Expertfea Com Catalog June 2014

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expert expert expert expertfea.com fea.com fea.com fea.com catalog catalog catalog catalog with with with with
21 FEA tutorials 21 FEA tutorials 21 FEA tutorials 21 FEA tutorials
available in available in available in available in June June June June 2014 2014 2014 2014
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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 gears meshing spur gears meshing spur gears meshing spur gears

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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

4

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

5

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"
6

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
7


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 plasticity pressing with plasticity pressing with plasticity pressing with plasticity
onto a plate onto a plate onto a plate onto a plate
(double symmetry) (double symmetry) (double symmetry) (double symmetry)
8

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

9


- 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

10

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
11

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
12

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
13

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
14

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
15

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
16

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
17

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
18

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
19

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
20

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
21


Static Structural FEA Static Structural FEA Static Structural FEA Static Structural FEA
of meshing bevel gears of meshing bevel gears of meshing bevel gears of meshing bevel gears (debugging (debugging (debugging (debugging
solution to achieve convergence) solution to achieve convergence) solution to achieve convergence) solution to achieve convergence)

22

CONTENT:

4. Static Structural FEA of meshing bevel gears.................. page 17
5. The end........................................................................... page 51

23


- 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

24

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"
25

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
26

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
27

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
28

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
29

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
30

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
31

1. Re-run the analysis with
high hopes this time :)
2. Our hopes were met,
because the analysis
successfully converged!
32

1. This is how the stress
looks at the last time step;
notice the peaks caused
by the teeth collisions
33

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
34


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 wedge crashing into a wall and a wedge crashing into a wall and a wedge crashing into a wall and a wedge
35

CONTENT:

4. Explicit Dyanmics FEA of a car body crashing................. page 17
5. The end.......................................................................... page 46

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- 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

37

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
38

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
39

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
40

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
41

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
42

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
43

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
44

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
45


Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of
a a a a copper sheet stamping copper sheet stamping copper sheet stamping copper sheet stamping
(double symmetry) (double symmetry) (double symmetry) (double symmetry)
46

CONTENT:

4. Static Structural FEA of a copper sheet stamping.......... page 17
5. The end.......................................................................... page 54

47


- 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.)

48

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
49

1. We have cut
half of the
assembly
longitudinally
and
transversally
50

1. Open Ansys
Structural into the
Import Geometry, Browse
for narrow_stamp.x_t,
Open
51

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
52

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
53

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
54

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
55

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
56

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
57

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
58

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
59

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
60


Static Structural Static Structural Static Structural Static Structural FEA of FEA of FEA of FEA of
rolling of a copper plate rolling of a copper plate rolling of a copper plate rolling of a copper plate
61

CONTENT:

4. Static Structural FEA of rolling of a copper plate............ page 17
5. The end.......................................................................... page 51

62

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?

63


- 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.

64

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
65

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
66

1. To look normally at
the sketch, press
Look At
Face/Plane/Sketch
2. Select Sketching tab
and press Rectangle
67

1. Draw a free-style
rectangle that will
contain the plate
2. Return to Modeling
tab than click Extrude
68

1. To extend the plate,
select its end, than
click New Sketch
2. Look at Face /
Plane; switch to
Sketching tab, Modify
69

1. Press Duplicate and
select the lines of the
rectangle
2. Right click,
Duplicate Selection
3. Back to Modeling
tab, press Extrude
70

1. The new Extrude
should have these
details
2. Having obtained
the optimized
geometry, Close
Design Modeler
71

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
72

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
73

1. Select the first
Bonded contact,
click on Contact and
select all 3 underside
faces that will touch
the Target, Apply
74

1. Solution, Strain,
Equivalent Plastic
2. To see the values
only in the piece,
select it, Apply
3. Solution, Stress,
Equivalent (von-Mises)
75

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
76

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
77

1. Select the
faces on the tip of
the piece, Apply
2. Right click on
Directional
Deformation,
Evaluate All Results
78

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
79

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
80

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!
81


Transient Structural Transient Structural Transient Structural Transient Structural FEA of FEA of FEA of FEA of
heat generated between heat generated between heat generated between heat generated between
a piston and a cylinder a piston and a cylinder a piston and a cylinder a piston and a cylinder
82

CONTENT:

4. Transient Structural FEA of heat generated between a
piston and a cylinder...................................................... page 17
5. The end.......................................................................... page 57

83


- 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.

