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Finite Element Analysis Hints and

Ansys Workbench Tutorial

Static Structural FEA of Static Structural FEA of Static Structural FEA of Static Structural FEA of

meshing spur gearsmeshing spur gearsmeshing spur gearsmeshing spur gears


CONTENT:

1. Introduction....................................................................... page 3

2. Advice and good practices for a future FEA engineer......... page 4

3. What we learn in this tutorial.............................................. page 16

4. Static Structural FEA of meshing spur gears...................... page 17

5. The end............................................................................. page 29


3. What we learn in this tutorial

- how to define and edit non-linear Contacts

- how to define and edit Joints

- how to define the Mesh

- how to define proper Output (including basic Fatigue Tool)

- how to read the Solver


4. Static Structural FEA of meshing spur gears

1. Open Ansys

Workbench; drag Static

Structural into the

Project Schematic area

2. Right click Geometry,

Replace Geometry, Browse for

2013_05_14_gears2_asm.STEP,

OK

3. Right click on the gear on the left and Rename it to "gear +Z";

Rename the other gear " gear - Z"


1. In Solution Output, select Time Increment to see its values, getting a hint on the trend of the solving process; after a bisection, these values will suddenly decrease

2. Check the values for the Contact Pressure as seen here; click on Probe than on the desired spots on the needed surfaces in contact




Static Structural FEA of a sphere Static Structural FEA of a sphere Static Structural FEA of a sphere Static Structural FEA of a sphere

pressing with plasticitypressing with plasticitypressing with plasticitypressing with plasticity

onto a plateonto a plateonto a plateonto a plate

(double symmetry)(double symmetry)(double symmetry)(double symmetry)


CONTENT:

1. Introduction.................................................................... page 3

2. Advice and good practices for a future FEA engineer...... page 4

3. What we learn in this tutorial........................................... page 16

4. Static Structural FEA of sphere-plate plasticity............... page 17

5. The end.......................................................................... page 45



- how to define Materials

- how to define and edit Contacts

- how to create the Mesh

- how to insert Supports

- how to define Symmetry Regions

- how to define proper Output

- how to read the Solver


4. Static Structural FEA of sphere-plate plasticity

1. Open Ansys

Workbench;

drag the

geometry file

from your

computer into

the Project

Schematic area

2. Drag the

Static Structural

analysis on the

Geometry tab

and release it

will share its

geometry file

3. Your Static

Structural

analysis should

look like this


1. Double click Model in

Static Structural and the

Mechanical window will open

like here

2. Expand the Geometry

tree and rename the parts

with more relevant names


1. The default contact is

Bonded; we will select for

Contact face the spherical

face (green here), than hit

Apply

2. For Target face we will

select the flat face of the

plate (green here), than

hit Apply


1. We will let Ansys WB

create the mesh

automatically by right

clicking on Mesh,

Generate Mesh

2. The Default mesh should look like this;

we will modify the parameters later, on the

next, more advanced tutorials; for now it is

helpful to account for the small number of

nodes and elements, which means less

time consumed with solving


1. During solving,

click on Solution

Information, Solution

output, Solver output

to see what the solver

is doing; these

messages will be

important later, when

we will need to

improve or debug

more complex

analyses

2. Change from Solver Output to Force Convergence to see a

graphical plot of how the solution will converge; as seen in the

Legend, the Force Convergence curve should intersect with

the Force Criterion curve in order to achieve convergence


2. Because the steps can

become very crowded, you

can "rarify them" by in 25

Display Points

3. This is how the analysis

looks at the end of the solving

time; the messages are not to

worry in this case

1. In this case, for faster solving

time, you can press Stop Solution

than click on Analysis Settings,

Solver Controls, Solver Type and

change from Program Controlled

to Direct, then hit Solve again


1. This is the

Equivalent

Stress plot

2. This is the

vertical

Directional

Deformation

plot

3. To see the

elements,

we can

press Show

Elements on

this top bar


1. This is the

Equivalent

Stress plot

where we can

see the

element edges

2. Plasticity means that we should have

remanent deformations; we can clearly see

this only if we apply the load than release it, to

see if the plate comes to its initial shape; to do

this, on Analysis Settings we change in Step

Controls the Number of Steps to 4


1. The Prescribed

Displacement was

initially -2 mm

2. We insert these values

to apply than release the

load that the quarter

sphere exerts on the plate


1. During solving time,

we can change the

Solution Output to Time

Increment to see how the

solver automatically

adjusts the time steps to

achieve convergence

2. The solved

analysis should look

like here when it

reaches time step 4


1. Looking for the

Stress plot, we can see

that, after the sphere

has risen to its initial

position, the plate

remains deformed; we

can animate the results

by clicking the play

button




Static Structural FEAStatic Structural FEAStatic Structural FEAStatic Structural FEA

of meshing bevel gearsof meshing bevel gearsof meshing bevel gearsof meshing bevel gears (debugging (debugging (debugging (debugging

solution to achieve convergence)solution to achieve convergence)solution to achieve convergence)solution to achieve convergence)


CONTENT:




4. Static Structural FEA of meshing bevel gears.................. page 17

5. The end........................................................................... page 51



- how to work with Contacts

- how to work with Joints, parameterize the Joints

- how to create, simplify and refine the Mesh, parameterize the Mesh

- how to simplify the 3D model in Ansys Workbench Geometry module

- how to define proper Solution output, parameterize the output

- how to debug the Solution if it does not converge, apply suitable

measures to achieve convergence

- how to use the parameters in defining Design Points, run multiple

consecutive scenarios without interfering in Ansys Workbench


4. FEA of a Static Structural case of meshing bevel gears

1. Open Ansys


Structural into the



Replace Geometry,

Browse for Bevel Gear

T24-T16-M3.IGS, OK

3. Right click on the gear highlighted in green and Rename it to "big_gear";

Rename the other gear " small_gear"


