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WS4.1-1 ANSYS, Inc. Proprietary 2009 ANSYS, Inc. All rights reserved.

April 28, 2009Inventory #002597

Workshop 4.1

Catalytic Converter

DesignModeler

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WS4.1: Catalyt ic Co nv erter



Workshop SupplementGoals

Goals:

Create the catalytic converter model shown below as 3 separate bodies Create separate sketches and perform a skin/loft operation to make the

converter body

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Workshop Supplement

Start Workbench. Doubleclick on Geometry under

Component Systems. This will create a

Geometry component inthe Project Schematicarea.

Double click

to launch DM (usemillimeter as the lengthunit)

Starting Workbench

Double click

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Workshop Supplement

1) Create the flange sketch #1 [Modeling] > A: Geometry > XYPlane

Toolbar: New Sketch Sketch1 will be created on XYPlane In the Details view, rename Sketch1

to BaseCircle. Toolbar: Look At icon

[Sketching] > Draw > Circle

Move the cursor over the sketchorigin, then when the P is displayed(auto-constraint), click on the leftmouse button. Click again to definethe radius.

[Sketching] > Dimensions > Radius Click on the circle to select it, then

click again on the screen to definewhere to place the dimension. In the Details view, define Dimensions

> R1 as 2.5.

Step 1

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Workshop Supplement

Create the flange sketch #1 (contd) [Sketching] > Modify > Split at Select

Right click anywhere on the Model view and select Split Edge into nEqual Segments from the pop -upmenu.

The Split tool will now change toSplit Equal Segments. Enter 8 forthe textbox n=.

In the Model View , select the circle.It will now be split into eightsegments.

Notes:We have now split the circle into 8segments. We will create the profile of theflange by lofting four sketches using thisone as our base. We will need to have thesame number of divisions on each sketch,all with similar orientations. To simplifythis, we will first reorient the circle by usinga Move command.

Step 1

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Workshop Supplement

Create the flange sketch #1 (contd) On the Selection Toolbar, select the

New Selection icon . Click on the Select Mode icon and

choose Box Select

Left click and drag to draw a box,selecting the entire circle. [Sketching] > Modify > Move

In the text boxes next to the Move tool, change r= to 22.5 and f= to 1.

Right-click on the Model View andselect Use Plane Origin as Handle.

This will make the moving referencepoint as the original, relative locationof the sketch origin.

Step 1

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Workshop Supplement

Create the flange sketch #1 (contd) Right click anywhere on the Model

View and select Rotate by rDegrees. This makes the movingoperation include a rotation, asspecified by the value of 22.5degrees entered earlier.

Right click anywhere on the ModelView and select Paste at Plane

Origin. This completes the moveoperation by moving the model to theorigin. Since the reference point wasthe origin, this results in no translationbut only a rotation, specified byr=22.5.

Right click anywhere on the Model

View and select and left-clickEnd . This completes the Move operation.

Step 1

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Workshop Supplement

Create the flange sketch #1 (contd) You should see that the segments

have been rotated by 22.5 degrees. Click on the Select Mode icon

and choose Box Select Left click and drag to draw a box,

selecting the entire circle. [Sketching] > Modify > Copy

Click on the Copy tool to copy thisprofile.

Right-click anywhere on the ModelView and select Use Plane Origin asPaste Handle to make the pasteoperation use the original, relativelocation of the sketch origin as thepasting point.

Step 1

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Workshop Supplement

2) Create the flange sketch #2 [Modeling] > Toolbar: XYPlane Toolbar: New Plane

Select the New Plane icon from the Active Plane/Sketch Toolbar . Thiscreates Plane4 based on XYPlane .

In the Details view, set Transform 1 toOffset Z, change FD1, Value to be 1.

Toolbar: Generate [Sketching] > Modify > Paste

Enter 0 for r= and 1.05 for f=. Right-click anywhere on the Model

View and select Scale by factor f.This will scale the original sketchprofile by a factor of 1.05 for our new

sketch.

Step 2

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Workshop Supplement

Create the flange sketch #2 (contd) Right-click on the Model View and select Paste at

Plane Origin. Our reference point was the sketchorigin from BaseCircle , and the pasting location is theorigin on Sketch2 , so this essentially copies theoriginal circle onto Sketch2 with a scale factor off=1.05.

Right-click on the Model View and select and left-click on End.This terminates the Pasteoperation.

Step 2

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Workshop Supplement

Create the flange sketch #2 (contd) [Modeling] > A: Geometry > XYPlane >

BaseCircle Right-click on BaseCircle and select

Always Show Sketch [Modeling] > A: Geometry > Plane4 >

Sketch2 Right-click on Sketch2 and select

Always Show Sketch. This keepsboth sketches visible so we can easilysee that one circle is the same as theother except for the Z offset and the1.05 scale factor.

Step 2

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Workshop Supplement

3) Create the flange sketch #3 Toolbar: XYPlane

Toolbar: New Plane Select the New Plane icon from

the Active Plane/Sketch Toolbar .This creates Plane5 based on

XYPlane . In the Details view, set Transform

1 to Offset Z, change FD1, Valueto 5.

Toolbar: Generate [Sketching] > Draw > Rectangle

Check Auto-Fillet checkmark nextto the Rectangle tool.

Click once to define one corner ofthe rectangle, click again to defineits diagonal, and click a third time

to define the fillet radius.

Step 3

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Workshop Supplement

Create the flange sketch #3 (contd) [Sketching] > Dimensions > General

Dimension the sketch as shown atright.

