(BSc. Mechanical Engineering UET, Lahore (City Campus ...

(BSc. Mechanical Engineering UET, Lahore (City Campus)) (MSc. Mechanical Engineering UET, Lahore (City Campus))

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Preface

The experiments to be performed in a laboratory should ideally be designed in such a way as

to reinforce the understanding of the basic principles as well as help the students to visualize

the various phenomenon encountered in different applications.

The objective of this manual is to familiarize the students with practical skills, measurement

techniques and interpretation of results. It is intended to make this manual self-contained in all

respects, so that it can be used as a laboratory manual. In all the experiments, the relevant

theory and general guidelines for the procedure to be followed have been given.

It is suggested that the students should complete the computations, is the laboratory itself.

However the students are advised to refer to the relevant text before interpreting the

results and writing a permanent discussion. The questions provided at the end of each

experiment will reinforce the students understanding of the subject and also help them to

prepare for viva-voce exams.

General Instructions to Students

The purpose of this laboratory is to reinforce and enhance your understanding of the

fundamentals of Creo. The experiments here are designed to demonstrate the

applications of the Creo-Parametric Modelling and to provide a more intuitive

and physical understanding of the theory. The main objective is to introduce a variety

of classical experimental and diagnostic techniques, and the principles behind these

techniques. This laboratory exercise also provides practice in making engineering

judgments, estimates and assessing the reliability of your measurements, skills which

are very important in all engineering disciplines.

Actively participate in class and don’t hesitate to ask questions. Utilize the

teaching assistants. You should be well prepared before coming to the laboratory,

unannounced questions may be asked at any time during the lab.

Cell phones are not allowed inside the laboratory.

Wish you a nice experience in this lab

TABLE OF CONTENTS

Preface .................................................................................................................................................... 3

General Instructions to Students ......................................................................................................... 4

List of Experiments ............................................................................................................................. 11

1 LAB SESSION 1 ............................................................................................................................... 12

1.1 Learning Objective: ............................................................................................................... 12

1.2 Apparatus ............................................................................................................................ 12

1.3 Related theory ..................................................................................................................... 12

1.4 Experimental procedure: ................................................................................................... 12

2 LAB SESSION 2 ............................................................................................................................... 15

2.2 Apparatus ............................................................................................................................ 15

2.3 Related theory ..................................................................................................................... 15

2.5 Materials creation Steps: ...................................................................................................... 15

2.5.1 Click on Engineering Data (See Figure below) .............................................................. 15

2.5.2 Click in the box ‘add new material’ (See Figure below). ............................................... 16

2.5.3 A new Material (name it MyMat etc) has been created. .............................................. 17

2.6 Example Problem .................................................................................................................. 18

2.6.1 Sketch creation ............................................................................................................. 19

2.6.2 Conversion of line bodies to sketches .......................................................................... 20

2.6.3 Cross section assigning.................................................................................................. 20

2.6.4 Cross section assigned .................................................................................................. 21

2.6.5 Circular section assignment .......................................................................................... 22

2.6.6 Line body created .......................................................................................................... 23

2.6.7 Model cell A4 launching ................................................................................................ 24

2.6.8 Line body imported in Model cell ................................................................................. 25

2.6.9 New material ‘My mat etc’ selection from the list ....................................................... 26

2.6.10 New material assigned .................................................................................................. 26

2.6.11 Messhing Done.............................................................................................................. 26

2.6.12 Loads and constraints Applied ...................................................................................... 27

2.6.13 Results obtained: axial forces ....................................................................................... 28

2.6.14 Analytical answers from text book ............................................................................... 29

2.6.15 Ansys results ................................................................................................................. 29

2.6.16 Comparison of analytical and ansys results .................................................................. 29

3 LAB SESSION 3 ............................................................................................................................... 30

3.2 Apparatus ............................................................................................................................ 30

3.3 Related theory ..................................................................................................................... 30

3.5 Case 1: Resultant determination: ...................................................................................... 31

