X direction it will have displaced 5 mm in the Y. Thus:

(1/5)*UX = (UY) UX = 5*(UY) 0 = 5*(UY) - UX

5 mm
Y

25 mm

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “ConstEqn.wbpz” and Open (location provided by
instructor).
When prompted, “Save” using the default name in the
same location as the archive file.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double click
(or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units are


2.
set to “Metric (mm, kg, s, mV, mA)”.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
Constraint equations are written in terms of remote points. Before we can
write the necessary expression we first need to create the remote points.

3. Highlight the Model branch in the tree.


3.

4. Highlight the top face of the hook tip (shown


here), RMB > Insert > Remote Point.
4.

5. Right click the new remote point and


rename “Tip Point”.
5.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing

6. Highlight the rectangular end of the hook. 6.


7. RMB > Insert > Remote Point.

7.

8. Right click the new remote point and


rename “Press Point”.
8.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
9. Highlight the Static Structural branch, RMB >
Insert > Remote Displacement.
9.

10. In the details for the remote displacement


change the scope method to “Remote Point”.
11. In the “Remote Points” field choose the point
“Press Point”. 10.
11.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
12. In the “Definition” section of the remote point
details enter a value of -25 for the X component. In
all other fields enter 0.

12.

13. From the Static Structural branch RMB > Insert >
Constraint Equation.

13.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
14. In the constraint equation worksheet “RMB >
Add” to insert the first row.

14.
15. Referring to the expression from page 5:
• Coefficient = 5
• Remote Point = “Tip Point”
• DOF Selection = Y Displacement 15.
16. Add a second row and configure as shown
below (coefficient = -1, remote point = “Press
Point” and DOF = X displacement).

16.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
17. Highlight the “Analysis Settings” branch.
17.
18. In the details change “Large Deflection” to “On”.
Since we are applying a displacement of 25 mm on
the model it means the geometry will change location
significantly. The large deflection option instructs the
solver to track the change in location of each node.
While beyond the scope of this course, the subject is
covered in detail in the ANSYS Mechanical Structural
Nonlinearities course. 18.

19. Solve. 19.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
Viewing deformation in the Y direction can confirm the desired behavior is being
simulated. Animation can also provide insight into how the constraint equation is
performing.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution Note
In the workshop we created 2 remote points as a part of the exercise however
only one was really necessary. The upper figure shows our original expression.
The lower figure is equivalent.

0 = 5*(UY)tippoint – (UX)prespoint

This is equivalent in this case

0 = 5*(UY)tippoint – (UX)tippoint

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 8.1
Multistep Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
The goal of this workshop is to perform a 3 step analysis on the pipe clamp
shown here:
• The bolt will receive a pretension bolt load in LS 1 (locked for LS 2 and 3).
• The pipe will receive an internal pressure during LS 2.
• The pipe will receive an axial force load during LS 3.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Pipe_Clamp.wbpz” and Open (location provided by
instructor).
When prompted, “Save” using the default name and the
same location.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Static Structural system double
click (or RMB > Edit) the “Model” cell.

1.

2. When Mechanical opens, verify the units


are set to “Metric (mm, kg, s, mV, mA)”.
2.

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
Before we begin preprocessing let’s inspect the model
as it is currently set up.
3. Expand the Connections and Contact branches to 3.
view the contacts.
– Browse the 4 contact pairs. They appear to be scoped
correctly but all behavior is currently bonded which we
will change (see below).

Contact below the bolt


head and between the
upper bolt and hole:
assumed no separation.

Contact between the


Contact in threaded clamp and pipe:
area: assumed bonded. assumed bonded.
5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
4. Highlight the 1st and 3d contact regions. 4.
5. In the details change the “Type” to “No
Separation”.
Our assumption of no separation contact means
some sliding can occur in those locations. 5.

Note, the contact between the clamp and the pipe


would normally be frictionless in an application like
this. However in the interest of time we wish to
avoid doing a nonlinear analysis and only 6.
demonstrate multi-step solutions. Thus bonded
contact is retained.
6. Toggle the “Show Mesh” icon to display
themesh.
– Notice a body size control has been added to the
bolt. As documented, it is recommended that a more
refined mesh be used with bolt pretension.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
• Note toggle off “Show Mesh” before
proceeding.
7.

7. Highlight the Analysis Setting branch. 8.


8. In the details set Number Of Steps = 3.

9. Highlight the cylindrical face on the bolt, RMB >


Insert > Bolt Pretension.

9.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
10. In the tabular data enter a preload of 1 for the
first load step (row 1).
10.
11. In rows 2 and 3 change the first column to
“Lock”.
11.

• When complete the table should appear as


shown here.

