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M&AE 3272 - Spring 2014

Module 3: Bicycle Component Modeling and Testing

M&AE 3272: Mechanical Property and Performance Laboratory

Bikes of the Future?

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MAE 3272 Blackboard site

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Module 3: Bicycle Component Modeling and Testing

M&AE 3272: Mechanical Property and Performance Laboratory

A/D Conversion; Signal Processing; and Display

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Measurement Systems:

Material or System under Test

Actuator

Actuator System

Control Stage

Sensing Element

Signal Conditioning/ Processing Stages

Transduction System

Stage 1

Stage n

Output Stage

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Module 3: Bicycle Component Modeling and Testing

Crank Geometry Crank designs based on past years M&AE 3250 designs ANSYS Modeling Model with ANSYS to find two locations for strain gage rosettes: (1) High stress concentration; (2) Uniform stresses Gaging and static testing Pre-machined crank arms provided; Gage with strain gage rosettes; Static loading; comparison with ANSYS modeling In-situ Testing Crank installed on bicycle: Pedal Force components; Crank Position; LabVIEW vi provided! (22 data sets) 2 Strain gage rosettes (2 times 3 strain components) Data Comparison Compare principal strains/directions with ANSYS model predictions Virtual Presentations Group prepares Data Sheet critically comparing static measurements/modeling; Results of dynamic testing; and a 5-Slide Presentation of results
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Module 3: Bicycle Component Modeling and Testing

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Module 3: ANSYS Component Modeling

1. Back-of-the-envelope estimates using beam theory 2. Import CAD geometry 3. Mesh, Setup Physics and Solve 4. Check results 5. Add gauges to CAD geometry 6. Calculate strain values for gages 7. Compare with measured values
Original Slide from R Bhaskaran, 2014

Covered in MAE 3250

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Module 3: ANSYS Component Modeling

Use Euler-Bernoulli beam theory See Pre-Analysis step in the tutorial

Original Slide from R Bhaskaran, 2014

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Module 3: Strain Gage Modeling in ANSYS

Extract average strain over the area covered by strain gage Create a surface element for each strain gage Shell element: shell181 Use for strain/stress evaluation only
Gage nodal displacements are calculated from underlying crank displacements
Not from stiffness matrix inversion Stiffness of gage is ignored
Original Slide from R Bhaskaran, 2013, 2014
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shell181: 4 nodes per element

M&AE 3272 - Lecture 8

Module 3: Strain Gage Modeling Procedure

Create surface on crank face
Plane > Sketch > Surface from sketch

Bond surface to crank face

Should happen automatically

Mesh surface with one shell181 element

Insert Commands Tell ANSYS to use shell181 purely for post-processing

Solve and view results

Use solution coordinate system to get strain component in direction ANSYS will do the transformation and averaging to find Original Slide from
M&AE 3272 - Lecture 8

R Bhaskaran, 2014

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Module 3: Strain Gage Modeling: Commands

See help for shell181 for more info

et: set element type keyopt: set keyoption to control element behavior

et, matid, 181: set element type to 181 (i.e. shell181) keyopt, matid, 1, 2: set keyoption #1 to 2 (strain/stress evaluation only)

Original Slide from R Bhaskaran, 2014

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Module 3: Strain Gage Modeling: Mesh

Original Slide from R Bhaskaran, 2013

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Strain Gage Modeling: Solution Coordinate System

Local coordinate system for element

Original Slide from R Bhaskaran, 2014

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Verification of ANSYS Results:

Check that:
Boundary conditions on displacement and traction are satisfied Equilibrium is satisfied: Reactions balance applied load ANSYS results are reasonably independent of the mesh ANSYS results compare well with EulerBenoulli beam theory
Original Slide from R Bhaskaran, 2014

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ANSYS Modeling: Mesh Refinement

Original Slide from R Bhaskaran, 2013

Need to check dependence of results on the mesh size

ANSYS (0.05 edge sizing)

ANSYS (0.075 edge sizing)

ANSYS (0.1 edge sizing)

Beam Bending Theory

xx
(micro-strain)
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-1239.9

-1239.4

-1239.0

-1227.9
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Module 3: Modeling - Four Bicycle Crank Designs

Crank #1: Crank #2:

Crank #3:

Crank #4:

Parasolid files of these geometries are available to you for direct input to ANSYS
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Module 3: ANSYS Component Modeling

Geometry import procedure:
https://confluence.cornell.edu/x/fQZoC

When both crank arm and pedal shaft are present, need to form new part to connect them.

Original Slide from R Bhaskaran, 2011

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Module 3: Modeling Loading Detail

Static Loading Case Pedal (Dynamic) Loading Case

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Module 3: ANSYS Component Modeling

Initial Mesh

Undeformed/Deformed Shape von Mises Stress

Refined Mesh
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Stresses and Deformations in Ductile Materials

2D State of Stress on Material Surface, e.g. x, y and xy ; Plane strain applies: x, y and xy . Failure (yielding) of ductile materials (e.g. metals) is due to a change of shape (twist, pull, bending). The 2nd Deviatoric Stress Invariant reaches a critical value. von Mises Yield Criterion: Maximum Distortion Energy/Volume is less than the Distortion Energy/Volume of yielding: UD = 1/(6*G){12 1*2 + 22} where 1 and 2 are the principal stresses; G is the Modulus of Rigidity For a tensile test: 1=Y; 2=0 (UD)Y = Y2/(6*G) .

von Mises Yield Criterion: 12 1*2 + 22 < Y2 Define: von Mises stress
M&AE 3272 - Lecture 8

{12 1*2 + 22}1/2 [MPa]

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Stresses and Deformations in Ductile Materials

von Mises Yield Criterion: Maximum Distortion Energy/Volume is less than the Distortion Energy/Volume of yielding: UD = 1/(6*G){12 1*2 + 22} where