3.5.1 Problem Chosen ............................................................................................................ 31

3.5.2 Lines Creation................................................................................................................ 31

3.5.3 Line body Created ......................................................................................................... 32

3.5.4 Loads and Constraints Applied ...................................................................................... 32

3.5.5 Result Obtained............................................................................................................. 33

3.6 Case 2: Oblique axis ............................................................................................................ 33

3.6.1 Geometry creation ........................................................................................................ 34

3.6.2 Geometry imported in model cell ................................................................................. 34

3.6.3 Coordinate system 1 created ........................................................................................ 35

3.6.4 Coordinate system 2 created ........................................................................................ 35

3.6.5 Loads and supports applied .......................................................................................... 36

3.6.6 Resultant with rectangular component calculated ....................................................... 37

3.6.7 Projection onto a-axis ................................................................................................... 37

3.6.8 Projection onto b-axis ................................................................................................... 38

4 LAB SESSION 4 ............................................................................................................................... 39

4.2 Apparatus ............................................................................................................................ 39

4.3 Related theory ..................................................................................................................... 39

4.4.1 Problem Chosen: ........................................................................................................... 39

4.4.2 Force P Calculation steps .............................................................................................. 40

4.4.3 Geometry creation ........................................................................................................ 40

4.4.4 Imported into model cell A4 ......................................................................................... 40

4.4.5 Loads and constraint applied ........................................................................................ 40

4.4.6 Force P Calculated: ........................................................................................................ 41

4.4.7 Bolt Reactions Calculation steps ................................................................................... 42

4.4.8 Loads and constraints ................................................................................................... 42

4.4.9 Force at Bolt Corner A ................................................................................................... 42

4.4.10 Force at Bolt Corner B ................................................................................................... 43

5 LAB SESSION 5 ............................................................................................................................... 44

5.1 Learning Objective: .............................................................................................................. 44

5.2 Apparatus ............................................................................................................................ 44

5.3 Related theory ..................................................................................................................... 44

5.5 Simple trusses ....................................................................................................................... 45

5.5.1 Problem chosen ............................................................................................................ 45

..................................................................................................................................................... 45

5.5.2 Geometry Creation: ...................................................................................................... 46

5.5.3 Axial Forces ................................................................................................................... 47

5.5.4 Reaction Pin A: .............................................................................................................. 47

5.5.5 Reaction Roller C ........................................................................................................... 48

5.6 Complex trusses .................................................................................................................... 48

5.6.1 Problem chosen ............................................................................................................ 48

..................................................................................................................................................... 49

5.6.2 ANSYS Results................................................................................................................ 49

5.6.3 Axial forces .................................................................................................................... 49

5.6.4 Support Reaction at A: .................................................................................................. 50

5.6.5 Support Reaction at G: .................................................................................................. 50

5.6.6 Further practices exercise with sample results ............................................................ 50

6 LAB SESSION 6 ............................................................................................................................... 79

6.2 Apparatus ............................................................................................................................ 79

6.3 Related theory ..................................................................................................................... 79

6.4.1 Exercises for points creation ......................................................................................... 80

7 LAB SESSION 7 ............................................................................................................................... 86

7.1 Apparatus ............................................................................................................................ 86

7.2 Related theory ..................................................................................................................... 86

8 LAB SESSION 8 ......................................................................................................................... 97

8.1 Learning Objective: ............................................................................................................ 97

8.2 Apparatus ............................................................................................................................ 97

8.3 Related theory ..................................................................................................................... 97

8.4.1 Problem chosen ............................................................................................................ 97

8.4.2 Geometry creation Link GCO ........................................................................................ 98

8.4.3 Model cell importing ..................................................................................................... 98

8.4.4 Loads and Constraints applied .................................................................................... 100

8.4.5 Total deformation link GCO ........................................................................................ 101

8.4.6 Force in link BC ............................................................................................................ 102

8.4.7 Geometry creation Link GCO ...................................................................................... 103