1. To find out the expected

life-time of the small gear,

on Fatigue Tool we will

select Life for the small

gear; notice the fatigue

criteria Ansys uses by

default

2. Right click on Contact

Tool, Insert, Gap


1. For computation, right

click on Solution, Solve

2. When the

solution is running,

this is how Solver

Output looks like,

obtaining a real-

time log with the

solver's processes


2. Extending the mesh refinement leads to

convergence on several steps; to rarify the seen

steps, select Solution Information, Display Points: 25

1. Being an important solver

parameter, you can see the Time

Increment as here


1. We still have no convergence; it is

time to refine once more the gears,

but because the number of nodes and

elements is high, let us cut the model

on the regions not FEA relevant: on

their centers

2. We go to Project

Schematic, right click

on Geometry, Edit

Geometry

3. To import the

gears, right click on

Import1, Generate


1. Select this face of the

small gear and click on

New Sketch button

2. To have a view normal to

sketch, select the Look at

Face/Plane/Sketch button;

instead Modeling, go to

Sketching tab, select

Circle and snap to the

center of the small gear


1. To cut the material on the

big gear, select the details

seen here, than right click

on Extrude2, Generate

2. We will suppress the

resulting cut cylinders; Ctrl

select the last 2 solids, right

click, Suppress Solid Bodies


1. Re-run the analysis with

high hopes this time :)

2. Our hopes were met,

because the analysis

successfully converged!


1. This is how the stress

looks at the last time step;

notice the peaks caused

by the teeth collisions


1. This is how the gaps in

contact look like

2. To easily make multiple

consecutive runs, we can

change the parameters

values for the items we

chose before; go to

Project Schematic, right

click on Parameter Set,

Edit




Explicit Dynamics Explicit Dynamics Explicit Dynamics Explicit Dynamics FEA of a car body FEA of a car body FEA of a car body FEA of a car body

crashing into a wall and a wedgecrashing into a wall and a wedgecrashing into a wall and a wedgecrashing into a wall and a wedge


CONTENT:




4. Explicit Dyanmics FEA of a car body crashing................. page 17

5. The end.......................................................................... page 46



- how to work with Dynamics, analyses that occur in time

- how to use Symmetry conditions for 3D bodies

- how to refine the Mesh or make it coarse, parameterize the mesh

- how to define proper Solution output and re-define it, parameterize the

output

- how to duplicate and re-use analyses

- how to use the parameters in defining Design Points, run multiple

consecutive scenarios without interfering in Ansys Workbench


4. Explicit Dyanmics FEA of a car body crashing

1. Open Ansys

Workbench; drag

Explicit Dynamics into

the Project Schematic


Replace Geometry,

Browse for

carbody_wall.STEP, Open

3. Open Mechanical

window, and selecting the

bodies in the tree we see

that only the highlighted

ones are relevant for our

analysis

Wall-Carbody FEA


1. Right click on the

highlighted unnecessary

bodies and suppress them

2. Select the last surface

body and insert 0.3 mm

for the Thickness; tick

the Thickness box to

parameterize it for later

usage

3. To achieve

deformations past the

Yield Point of the

material, change it to

nonlinear: Assignment,

Import


1. We can see that the mesh is with TET

elements on the wall (as we requested

before) and quadrilateral elements on the

carbody; also, for Explicit Dynamics, the

number of nodes and elements is too

high, leading to 6-10 hours of solving time

2. Click on Mesh and make

Sizing, Smoothing, Low; right

click on Mesh, Update

3. Now the number of

nodes and elements is

2.5 times smaller, which

will lead to less than 30

min solving time


1. Clicking on Solution Information, Solution Output , Energy

Conservation will give us this windows; even though the amount

of work done fluctuates, it is most important for the Energy Error

not to increase (the default is set to 10%=0.1), or else will lead to

stopping the solving

2. Clicking on Solution Information, Solution Output , Energy

Summary will give us this window; it is most important for the

Hourglass Energy not to increase, as seen here


1. As the solving continues, we can see that the fluctuations of

Work Done subside, which is a very good sign and the value for

Energy Error is constant and low

2. Also, we can see that the fluctuations of the Kinetic Energy

subside, which is a very good sign and there is no sign of the

Hourglass Energy


1. After ~24 min of

solving, the solution

is done, as seen here

2. Here is the

Displacement plot of

the wall: ~500mm as

we imposed

3. Here we see the overall Stress plot, with some high

values given by the coarse mesh we used in the wall;

let us scope only the carbody to see its stress plot


Carbody-Wedge FEA

1. To realize the second

analysis, with the carbody

colliding with a wedge block,

right click on Explicit

Dynamics, Duplicate

2. Both analyses should look

like here; rename the items

as seen here, for better

visualization

3. Right click Geometry, Replace

Geometry, Browse for

carbody_wedge.STEP, Open


1. This is the stress plot for the

carbody, with a maximum on

the impact region; let us

parameterize Maximum Value

Over Time, Maximum

2. This is the displacement plot for the front

of the carbody; the value is true, because if

the carbody travels with 50 m/s, than in

0.02 s it will travel with 1 m/s; let us

parameterize it by ticking on Maximum

Value Over Time, Minimum




Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of

a a a a copper sheet stampingcopper sheet stampingcopper sheet stampingcopper sheet stamping

(double symmetry)(double symmetry)(double symmetry)(double symmetry)


CONTENT:




4. Static Structural FEA of a copper sheet stamping.......... page 17

5. The end.......................................................................... page 54



- how to assign non-linear materials

- how to use Symmetry conditions on 2 axes for 3D bodies

- how to properly assign different elements and refine the Mesh

- how to edit the geometry in Ansys Workbench

- how to define complex Analysis Settings and stabilize the solving

- how to define proper Solution output; how to investigate the output of

the Contacts (Pressure, Status, Stress etc.)


