MACE 61059 Finite Element Mini Project: Modelling With Ansys

MINI PROJECT: MODELLING WITH ANSYS
MACE 61059 FINITE ELEMENT MINI PROJECT: MODELLING WITH ANSYS
NAME: MUHAMMAD SYAFIQ HISYAM MOHD SHAFFIAI STUDENT ID: 8492145 SUBMISSION DATE: 20TH MARCH 2013

INTRODUCTION The purpose of this project is to modelled the notched component given in figure using the Finite Element software package ANSYS. The main concerned from the project was the issues that arising from the loading of a simple notched component. Proper loading and constraints application were examined during modelling process. The notched component is loaded through 6mm diameter pins inserted in the holes and through a 12.68mm roller located in the notch. For the modelling, mesh size 2 were used, and it does give the results that were desired for the purpose of this project.
Figure 1
Notched Bar

WORK DESCRIPTION In this project, three loads models applied at holes C (Figure 2) were considered with given value of force P = 15kN. From the loading and material description, it will result a high direct and bending stress at the notch section, A, and smaller stress at the opposite edge, B. The three loads models are: i. ii. iii. A point load at C. A uniform pressure loading at C. A load applied through pins of 6mm diameter at C.
The description for the material is as below: Steel Bar: Material Youngs Modulus Poissons Ratio - Mild Steel - 211GN/ m2 - 0.33
Steel Pins and Roller: Youngs Modulus Poissons Ration - 400GN/m2 - 0.33
Figure 2

MODELLING WORKS: HALF BAR Since the bar was symmetrical at section DD, the section was considered as Y-axis and axis of the bar as X-axis. The boundary conditions for the bar were applied on the line at section AB, which is fixed along X-axis and at nodes of B, which is fixed at Y-axis. Case 1 : A point load at C For this case, a point load of P = 15000 N was applied on nodes at point C in X-direction. The results from the applied load are shown below. To plot the graph, the path that has been chosen is along the nodes on line AB.
Figure 3.1
Deformed Shapes
Figure 3.2
Von Mises Stress
Figure 3.3
Stresses at Point C
Figure 3.4
Stress in X-direction
Figure 3.5
Direct Stress in Y-Direction
Figure 3.6
Shear Stress
Figure 3.7
Stress for Full Section
Figure 3.8
Moment of Section

From the results obtained, it can be concluded that: 1. From the Von Mises Contour plot, it indicates that there is no stress at the notch. The highest stress value is at point C. 2. From the offset loading formula (Figure 3.9), the value obtained from calculation is 470.34 N/mm2. The stress obtained for X-direction along line AB from the modelling is 809.19 N/mm2.
Figure 3.9
Offset Loading Formula
3. From ANSYS, the workdone is calculated from the strain energy in the sum of element table which is 1176.06 J. 4. When the Von Mises yield stress is 700 MP, the yield load of the bar is equal to 12975.94 N. 5. From the Von Mises contour plot, the stress has a high value at the hole at point C, and if the structure failed, it will fail at this point. 6. The stress for full section is 1377.597 x 101 N which is less than the applied force, P, and the moment obtained is 3381.458 x 102 Nmm. 7. From the two other checks that been applied, the direct stress obtained is 120.847 N/mm2, and the shear stress is 24.613 N/mm2.

Case 2 : A uniform pressure loading at C For this case, a uniform load of P = 806.45 N/mm 2 was applied on lines along point C in Xdirection. The results from the applied uniform load are shown below. To plot the graph, the path that has been chosen is along the nodes on line AB.
Figure 4.1
Deformed Shape
Figure 4.2
Stress at hole C
Figure 4.3
Stress at notch D
Figure 4.4
Figure 4.5
Direct Stress
Figure 4.6
Shear Stress
Figure 4.7
Figure 4.8
Moment of Section