84

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...
85

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
86

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
87

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
88

1. With the selection filter on
Body, select the piston, Apply,
Orientation, Y Axis
2. Solution, Deformation,
Directional Velocity
89

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
90

1. For Contact Tool, because
the default is Status, change
Type to Pressure
2. Solution, Probe, Joint
3. Boundary Condition,
Revolute - ConnectingRod; To
PistonHead;
91

1. This is the vertical
displacement of the
piston, with a
sinusoidal shape, as
we would expect it
92

1. This is the Temperature plot
inside the cylinder
2. This is the Temperature plot
outside the piston
93


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

94

CONTENT:

4. Modal analysis and random vibrations
using PSD on a PCB........................................................ page 17
5. The end.......................................................................... page 63

95


- 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.

96

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
97

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
98

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
99

1. No interference now
2. This is the 2nd mode
3. This is the 3rd mode
100

1. This is the 4th mode
101

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.
102

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
103

1. Right click, Clear
Generated Data
2. Having active the
Body selection filter,
click the capacitors,
green here, Apply
104

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
105

1. The Response PSD plot looks like
here; close Mechanical window
2. Drag Random Vibration on Modal Solution;
name it Random Vibration Z axis
106

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)
107


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 load under load under load under load
108

CONTENT:

4. Static Structural FEA of a roller bearing under load......... page 17
5. The end.......................................................................... page 41

109


- 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.

110

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...
111

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
112

1. Right click on
Contacts,
Insert, Joint
2. Connection Type,
Body-Ground
113

1. Select the outer
face of the bearing,
green, here, Mobile,
Scope, Apply
2. From Connections
toolbar, select Body-
Ground, Revolute
114

1. Select the inner face of
the bearing, green here,
Mobile, Scope, Apply
2. Drag a window as
shown here, to
include all bodies
115

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
116

1. This is the Stress plot
2. This is the Contact
Status plot
117

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
118


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 PLANER PLANER PLANER PLANER
119

CONTENT:

4. Explicit Dynamics FEA of machining with a planer........... page 17
5. The end........................................................................... page 30

120


- 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

121

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
122

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"
123

After Apply, select Type,
Number of Divisions, 10
124

Go to Analysis
Settings and insert
End Time, 0.00075
From Environment
toolbar select Velocity
To define the needed
output, select Solution,
Deformation, Directional
125

Solution, Total Velocity
Solution, Stress,
Solution, Strain,
Equivalent Plastic
126

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
127

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
128

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
129

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!
130


STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A STATIC STRUCTURAL FEA OF A
THREADED BOLT THREADED BOLT THREADED BOLT THREADED BOLT- -- -WASHER WASHER WASHER WASHER- -- -NUT NUT NUT NUT
CONNECTION CONNECTION CONNECTION CONNECTION
131

CONTENT:

4. Static Structural FEA of a threaded bolt-washer-nut
connection......................................................................... page 17
5. The end........................................................................... page 54

132


- 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

133

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...
134

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
135

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
136

From tree click on
Solution, than go to the
upper toolbar,
Deformation, Total
Deformation, Directional
With selection filter on
Body, click the bolt, Apply
137

Solution, Stress,
Scope only the
washer, Apply
Right click on the previously
created Equivalent Stress,
Duplicate
138

Scope only
the bolt, Apply
Solution, Strain,
Scope only the nut, Apply
139

To proceed to the solving part,
right click on Solution, Solve
Firstly, the mesh is created
and this is how it looks like
140

Clicking Solver Output
gives this solver log
141

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
142

As the solving continues, the spikes may
get pretty crowded, as seen here
This is the Directional Deformation
plot in bolt and washer
143

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
144


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
PINS PINS PINS PINS
145

CONTENT:

4. Explicit Dynamics FEA of the impact between a bowling ball and its
pins............................................................................... page 17
5. The end........................................................................... page 53

146


- 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

147

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
148

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
149

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
150

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
151

For the ball to run into
the pins, select X
Component, Tabular
152

This is the Energy Conservation
plot before any collision
153

For easier reading,
insert 100 Display
Points (instead of 0)
and we will obtain a
better resolution
154

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
155

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
156

Right click on the newly created Directional
Deformation, Evaluate All Results
157