4. Static Structural FEA of a copper sheet stamping (double

symmetry)

1. This is the geometry

setup in Solidworks,

before it was simplified,

for easier meshing and

solving time


1. We have cut

half of the

assembly

longitudinally

and

transversally


1. Open Ansys


Structural into the



Import Geometry, Browse

for narrow_stamp.x_t,

Open


1. In Mechanical it will

open the 3D model ready

for pre-processing

2. Let us change the

material of the plate to

a nonlinear one. After

we rename the parts

as here, click on plate,

Material, Assignment,

Import


1. Create also a Symmetry Region for

the die faces, as seen here in green

2. After having finished defining the symmetry

conditions for X axis, you can rename them, than

select all 3 Symmetry Regions to check if they are

properly defined, as seen here in red


1. Select the plate, Apply than choose

Method, Tetrahedrons

2. Let us refine the mesh on the multiple rounds of

the die; right click on Mesh, Sizing, select the rounds

shown green here, Element Size 0.1 mm, Apply


2. Because we need to round the

outer edge of the plate, we will go to

project Schematic window, right

click on Geometry, Edit Geometry

3. In the DesignModeler window,

to import the geometry, right click

on Import1, Generate

1. Click on Model, Show All Bodies; let us refine

the surface mesh of the underside of the plate

seen here in green: right click on Mesh, Sizing, 1

mm, Apply


1. We will insert a

downwards displacement

on the punch: right click

on Static Structural,

Insert, Displacement,

Apply

2. We select from the

punch these 3 faces in

green


1. To find out the stress in all bodies:

right click on Solution, Insert,

Stress, Equivalent von-Mises

2. To find out the stress only in

the plate, let us duplicate the

previous one: right click on

Equivalent Stress, Duplicate

3. With Body filter pressed, select the

plate than Apply


1. To find out how much plasticity

we will have in the plate, right click

on Solution, Insert, Strain,

Equivalent Plastic

2. We will scope only the plate, Apply

3. To find out how the contacts

behave, right click on Solution,

Insert, Contact Tool, Contact Tool


1. We are interested in the

Contact Pressure: click on

Status and change Type to

Pressure

2. Before solving this

analysis, let us see the

Mesh: right click on it,

Generate Mesh

3. The mesh should look like

here; right click on Solution,

Solve


1. The Directional

Deformation on Z axis

looks like this

2. The Stress in all

bodies looks like this

3. The Stress only in

the plate looks like this




Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of

rolling of a copper platerolling of a copper platerolling of a copper platerolling of a copper plate


CONTENT:




4. Static Structural FEA of rolling of a copper plate............ page 17

5. The end.......................................................................... page 51


2. Advice and good practices for a future FEA engineer

a) Where do I find info and docs?

b) Where do I find 3D models for FEA practice?

c) Where do I find databases with materials?

d) What should I know about the meshing procedures?

e) How can I validate my FEA results/analyses?

f) Advice for future eastern and mid-eastern FEA engineers.

g) What should I do to become an FEA expert, with strong knowledge and

experience?



- how to assign non-linear materials

- how to edit the geometry in Ansys Workbench

- how to resize the Mesh

- how to define Joints

- how to define complex Contacts


- how to define proper Solution output: Force and Moment Reactions,

Contact Pressure, Plastic Strain etc.


4. Static Structural FEA of rolling of a copper plate

1. Start a Static Structural

analysis, right click on

Geometry and Insert

2013_07_21_rolling.stp

2. Because the plate is too

wide and too short, we will

optimize it: Right click on

Geometry, Edit Geometry

in Design Modeler


1. This is how to

initial geometry looks

in Design Modeler

2. With Selection filter on

Faces (Ctrl+F), click on

one of the lateral sides of

the plate


1. To look normally at

the sketch, press

Look At

Face/Plane/Sketch

2. Select Sketching tab

and press Rectangle


1. Draw a free-style

rectangle that will

contain the plate

2. Return to Modeling

tab than click Extrude


1. To extend the plate,

select its end, than

click New Sketch

2. Look at Face /

Plane; switch to

Sketching tab, Modify


1. Press Duplicate and

select the lines of the

rectangle

2. Right click,

Duplicate Selection

3. Back to Modeling

tab, press Extrude


1. The new Extrude

should have these

details

2. Having obtained

the optimized

geometry, Close

Design Modeler


1. Back to Project

Schematic, right

click on Model, Edit

2. Mechanical window will

show us this initial setup;

right click on the parts,

Rename, if you are more

into English


1. To assign the material

to the piece, select it and

go to Import

2. Select the first

Bonded contact, click

on Target and select

both external faces of

the wheel, Apply


1. Select the first

Bonded contact,

click on Contact and

select all 3 underside

faces that will touch

the Target, Apply


1. Solution, Strain,

Equivalent Plastic

2. To see the values

only in the piece,

select it, Apply

3. Solution, Stress,

Equivalent (von-Mises)


1. Solution, Probe,

Force Reaction

2. Solution Output,

Force Convergence will

give a similar plot; some

bisections can be seen

because the high

plasticity that appears

due to increased

thickness of the piece


1. Solution Output, Time Increment

will show how the solver automatically

varies the time steps, in order to

achieve convergence; usually, the

time increments decrease after a

bisection, trying to rise again

2. Right click on

Directional Deformation,

Clear Generated Data


1. Select the

faces on the tip of

the piece, Apply

2. Right click on

Directional

Deformation,

Evaluate All Results


1. The result makes

more sense now,

showing clearly that

the front of the

piece advanced

with ~85mm

2. The Equivalent Plastic Strain

looks like this; because copper

alloys generally break at 30 %,

the values we obtained are for a

thicker than normal plate; to

avoid these high strains, in a

factory, the thinning is done in

multiple stages / passes


2. Right click on Directional

Deformation 2, Evaluate All Results

1. Very interesting would be to find out the lateral

deformation of the piece, how much its width is

increased due to rolling? Solution, Directional

Deformation, select both lateral faces,

Orientation, Z Axis, Apply


1. The Directional Deformation of piece

on Z axis look like here, showing clearly

that each face widened with ~7.8 mm;

congratulations, you have successfully

finished this nice FEA tutorial!




