Introduction

This report will go through the design of a 2D model with analysis carried out on Autodesk
Simulation Mechanical. The results simulated will be compared with theoretical results as well as 3D
results. Models with different diameters will also be considered. Also, models with different shape
holes will be considered.

Objectives:
Describing and explain the steps taken to produce the design and to carryout analysis with relevant
printouts.

Discussing the results obtained and exploring variations and making recommendations. Evaluating
and reporting on the effect of mesh density and comparing it against the stress concentration factor
obtained.

Evaluating the Effects of a square in place of the hole.

Comparing with 3D analysis of a STEP model from Creo – PTC

2D Design and Analysis procedure

Both the design and analysis of the 2D model is done using the Autodesk software.

This was the design that was used.

The values I used were:

Y=200mm

Z=100mm

C=50mm

D=40mm

X=100mm

The metric unit is initially selected, then custom is selected so that the length unit can be changed to
mm.

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The model is created in Autodesk using the following functions: -
Right click on Plane 2 YZ, after which sketch is selected.

Create this at the centre leaving all the co-ordinates at

zero.

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-The second set of co-ordinates are then selected (X=0, Y=200, Z=100).

To produce the circle, the Circle tab is used producing a drop down before selecting the centre and
radius, however this time the centre and radius option is selected.

-Another window pops up where the co-ordinates of the circles distance from the rectangle are to
be selected (X=0, Y=100, Z=50), this step determines the centre of the hole.

-The second set of co-ordinates are then to be selected to define the outline of the circle (X=0,
Y=100, Z=70), this step determines the diameter of the circle.

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 The mesh density is then selcted (200)

The thickness of the model is calculated using the formula

(y/10), therefore in this case, the thickness is calculated to
(200/10=20). The thickness is then set to this using the
following functions in Autodesk:

The element material of the model is then selected; the material of the model is to be made of is
AISI4130. The material is then set to this using the following functions in Autodesk:

The element type and element definition is set to 2D.

After creating the model, the surface boundary conditions are applied on the left side of the model,
and pressure tractions are applied on the right side.

The Surface boundary constraints on the left side are fixed to fix the boundary condition in all
directions.

This completes the 2D model is then complete with the following dimensions:
Y (length)=200mm
Z (height)=100mm
X (distance from centre point of circle to each end of rectangle (Horizontally))=100mm
C (distance from centre point of circle to each end of rectangle (Vertically))=50mm
D (diameter of circle)=40mm
Area = (Height –Diameter) x thickness = (100-40) x 20 = 1200mm2

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The pressure applied on the right hand side is calculated using the following procedure:

The stress across the right hand side surface of the model is to be calculated, this can be done using
the formula Stress=Force/Area.
Calculating the area of right hand side, the thickness is 20mm, the length being 100m, the area is=20
x 100=2000mm2.
Calculating the stress across the right hand side, use force/area, which comes out to
60,000N/2000mm2=30N/mm2.
Therefore to calculate the stress, the formula Stress=Force/Area is used:
60000/(100-40) x 20=60000/1200=50N/mm2

Using the Kt Value

given above (2.24),
multiply the stress
across the
concentration factor
by this value, 2.24 x
50=112N/mm2.

The surface pressure/traction is then applied onto the right hand side

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Analysis is then carried out on the model.

These are the analysis results for the model with mesh density set at 200.

Set the Tensor to the YY component to obtain the above result, allowing the stress values to be seen.
The visual style dropdown then provides a shaded with mesh option, this displays a shaded view of
the model and constructs mesh lines, showing how much the forces have affected the model. After
selecting this, select Loads and Constraints, which provides the arrows shown in the screeenshot
representing the direction of the forces.

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Densities:

200:

400:

500:

1000:

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2000:

5000:

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3D Model
Creo was used to create the 3D model. This was simulated in Autodesk

The model is then saved as a STEP file, so that the file can be exported and opened in Autodesk
ready for analysis.

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In Autodesk:
The constraints are then applied to the left hand side of the model, the left hand side is
highlighted, and once right clicked on, the add option produces a drop down after which
Nodal General Constraints is selected.

The right hand side is then highlighted, and upon right clicking, the add option produces a
drop down after which Nodal Forces is selected.

The thickness is then set to 20mm, by right clicking on element definition, and selecting element
definition, where the thickness can be changed.

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The 3D Model stress analysis provides a maximum stress of 106.0307Nmm2, whereas the 2D model
provides a maximum stress of 112.6325Nmm2 at a mesh density of 5000. This may be due to
variations between the two programmes in which both models were created.

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Changing Diameter of the hole
10mm diameter
The diameter of the hole is changed to 10mm to see how this affects the analysis results.
The model is made initially using the Creo software, using the same method as before.

Once again, the model is saved as a step file, so that it can be exported into the Autodesk
software.
Once opened in Autodesk, the material is once again selected at AISI 4130.

The constraints and forces are again applied onto the model. The same magnitude of force
is applied as the number of nodes are still the same even though the diameter has changed.

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70mm diameter
The same is done for the model, however this time a 70mm diameter is used for the hole.

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Changing the Material of the model:
Right clicking the element material, allows the material of the model to be edited, this is
changed to Plastic Nylon type 6/6, the analysis is then carried out on the model composed
of the new material.

Circular Plate with 2 holes

The above model layout is then produced using the Creo software as displayed below.

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Once again, the model is saved a STEP file, so that the file can be located and opened in the
Autodesk software. The same forces and constraints are applied to the model, and the
material is kept as AISI 4130 steel.

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Real Life Model

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The material chosen is Stainless Steel

When applying Nodal Forces, the average weight of an adult in UK is used, average adult weight is
calculated using
Mens average weight + Womens average weight 83.6kg + 70.2kg
Average Adult weight= 2
= 2
=76.9kg

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The average weight is then multiplied by 9.81 to take into account gravity and calculate the force
applied on the trolley, we use the following formula:
Average Adult weight x 9.81 (gravitational force) = 76.9kg x 9.81= 754.389N

However, as not all the users of the zip line trolley are to be of average weight, a safety factor has to
be put into place ensuring that the trolley doesn’t fail, for this reason, 5000N is added to the
Average force, assuming the largest weight that will be applied to the trolley is
754.389+5000N 5754.389N
= 586.58kg
9.81 9.81

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The Kt Value is then calculated using the efatigue website, the dimensions are inputted and the Kt
value is calculated using this.

Comparison of 2D and 3D model

The Autodesk model is able to analyse models, however struggles when analysing more complex
models, the models are also complicated to create. The plate or model can be further edited as the
mesh density can be varied to obtain different stress results with more precision. The Creo model is
able to create complicated models as it has various other tools and settings that enable us to expand
on model dimensions and details further. Also when carrying out analysis of both the 2D and 3D
models, the analysis results tend to differ, this can be due to various reasons such as the little details
and dimensions may have changed when the model is being transferred over into Autodesk.
However, there are some details that are harder to configure on the 3D model, than on the 2D
model, such as the mesh density of the models, Autodesk allows for this to be done easily on the 2D
models, but less so on the 3D models.
Analysis on the 3D models varies, depending on the mesh density, similar to the 3D model, however
on the 3D model, when the mesh density is set to 20%, rather than 100%, the analysis results seem
to be more accurate.

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