8.4.8 Model cell importing ................................................................................................... 103

8.4.9 Loads and Constraints applied .................................................................................... 104

8.4.10 Total deformation link BC ........................................................................................... 104

8.4.11 Moment about A calculated ....................................................................................... 104

9 LAB SESSION 9 ....................................................................................................................... 106

9.1 Learning Objective: .......................................................................................................... 106

9.2 Apparatus .......................................................................................................................... 106

9.3 Related theory ................................................................................................................... 106

9.4 Experimental procedure: ................................................................................................. 106

9.4.1 Problem chosen .......................................................................................................... 106

9.4.2 Car Body geometry mapped with wheels added ........................................................ 107

9.4.3 Jack C supressed temporarily ...................................................................................... 107

9.4.4 Gravity added .............................................................................................................. 108

9.4.5 All oads and constraints added ................................................................................... 108

9.4.6 Total deformation in case Jack D ................................................................................ 109

9.4.7 Force at wheel A in case jack at D ............................................................................... 110

9.4.8 Force at wheel B in case jack at D ............................................................................... 111

9.4.9 Force at jack D ............................................................................................................. 111

9.4.10 Engineering data materials and geometries interlinking between cells ..................... 112

9.4.11 Jack D suppressed ....................................................................................................... 113

9.4.12 Gravity and other loads and constraints added .......................................................... 114

9.4.13 Total deformation in case of Jack at C ........................................................................ 114

9.4.14 Force at wheel A in case of Jack at C........................................................................... 115

9.4.15 Force at wheel B in case of Jack at C ........................................................................... 116

9.4.16 Force at Jack C ............................................................................................................. 116

10 LAB SESSION 10 ................................................................................................................. 117

10.2 Apparatus .......................................................................................................................... 117

10.3 Related theory ................................................................................................................... 117

10.4.1 Mass volume created .................................................................................................. 117

10.4.2 Imported in model cell ................................................................................................ 118

10.4.3 Spring with its properties inserted.............................................................................. 119

10.4.4 Remote displacement added ...................................................................................... 119

10.4.5 Solved and Frequency calculated ............................................................................... 120

11 LAB SESSION 11 ................................................................................................................. 121

Estimate steady state temperature distribution in a heat sink of a computer processor. ................. 121

11.2 Apparatus .......................................................................................................................... 121

11.3 Related theory ................................................................................................................... 121

11.4.1 Problem Chosen .......................................................................................................... 122

11.4.2 Geometry creation-sketch .......................................................................................... 123

11.4.3 Extruded ...................................................................................................................... 124

11.4.4 Imported in model cell ................................................................................................ 125

11.4.5 Steady-state thermal settings and properties ............................................................ 126

11.4.6 Temperature distribution ........................................................................................... 127

11.4.7 Total heat flux ............................................................................................................. 128

11.4.8 Directional heat flux .................................................................................................... 128

12 LAB SESSION 12 ................................................................................................................. 129

12.2 Apparatus .......................................................................................................................... 129

12.3 Related theory ................................................................................................................... 129

12.4.1 Sketching creation ....................................................................................................... 130

12.4.2 Extrusion ..................................................................................................................... 130

12.4.3 Wheels creation .......................................................................................................... 131

12.4.4 Wheels creation .......................................................................................................... 131

12.4.5 Enclosure ..................................................................................................................... 132

12.4.6 Enclosure with truck ................................................................................................... 133

12.4.7 Meshing ....................................................................................................................... 133

12.4.8 Velocity vector plotting ............................................................................................... 134

12.4.9 Pressure distribution ................................................................................................... 135

12.4.10 Velocity streamline ................................................................................................. 136

13 LAB SESSION 13 ................................................................................................................. 137

13.2 Apparatus .......................................................................................................................... 137

13.3 Related theory ................................................................................................................... 137

13.4.1 Problems Chosen ........................................................................................................ 137

14 LAB SESSION 14 ................................................................................................................. 149

14.2 Apparatus .......................................................................................................................... 149

14.3 Related theory ................................................................................................................... 149

List of Experiments

Lab Session No. Description

Lab Session No. 1. Learning and understanding to draw models for FEA in ASYS Workbench

Lab Session No. 2. New materials creation ,their assigning and constraints controlled sketches

creation for line bodies

Lab Session No. 3. Determining resultants of various concurrent forces, finding the unknown

forces, Cartesian components, oblique axis components

Lab Session No. 4. Determining the equilibrium of various bodies under coplanar non-concurrent

forces and moments including the equilibrium of various beams types.