12. Highlight the inner surface of the pipe.


12.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
13. RMB > Insert > Pressure.
14. In the tabular data enter a value of 0.1 in row 2.
– When complete, the table should appear as shown
below. Note, the first 2 rows should default to 0 while
the 3d row should maintain the load entered. 13.
– The graph (on left) provides a visual confirmation.

14.

Notice in the table there appears to be a duplication of rows. Why? In


nonlinear and transient analyses loads are often ramped from a starting to an
ending value. Step 1 appears twice in the table to allow ramping from 0 to 1. In
static analysis it is meaningless.
9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Solution
15.
15. Highlight the end face of the pipe.
16. RMB > Insert > Force.
17. In the tabular data enter a value of 10 in row 3
(LS 3).
• Note, when complete the table should appear as
below. It may be necessary to enter a 0 for LS 2.

16.

17.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
18. Highlight the cylindrical face of the mounting 18.
hole.
19. RMB > Insert > Fixed Support.

19.

20. Solve: this will cause all load steps to be solved


sequentially.
20.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Background
• Note, highlighting the Analysis Settings branch and displaying the legend
(RMB > Show Legend). This graphically shows the solution processes. Use
the “Visibility” section of the details to further configure the display.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Postprocessing
8. Request deformation and stress plots to review the solutions. Retrieve
different time points to see the complete solution.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 9.1
Free Vibration Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
Our goal is to investigate the vibration characteristics of the machine frame
shown here. We want to solve 2 modal analyses using different mounting points
on the frame.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
The frame contains 8, 20 mm diameter mounting holes. In the first analysis the
frame will be constrained by all 8 holes. In the second analysis we’ll only constrain
the corner holes. To simplify the setup we’ll create several named selections.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Units
Open the Project page.
From the “Units” menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, N, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
1. From the Toolbox double click “Modal”
to create a new system.

1.

2. RMB the “Geometry” cell and browse to


“Machine_Frame.stp”.

3. Double click “Model” to open the


Mechanical application.

2.

3.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Setup
4. Set the working Unit System:
• Units > Metric (mm, kg, N, s, mV, mA)

4.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Create Named Selections
5. Create the first Named Selection:
a. Highlight the Model branch, RMB > Insert > Named Selection.

5a.

b. In the Named Selection details change the scoping method to


“Worksheet”.

5b.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Create Named Selections
6. Create the first Named Selection:
a. In the Worksheet, RMB > Add Row.
b. Pick the action “Add” and configure as shown
6a.
below.
c. Generate.
d. Rename to “Eight Holes”. 6d.

6c.

6b.

Knowing the holes are 20 mm diameter we use the “radius” criteria to


create a named selection containing all of the mounting holes.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Create Named Selections
7. Create a second Named Selection:
a. Highlight the named selection “Eight Holes”,
RMB > Duplicate.
b. Rename the new named selection “Four Holes”. 7a.
c. In the details verify the scoping method is still
set to “Worksheet”.

7b.
7c.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Create Named Selections
8. Create a second Named Selection:
a. RMB and “Add Row”.
b. Pick the action “Remove” and configure as
shown below.
8a.
c. Generate.

8c.

8b.

Using the “remove” operation and a range in the X direction we have


eliminated the interior holes from the named selection.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
9. Apply supports to model (highlight the “Modal”
branch (A5):
a. From the Supports menu select a “Cylindrical Support”.

9a.
b. Switch the scoping method to “Named Selection”.
c. From the named selection list choose “Eight Holes”.
d. Change the Tangential setting to “Free”.
9b.
9c.

9d.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Analysis Settings
Set Options for Modal Analysis:
10. Highlight “Analysis Settings” to set the “Max
Modes to Find” (defaults to 6 modes).

10.

As a final check verify the status symbols next to


the branches. All branches should have either:
• Yellow Lightening bolt (ready to be solved).
• Green check mark (fully defined).

DO NOT SOLVE YET!

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
11. Add a second modal analysis:
• Return to the Workbench Project, highlight the “Setup” cell, RMB > Duplicate.

11.

The schematic should look like


this after duplicating.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
12. Change the supports in the second environment:
a. Highlight the “cylindrical support” in the
second environment (Modal (B5)).

12a.

b. In the details pick the named selection “Four


Holes” from the list.
12b.

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
13. Solve both environments:
a. Highlight the Model branch.
13a.
b. RMB > Solve.
Note, by solving from the Model branch,
both environments will be solved. 13b.

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Results
14. Select Mode shapes to view (repeat this for both Solution branches):
a. Click on the “Solution” branch. This will display the “Graph” and the “Tabular
Data” showing a summary of the frequencies at which the modes occur.
b. In the “Graph” RMB > “Select All” to select all modes.
– Note : This can be done from the “Tabular Data” as well.
c. RMB > “Create Mode Shape Results”.
d. Click Solve to view the results. 14d.