Transient Structural Transient Structural Transient Structural Transient Structural FEA of FEA of FEA of FEA of

heat generated betweenheat generated betweenheat generated betweenheat generated between

a piston and a cylindera piston and a cylindera piston and a cylindera piston and a cylinder


CONTENT:




4. Transient Structural FEA of heat generated between a

piston and a cylinder...................................................... page 17

5. The end.......................................................................... page 57



- how to simplify a complex model

- how to assign a complex Contact

- how to insert Joints, with the ground and between bodies

- how to resize the Mesh

- how to prescribe APDL commands


- how to define proper Solution output: User Defined Result

(Temperature), Force Reaction, Contact Pressure, Plastic Strain,

Velocity etc.


4. Transient Structural FEA of heat generated between a

piston and a cylinder

1. Start a Transient Structural

analysis, right click on Geometry,

Import Geometry, Browse:

piston2_tutorial7.x_t

2. Right click on Model,

Refresh, than Edit...


1. When Mechanical window

opens, this is how the imported

model looks like; we will simplify

it for faster solving time

2. Select with Ctrl pressed the

shown parts, right click,

Suppress Body


1. With the unnecessary parts

removed, we should see this

from under the cylinder

2. Go to Connections,

Contacts and observe that the

contacts for the suppressed

parts automatically became

suppressed; select the only

valid contact, right click on it

than Rename Based on

Definition


1. Select the hole on the

crank, seen here in green,

than go to Reference,

Scope, Apply

2. Select the

corresponding hole on the

connecting rod, seen here

in green, than go to

Mobile, Scope, Apply


1. With the selection filter on Body, select the piston, Apply, Orientation, Y Axis

2. Solution, Deformation, Directional Velocity


1. Again, we select only the piston, as we did before: select the piston, Apply, Orientation, Y Axis

2. Solution, Stress, Equivalent (von Mises)

3. Solution, Contact Tool


1. For Contact Tool, because the default is Status, change Type to Pressure

2. Solution, Probe, Joint

3. Boundary Condition, Revolute - ConnectingRod; To PistonHead;


1. This is the vertical displacement of the piston, with a sinusoidal shape, as we would expect it


1. This is the Temperature plot inside the cylinder

2. This is the Temperature plot outside the piston




Modal analysis and random vibrations Modal analysis and random vibrations Modal analysis and random vibrations Modal analysis and random vibrations

using PSD on a PCBusing PSD on a PCBusing PSD on a PCBusing PSD on a PCB


CONTENT:




4. Modal analysis and random vibrations

using PSD on a PCB........................................................ page 17

5. The end.......................................................................... page 63



- how to assign new materials

- how to edit the Contacts

- how to define a Modal analysis and ask for natural frequencies

- how to understand an interpret Random vibration analyses

- how to define Random vibrations analyses on all 3 axes

- how to check the strength of parts using Equivalent Stress and

Response PSD results etc.


4. Modal analysis and random vibrations using PSD on a PCB

1. Drag a Modal analysis in Project Schematic

window, right click on Geometry, Import

Geometry, Browse: 2013_07_26_PCB.step

2. Double click on Model and the Mechanical

window will open showing the imported

geometry; we can see some support bushings

underneath the PCB


1. We will

remove these

bushings:

select with Ctrl

pressed all 4

bushings, right

click, Suppress

Body

2. Because it's not default in Ansys library, we will create the

material for the PCB, which is a layered epoxy composite called

FR4; select the last part, Material, New material


1. Having the materials that we need,

click Refresh Project, Return to Project

2. Back to mechanical window, select

with Shift pressed, from the tree all the

parts, green intense here, except the last

one (the PCB), Material, Assignment,

Aluminum Alloy


1. No interference now

2. This is the 2nd mode

3. This is the 3rd mode


1. This is the 4th mode




As a reminder, we will quote the basics of Random analysis

from:

http://www.sharcnet.ca/Software/Fluent13/help/wb_sim/ds_spectral_analysis_type.html

Random Vibration Analysis

Introduction

This analysis enables you to determine the response of structures to vibration loads that are random

in nature. An example would be the response of a sensitive electronic component mounted in a car

subjected to the vibration from the engine, pavement roughness, and acoustic pressure.

Loads such as the acceleration caused by the pavement roughness are not deterministic, that is, the

time history of the load is unique every time the car runs over the same stretch of road. Hence it is

not possible to predict precisely the value of the load at a point in its time history. Such load

histories, however, can be characterized statistically (mean, root mean square, standard deviation). Also random loads are non-periodic and contain a multitude of frequencies. The frequency content

of the time history (spectrum) is captured along with the statistics and used as the load in the random vibration analysis. This spectrum, for historical reasons, is called Power Spectral Density

or PSD.

In a random vibration analysis since the input excitations are statistical in nature, so are the output

responses such as displacements, stresses, and so on.

Typical applications include aerospace and electronic packaging components subject to engine vibration, turbulence and acoustic pressures, tall buildings under wind load, structures subject to earthquakes, and ocean wave loading on offshore structures.