Lab Session No. 5. Determine axial forces, deflections and supports reactions in the members of

simple and complex 2D structures and their comparison with analytical results

Lab Session No. 6. Learning to draw 3D geometries by combining sketches and 3D points creation

for various 3D structures

Lab Session No. 7. Determine axial forces, deflections and supports reactions in various 3D

structures and their comparison with analytical results

Lab Session No. 8. Determining the forces in various links of machinery and different types of

frames.

Lab Session No. 9. Creation of solid modelling to determine the equilibrium of various bodies

under space, non-coplanar non-concurrent forces and moments

Lab Session No. 10. Modelling and simulating single and multiple degrees of freedom vibration

systems and finding their natural frequencies and modes of vibrations.

Lab Session No. 11. Estimate steady state temperature distribution in a heat sink of a computer

processor.

Lab Session No. 12. Analyse air streamline flow over a vehicle modelled as solid body.

Lab Session No. 13. Determine the maximum deformation and Von-mises stresses in a garden

fountain and in a decorative vase under hydrostatic pressure.

Lab Session No. 14. Determine the temperature and velocity distribution behaviour in the mixing

streams of hot and cold fluids in a mixing elbow.

Prepared and Compiled by ©HM Shahid Akbar (Assistant Professor Mechanical Engineering Department KSK)

1 LAB SESSION 1 Statement: Learning and understanding to draw models for FEA in ASYS Workbench

1.1 Learning Objective: At the end of this study, the student will be able to:

Draw any type of sketch for any 3D model.

Apply different constraints and control the sketch drawn.

Dimension the sketches drawn as required.

1.2 Apparatus PCs with ANSYS v15.0 or above installed

1.3 Related theory Various tutorials and instructions during lab sessions will be covering all theoretical concepts applied.

1.4 Experimental procedure: Following exercises have been suggested as basic exercises

2 LAB SESSION 2 New materials creation, their assigning and constraints controlled sketches creation for line bodies.

Create and define new materials and their assignment the bodies created for analysis

Mapping and estimating many solid bodies in the universe as line bodies using suitable cross

sections.

2.4 Experimental procedure:

2.5 Materials creation Steps:

2.5.1 Click on Engineering Data (See Figure below)

2.5.2 Click in the box ‘add new material’ (See Figure below).

2.5.3 A new Material (name it MyMat etc) has been created.

2.6 Example Problem

2.6.1 Sketch creation

2.6.2 Conversion of line bodies to sketches

2.6.3 Cross section assigning

2.6.4 Cross section assigned

2.6.5 Circular section assignment

2.6.6 Line body created

2.6.7 Model cell A4 launching

2.6.8 Line body imported in Model cell

2.6.9 New material ‘My mat etc’ selection from the list

2.6.10 New material assigned

2.6.11 Messhing Done

2.6.12 Loads and constraints Applied

2.6.13 Results obtained: axial forces

2.6.14 Analytical answers from text book

2.6.15 Ansys results

Node Number Element Number Directional Axial Force (N)

1 1 735.18

3 2 367.65

1 3 -734.95

2.6.16 Comparison of analytical and ansys results MEMEBR AB:( 736-735.18)*100/736=0.11 %

MEMEBR AB:( 368-367.65)*100/736=0.09 % etc

3 LAB SESSION 3 Determining resultants of various concurrent forces, finding the unknown forces, Cartesian

components, oblique axis components:

Techniques for creating & manipulating geometries for various type of problems.