14a.
14c.
14b.

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
Comparing the 2 solutions shows very little difference in the 2 environments until
the 6th mode.

8 Holes Constrained

4 Holes Constrained

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
Comparing the 6th mode from each solution shows the
difference.
• Note: using the viewports “Horizontal Viewports” option
you can display both results as shown here.

8 Holes Constrained

4 Holes Constrained

18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
16. Create a histogram to compare the two results:
a. Hold the CTRL key and highlight both Solution branches.
b. Click the “Chart/Table” icon.
16b.

The chart/table tool


provides a convenient
16a. method to compare
multiple items.

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 10.1
Steady State Thermal Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
In this workshop we will analyze the pump housing shown below for its heat
transfer characteristics.
Specifically a plastic and an aluminum version of the housing will be analyzed using
the same boundary conditions.
Our goal is to compare the thermal results for each configuration.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
Assumptions:
The pump housing is mounted to a pump which is held at a constant 60 °C. We
assume the mating face on the pump is also held at this temperature.
The interior surfaces of the pump are held at a constant temperature of 90 °C by
the fluid.
The exterior surfaces are modeled using a simplified convection correlation for
stagnant air at 20 °C.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Project Schematic
1. From the Toolbox, double click
“Steady-State Thermal” to create a
new Steady State Thermal system.

1.

2. RMB the Geometry cell and


“Import Geometry” – browse to 2.
the file: “Pump_housing.stp”.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Project Schematic
3. Double click “Engineering Data” and
activate the Data Source filter. 3.

4. With “General Materials” highlighted click


the ‘+’ next to “Aluminum Alloy” and
“Polyethylene” properties to add them to
the project.

4.
5. “Return to Project”. 5.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Project Schematic
6. Double click the “Model” cell to open the
Mechanical application.
6.

7. From the Units menu choose/verify:


• “Metric (mm, kg, N, s, mV, mA)”
• “Celsius (For Metric Systems)”
7.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
8. Change the material and mesh on the
pump housing (part ‘1’):
a. Highlight “1” under geometry. 8a.
b. From details assign the material
“polyethylene”.
c. Highlight the Mesh branch and set the
mesh relevance = 100.

8b.

8c.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
9. Apply temperatures (highlight the Steady 9a. 9b.
State Thermal branch):
a. Select the interior surfaces (13 faces) of
the pump housing (hint: use “Extend To
Limits” selection feature).
b. RMB > Insert > Temperature.
c. Set “Magnitude” field to 90 °C.

d. Select the mating surface of the


pump housing. 9c.
e. “RMB > Insert > Temperature”.
f. Set “Magnitude” field to 60 °C. 9e.

9d.
9f.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
10. Apply Convection: 10b.
10a.
a. Select the exterior (32) surfaces of the pump housing
(hint: use extend to limits).
b. “RMB > Insert > Convection”.
c. In the “Details of Convection” click in the “Film
Coefficient” field and choose “Import . . . ”.

Be sure to choose import for convections.

d. “Import” the correlation “Stagnant Air – Simplified


Case”.
e. Set the “Ambient Temperature” field to 20 °C.

10c.
10d.

10e.
10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Solution – Model A
11. Solve the model. 11.

12. When the solution is complete insert Temperature and Total Heat Flux results
(solve to evaluate results).
12.

Results for polyethylene model.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Model B Setup
13. From the project schematic RMB in the A1
cell and “Duplicate”.

13.
14. Double click the Model branch in the
second (B) system.

14.

15. When the new model opens change the


material to “Aluminum Alloy” as in step 8.

15.
16. Solve the model.
16.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution – Model B

Results for aluminum alloy model.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Postprocessing
Compare Heat Flux:
• Highlight the “Total Heat Flux” results from each model and switch to vector display
mode.

Activate vector display

Control vector density

Polyethylene Aluminum

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 11.1
Meshing Evaluation
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
In this workshop an arm from a mechanism will be solved using several different
meshes for comparison.
Our goal is to explore how meshing changes can have dramatic effects on the
quality of the results obtained.

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
In the loading conditions being simulated the arm is experiencing both tensile and
bending loads as shown here.
Our area of interest is the web section that reinforces the interior of the arm.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Project Schematic
1. From the Toolbox double click “Static
Structural” to create a new system.

1.

2. RMB the geometry cell and “Import 2.


Geometry” and browse to
“Mesh_Arm_2.stp”.