2. The result should

look like this

3. Opening the

Mechanical window we

see that Ansys "forgets"

the Modal solution, so

we need to Solve it again

1. In Project Schematic,

drag Random Vibration to

the Solution of our Modal

analysis, than drop


1. Right click, Clear

Generated Data

2. Having active the

Body selection filter,

click the capacitors,

green here, Apply


1. Because we let 1 Sigma for the Scale

Factor, in 68.269% of the time, the stress

will be under this value shown here;

nevertheless, the stress values exceeds

the Ultimate Tensile Stress for Aluminum

alloys, meaning that these legs will break

under the imposed PSD for X axis


1. The Response PSD plot looks like

here; close Mechanical window

2. Drag Random Vibration on Modal Solution;

name it Random Vibration Z axis


1. To obtain plots for Y axis with

Response PSD vs. PSD G

Acceleration, select them both with

Ctrl pressed and click New Chart

and Table; Rename to Chart Z axis

2. This is the resulting chart, with overimposed values for both

curves; notice that we obtain peaks in Response PSD at the first

and second natural frequencies, which are 228.3 and 500.98 Hz

(see Total Deformations in Modal analysis)




Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing Static Structural FEA of a roller bearing

under loadunder loadunder loadunder load


CONTENT:




4. Static Structural FEA of a roller bearing under load......... page 17

5. The end.......................................................................... page 41



- to define complex multiple Contacts

- to define multiple Joints

- to modify the Mesh to suit analysis' needs

- to define proper Analysis Settings and stabilize the solving

- to define proper output for forces, moments, rotations, contact

behavior etc.


4. Static Structural FEA of a roller bearing under load

1. Drag a Static Structural analysis in Project

Schematic window, right click on Geometry,

Import Geometry, Browse:

2013_08_01_roller_bearing1.x_t

2. After import, right click Model, Edit...


1. To ignore the roller cage, in

Mechanical window, right click on

cage;CirPattern1, Suppress Body

2. Right click on Contacts, Delete

3. Right click on Contacts, Insert,

manual Contact Region


1. Right click on

Contacts,

Insert, Joint

2. Connection Type,

Body-Ground


1. Select the outer

face of the bearing,

green, here, Mobile,

Scope, Apply

2. From Connections

toolbar, select Body-

Ground, Revolute


1. Select the inner face of

the bearing, green here,

Mobile, Scope, Apply

2. Drag a window as

shown here, to

include all bodies


1. Method, Tetrahedrons

2. Right click on Mesh,

Insert, Sizing

3. Select the inner and outer faces of the bearing,

green here, Apply, Element Size = 35 mm


1. This is the Stress plot

2. This is the Contact

Status plot


1. This is the Joint Probe

showing Total Moment

2. This is the Joint

Probe showing the

Relative Rotation; feel

free to modify the

friction coefficient,

the rotational velocity

and the bearing load

and compare the

results;

congratulations, you

have successfully

finished this nice FEA




EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF EXPLICIT DYNAMICS FEA OF MACHINING MACHINING MACHINING MACHINING

WITH A WITH A WITH A WITH A PLANERPLANERPLANERPLANER


CONTENT:




4. Explicit Dynamics FEA of machining with a planer........... page 17

5. The end........................................................................... page 30



- to assign Explicit Materials

- to define various body loads

- to mesh in a simplified manner, for faster solving time

- to define proper Analysis Settings for split second event

- to define proper output for velocity, stress, strain etc.

- to interpret the behavior of the solver


To take into account our new

materials, exit by clicking Refresh

project, than Return to Project

Back to project Schematic, right click on

Geometry, Import Geometry, Browse for

2013_09_11_machining3.x_t

As an easier reminder, you

can rename the Geometry:

right click, Rename to

2013_09_11_machining3.x_t


Let us define the pre-

processing conditions: right

click on Model, Edit...

In Mechanical window, right

click on first body from the

tree, Rename it to "piece"

Right click on the second

body from the tree, Rename

it to "tool"


After Apply, select Type,

Number of Divisions, 10


Go to Analysis

Settings and insert

End Time, 0.00075

From Environment

toolbar select Velocity

To define the needed

output, select Solution,

Deformation, Directional


Solution, Total Velocity

Solution, Stress,


Solution, Strain,

Equivalent Plastic


Select only the piece,

green here, Apply

Preparing of the model is

done, let us proceed to the

solving stage: right click on

Solution, Solve


If you click

immediately on

Solution

Information you

will see how a

log with a pre-

solver setup, as

shown here

If you click on Solver Output you

will see that, initially, Ansys

Workbench predicts that the

analysis will be done in 9.9 minutes;

but this is done prior having the

collision and the large deformations


Click on Solution Output,

Time Increment, we see that

it fluctuated initially, but it's

stabilized afterwards

As we said, the solver was

wrong to assume 9.9 minutes

of solving and, after collision is

established, we see that it

takes almost double


This is the Total

Velocity plot

This is the Stress plot

This is the Strain plot only in

piece. Congratulations, you have

successfully finished this simple

Explicit Dynamics analysis!




STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A

THREADED BOLTTHREADED BOLTTHREADED BOLTTHREADED BOLT----WASHERWASHERWASHERWASHER----NUT NUT NUT NUT

CONNECTIONCONNECTIONCONNECTIONCONNECTION


CONTENT:




4. Static Structural FEA of a threaded bolt-washer-nut

connection......................................................................... page 17

5. The end........................................................................... page 54



- to assign solvable Contacts, and Joints that mimic the real load


- to define proper Analysis Settings and stabilize the solving

- to define proper output for deformation, stress, strain, reactions etc.

- to customize the solver's response

- to create full and section views for better handling and result probing


4. Static Structural FEA of a threaded bolt-washer-nut

connection

Drag and drop Static Structural from

left column called Analysis Systems;

right click on Geometry, Import

Geometry, Browse:

2013_09_30_bolt_washer4.x_t

After the import is done, right

click on Model, Edit...


