Modeling ProcedurePLANE82 – 8-Noded Quadrilateral

SOLID186 – Ten-Noded Tetrahedral

198 Elements

5247 Elements

*Needed mid-nodes to model curves

ConvergenceTesting Performed To Ensure Model Precision

Meshes under 2000 elements exhibited inconsistent results

Mesh 9198 Elements

Mesh 7305 Elements

Mesh 6348 Elements

Mesh 5424 Elements

0 1000 2000 3000 4000 50009

10

11

12

13

14

15

Element Number

Equi

vale

nt S

tress

(MPa

)

Mesh 4640 Elements

Mesh 3919 Elements

Mesh 21239 Elements

Mesh 11749 ElementsMesh 1-Refined5247 Elements

Experimental Strain Testing

Averaged Elemental Equivalent Stresses over Gauge Region

Applied Load in Instron Machine

Experimental Strain Testing

0 0.5 1 1.5 20

5

10

15

20

Experimental StressANSYS 2D StressANSYS 3D Stress

Load at Cam Handle [kN]

Equi

vale

nt S

tress

[MPa

]

Photoelastic Comparison

Simulated loading in Photoelastic Apparatus

Created photoelastic model of cam lobe from clear polymer

Stress concentrations closely matched FE predictions

Photoelastic Comparison

General stress fields similar

Hard to simulate photoelastic stress fringes

Would have more success with Material specifications

Failure Analysis

30 kN(6750 lb)

20 kN(4500 lb)

15 kN(3350 lb)

Stress Results for 12.5 kN

(2800 lb)Loads Exceeding 12.5 kN were found to cause excessive plastic failure

Main failure regions were not in the arches

UIAA Standards require 12 kN rating for rope

Manufacturer Rating: 14.4 kN