3. Double click the “Model” cell to open 3.


the Mechanical application.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
4. Set the working unit system:
– “Units > Metric (mm, kg, N, s, mV, mA)”.
7.
5. Apply the tensile force on the arm (highlight the static
structural branch):
a. Highlight the smaller interior cylindrical face.
b. RMB > Insert > Force
c. In the detail window choose the component method and
enter 5000N in the Y direction. c.

b.

a.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
6. Apply the bending force to the arm:
a. Highlight the circular face at the base of the
a.
smaller end of the arm.
b. “RMB > Insert > Force”.
c. In the detail window choose the component
method and enter 1000N in the -Z direction.

b.

c.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
7. Apply the fixed support on the arm:
a. Select the larger diameter interior cylindrical face.
b. RMB > Insert > Fixed Support.

b.

a.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Meshing
8. Mesh the arm using all default settings:
a. Highlight the mesh branch.
b. “RMB > Generate Mesh”.

a.

b.

Inspection of the completed mesh shows a


very coarse result. In real applications we
would likely refine the mesh before solving.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Meshing
9. Check the element quality:
a. Highlight the Mesh branch.
b. In the Statistics details set “Mesh Metric” to “Element Quality”.

a.

b.

The element quality plot shows that some elements are of a relatively low quality.
However, to illustrate some of the practices and tools we’ll solve the model as it is.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Solution
10. Request Results:
a. Highlight the “Solution” branch (A6).
b. RMB > Insert > Stress > Equivalent Von Mises Stress.
c. RMB > Insert > Stress > Error.
b.
a.

11. Solve the model: c.


a. Click Solve.

a.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Result Interpretation
12. View Initial Results:
The stress result shows one of the web sections
may be an area of concern. In reviewing the error
plot however we confirm there is a rapid
transition from high to low energy in adjacent
elements. This is an indication that mesh
refinement is recommended.

Structural Error

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Re-Meshing
At this point there are numerous mesh controls we could employ to
improve the mesh. We’ll focus on the potential problem area
indicated in the results using several meshing controls.

13. Change the global mesh settings:


a. Highlight the mesh branch.
b. In the details change the “Relevance
Center” to “Medium”.

b.
a.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Re-Meshing
14. Add a mesh size control:
a. Highlight the 2 faces at the bottom of
the cavity (shown at right). a.
b. Choose “Extend to Limits”.
c. RMB > Insert > Sizing.
d. In the details set the element size to
3mm.

c.

b.

Note: extend to limits


should result in 72
d. faces being selected.

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Re-Meshing
15. Remesh the model: a.
a. Highlight the “Mesh” branch.
b. RMB > Generate Mesh.
b.

The new mesh shows we’ve accomplished


refinement around the region of interest.

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Re-Meshing
16. Again reviewing the element quality metric from the mesh statistics detail an
improvement can be seen.

Original Mesh Refined Mesh

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
– Solve the model and review results as before.
– A comparison of stresses from our original mesh shows the maximum value has
gone from approximately 62 to 60.6 MPa

Original Mesh Refined Mesh

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
Compare error plots for the region of interest.

Original Mesh Refined Mesh

• It’s clear the refinement has reduced the rapid transition in energy values
when compared to the original mesh.

18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Conclusion
Notice that there are still areas of high energy transition in the model. Our mesh
refinement has addressed our stated goal but not the entire model. Each
simulation is unique and will require different approaches to insure high quality
results.

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Workshop 12.1
Parameter Management
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Goals
• Use the Workbench Parameter Workspace to setup multiple scenarios to explore
structural responses in the bracket shown.
• Material thickness will be varied in the gusset with the bracket thickness held
constant then the process will be reversed.

Bracket

Gusset

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Open the Project page.
From the Units menu verify:
• Project units are set to “Metric (kg, mm, s, C, mA, mV).
• “Display Values in Project Units” is checked.

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
1. From the Toolbox double click “Static
Structural” to create a new system.

1.

2. RMB the geometry cell and “Import 2.


Geometry” and browse to “Bracket.stp”.

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Preprocessing

3. Double click the “Model” cell to open the


Mechanical application.

3.

4. Set/verify the working unit system: 4.


– “Units > Metric (mm, kg, N, s, mV, mA)”.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
5. Highlight the part “Bracket” and enter a
thickness = 2mm in the details.
6. Highlight the part “Gusset” and enter a thickness
= 1mm in the details.
7. Make both thicknesses parametric by toggling
the check box.
5.

7.

6.
8. Highlight the Geometry branch and, in the
Property details, toggle the Mass parameter on.

8.
6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
9. Highlight the Connections branch, RMB > Insert >
Connections Group.
9.

10. In the details for the connections group change the


Auto Detections for Face/Edge to “Yes”.

10.

11. Highlight the connections group “RMB > Create


Automatic Connections”. 11.