In the Details view, changeDimensions to be the values shown inthe right plot

On the toolbar click New Selectionicon and set the mode to BoxSelect

Left click and drag to select the entiresketch.

[Sketching] > Modify > Copy Right-click anywhere on the Model

View and select Use Plane Origin asHandle.

Step 3

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Workshop Supplement

4) Create the flange sketch #4 [Modeling] > A: Geometry > Plane6

Highlight XY Plane Toolbar: New Plane

Select the New Plane icon from the Active Plane/Sketch Toolbar . Thiscreates Plane6 based on XYPlane .

In the Details view, set Transform 1 toOffset Z, change FD1, Value to 6.

Toolbar: Generate [Sketching] > Modify > Paste

Enter 0 for r= and 1.05 for f=. Right-click anywhere on the Model View andselect Scale by factor f. (scales theoriginal sketch profile by a factor of1.05).

Right-click on the Model View and

select Paste at Plane Origin. Ourreference point was the sketch originfrom Plane5 , and the pasting location isthe origin on Plane6 , so this copies therectangle onto Plane6 and scales it by1.05. Right-click on the Model View and select and left-click End .

Step 4

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Workshop Supplement

Create the flange sketch #4 (contd) [Modeling] > Unnamed > Plane5 >


Always Show Sketch [Modeling] > Unnamed > Plane6 >


Always Show Sketch. This makesboth sketches visible at the sametime, so we can easily see that theoriginal profile is indeed scaled by afactor of 1.05.

Step 4

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Workshop Supplement

5) Create the flange Toolbar: Skin/Loft

Select the Skin/Loft icon and the Details view, Profiles should

be active. Hold the CTRL key and, from the

graphics window select the foursketches shown at the right in thedirection noted by the solid arrow.They will highlight in yellow.

Note: it is only necessary to selectone line from each sketch.

Apply A grey line appears showing the

lofting behavior. In this case, thelofting looks correct. If your grey linedoes not seem correct, i.e. it appearstwisted, this can be resolved by right-clicking anywhere on the Model View and selecting Fix Guide Line.

Step 5

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Workshop Supplement

Create the flange (contd) Select the four vertices, which are

circled on the top-right image. Thisredefines the lofting guide such thatthe model will not twist.

After this is done, the guiding profile,should be defined correctly.

Step 5

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Workshop Supplement

Create the flange section (contd) Set the Merge Topology option to Yes. Toolbar: Generate

The resulting solid (shown here inwire frame display) appears on theright.

Notes: Setting Merge topology to yesoptimizes the number faces for the skin/loftoperation. This results in a smoother surfacemesh.

Step 5

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Workshop Supplement

6) Create the pipe bend [Modeling] > A: Geometry > XYPlane Toolbar: New Sketch

Sketch5 will be created on XYPlane Choose the Look At icon In the Details view, rename Sketch5

to RevolveAxis. [Sketching] > Draw > Line

Create a single line as shown on thebottom-right. Make sure it has anauto- constraint of V (vertical).

[Sketching] > Dimensions > General Dimension the distance of the line

from the vertical axis Y as 15.

Step 6

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Workshop Supplement

Create the pipe bend (contd) [Modeling] > A: Geometry > XYPlane >

BaseCircle Toolbar: Revolve

In the Details view, change BaseObject to BaseCircle.

Add RevolveAxis as the Axis. Look at the Model View. The

revolution operation is in the wrongdirection, so change Direction toReversed with the pull -down menu.

Change FD1, Angle (>0) to 45. Therevolve preview should look similar tothe top-right image.

Toolbar: Generate This will generate the pipe bend.

Step 6

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Workshop Supplement

7) Create New Plane at the pipe end Left click the pipe end to highlight it, click New Plane icon, leave everything as default in

detailed window, click Generate. Toolbar: Extrude

In the Details view, change FD1, Depth (>0) to 10 Toolbar: Generate

The straight end of the pipe should be generated.

Step 7

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Workshop Supplement

You have created one end of the catalytic converter.To create the other end, you can copy the solid part

you have created to a new plane. The first step is to create the destination plane. Select

Plane 6 from the tree view. You can see that it islocated at the base of the solid part. Make sure thatPlane 6 is selected as the Active Plane and click onthe New Plane icon. Plane 8 will be located 20 mmfrom Plane 6 in the +z direction. You should also

reverse the normal direction. Once you have enteredthe data, click on Generate to create Plane 8. You will now copy the solid part you have created from

Plane 6 to Plane 8. Click on Create/Body Operationand change the type to Move. Select the Body andclick Apply. Change Preserve bodies to Yes. Set theSource Plane to Plane 6 and the Destination Plane toPlane 8 and click Generate.

Step 7

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ANSYS Inc Proprietary April 28 2009

Workshop Supplement

You will now complete the model by extruding the sketchon Plane 6 to the base face of the new end of the catalytic

converter that you just created.Notes: This new solid will represent the porous region of

the converter. To be able to identify this internalmesh region and set flow resistances, this solidshould NOT be merged with the rest of thegeometry. To keep it separated it will begenerated as a Frozen Material.

Set the 3D operation to be Extrude. Click in the Base Object List, highlight Sketch 4 in the

tree view (located as a sub-object of Plane 6). Youshould see the base profile of the first end sectionbecome highlighted. Click Apply.

Set the Operation to Add Frozen and the Type to ToNext.

Click on Generate to add the material. Note that thenumber of bodies and parts has now increased to three.

Step 7

DM_12_CH04_WS1

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