From the results obtained, it can be concluded that: 1. From the Von Mises Contour plot, it indicates that the stress at the notch D is lower than at C. the maximum value of stress at notch D is 901.227 N/mm2. 2. From the offset loading formula (Figure 3.9), the value obtained from calculation is 470.34 N/mm2. The stress obtained for X-direction along line AB from the modelling is 809.196 N/mm2.
Figure 3.9
3. From ANSYS, the workdone is calculated from the strain energy in the sum of element table which is 823.425 J. 4. When the Von Mises yield stress is 700 MP, the yield load of the bar is equal to 12975.84 N. 5. From the Von Mises contour plot, the stress has a high value at the hole at point C, and if the structure failed, it will fail at this point. 6. The stress for full section is 1377.594 x 101 N which is less than the applied force, P, and the moment obtained is 3381.451 x 102 Nmm. 7. From the two other checks that been applied, the direct stress obtained is 120.846 N/mm2, and the shear stress is 24.612 N/mm2.

Case 3 : A load applied through pins of 6 mm diameter at C For this case, a different material was applied for the pins at point C and meshing part have been done separately. A point load of P = 15000 N was applied on the middle nodes through the pins of 6 mm diameter at point C in X-direction. The results from the applied load are shown below. To plot the graph, the path that has been chosen is along the nodes on line AB.
Figure 5.1
Deformed Shape
Figure 5.2
Von Mises Contour stress at pin C
Figure 5.3
Von Mises Contour stress at notch D
Figure 5.4
Figure 5.5
Direct Stress
Figure 5.6
Shear Stress
Figure 5.7
Figure 5.8
Moment of section
From the results obtained, it can be concluded that:

1. From the Von Mises Contour plot, it indicates that the stress at the notch D is lower than at C. the maximum value of stress at notch D is 826.579 N/mm2. 2. From the offset loading formula (Figure 3.9), the value obtained from calculation is 470.34 N/mm2. The stress obtained for X-direction along line AB from the modelling is 830.539 N/mm2.
Figure 3.9
3. From ANSYS, the workdone is calculated from the strain energy in the sum of element table which is 791.26 J. 4. When the Von Mises yield stress is 700 MP, the yield load of the bar is equal to 12642.39 N. 5. From the Von Mises contour plot, the stress has a high value at the pin at point C, but the stress is lower than in the case 1 and 2, and if the structure failed, it will fail at pin. But, higher stress value at holes has a higher chance of failing than pins. 6. The stress for full section is 1418.644 x 101 N which is less than the applied force, P, and the moment obtained is 3530.427x 102 Nmm. 7. From the two other checks that been applied, the direct stress obtained is 108.815 N/mm2, and the shear stress is 24.47 N/mm2.
MODELLING WORKS: FULL BAR
For this asymmetric loading case, the bar is loaded horizontally with load of 15000 N applied through the 12.68 mm diameter roller. The boundary conditions for the bar were applied on the holes at C for case 1 without pins which is fixed along X-axis and Y-axis, and at pins for case 2, which is fixed at all degree of freedom. Case 1 : Boundary Condition fixed at X and Y Direction. For this case, a point load of P = 15000 N was applied on pin at D in X-direction. The boundary condition for this case is fixed at X and Y-direction for both holes C. The results from the applied load are shown below. To plot the graph, the path that has been chosen is along the straight line from the top of the circular holes C1 (Left side) and C2 (Right side), to the bottom of the bar. For full bar case, the graph for both holes has been separately.
Figure 6.1
Deformed Shape
Figure 6.2
Von Mises Stress Contour
Figure 6.3
Stress at Holes C1 and C2
Figure 6.4(a) Stress at holes C1
Figure 6.4(b) Stress at holes C2
Figure 6.5(a) Direct Stress at holes C1
Figure 6.5(b) Direct Stress at holes C2
Figure 6.6(a) Shear Stress at holes C1
Figure 6.6(b) Shear Stress at holes C2
Figure 6.7(a) Stress of full section at holes C1
Figure 6.7(b) Stress of full section at holes C2
Figure 6.8(a) Moment at holes C1
Figure 6.8(b) Moment at holes C2