7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
12. Apply constraints to the model (highlight “Static
Structural” branch (A5): a.
a. Select the edge of one hole.
b. RMB > Insert > Fixed Support.

c. Highlight the face surrounding the fixed hole.


d. RMB > Insert > Frictionless Support. b.

d.

c.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
13. Apply Loads to the model:
a. Select the of the hole shown below.
b. RMB > Insert > Force.
c.
c. In the Details switch to the component method.
d. Enter a magnitude of -20 N in the X direction.

d.

a.

b.

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Solution Setup
14. Insert Results (highlight
Solution branch (A6): a.
a. RMB > Insert > Stress >
Equivalent (von Mises).

15. In the result detail, toggle the


“Maximum” result as a
parameter.

15.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Parameter Management
16. Access the Parameter Set:
a. From the schematic double click “Parameter Set”.
When the parameter workspace opens make sure the 2
thicknesses, the mass and the stress are all shown
in the parameter list.

a.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
17. Enter thickness values as shown below. For the first 3 DPs the bracket will
be held constant while the gusset thickness varies. For the last 3 the reverse
will be solved.

17.

18. “Update All Design Points” will instruct Mechanical to execute a solve for
each scenario in the Design Point table.

18.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
Once the update process begins a message will appear as shown here. In fact the
Mechanical application window will close during the update process. This is
normal.

When the updates are complete the table will show calculated values for both
output parameters.

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
19. There are several ways we can present the design point information. In this
case we’ll see how output quantities vary with each design point:
a. Highlight the output parameter “Equivalent Stress Maximum” (P5 here).
b. Double click the “Design Points Vs P5” choice in the Toolbox (again, parameter
numbers will vary depending on the order of their definition).

b.

a.

• Repeat the above steps with the “Geometry Mass” parameter (P3 in this case).

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
20. Highlight the stress per design point chart to display (here the charts have been
renamed according to their content):

20.

Stress per Design Point

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
21. Highlight the mass plot to display.

21.

Mass per Design Point

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Parameter Management
Repeat step 19 and create a stress vs DP plot.
In the properties window choose to display “Geometry Mass” on the right side Y
axis as shown below.

Plots like this one allow us to visualize the trade off that often accompanies these
kinds of choices.

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Appendix A
Linear Buckling Analysis
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Chapter Overview
In this chapter, performing linear buckling analyses in Mechanical will be covered.

Contents:
A. Background On Buckling
B. Buckling Analysis Procedure
C. Workshop 7-1

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


A. Background on Buckling
Many structures require an evaluation of their structural stability. Thin columns,
compression members, and vacuum tanks are all examples of structures
where stability considerations are important.
At the onset of instability (buckling) a structure will have a very large change in
displacement {x} under essentially no change in the load (beyond a small
load perturbation).

F F

Stable Unstable

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Background on Buckling
Eigenvalue or linear buckling analysis predicts the theoretical buckling strength of
an ideal linear elastic structure.
This method corresponds to the textbook approach of linear elastic buckling
analysis.
• The eigenvalue buckling solution of a Euler column will match the classical Euler solution.
Imperfections and nonlinear behaviors prevent most real world structures from
achieving their theoretical elastic buckling strength.
Linear buckling generally yields unconservative results by not accounting for these
effects.
Although unconservative, linear buckling has the advantage of being
computationally cheap compared to nonlinear buckling solutions.

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Basics of Linear Buckling
For a linear buckling analysis, the eigenvalue problem below is solved to get the
buckling load multiplier li and buckling modes yi:

K   li S y i   0
Assumptions:
• [K] and [S] are constant:
– Linear elastic material behavior is assumed
– Small deflection theory is used, and no nonlinearities included

It is important to remember these assumptions related to performing linear


buckling analyses in Mechanical.

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B. Buckling Analysis Procedure
A Static Structural analysis will need to be performed prior to (or in conjunction
with) a buckling analysis.

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… Geometry and Material Properties
Any type of geometry supported by Mechanical may be used in buckling analyses:
• Solid bodies
• Surface bodies (with appropriate thickness defined)
• Line bodies (with appropriate cross-sections defined)
– Only buckling modes and displacement results are available for line bodies.
• Although Point Masses may be included in the model, only inertial loads affect point
masses, so the applicability of this feature may be limited in buckling analyses

For material properties, Young’s Modulus and Poisson’s Ratio are required as a
minimum

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… Contact Regions
Contact regions are available in free vibration analyses, however,
contact behavior will differ for the nonlinear contact types
exactly as with modal analyses.
Discussed earlier (see chapter 5).

Linear Buckling Analysis


Contact Type
Initially Touching Inside Pinball Region Outside Pinball Region
Bonded Bonded Bonded Free
No Separation No Separation No Separation Free
Rough Bonded Free Free
Frictionless No Separation Free Free

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Loads and Supports
At least one structural load, which causes buckling, should be applied to the
model:
• All structural loads will be multiplied by the load multiplier (l) to determine the buckling
load (see below).
• Compression-only supports are not recommended.
• The structure should be fully constrained to prevent rigid-body motion.