The needed variation in
time, of the pin's
height, looks like here
158

Let us parameterize the extreme
values for later solving; check the
boxes in front, as seen here
marked with blue P letters
159

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
160


STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING STATIC STRUCTURAL FEA OF STAMPING
WITH HALF SYMMETRY WITH HALF SYMMETRY WITH HALF SYMMETRY WITH HALF SYMMETRY
161

CONTENT:

4. Static Structural FEA of stamping with half symmetry..... page 17
5. The end........................................................................... page 52

162


- 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

163

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...
164

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
165

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
166

When we have this
magnitude of zoom, we
can stop zooming
Select the cut surface of the
die (green here, Apply)
167

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
168

With Ctrl pressed, click the lateral
surface to unselect it (blue here),
than click the spherical surface,
(green here); Apply
169

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
170

This is the result
Environment,
Fixed Support
Select the outer
faces of the die
(green here), Apply
171

With selection
filter on Body,
select the piece
(green here,
Apply)
Solution, Tools,
Contact Tool
Uncheck the second
contact, to have this result
172

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
173

This is the max. pressure
plot in first Contact Tool
174

For Contact Tool 2, retrieve
also the value from second 6
175

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!
176


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 skyscraper PSD on a real size skyscraper PSD on a real size skyscraper PSD on a real size skyscraper
177

CONTENT:

4. Seismic Random Vibration analysis using PSD on a real size
skyscraper......................................................................... page 17
5. The end.......................................................................... page 68

178


- 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.

179

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
180

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
181

Right click on Mesh, Insert, Sizing
With selection filter on Body,
click the 6 columns (green
here), Geometry, Apply
182

Assign them Element
Size, 1000 mm
To see the mesh, right
click on it, Generate Mesh
183

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
184

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
185

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
186

Solution,
Probe,
Response PSD
187

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
188


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 PLASTICITY CLAMP WITH PLASTICITY CLAMP WITH PLASTICITY CLAMP WITH PLASTICITY

189

CONTENT:

4. Static Structural FEA of toggle clamp with plasticity....... page 17
5. The end........................................................................... page 47

190

- 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.

191

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
192

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
193

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
194

Select both bolt holes, Scope, Apply
Connections, Body-Ground, Fixed, select the
underside of the base plate, Scope, Apply
195

Connections, Body-Body, Revolute
Select the outer surface, green
here, Reference Scope, Apply
196

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
197

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
198

Solution, Strain,
Equivalent Total
With selection filter on Body,
select this green part, Apply
199

If at Solution Output you
choose Force Convergence
you will see this window
200

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
201

This is the Equivalent Total Strain plot
202


TRANSIENT STRUCTURAL FEA OF BENDING A
LAMELLA WITH PLASTICITY AND SPRING BACK
EFFECT

203

CONTENT:

4. Transient Structural FEA of bending a lamella with plasticity
and spring back effect....................................................... page 17
5. The end........................................................................... page 48

204


- 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

205

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 effect spring back effect spring back effect spring back effect

Firstly, make sure
that you have a
proper geometry,
like the one we
provide, shown
here
206

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"
207

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
208

The mesh looks like here,
with an optimum number of
nodes and elements, to
ensure short solving time
Analysis Settings,
Number of Steps = 30
209

Select the external faces of the
die, green here, Apply
Right click Transient (A5), Insert, Displacement
210

Select all lateral
faces, green here,
Apply; Z
Component = 0 mm
Solution, Deformation, Directional
211

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)
212

With selection filter on Body, click the lamella, Apply
Solution, Strain, Equivalent Total;
with selection filter on Body, click
the lamella, Apply
213

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
214

This is the Directional Deformation plot
on Y axis, vertically; observe a
remanent deformation of 0.626 mm,
due to the spring back effect
215

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
216


TRANSIENT STRUCTURAL FEA OF A GRIPPER
WITH GEARS AND JAWS

217

CONTENT:

4. Transient Structural FEA of a gripper with gears and
jaws.................................................................................... page 17
5. The end........................................................................... page 50

218


- 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

219

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"
220

Right click Model, Edit...
With Shift or Ctrl pressed, select
all the parts named "Claw-
Bolt1", right click, Suppress
221

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
222

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
223

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
224

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
225

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
226

This is the resulting
Spring joint
For verification, select with Shift pressed
all 12 joints and they should look like here
227

