ANSYS SOFTWARE QUESTION BANK FOR BAJA 2014

Sl no. 1 Questions How can I calculate front impact,side & rollover impact force? Or what is the value of 10G? Answers You can Use Newton's 2nd Law of motion: F =ma where, m=total mass of vehicle, a= acceleration/deceleration of the vehicle during impact. 10G means the decelaration of the vehicle is 10 times of "the accelaration due to gravity" i.e. 98.1 m/s 2 Grid Independence Test is to be carried out to evaluate proper mesh size to be taken for analysis. Optimum mesh size can be taken when the mesh to mesh stress variation is minimum (less than 3%) It is used to model pipes that have cross-secton distortion & used for curved pipe structures . It is related to the mesh & acts much like a mesh control. Pipe elements has to be created from line bodies. Set Model type to "Pipe" in line body's (Geometery Object) Details view Definition category. Mesh linebody with higher order elments (Set "Element Midside Nodes" option under Advanced category of the Mesh object to "Kept") Not mandatory, but recommended for utilizing the parametric design capability of ANSYS Workbench at the initial stage of design You need to convert wireframe into Line body. Then assign cross-section by Concept->Cross setion in DesignModeler

What is the optimum element size for meshing for rollcage in workbench?

Where should we use pipe idealisation and why?

4 5

It is mandatory to draw the rollcage model in ANSYS modeling? How can we assign two different cross sections to rollcage if the wireframe file is being imported to ANSYS workbench?

Isn't 3g frontal impact force enough considering our design?

The impact load usually depends on maximum vehicle speed and the rollcage member capability to absorb the impact energy. For example, if you drop a rollcage having a suspension system, the impact load that it receives is very low compared to a rollcage having no suspension system.

7 8 9 10

What is the criterion of deciding the magnitude of forces to be applied? Can I use pipe 16 element instead of pipe 289 in mechanical APDL? Why pipe element is used and not shell? How to change the element from beam to pipe? Yes you can. But use PIPE18 for curved pipe element, PIPE17 for a pipe tee element, PIPE20 for a plastic straight pipe element Pipe element is a line body element. Shell element can be used if you model pipes using surfaces In model, go to line body's (Geometery Object) - Details view Definition category, the Model Type option -set to Pipe Impact load depends on how slowly the member absorbs impact energy. Direction can be decided based on the resultant moving direction of the member just before impact. Usually many possibilities are possible. Worst case conditions needs to be analyzed first. Safety factor to be decided based on the severity of damage and probability of occurance You can apply force on a point by creating Point of type "Point Load" in DesignModeler if it is line body. If you use 3D models, surface pressure can also be used instead of point load First order mesh have nodes at conrner points. Second order mesh also includes nodes at mid points of a element edges and hence more accuratly predicts defelection and stresses

11

How to decide the magnitude and direction of forces acting in these tests?

12 13

Is it okay to have safety factor in between 1-2 to have minimum weight ? If we import the rollcage in ANSYS Workbench then how to apply point loads

14

What is second order mesh?

15

How to find the suspension mounting points in a rollcage modeled in CATIA?

Suspension mounting points should be decided before modeling

16

How to acomodate the properties of beam and that of pipe idealization if we have modeled our model in CATIA? How to perform modal analysis? If we are using beam elements like beam188 and beam 189 then how do they affect the results? Which point of the rollcage should be fixed during modal analysis?

BEAM or PIPE element can only be generated for line body (2D-geo). Not applicable for 3D models having surfaces Modal analysis needs a line, shell or solid model. Pl refer WB documents for procedure

17

18

You may not find any difference if your geometry has no curved elements

19

No constraint is required

20

If we use upward force, we need to apply force on the four wheel mounting and fix the interior joints. In In the drop test, a downward force was applied on the roll cage. Why was it not this case we will not have the effect of each component mass in the rollcage. Hence the downward upwards as the force from the ground will act in the upward direction? loading is preferred Can we perform multibody dynamics in ANSYS? Yes CFD analysis can be used to optimize brake component cooling. Since BAJA vehicles are not running at very high speed, aerodymanic analysis may not be required. However it is preferred if time is available AISI 4130 is costlier than AISI 1018 but is has higher strength and lower mass/volume. Apply force on left Side Impact Member (SIM) & Lower Frame Side (LFS) member. Constrain right SIM & LFS members as fixed Research has found that the human body will sustain upto an accelaration/decelaration equal to 10 times the "accelaration due to gravity" Even if the driver is not directly hurt by any materials, death is possible above 10G. Hence we use 10G force for front impact analysis

21

22

How do you rate the necessity of performingCFD analysis on a BAJA vehicle?

23 24

How can I get AISI 4130? Will it be cost effective as compared to mild steel? For side impact test where should we apply constraints?

25 26

How do we calculate the maximum g-force the driver can handle? Isn't 10G force confirms safety of driver rather than material safety.

27

How can I get the total mass of rollcage by importing geometry into ANSYS?

In Model, click on Geometry & refer "Geometry Properties" in "Details of Geometery" to get mass of Roll cage Convert the 2D sketch into line bodies and go for meshing.

28

How to do 2D meshing of rollcage in Workbench using line models?

29 30

While doing front or side impact analysis, can we apply constrain on edges or a Yes faces instead of points? What are the of cross section roll cage? How to calculate loads in dynamics impact, say car going at a velocity of 60kmph how much force is it going to encounter in frount impact? How to specify only a certain degress of freedom? What is the exact youngs modulus value for 4130 chrome alloy? You need to define the actual cross section of the pipes used in roll cage and apply the relevent crosssection to each line bodies Force*distance travel after impact = 1/2 (mass of vehicle * vel^2). Solve for force. Distance of travel is spring compression length in case of drop test. It is displacement of the point of contact after impact (no simple calculation for the displacement in case of front impact) Use "Displacement" or "Remote Displacement" boundary condition 2.05e11 Pa

31

32 33

34

How to calculate natural frequecy of rollcage element and what can be said as a Work on modal analysis in Workbench with no constrained applied to roll cage & check out frequency result of modal analysis? generated. It should not match with frequency of any other vibrating component of vehicle.

35

Can you please let us know the name of the university and the professor who works for research in composites?

Professor Everbarbero from West Verginia Univerity. You can refer to this site for further details. It also has a video on composite analysis using ANSYS.Link: http://www.mae.wvu.edu/barbero/feacm/

36

How to do the thermal analysis of brake rotor?

Calculate the torque, convert forces coming onto the rotor into thermal energy/load and apply the same thermal load on the rotor model for analysis. First of all try to analyse/optimize each part. Remove unsprung/unwanted masss from the component by analysis results. Another way is to make use of composites. Reducing weight of roll cage is an important consideration with regards to material used and design.

37

Please suggest a few ways to reduce weight of the vehicle?