This is the 3D model; for easier

handling, right click on each

part from the Model tree,

Rename: washer (than nut, than

bolt) as seen here


With Ctrl key pressed, click Scope,

Target, 4 Faces and deselect the

top and the bottom of the thread

The result should look

like this; Apply


From tree click on

Solution, than go to the

upper toolbar,

Deformation, Total

Deformation, Directional

With selection filter on

Body, click the bolt, Apply


Solution, Stress,


Scope only the

washer, Apply

Right click on the previously

created Equivalent Stress,

Duplicate


Scope only

the bolt, Apply

Solution, Strain,


Scope only the nut, Apply


To proceed to the solving part,

right click on Solution, Solve

Firstly, the mesh is created

and this is how it looks like


Clicking Solver Output

gives this solver log


To obtain an easier readable

graphical representation of

this log, select Solution Output,

Force Convergence

This is how the Force

Convergence plot looks like;

observe that the analysis

performs well, the bisections

being expected due to the high

contact forces


As the solving continues, the spikes may

get pretty crowded, as seen here

This is the Directional Deformation

plot in bolt and washer


This is the Stress plot in washer; the extremely

high values appear because we exaggerated with

the pressing of the bolt and the materials we used

do not suffer plasticity; assign non-linear materials

to all parts, re-solve and see the difference

This is the contact Pressure for

the Frictional contact




EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT EXPLICIT DYNAMICS FEA OF THE IMPACT

BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS BETWEEN A BOWLING BALL AND ITS

PINSPINSPINSPINS


CONTENT:




4. Explicit Dynamics FEA of the impact between a bowling ball and its

pins............................................................................... page 17

5. The end........................................................................... page 53



- to edit the 3D model to obtain shell elements


- to define proper Analysis Settings correlated with the nodes and

elements number

- to define proper output for deformation, stress, velocity etc.

- to properly observe the solver's response

- to parameterize the input data for automatic solving of multiple FEA

scenarios in the same file


4. Explicit Dynamics FEA of the impact between a bowling ball and its

pins

Drag and drop Explicit Dynamics from left column called

Analysis Systems; right click on Geometry, Import Geometry,

Browse: 2013_10_01_bowling1.x_t

Right click on Geometry,

Edit Geometry in

DesignModeler


In DesignModeler

window, right click on

Import1, Generate

This is the result of the import: the

walls are solid and we will make

them thin, to have shell elements


In the main window, right

click Model, Edit...

This is how the geometry looks like; because we have

question mark in front of Geometry, we need to define the

thickness of the surfaces/shells we crated in DesignModeler


Select the last 2 parts and assign them 5mm thickness

(the lateral walls were united into one surface)

With the Face filter active,

click the ball, Apply


For the ball to run into

the pins, select X

Component, Tabular


This is the Energy Conservation

plot before any collision


For easier reading,

insert 100 Display

Points (instead of 0)

and we will obtain a

better resolution


This is the Total Deformation plot in all bodies; ~8 meters is

the height that a pin reached because it fell off the "bowling

alley" and is headed to the abyss


This is the Directional Velocity

plot on X axis for the ball; its

fluctuation can be seen in the

bottom graph

If, for instance, you need the investigate the trajectory of

any pin, you can create a Directional Deformation plot

(vertical here), select the pin, Apply


Right click on the newly created Directional

Deformation, Evaluate All Results


The needed variation in

time, of the pin's

height, looks like here


Let us parameterize the extreme

values for later solving; check the

boxes in front, as seen here

marked with blue P letters


To find out if we will have other

parts that will eventually fall into

the abyss, let us parameterize

the maximum displacement, as

seen here




STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING

WITH HALF SYMMETRYWITH HALF SYMMETRYWITH HALF SYMMETRYWITH HALF SYMMETRY


CONTENT:




4. Static Structural FEA of stamping with half symmetry..... page 17

5. The end........................................................................... page 52



- to assign non-linear materials

- to simplify the 3D model and apply symmetries

- to assign complex contacts suitable to large strains

- to define proper Analysis Settings to ensure smooth solving

- to define proper output for stress, strain, tools, probes etc.

- to properly observe the solver's response

- to re-evaluate the output data according to most important steps


4. Static Structural FEA of stamping with half symmetry

First, make sure

that you have a

proper geometry,

like the one we

provide, shown

here

Drag and drop Static Structural from left column called Analysis

Systems; to insert the material for the copper plate, right click

on Engineering Data, Edit...


Once the model is imported,

select XYPlane, than press New

Sketch button, as seen here

To normally look at the

sketch, press Look at

Face/Plane/Sketch button


If at first the zoom level doesn't reveal the entire

model, use Box zoom and drag several windows with

it in the center of the coordinate system we see

Box zoom several times in

the center, as seen here

Then the model starts to

appear; repeat the

zooming


When we have this

magnitude of zoom, we

can stop zooming

Select the cut surface of the

die (green here, Apply)


Observe that our symmetries are as default, about X

axis which is normal to the cut surfaces, red axis here

Right click on Connections,

Contacts, Rename based on

Definition

Select with Ctrl pressed both

contacts, Flip Contact/Target


With Ctrl pressed, click the lateral

surface to unselect it (blue here),

than click the spherical surface,

(green here); Apply


This is how the Target part of the

first contact should look like

(green here); right click anywhere,

Show All Bodies

Select the touching

surfaces, Apply,

Element Size = 1


This is the result

Environment,

Fixed Support

Select the outer

faces of the die

(green here), Apply


With selection

filter on Body,

select the piece

(green here,

Apply)

Solution, Tools,

Contact Tool

Uncheck the second

contact, to have this result


Select Status and replace

with Pressure, as seen here

It's very useful to hit Interrupt Solution after some solving was

done, to check if the analysis performs as desired; notice the

Pause symbol near Solution, which means that the analysis

can be continued


This is the max. pressure

plot in first Contact Tool


For Contact Tool 2, retrieve

also the value from second 6


The Reaction

Force plot gives

us the value

required to

stamp the sheet-

metal; max. value

at second 6,

where we have

the max. depth of

the punch;

congratulations,

you have

successfully

finished this nice

FEA!




