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Table of Contents
14.5 Release
Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
Workshop Table of Contents
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
4.1 Meshing Control WS4.1 10.1 Steady State Thermal Analysis WS10.1
6.1 Contact Offset Control WS6.1 Appendix A – Linear Buckling Analysis WSAA.1
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.
1.
2.
2. RMB in the Geometry cell and
Import Geometry. Browse to the file
“Cap_fillets.stp”.
When Mechanical
starts if the Wizard
is not displayed,
use the icon to
open it.
a.
b.
c.
9.
10.
a.
b.
c.
b.
a.
c.
d.
a.
b.
c.
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.
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.
a.
b.
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
Force = 2500 N
2
2. RMB the Geometry cell and request
“Properties”.
7b.
8b.
9a.
9. Set the contact options:
a. Highlight the contact branch branch.
b. Change the contact type to “No Separation”.
9b.
10d.
10c.
11c.
11d.
11b.
11e.
12a.
12b.
13d.
13b.
13a.
15c.
16b.
16d.
16c.
- 92,000 N*mm
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.
1.
3.
5.
6 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
6. In the Selection dialog enter the name
“Fixture”. 6.
7.
7. Choose “Apply geometry items of same:”.
8.
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.
16.
19.
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.
24.
23.
25.
26.
30.
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.
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.
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.
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
1.
5c.
5b.
5d.
5e.
7 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
6. Modify the Named Selection:
a. Highlight the “TopHoles” named selection branch.
6a.
b. In the worksheet RMB > Add Row.
6b.
6c.
8 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . 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).
7c.
7b.
9 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . Preprocessing
8. Modify the “BottomHole” NS:
a. Change the operator field from “Less Than” to “Greater Than”.
b. Generate.
8b.
8a.
9d.
9c.
12c.
12d.
13b.
14. Solve
14.
13c.
13d.
15 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
. . . 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.
14b.
A check of the details
for the force reaction
indicates we have a
force balance in the
solution.
15b.
16c.
• 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).
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.
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.
1.
2.
3.
3. Double click the “Model” cell to start
the Mechanical application.
7.
The finer mesh is visually
obvious. The details show an
increase in the number of
elements as expected.
8.
Since it appears that the sliver area is closer to
being tangent to the sides, we will combine
these into virtual cells.
Sliver
As shown map
meshing results is
elements on the
11b.
selected faces which
share very regular
shapes.
11c.
13.
12c.
12d.
15.
14c.
14d.
14e.
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.
1.
5a.
5c.
5b.
6a.
7a.
7. Change the material on the pump housing:
a. Highlight “PumpHousing” under geometry.
b. From details change the material assignment to 7b.
“Polyethylene”.
8b.
9b.
9c.
9d.
10a.
10b.
C:\Program Files\ANSYSInc\v140\AISOL\DesignSpace\DSPages\macros
11c.
11b.
11d.
• 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.
19b.
19a.
20. Solve
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.
1.
5b.
Mobile
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.
7c.
8a.
8b.
Repeat steps 6 through 8 for the remaining three
holes.
9c.
9d.
10b.
10c.
13b. 13c.
13a.
Beam
Connections
15b.
A sample of one of the
details windows for
the beam sections
shown here displays
the various results
15c.
available
16c.
16b.
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.
1.
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
• From the information panel we can see 8.89 – 8.5 = 0.39 mm gap.
7.
6.
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.
1.
4.
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.
14.
15.
20. Highlight the circular top face on the piston shown 19.
here.
21. RMB > Insert > Pressure.
20.
21.
22.
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.
247 mm
Analysis Model
1.
3.
4.
17.
18.
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.
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.
5 mm
Y
25 mm
1.
7.
12.
13. From the Static Structural branch RMB > Insert >
Constraint Equation.
13.
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.
0 = 5*(UY)tippoint – (UX)prespoint
0 = 5*(UY)tippoint – (UX)tippoint
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.
1.
9.
14.
16.
17.
19.
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.
1.
2.
3.
4.
5a.
5b.
6c.
6b.
7b.
7c.
8c.
8b.
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.
10.
11.
12a.
14a.
14c.
14b.
8 Holes Constrained
4 Holes Constrained
8 Holes Constrained
4 Holes Constrained
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.
1.
4.
5. “Return to Project”. 5.
8b.
8c.
9d.
9f.
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.
13.
14. Double click the Model branch in the
second (B) system.
14.
15.
16. Solve the model.
16.
Polyethylene Aluminum
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.
1.
b.
a.
b.
c.
b.
a.
a.
b.
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.
a.
Structural Error
b.
a.
c.
b.
• It’s clear the refinement has reduced the rapid transition in energy values
when compared to the original mesh.
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
1.
3.
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.
d.
c.
d.
a.
b.
15.
a.
17.
18. “Update All Design Points” will instruct Mechanical to execute a solve for
each scenario in the Design Point table.
18.
When the updates are complete the table will show calculated values for both
output parameters.
b.
a.
• Repeat the above steps with the “Geometry Mass” parameter (P3 in this case).
20.
21.
Plots like this one allow us to visualize the trade off that often accompanies these
kinds of choices.
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
F F
Stable Unstable
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
For material properties, Young’s Modulus and Poisson’s Ratio are required as a
minimum
F x l = Buckling Load
Fbuckle = (Fapplied x l)
EI
P' K
2
2
L
For the case of a fixed / free beam the parameter K = 0.25.
• 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)
1.
2. Drag/drop a “Linear Buckling” system
onto the “Solution” cell of the static
structural system.
2.
“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.
c.
b.
a. c.
b. c.
d.
c.
a.
b.
12a.
11b.
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.
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.
a.
b.
c.
Introduction to ANSYS
Mechanical
1 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
C. Workshop BB.1 – Submodeling
4b.
4a. 4c.
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.
8c.
8d.
8b.
9. Solve 9.
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.
11d.
11c
11 © 2012 ANSYS, Inc. December 19, 2012 . Release 14.5
. . . 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.
12d.
12 © 2012 ANSYS, Inc. December 19, 2012 Release 14.5
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.
14b.
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.
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.
Although not part of the workshop, if time permits, you may complete
the verification techniques shown on the remainder of the pages.