Using Ansys to Find the resultants of forces

Using Ansys to Find the oblique components of of forces

Using Ansys to Find the Projection of given forces along various oblique axis

Application of various constraints and loads applications techniques

Exercising of local Coordinates creation and its application

3.4 Experimental procedure: Note: Initial steps are same as discussed in Lab session No. 2. Other necessary different steps are

given with screenshots as below:

3.5 Case 1: Resultant determination:

3.5.1 Problem Chosen

3.5.2 Lines Creation

3.5.3 Line body Created

3.5.4 Loads and Constraints Applied

3.5.5 Result Obtained

3.6 Case 2: Oblique axis

3.6.1 Geometry creation

3.6.2 Geometry imported in model cell

3.6.3 Coordinate system 1 created

3.6.4 Coordinate system 2 created

3.6.5 Loads and supports applied

3.6.6 Resultant with rectangular component calculated

3.6.7 Projection onto a-axis

3.6.8 Projection onto b-axis

4 LAB SESSION 4 Determining the equilibrium of various bodies under coplanar non-concurrent forces and moments

including the equilibrium of various beams types. 4.1 Learning Objective: At the end of this study, the student will be able to:

Techniques for creating & manipulating geometries for various type of planar problems.

Using Ansys to analyse any kind of beams and their supports.

To model and analyse only required geometry for analysis instead of exactly creating the

geometry as it appears in apparent form in real life.

4.4.1 Problem Chosen:

Figure 1 : Planar Wrench analysis: J.L Meriam 6e, p157

4.4.2 Force P Calculation steps

4.4.3 Geometry creation

4.4.4 Imported into model cell A4

4.4.5 Loads and constraint applied

4.4.5.1 Total deformation

4.4.6 Force P Calculated:

4.4.7 Bolt Reactions Calculation steps

4.4.8 Loads and constraints

4.4.9 Force at Bolt Corner A

4.4.10 Force at Bolt Corner B

5 LAB SESSION 5 Determine axial forces, deflections and supports reactions in the members of simple 2D structures and

their comparison with analytical results

5.1 Learning Objective:

At the end of this study, the student will be able to:

Techniques for creating & manipulating geometries for various type of truss problems.

Using Ansys to analyse simple types of trusses and apply roller and pin supports.

Obtain axial forces in members.

5.5 Simple trusses

5.5.1 Problem chosen

Analytical Answers: Beer Johnston 11th ed. 6.2 FAB = 1.700 kN T; FAC = 2.00 kN T; FBC=

2.50 kN T.

5.5.2 Geometry Creation:

5.5.3 Axial Forces

5.5.4 Reaction Pin A:

5.5.5 Reaction Roller C

5.6 Complex trusses

5.6.2 ANSYS Results

5.6.3 Axial forces

5.6.4 Support Reaction at A:

5.6.5 Support Reaction at G:

5.6.6 Further practices exercise with sample results

6 LAB SESSION 6 Learning to draw 3D geometries by combining sketches and 3D points creation for various 3D

structures

Techniques for creating & manipulating geometries for various type of 3D structures truss

problems.

Using Ansys to analyse space types of 3D trusses and apply analyse any kinds of supports.

Obtain axial forces in members and the supports reaction.

Design various structures as trusses and analyse them by the ways learnt

6.4.1 Exercises for points creation

7 LAB SESSION 7 Determine axial forces, deflections and supports reactions in various 3D structures and their

comparison with analytical results

Learning Objective:

At the end of this study, the student will be able to:

Techniques for creating & manipulating geometries for various type of 3D structures truss

problems.

Using Ansys to analyse space types of 3D trusses and apply analyse any kinds of supports.

Obtain axial forces in members and the supports reaction.

Design various structures as trusses and analyse them by the ways learnt

Same as described in lab session no. 7

8 LAB SESSION 8 Determining the forces in various links of machinery and different types of frames.

Techniques for creating & manipulating geometries for various type of machinery links and

frame problems.