Seismic Random Vibration analysis using Seismic Random Vibration analysis using Seismic Random Vibration analysis using Seismic Random Vibration analysis using

PSD on a real size skyscraperPSD on a real size skyscraperPSD on a real size skyscraperPSD on a real size skyscraper


CONTENT:




4. Seismic Random Vibration analysis using PSD on a real size

skyscraper......................................................................... page 17

5. The end.......................................................................... page 68



- how to assign new materials

- how to manage only important parts

- how to define a Modal analysis and ask for natural frequencies

- how to understand and interpret Random Vibration analyses

- how to define Random Vibrations analyses on all 3 axes

- how to check the strength of parts using Equivalent Stress and

Response PSD results etc.


4. Seismic Random Vibration analysis using PSD on a real size

skyscraper

Drag a Modal analysis in Project Schematic

window, right click on Engineering Data, Edit...

Click the button Engineering Data Sources

to reveal all material libraries


From General Materials tab, choose

Concrete by clicking the yellow plus sign

For the new material to be taken into

account by Ansys, click Refresh

Project, Return to Project


Right click on Mesh, Insert, Sizing

With selection filter on Body,

click the 6 columns (green

here), Geometry, Apply


Assign them Element

Size, 1000 mm

To see the mesh, right

click on it, Generate Mesh


After the solving is

finished, here is the

Total Deformation plot

for the 1st vibration

mode; the magnitude of

the deformation is not

realistic in any modal

analysis, only the

tendency of the

deformation is; most

important here are the

natural frequencies

found by FEA


This is the Total

Deformation plot for the

5th vibration mode

Because we have finished with

the Modal analysis, which is the

basis of every vibration

simulation, Let us leave this

window; File, Close Mechanical


Back to project Schematic, drag and drop

Random Vibration from the left toolbox

onto the Solution of the Modal analysis

Right click on

Equivalent Stress,

Duplicate

Select only the

concrete part,

Apply


Solution,

Probe,

Response PSD


Once the analysis is solved, let us

change the orientation to Y Axis,

which is the vertical one

Right click on Directional

Deformation, Evaluate All

Results




STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE STATIC STRUCTURAL FEA OF A TOGGLE

CLAMP WITH PLASTICITYCLAMP WITH PLASTICITYCLAMP WITH PLASTICITYCLAMP WITH PLASTICITY


CONTENT:




4. Static Structural FEA of toggle clamp with plasticity....... page 17

5. The end........................................................................... page 47



- to assign non-linear materials, that allow plasticity

- to properly mesh the contacts

- to assign many types of Joints

- to define proper Analysis Settings to stabilize the solving

- to define proper output for stress, strain, tools, probes etc.


4. Static Structural FEA of toggle clamp with plasticity

Firstly, make sure

that you have a

proper geometry,

like the one we

provide, shown

here


Select Contacts, right click,

Rename Based on Definition;

select each contact and look

at the mating parts; we will

suppress the contacrts that

are not of interest in this FEA

Select the shown contacts with Ctrl

pressed, right click, Suppress


Select 4th contact, which is very important; observe

that it is incomplete, because it does not contain all the

surfaces that will later touch the handle, red here

Click Contact, 3 Faces and, with Ctrl pressed add these 3

surfaces, green here, to obtain 6 faces for the Contact, Apply


Select both bolt holes, Scope, Apply

Connections, Body-Ground, Fixed, select the

underside of the base plate, Scope, Apply


Connections, Body-Body, Revolute

Select the outer surface, green

here, Reference Scope, Apply


Selecting Static Structural will activate the

Environment upper toolbar; Loads, Joint

Select the first Revolute joint

Insert these Details;

observe that the arrow

shows a proper rotation

Insert these values in the table


Select Directional

Deformation, than

click on the surface

of the washer that

touches the spring,

green here, Apply

Select the

Coordinate System

we just created


Solution, Strain,

Equivalent Total

With selection filter on Body,

select this green part, Apply


If at Solution Output you

choose Force Convergence

you will see this window


After 10-15 minutes, the analysis

is solved; this is the Total

Deformation plot


plot, where we see the washer

(hence this side of the spring),

which is displaced with ~34 mm


This is the Equivalent Total Strain plot




TRANSIENT STRUCTURAL FEA OF BENDING A

LAMELLA WITH PLASTICITY AND SPRING BACK

EFFECT


CONTENT:




4. Transient Structural FEA of bending a lamella with plasticity

and spring back effect....................................................... page 17

5. The end........................................................................... page 48



- to assign non-linear materials, that allow plasticity and spring back

- to properly mesh the contacts

- to assign many types of restraints, to achieve convergence


- to define proper output for stress, strain, tools, probes and results

depending on time


4.4.4.4. Transient Structural Transient Structural Transient Structural Transient Structural FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and FEA of bending a lamella with plasticity and

spring back effectspring back effectspring back effectspring back effect

Firstly, make sure

that you have a

proper geometry,

like the one we

provide, shown

here


Drag Transient Structural from Toolbox. To allow plasticity in

the parts, let us define the non-linear material: right click

Engineering Data, Edit...

Back to Project Schematic, right click on

Geometry, Import Geometry, Browse...

"2013_11_13_bending_lamella1.x_t"


Right click on Model, Edit...