From the results obtained, it can be concluded that: 1. From the Von Mises Contour plot, it indicates the variation of stress at D, and very low value of stress at C. 2. From the offset loading formula (Figure 3.9), the value obtained from calculation is 470.34 N/mm2. The stress obtained along the path at C is 226.56 N/mm2.
Figure 3.9
3. From ANSYS, the workdone is calculated from the strain energy in the sum of element table which is 549.691 J. 4. When the Von Mises yield stress is 700 MP, the yield load of the bar is equal to 2331 N. 5. From the Von Mises contour plot, the stress has a very low value at point C, but the stress is higher at D, and if the structure failed, it will fail at notch D. 6. The stress for full section is 7166.027 N at C 1 and 7047.693 N at C2 which is less than the applied force, P, and the moment obtained is 2123.482 x 10 2 Nmm at C1, and 1978.693 x 102 at C2. 7. From the two other checks that been applied, the direct stress obtained is 87.552 N/mm 2 at C1, and 92.019 N/mm2 at C2 and the shear stress is 124.724 N/mm2 at C1, and 148.555 N/mm2 at C2.

Case 2 : Boundary Condition fixed at all Degree of Freedom. For this case, a point load of P = 15000 N was applied on pin at D in X-direction. The boundary condition for this case is fixed at all degree of freedom for both holes with pins at C. The results from the applied load are shown below. To plot the graph, the path that has been chosen is along the straight line from the top of the circular holes C 1 (Left side) and C2 (Right side), to the bottom of the bar. For full bar case, the graph for both holes has been separately.
Figure 7.1
Deformed Shape
Figure 7.2
Stress at pin D
Figure 7.3(a) Stress at C1
Figure 7.3(b) Stress at C2
Figure 7.4(a) Stress X-direction at C1
Figure 7.4(b) Stress X-direction at C2
Figure 7.5(a) Direct stress at C1
Figure 7.5(b) Direct Stress at C2
Figure 7.6(a) Shear Stress at C1
Figure 7.6(b) Shear Stress at C2
Figure 7.7(a) Stress full section at C1
Figure 7.7(b) Stress full section at C2
Figure 7.8(a) Moment at C1
Figure 7.8(b) Moment at C2

From the results obtained, it can be concluded that: 1. From the Von Mises Contour plot, it indicates the variation of stress at D, and very low value of stress at C. 2. From the offset loading formula (Figure 3.9), the value obtained from calculation is 470.34 N/mm2. The stress obtained along the path at C is 226.56 N/mm2.
Figure 3.9
3. From ANSYS, the workdone is calculated from the strain energy in the sum of element table which is 576.771 J. 4. When the Von Mises yield stress is 700 MP, the yield load of the bar is equal to 2331 N. 5. From the Von Mises contour plot, the stress has a very low value at point C, but the stress is higher at D, and if the structure failed, it will fail at pin D. 6. The stress for full section is 5347.937 N at C 1 and 5162.58 N at C2 which is less than the applied force, P, and the moment obtained is 1534.324 x 102 Nmm at C1, and 1546.961 x 102 Nmm at C2. 7. From the two other checks that been applied, the direct stress obtained is 47.035 N/mm 2 at C1, and 45.859 N/mm2 at C2 and the shear stress is 112.439 N/mm2 at C1, and 106.455 N/mm2 at C2.

CONCLUSION The value obtained is inconsistence from the modelling in ANSYS might due to the mesh size use which smaller meshes will give more accurate value. The constraint provided in the modelling have effects on the value obtained, which shows the inconsistencies in the results. From all the values obtained from the half bar cases, case 3 give more accurate value since the value obtained is almost as the given force and moment value from the calculations. From the values obtained in full bar cases, case 2 give more accurate value than the first case, which it shows the value obtained is almost as the given force and calculated moment value.

MACE 61059 Finite Element Mini Project: Modelling With Ansys

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MACE 61059 Finite Element Mini Project: Modelling With Ansys

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MINI PROJECT: MODELLING WITH ANSYS