Obtain forces and reactions in various members by isolating them.

Design various machines and analyse them by the ways learnt

8.4.2 Geometry creation Link GCO

8.4.3 Model cell importing

8.4.4 Loads and Constraints applied

8.4.5 Total deformation link GCO

8.4.6 Force in link BC

8.4.7 Geometry creation Link GCO

8.4.8 Model cell importing

8.4.9 Loads and Constraints applied

8.4.10 Total deformation link BC

8.4.11 Moment about A calculated

9 LAB SESSION 9 Creation of solid modelling to determine the equilibrium of various bodies under space, non-coplanar

non-concurrent forces and moments

Solid geometries for different physical problems in universe

Analyse the 3D solid bodies in conjunction with any line bodies if involved.

Apply successfully 3D modelling commands

9.4.2 Car Body geometry mapped with wheels added

9.4.3 Jack C supressed temporarily

9.4.4 Gravity added

9.4.5 All oads and constraints added

9.4.6 Total deformation in case Jack D

9.4.7 Force at wheel A in case jack at D

9.4.8 Force at wheel B in case jack at D

9.4.9 Force at jack D

9.4.10 Engineering data materials and geometries interlinking between cells

9.4.11 Jack D suppressed

9.4.12 Gravity and other loads and constraints added

9.4.13 Total deformation in case of Jack at C

9.4.14 Force at wheel A in case of Jack at C

9.4.15 Force at wheel B in case of Jack at C

9.4.16 Force at Jack C

10 LAB SESSION 10 Modelling and simulating single and multiple degrees of freedom vibration systems and finding their

natural frequencies and modes of vibrations.

Create a single and multiple DOFs mass spring system for mechanical vibrations module

Simulate and obtain the mode shapes and frequencies of the vibratory systems

Solve and model various types of vibrations problem as they appear in text book

recommended.

10.4.1 Mass volume created

10.4.2 Imported in model cell

10.4.3 Spring with its properties inserted

10.4.4 Remote displacement added

10.4.5 Solved and Frequency calculated

Similarly many problems from the textbook of mechanical vibrations are suggested as the practice.

11 LAB SESSION 11

Estimate steady state temperature distribution in a heat sink of a computer processor.

Understand the distribution of heat.

Simulate and obtain the mode shapes and frequencies of the vibratory systems

Solve and model various types of vibrations problem as they appear in text book

recommended.

11.4.1 Problem Chosen

11.4.2 Geometry creation-sketch

11.4.3 Extruded

11.4.4 Imported in model cell

11.4.5 Steady-state thermal settings and properties

11.4.6 Temperature distribution

11.4.7 Total heat flux

11.4.8 Directional heat flux

12 LAB SESSION 12 Analyze air streamline flow over a vehicle modelled as solid body

Understand the stream line fluid flow.

Simulate and obtain the velocity and pressure distribution

12.4.1 Sketching creation

12.4.2 Extrusion

12.4.3 Wheels creation

12.4.4 Wheels creation

12.4.5 Enclosure

12.4.6 Enclosure with truck

12.4.7 Meshing

12.4.8 Velocity vector plotting

12.4.9 Pressure distribution

12.4.10 Velocity streamline

13 LAB SESSION 13 Determine the maximum deformation and Von-mises stresses in a garden fountain and in a decorative

vase under hydrostatic pressure.

Understand the application of hydro static pressure.

Create surface bodies and uses of symmetries.

Observe the effect of various fluid properties

13.4.1 Problems Chosen

14 LAB SESSION 14 Determine the temperature and velocity distribution behaviour in the mixing streams of hot and cold

fluids in a mixing elbow.

Understand the behaviour of mixing hot and cold fluids.

Understand their streamline flow.

Understand the application of CFX module of ANSYS

14.4 Experimental procedure: Note 1: Initial steps are same as discussed in Lab session No. 2. Other necessary different steps are

Note 2: A separate tutorial is provided describing complete procedure in detail

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