This is the 3D model; if you like

English names, let us change the

default ones; right click each part,

Rename and assign different names

Rename the parts as here


The mesh looks like here,

with an optimum number of

nodes and elements, to

ensure short solving time

Analysis Settings,

Number of Steps = 30


Select the external faces of the

die, green here, Apply

Right click Transient (A5), Insert, Displacement


Select all lateral

faces, green here,

Apply; Z

Component = 0 mm

Solution, Deformation, Directional


With selection filter on Body, click

the punch and the lamella, Apply;

orientation, Y Axis

With selection filter on Face, click

the top face of the lamella, Apply;

orientation, Y Axis

Solution, Stress, Equivalent (von-Mises)


With selection filter on Body, click the lamella, Apply

Solution, Strain, Equivalent Total;

with selection filter on Body, click

the lamella, Apply


Making Display Points = 35 will give

you a rarified plot, with last 35

substeps/increments

After ~1 hour solving time, the analysis

is done; this is the Total Deformation

plot in all parts


This is the Directional Deformation plot

on Y axis, vertically; observe a

remanent deformation of 0.626 mm,

due to the spring back effect



on Y axis, vertically, on the upper face of

the lamella; the spring back effect is

seen more clear on both green and red

line, in the lower Graph tab




TRANSIENT STRUCTURAL FEA OF A GRIPPER

WITH GEARS AND JAWS


CONTENT:




4. Transient Structural FEA of a gripper with gears and

jaws.................................................................................... page 17

5. The end........................................................................... page 50



- to take advantage of rigid bodies

- to properly set-up the contacts in moving gears

- to assign many types of joints (12 different ones)


- to define proper output for stress, strain, tools, lots of probes and

results depending on time


4.4.4.4. Transient Structural FEA of a gripper with gears and jaws

Firstly, make sure

that you have a

proper geometry,

like the one we

provide, shown

here

Double click Transient Structural from Toolbox.

Right click Geometry, Import Geometry,

Browse... "2013_12_08_claw_gears1.x_t"


Right click Model, Edit...

With Shift or Ctrl pressed, select

all the parts named "Claw-

Bolt1", right click, Suppress


For easier handling, right click

on the active parts and Rename

them as seen here

Select first 3 parts, green

here, and make their

Stiffness Behavior, Rigid


Right click on Contacts,

Rename Based on Definition

With Shift

pressed select all

contacts, than

with Ctrl unselect

the ones marked

with green check

(as seen here),

right click on the

inactive selected

contacts,

Suppress


Properly suppressed,

the unnecessary

contacts receive an X

sign in front

As an exercise, do a similar Revolute

Joint for the other gear, transparent here


Connections, Body-Body,

Revolute

For Reference, Scope, select this cylindrical

surface of the Housing plate, green here, Apply

For Mobile, Scope, select the corresponding

surface of the Link, green here, Apply


For Reference, Scope, select this cylindrical

surface of the Jaw, green here, Apply

For Mobile, Scope, select the

corresponding surface of the Link,

green here, Apply


This is the resulting

Spring joint

For verification, select with Shift pressed

all 12 joints and they should look like here


Solution, Deformation,

Directional

Right click anywhere, Show All

Bodies; Orientation, Z Axis,

select with Ctrl pressed these

green surfaces, Apply


Solution, Tools, Contact Tool

Right click Status, Duplicate

Change Status 2's Type to Pressure

Solution, Probe, Force Reaction


Insert these details


Click on Solution

Information to see what

the solver is doing


For a graphical representation of the solver's activity, change

Solver Output to Force Convergence; for a rarified plot, make

Display Points = 35


After ~25 min, the solve is finished;

this is the Total Deformation plot


This is the Strain plot


This is the Stress plot


plot showing the displacement/ the

stroke of the jaws




TRANSIENT STRUCTURAL FEA OF A

MISALIGNED 4-CYLINDER ENGINE


CONTENT:




4. Transient Structural FEA of a misaligned 4-cylinder

engine................................................................................ page 17

5. The end........................................................................... page 56



- to properly set-up the contacts in moving parts

- to pre-investigate the contact behavior, for a proper definition

- to assign many types of joints (14 different ones)


- to define proper output for stress, strain, tools, lots of probes and

results depending on time


4.4.4.4. Transient Structural FEA of a misaligned 4-cylinder engine

Firstly, make sure

that you have a

proper geometry,

like the one we

provide, shown

here


Double click Transient Structural from Toolbox.

Right click Geometry, Import Geometry,

Browse... " 2013_12_09_engine1.x_t"

Right click Model, Edit...


In Mechanical window, expand Connections and right

click on Contacts, Rename Based on Definition

To check for interferences in

contact areas, right click on

Contact Tool, Insert,

Penetration

Right click, Generate Initial Contact Results


Initial Information shows, in orange, 2 contacts that are to worry

The max. penetration value

helps us define the Pinball

Radius, for the contact to

work without interference;

this is why we used 0.05

mm, bigger than the max.

penetration


For an easier view on

the piston, select any

face of the block, right

click, Hide Body


For Mobile, Scope, select

the 4 outer faces of the

corresponding piston

(green here), Apply


Right click any where,

Show All Bodies; for

verification, this is how

the Translational joint

looks like, when it's

finished

Solution, Stress,



Select all the pistons, Apply

Select the crankshaft, Apply


Solution, Probe, Force Reaction

Location Method, Contact

Region, select the last contact

from the drop down list

Duplicate the Force Reaction


Change the Contact

Region, as seen here

Solution, Tools, Contact Tool

Uncheck the last 4 contacts,

to have only the first ones

active, as seen here


Right click Status, Duplicate


Selecting Solution,

Information, this is the

log of the solver,

called Solver Output


Change Solver Output to

Force Convergence to

obtain a graphical

representation of the

solver's activity; we

observe that the analysis

converges nicely

Choosing Force Convergence

instead of Solver Output you will

obtain such a plot that shows a

nice convergence trend


After ~1 hour of solving time, this

is the Total Deformation plot



in pistons




STATIC STRUCTURAL DETAILED FEA OF

VERIFICATION OF M10 SCREWS USING BOLT

PRETENSION


CONTENT:




4. Static Structural detailed FEA of verification of M10 screws using

Bolt Pretension................................................................... page 17

5. The end........................................................................... page 54



- to properly set-up the Contacts , Named Selections, Object Generator

- to investigat

Expertfea Com Catalog September 2014

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Transcript of Expertfea Com Catalog September 2014