F x l = Buckling Load

In a buckling analysis all applied


loads (F) are scaled by a
multiplication factor (l) until the
critical (buckling) load is reached

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Loads and Supports
Special considerations must be given if constant and proportional loads are
present.
• The user may iterate on the buckling solution, adjusting the variable loads until the load
multiplier becomes 1.0 or nearly 1.0.
• Consider the example of a column with self weight WO and an externally applied force A.
• A solution can be reached by iterating while adjusting the value of A until l = 1.0. This
insures the self weight = actual weight or WO * l  WO .

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Buckling Setup
Buckling analyses are always coupled to a structural analysis within the project
schematic.
• The “Pre-Stress” object in the tree contains the results from a structural analysis.
• The Details view of the “Analysis Settings” under the Linear Buckling branch allows the
user to specify the number of buckling modes to find.

11 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Solving the Model
After setting up the model the buckling analysis can be solved along with the static
structural analysis.
• A linear buckling analysis is more computationally expensive than a static analysis on the
same model.
• The “Solution Information” branch provides detailed solution output.

12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Reviewing Results
After the solution is complete, the buckling modes can be reviewed:
• The Load Multiplier for each buckling mode is shown in the Details view as well as the
graph and chart areas. The load multiplier times the applied loads represent the
predicted buckling load.

Fbuckle = (Fapplied x l)

13 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Reviewing Results
Interpreting the Load Multiplier (l):
• The tower model below has been solved twice. In the first case a unit load is applied. In
the second an expected load applied (see next page)

14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Reviewing Results
Interpreting the Load Multiplier (l):

BucklingLoad  l *Unit _ Load


 BucklingLoad  l

BucklingLoad  l * Actual _ Load


BucklingLoad
  l  Safety _ Factor
Actual _ Load

15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


… Reviewing Results
The buckling load multipliers can be reviewed in the “Timeline” section of the
results under the “Linear Buckling” analysis branch
• It is good practice to request more than one buckling mode to see if the structure may be
able to buckle in more than one way under a given applied load.

16 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


C. Workshop AA.1 – Linear Buckling

• Workshop WSAA.1 – Linear Buckling


• Goal:
– Verify linear buckling results in Mechanical for the pipe model
shown below. Results will be compared to closed form
calculations from a handbook.

17 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Goals
The goal in this workshop is to verify linear buckling results in ANSYS Mechanical.
Results will be compared to closed form calculations from a handbook.
Next we will apply an expected load of 10,000 lbf to the model and determine its
factor of safety.
Finally we will verify that the structure’s material will not fail before buckling
occurs.

18 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions
The model is a steel pipe that is assumed to be fixed at one end and
free at the other with a purely compressive load applied to the
free end. Dimensions and properties of the pipe are:
OD = 4.5 in ID = 3.5 in. E = 30e6 psi, I = 12.7 in^4, L = 120 in.
In this case we assume the pipe conforms to the following handbook
formula where P’ is the critical load:


  EI 
P'  K  
2

2 
 L 
For the case of a fixed / free beam the parameter K = 0.25.

19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Assumptions

• Using the formula and data from the previous page we can
predict the buckling load will be:


  2  30e6  12.771 
P'  0.25  

2   65648.3lbf
 (120) 

20 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
1. Double click Static Structural in the
Toolbox to create a new system.

1.
2. Drag/drop a “Linear Buckling” system
onto the “Solution” cell of the static
structural system.

2.

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Project Schematic
• When the schematic is correctly set up it should appear as shown
here.

“Drop Target”

• The “drop target” from the previous page indicates the outcome of
the drag and drop operation. Cells A2 thru A4 from system (A) are
shared by system (B). Similarly the solution cell A6 is transferred to
the system B setup. In fact, the structural solution drives the
buckling analysis.

22 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Verify that the Project units are set to “US Customary (lbm, in, s, F, A, lbf, V).
Verify units are set to “Display Values in Project Units”.

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. . . Project Schematic
3. From the static structural system (A),
double click the Engineering Data cell. 3.

4. To match the hand calculations referenced


earlier, change the Young’s modulus of the
structural steel.
a. Highlight Structural Steel.
b. Expand “Isotropic Elasticity” and modify
Young’s Modulus to 3.0E7 psi. a.
c. “Return to Project”.

c.

Note : changing this property here does not affect the


stored value for Structural Steel in the General Material
library. To save a material for future use we would
“Export” the properties as a new material to the material
library. b.
24 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Project Schematic
5. From the static structural system (A),
RMB the Geometry cell and “Import
Geometry”. Browse to the file
“Pipe.stp”.
5.