Solution, Deformation,
Directional
Right click anywhere, Show All
Bodies; Orientation, Z Axis,
select with Ctrl pressed these
green surfaces, Apply
228

Solution, Tools, Contact Tool
Right click Status, Duplicate
Change Status 2's Type to Pressure
Solution, Probe, Force Reaction
229

Insert these details
230

Click on Solution
Information to see what
the solver is doing
231

For a graphical representation of the solver's activity, change
Solver Output to Force Convergence; for a rarified plot, make
Display Points = 35
232

After ~25 min, the solve is finished;
this is the Total Deformation plot
233

This is the Strain plot
234

This is the Stress plot
plot showing the displacement/ the
stroke of the jaws
235


TRANSIENT STRUCTURAL FEA OF A
MISALIGNED 4-CYLINDER ENGINE

236

CONTENT:

4. Transient Structural FEA of a misaligned 4-cylinder
engine................................................................................ page 17
5. The end........................................................................... page 56

237


- 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

238

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
239

Double click Transient Structural from Toolbox.
Browse... " 2013_12_09_engine1.x_t"
240

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
241

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
242

For an easier view on
the piston, select any
face of the block, right
click, Hide Body
243

For Mobile, Scope, select
the 4 outer faces of the
corresponding piston
(green here), Apply
244

Right click any where,
Show All Bodies; for
verification, this is how
the Translational joint
looks like, when it's
finished
Solution, Stress,
245

Select all the pistons, Apply
Select the crankshaft, Apply
246

Solution, Probe, Force Reaction
Location Method, Contact
Region, select the last contact
from the drop down list
Duplicate the Force Reaction
247

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
248

249

Selecting Solution,
Information, this is the
log of the solver,
called Solver Output
250

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
251

After ~1 hour of solving time, this
is the Total Deformation plot
252

in pistons
253


STATIC STRUCTURAL DETAILED FEA OF
VERIFICATION OF M10 SCREWS USING BOLT
PRETENSION

254

CONTENT:

4. Static Structural detailed FEA of verification of M10 screws using
Bolt Pretension................................................................... page 17
5. The end........................................................................... page 54

255


- to properly set-up the Contacts , Named Selections, Object Generator
- to investigate the validity of the results with Structural Error tool
- to optimize the geometry and the mesh where needed
- to define proper output for stress, strain, tools etc.
- to re-run the FEA with non-linear materials

256

4. 4. 4. 4. Static Structural FEA of verification of M10 screws using Bolt
Pretension

Firstly, make sure
that you have a
proper geometry,
like the one we
provide, shown
here
Double click Static Structural from Toolbox.
Browse... " 2013_12_20_flanges_bolts1.x_t"
257

For last 4 features, let us change the
measurement unit to MPa, as seen here
For the very common bolt steel
with 8.8 grade, insert these values
258

Refresh Project, Return to Project
Right click Component2, Rename to:
"nut M10"; right click Component1,
Rename to: "bolt M10"
259

To set the mesh size for the rest of
the parts, right click on Body Sizing,
Duplicate
Click Geometry, 8 Bodies, zoom with middle mouse
to properly select the flanges and the spacer
between them, Apply, Element Size = 4 mm
260

Make sure you have checked Named
Selections toolbar from View menu
261

With selection filter on Face, select with Ctrl
pressed the 4 cylinders of the bolts (green here),
than press Create Named Selection button
262

Uncheck the contact from the
ring and the bonded ones, as
seen here
Change Type of Status 2
to Pressure
Right click Pressure, Duplicate
263

Change Type of
Pressure to Penetration
Right click Solution
Information, Solve
264

This is how
Solver Output
shows the
activity of the
solver
Change Solver Output to
Force Convergence for a
graphical representation
of the solver's activity
265

This is the force Convergence plot where
we will see when the solver converges
After the successful finish of the solving,
make sure that the results scale is 1 and
check the axial Directional Deformation
266

This is the stress only in
the bolts; click on the
upper Probe button than
on different points to find
out the stress where
needed; compared to the
Yield Stress of 640 MPa,
we are exactly fine
267

After we have adjusted the legend to visible, this is the Safety
Factor plot in the M10 screws, related to Yield Stress
268

To illustrate the Contact Tool, use 4
viewports pressing the respective
button in the upper toolbar
269


STATIC STRUCTURAL FEA OF A PIN LARGELY
DEFORMING A RUBBER SEALING
270

CONTENT:

4. Static structural FEA of a pin largely deforming a
rubber sealing................................................................... page 17
5. The end........................................................................... page 35

271


- to assign hyperelastic and plastic materials
- to set-up a proper mesh with dropped midside nodes
- to correctly assign contacts between distinct parts and between
features of the same part
- to set-up a multi-step Static Structural FEA
- to define proper output for stress, strain, tools etc.