1 and 2 are the principal stresses;

G is the Modulus of Rigidity. For a tensile test: 1=Y; 2=0 (UD)Y = Y2/(6*G) . von Mises Yield Criterion:

12 1*2 + 22 < Y2
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Module 3: ANSYS Component Modeling

Import Parasolid crank design: File->Import->Para Select solid facets display mode: Utility Menu->Plotctrls->Style->Solid Model Facets (Select Normal Faceting); Utility Menu->Plot->Volumes Scale Object to `meters: Main Menu->Preprocessor->Modeling->Operate->Scale>Volumes (Pick all) RX, RY, RZ: 1000 each Verify geometry: Utility Menu->List->Keypoint->Coordinates only (Compare keypoint locations with Solidworks drawing) `Glue volumes to share Main Menu->Preprocessor->Modeling->Operatecommon areas between crank >Booleans->Glue->Volumes (Pick ALL) and pedal shaft: Check Command Window; look for GLUE VOLUMES HINT: When using MESH200 elements, select the z-Face of both the crank arm and pedal shaft to insure that the nodes of each element coincide. COMPUTE: Region of maximum change of von-Mises stress; (for best location of e-gages) Region of most uniform deformation (large values!) DELIVERABLES: Iso-metric views of original mesh; Refined mesh; Plot of (Annotate plots: Name; View) element solution for von-Mises stress (Original/Refined).
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Module 3: ANSYS Component Modeling - 2

COMPUTE (for best location of -gages):
Region of maximum von-Mises stress; Region of most uniform deformation but large!

DELIVERABLES:
(Annotate plots: Name; View) Iso-metric views of original mesh Refined mesh Plot of von-Mises stress (Original/Refined).
Original Slide from R Bhaskaran, 2011
M&AE 3272 - Lecture 8

Saving Images in ANSYS Mechanical

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Module 3: ANSYS Component Modeling

Initial Mesh

Undeformed/Deformed Shape von Mises Stress

Refined Mesh
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Measurement of Deflections, Strains and Stresses in a crank arm:

Specimen surface is in a state of plane stress. e.g. x, y and xy . Equations of plane strain apply; e.g. x, y and xy . Measure strains x, y on the specimen surface. How can one measure the shear strain? How can one determine the principal strains, 1, 2 principal stresses, 1, 2 ,and their direction, ? Solution: Three strain gages oriented at different directions mounted on the surface of the specimen.
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Strain Gage Rosette: Determination of Principal Strains/Stresses

Omega: SGD-1/350-RY83

Three (3) strain gages mounted in different directions. Each gage measures longitudinal strain only (or corrections
for cross-sensitivity are made prior to data analysis.)

All gages measure strain at the same point (close at least.)

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Plane Strain Transformation Equations:

sin2 + xy sin cos 1 xy 1 sin = ( x + y) + ( x y) + 2 2 2

x y x

cos2 +

cos2 xy sin cos 1 xy 1 sin = ( x + y) ( x y) 2 2 2

y x)

sin2 +

x y = 2 ( y = (
M&AE 3272 - Lecture 8

sin cos + xy (cos2 sin2 )

y ) sin 2 + xy cos 2
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Plane Strain Transformations: Mohrs Circle

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Rectangular Strain Gage Rosette: Determination of Principal Strains

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Rectangular Strain Gage Rosette: Principal Strains via Mohrs Circle

When the x-Axis coincides with the A-Gage and the y -Axis with the C-Gage : xy = 2 B Then . . . x = A ; y = C ;
2

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Determination of Principal Stresses and von Mises Stress:

For a specimen in plane stress , we only have the principal strains 1 , 2 and principal stresses 1 , 2 : ( E - Youngs Modulus ; - Poissons ratio ) Principal Stresses : 1 = 2 von Mises Stress : vM =
M&AE 3272 - Lecture 8

E ( (1 2) E ( = (1 2)

+ +

2) 1)

2 + 2 1 1 2 2

< Y
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Module 3: Bicycle Crank Gaging

Cable Connector should be in

direction of crank shaft. Wires long-enough to overlap the end of the crank arm. Wires on outside of crank arm! Wires should be firmly attached to crank arm.
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LabVIEW : cycle_test.vi

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Module 3: Bicycle Component Modeling and Testing

etc. . .

etc. . .

etc. . .

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Class Schedule (April 7th to May 2nd):

Mon, Mar 24, 2013 -- Module 3 Schedule WEEK (March 24th-28th): ANSYS Tutorial and Assignment. All students are to work on the ANSYS Tutorial. There areth two assigned problems/exercises which each of you will hand in. A dog-bone shaped crank arm with mounted strain-gage: (1) Find strain at gage center using Beam Theory; (2) Use ANSYS to compute average strain over gage area; (3) Repeat with gage rotated at 45-deg to x-axis. THIS WEEK (April 7th-11th): ANSYS Modeling of your Crank Arm. Each group of students is to carry out the modeling of their assigned crank subject to a 100 lb static load. You should reconnect with your Groups (same as Module 2 THE NEXT WEEK: April 14th-18th OPEN Labs The labs will be run as OPEN-LAB periods for the gaging of your crank arm. First get approval from your TA for your plans for mounting gages and the bag of parts for your crank arm. TA's will be in the Lab during your normal Lab Session times. You can reach them at other times as well. Any TA can approve your plans. Also static testing of your crank arm. Static Testing Schedule will be posted. AND THE FINAL TWO WEEKS: April 21st 25th: Static testing of your crank arm. Testing Schedule will be posted. April 28th- May 2nd: Dynamic testing of the class crank arm. Posted Schedule. Course Link: Syllabus and Schedule / Lab Schedule

Due: Friday, April 11 , 6pm

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