6. Double click the Model cell to start


Mechanical. 6.

• When the Mechanical application opens the tree


will reflect the setup from the project schematic.
25 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Preprocessing
7. Set the working unit system to the U.S. customary
system:
a. U.S. Customary (in, lbm, psi, °F, s, V, A).
8. Apply constraints to the pipe:
a. Highlight the Static Structural branch (A5). a.
b. Select the surface on one end of the pipe.
c. “RMB > Insert > Fixed Support”.

b.

a. c.

26 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Environment
9. Add buckling loads:
a. Select the surface on the opposite end of the pipe from the a.
fixed support.
b. “RMB > Insert > Force”.
c. In the force detail change the “Define by” field to
“Components”.
d. In the force detail enter “1” in the “Magnitude” field for the
“Z Component” (or use -1 depending on which ends of the
pipe are selected).

b. c.

d.

27 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Environment
10. Solve the model:
a. Highlight the Solution branch for the Linear Buckling analysis
(B6) and Solve.
– Note, this will automatically trigger a solve for the
static structural analysis above it.
11. When the solution completes:
a. Highlight the buckling “Solution” branch (B6).
– The Timeline graph and the Tabular Data will display a.
the 1st buckling mode (more modes can be requested).
b. RMB in the Timeline and choose “Select All”.
c. RMB > “Create Mode Shape Results” (this will add a “Total
Deformation” branch to the tree).

c.
a.
b.

28 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Results
– Click “Solve” to view the first mode

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. . . Results
12. Change the force value to the expected load (10000
lbf):
a. Highlight the “Force” under the “Static Structural (A5)”
branch
b. In the details, change the “Z Component” of the force
to 10000 (or use -10000 depending on your selections). 11a.
13. Solve:
a. Highlight the Linear Buckling Solution branch (B6),
RMB and “Solve”.

12a.
11b.

30 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Results
When the solution completes note the “Load Multiplier” field now shows a value
of 6.56. Since we now have a “real world” load applied, the load multiplier is
interpreted as the buckling factor of safety for the applied load.

Given that we have already calculated a buckling load of 65600 lbf, the result is
obviously trivial (65600 / 10000). It is shown here only for completeness.

31 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Verification
A final step in the buckling analysis is added here as a “best practices” exercise.

We have already predicted the expected buckling load and calculated the factor of
safety for our expected load. The results so far ONLY indicate results as they
relate to buckling failure. To this point we can say nothing about how our
expected load will affect the stresses and deflections in the structure.

As a final check we will verify that the expected load (10000 lbf) will not cause
excessive stresses or deflections before it is reached.

32 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Verification
14. Review Stresses for 10,000lbf load:
a. Highlight the “Solution” branch under the “Static
Structural” environment (A6).
b. RMB > Insert > Stress > Equivalent Von Mises Stress.
c. RMB > Insert > Deformation > Total.
d. Solve.

a.

b.

c.

33 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Verification
A quick check of the stress results shows the model as loaded is well within the
mechanical limits of the material being used (Engineering Data shows
compressive yield = 36,259 psi).
As stated, this is not a required step in a buckling analysis but should be regarded
as good engineering practice.

34 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Appendix B
Submodeling
14.5 Release

Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
C. Workshop BB.1 – Submodeling

• Workshop WSBB.1 – Submodeling


• Goal:
– Solve a full model (coarse mesh) and then setup and solve a
submodel representing a portion of the full model (fine mesh).

Full Model Submodel

2 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Approach
Submodeling requires the use of 2 geometry models. One model to represent the
full geometry and another representing a portion of the full model. For this
exercise we used the ANSYS DesignModeler application to slice a piece from the
full model.

Full Model Submodel

3 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Project Schematic
Begin a new Workbench session and, from the Project
page, choose “Restore Archive . . . “ and browse to the
file “Submodeling_WS_APPXB.wbpz” and Open (location
provided by instructor).
When prompted, “Save” using the default name and the
same location.

From the “Units” menu verify:


• Project units are set to “Metric (kg, mm, s, ºC, mA, N, mV).
• “Display Values in Project Units” is checked (on).

4 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Project Schematic
When the archive is opened note the existing static
structural system has been renamed “Full Model”.
1. From the Static Structural system double click (or 1.
RMB > Edit) the “Model” cell.

2. When Mechanical opens, verify the units are set to


“Metric (mm, kg, s, mV, mA)”. 2.

5 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Preprocessing
3. Highlight the mesh branch, RMB > Generate Mesh.
3.
4. Apply a pressure load:
a. With the static structural branch highlighted, select one
of the interior surfaces of the housing and choose
“Extend to Limits” (should result in 13 faces).
b. “RMB > Insert > Pressure”.
c. Enter Magnitude “1000” Mpa in the details.