272

4. Static structural FEA of a pin largely deforming a rubber sealing

Firstly, make sure
that you have a
proper geometry,
like the one we
provide, shown
here
Drag Static Structural from Toolbox to Project
Schematic. Right click Geometry, Import Geometry,
Browse... " 2014_01_29_sealing_1lip4.x_t "
273

On the Environment toolbar, choose
Supports, Displacement
Select the outer face of the pin, Apply.
X and Z Component = 0 mm and for Y
Component choose Tabular Data.
274

Insert these values in Y column.
On the Environment toolbar, choose
Supports, Fixed Support.
275

Click the green face,
than propagate the
selection with Extend to
Limits, Apply.
Click the green face,
than propagate the
selection with Extend to
Limits, Apply.
On the Solution toolbar, choose Deformation, Total.
Solution toolbar, Deformation, Directional.
Orientation = Y Axis
276

Solution, Stress, Equivalent (von-Mises).
Solution, Strain, Equivalent (von-Mises).
Select the sealing, Apply.
Solution, Tools, Contact Tool.
We are not interested of what happens
between the polyethylene reinforcement
and the surrounding rubber, so uncheck
the Bonded contact, as seen here
277

Right click Contact Tool, Insert, Pressure
Solution, Probe, Force Reaction.
Location Method = Contact Region.
Contact Region = Frictionless - pin To
sealing.
Right click Solution (A6), Solve.
278

During solving, if you select Solution
Information = Force Convergence, you
will get a similar plot, very helpful on
judging the tendency of the solution
computation.
Right click Equivalent
Stress, Evaluate All Results.
Scope only for the
reinforcement, Apply.
279

This is the Stress plot only in
the reinforcement.
This is the Status of the
Contact Tool.
280


TRANSIENT STRUCTURAL FEA OF A SMALL SKID
STEER LOADER

281

CONTENT:

4. Transient structural FEA of a small skid steer loader....... page 17
5. The end........................................................................... page 49

282


- to work with both rigid and flexible bodies
- to correctly assign many different joints (23)
- to set-up a multi-step Transient Structural FEA
- to define proper output for stress, deformation, velocity, probes etc.

283

4. Transient structural FEA of a small skid steer loader

Firstly, make sure
that you have a
proper geometry,
like the one we
provide, shown
here.
Drag Transient Structural from Toolbox to Project
Schematic. Right click Geometry, Import Geometry,
Browse... " 2013_10_18_loader_asm.x_t ".
284

Right click Contacts, Delete.
Select first 9 components (green
here), with Shift pressed and
make Stiffness Behavior, Rigid.
285

From the upper Connections toolbar, choose Body-Ground, Fixed.
Let us fix the loader body: select the underside, green here, Apply.
From the Connections toolbar, choose Body-Ground, Revolute.
286

Select the green surface from Component10, Apply. Repeat the
Revolute Joint for the Component15 on the other side.
Selecting with Shift pressed all 23 joints, they should
look like here. 11 pairs of mirrored joints and 1 joint
fixes the excavator body.
287

To simulate a load in
the hoe, right click
Transient (A5), Insert,
Pressure
Click Analysis Settings and make
Number of Steps = 10.
Select with Shift pressed all 10 steps
from the lower right Graph tab and
insert these values for Initial,
Minimum and Maximum Time Step
288

Click inside of the hoe, Apply.
Magnitude = 0.07 MPa
Choose from Solution toolbar,
Stress, Equivalent (von-Mises)
289

With selection filter on Body, click the 5
parts, green here, Apply
Choose from Solution toolbar, Deformation, Directional
Select only the hoe, Apply. Orientation, Y Axis.
290

To see how the FEA evolves, make Solution
Output, Force Convergence. Display Points, 35
291

This is the Stress in pistons.

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