4b.
4a. 4c.

6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
5. Add a force to the housing:
a. Select the cylindrical face of the center hole in the
housing. 5a.
b. “RMB > Insert > Force”.
c. Define by components and enter 200 N X component.
6. Add a compression only support:
a. Select the planar surface on the back of the housing.
b. “RMB > Insert > Compression Only Support”.
5b.

6a.

5c.

6b.
7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
7. Create a named selection containing the countersink
faces:
a. Highlight one countersink face, RMB > Create Named
Selection.
b. In the dialog box enter “Countersinks” and “Apply geometry 7a.
items of same: size” and OK.
– The resulting NS should contain 8 faces as shown.

7b.

8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


. . . Preprocessing
8. Add frictionless supports to countersink
faces: 8a.
a. Highlight the Static Structural branch.
b. RMB > Insert > Frictionless Support.
c. In the details change scoping method to
“Named Selections”.
d. Select the “Countersinks” named
selection.

8c.
8d.

8b.
9. Solve 9.

9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Full Model Solution
10. When the solution completes highlight the Solution branch:
a. Insert an Equivalent Stress object, RMB > Evaluate All Results.

10a.

As the plot shows the potential problem areas are around the countersink holes in the
housing. An efficient approach to investigate these areas in more detail is to create a
submodel of this part of the geometry. In this example we have used ANSYS DesignModeler
geometry application to slice out a portion of the model which we will use next.

10 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5


Submodeling Schematic
11. Set up the Submodel in the project:
a. Drag & Drop a new standalone Static
Structural system into the project and
rename “Submodel”.
b. From the geometry cell in the new system
RMB > Import Geometry > browse to the
file “Submodel3.stp”.
c. Drag & Drop the Solution cell from the 11a.
full model onto the Setup cell in the
submodel.
d. Double click the Model cell to start
Mechanical. 11b
.

11d.

11c
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. . . Preprocessing
12. When Mechanical opens, mesh the submodel:
a. Highlight the Mesh branch and, in the Sizing section
of the details enter Element Size = 2 mm.
b. From the Mesh branch RMB > Insert > Method and 12a.
scope it to the body of the geometry.
c. Change the method to “Hex Dominant”.
d. From the mesh branch RMB > Generate Mesh.

12b.

Note that in the interest of time


we have not refined the mesh
as much as one might in actual
practice. 12c.

12d.
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Importing Displacements
In the new Mechanical session you will see a “Submodeling” branch.
13. Import displacements from the full model:
a. Highlight “Submodeling” RMB > Insert > Displacement.

13d.

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. . . Importing Displacements
14. Map displacements from the full model onto the
submodel: 14a.
a. Select the 3 faces on the model representing the cut
boundaries.
b. In the details of the imported displacement “Apply” the
selected geometry.
c. Highlight “Imported Displacement” RMB > Import Load.

14b.

Since the solution of the full model was static, the


default import is from the “End Time”. If the full
model had been a multi-step or transient analysis we
could have chosen any solution points to map from. 14c.
14 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Adding Boundary Conditions
Add boundary conditions to match the full model.
15. Highlight the static structural branch and add a
frictionless support:
a. Select the countersink face, RMB > Insert > 15a.
Frictionless Support.

16. Highlight the static structural branch and add a


compression only support:
a. Select the bottom face of the submodel, RMB >
Insert > Compression Only Support.

Recall that the full model contained both a pressure load and
a force. Since no part of the submodel contains regions where 16a.
these loads were applied we do not add them. Their effect is
seen in the displacements mapped to the cut boundaries.

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Solving the Submodel
17. Solve.
17.

If we add equivalent stress to the submodel and compare it to the full model, a
significant change can be seen (> 20%). A part of any submodeling solution
should include some form of verification regarding the location of the cut
boundaries. The goal is to evaluate the results of both models on or near the cut
boundary to make sure they are in reasonable agreement. If they do not agree it
indicates the cut boundaries are too close to the stress concentration.

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Cut Boundary Verification
One technique might be to simply query the model using probes to get a feel for
how well the 2 results agree. While this is quick and easy, a drawback is it relies
on an “eyeball” location for the probes. Another technique is to compare path
plots (see next page).

Although not part of the workshop, if time permits, you may complete
the verification techniques shown on the remainder of the pages.

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. . . Cut Boundary Verification
In the submodel we choose the corner points and connect them with a path.
From the selection information we can determine where these end points need
to be in the full model in order to duplicate the path. Here we have located 2
coordinate systems in the full model using the selection information from the
submodel.

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. . . Cut Boundary Verification
Comparing the 2 path plots indicates we have reasonably good agreement
between the models near the cut boundaries.

Submodel Full Model


19 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5

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