Cad/Cam Lab: Venkitaraj K P

CAD/CAM LAB
Engineering analysis with ANSYS software

VENKITARAJ K P
Introduction to Finite Element Method (FEM)
In order to analyse an engineering system, a mathematical model is developed to describe the
system.
While developing the mathematical model, some assumptions are made for
simplification. Finally, the governing mathematical expression is developed to describe the
behavior of the system. The mathematical expression usually consists of differential equations
a n d given conditions. The best way to solve any physical problem governed by a differential
equation is to obtain the analytical solution. There are many situations, however, where the
analytical solution is difficult to obtain. The region under consideration may be so irregular that it is
mathematically impossible to describe the boundary. The configuration may be composed off
several different materials whose regions are mathematically difficult to describe. Problems
involving anisotropic materials are usually difficult to solve analytically, as are equations having
non-linear terms.
A numerical method can be used to obtain an approximate solution when an analytical solution
can not be developed. Especially, the finite element method h a s been one of the major
numerical solution techniques. One of the major a d v a n t a g e s o f the finite element method is
that a general purpose computer program can be developed easily to analyse various kinds of
problems. In particular, any complex shape of problem domain with prescribed conditions can be
handled with ease using the finite element method. The underlying premise of the method states
that a complicated domain can be sub-divided into a series of smaller regions in which the differential
equations are approximately solved. By assembling the set of equations for each region, the behavior
over the entire problem domain is determined. Each region is referred to as an element and the
process of subdividing a domain into a finite number of elements is referred to as discretization.
Elements are connected at specific points, called nodes, and the assembly process requires that the
solution be continuous along common boundaries of adjacent elements.
Element types
DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING ADOOR
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Introduction to ANSYS
ANSYS is a general-purpose finite-element modeling package for numerically solving a wide variety
of mechanical problems. These problems include static/ dynamic, structural analysis (both linear and
nonlinear), heat transfer, and fluid problems, as well as acoustic and electromagnetic problems.
Treatment of engineering problems basically contains three main parts: create a model, solve the
problem, analyse the results. ANSYS, like many other FE-programs, is also divided into three main
parts (processors) which are called pre-processor, solution processor, postprocessor.
During the analysis you will communicate with ANSYS via a Graphical User Interface (GUI), which is
described below and seen in Figure below.

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Pre-processor
Within the pre-processor the model is set up. It includes a number of steps and usually in the
following order:
Build geometry. Depending on whether the problem geometry is one, two or three dimensional, the
geometry consists of creating lines, areas or volumes. These geometries can then, if necessary, be
used to create other geometries by the use of boolean operations. The key idea when building the
geometry like this is to simplify the generation of the element mesh. Hence, this step is optional but
most often used. Nodes and elements can however be created from coordinates only.
Define materials. A material is defined by its material constants. Every element has to be assigned a
particular material.
Generate element mesh. The problem is discretized with nodal points. The nodes are connected to
form finite elements, which together form the material volume. Depending on the problem and the
assumptions that are made, the element type has to be determined. Common element types are
truss, beam, plate, shell and solid elements. Each element type may contain several subtypes, e.g.
2D 4-noded solid, 3D 20-noded solid elements. Therefore, care has to be taken when the element
type is chosen.
The element mesh can in ANSYS be created in several ways. The most common way is that it is
automatically created, however more or less controlled. For example you can specify a certain
number of elements in a specific area, or you can force the mesh generator to maintain a specific
element size within an area. Certain element shapes or sizes are not recommended and if these limits
are violated, a warning will be generated in ANSYS. It is up to the user to create a mesh which is able
to generate results with a sufficient degree of accuracy.
PREP7 pre-processor is used to define the element types, element real constants, material
properties, and the model geometry.

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Solution processor
Here you solve the problem by gathering all specified information about the problem:
Apply loads: Boundary conditions are usually applied on nodes or elements. The prescribed quantity
can for example be force, traction, displacement, moment, rotation. The loads may in ANSYS also be
edited from the pre-processor.
Obtain solution: The solution to the problem can be obtained if the whole problem is defined.
Postprocessor
Within this part of the analysis you can for example:
Visualise the results: For example plot the deformed shape of the geometry or stresses.
List the results: If you prefer tabular listings or file printouts, it is possible
Two postprocessors are available:
(1) POST1: The general postprocessor is used to review results at one substep (time step) over the
entire model or selected portion of the model.
(2) POST26: The time history postprocessor is used to review results at specific points in the model
over all time steps.
Application of ANSYS to Stress Analysis
Picking an Element Type for Structural Analysis
The table below shows the most commonly used element types for stress analysis.
Elements are organized into groups of similar characteristics. These group names make up the first
part of the element name (PLANE, SOLID, SHELL,etc). The second part of the element name is a
number that is more or less (but not exactly) chronological. As elements have been created over the
past 30 years the element numbers have simply been incremented. The earliest and simplest
elements have the lowest numbers (LINK1, BEAM3, etc), the more recently developed ones have
higher numbers. The 18x, 20x, and 22x series of elements (SHELL181, SOLID187, etc) are the
newest and most modern in the ANSYS element library.

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Element order refers to the interpolation of an elements nodal results to the interior of the element.
This determines how results can vary across an element. Element order can be linear or quadratic.
Linear elements do not have midside nodes. Naturally a linear element is computationally faster than
a quadratic element.
Quadratic elements have midside nodes. The shape function for strains varies in some nonlinear
fashion between the corner nodes. Whereas linear elements are flat on both the sides and in-plane, a
quadratic element can follow a curvature in both directions and is more accurate for a given number
of nodes in the model
Some considerations in picking an element order:
For in-plane bending type problems, quadratic elements are much better than linear
elements.
Linear elements are more sensitive to non-perfect element shapes (i.e., have more error). A
linear element is probably better in a mapped mesh than a free mesh.
For out-of-plane, plate type bending, there isnt much difference between linear and quadratic
elements.
As a general rule of thumb, one quadratic element containing three nodes should be more
accurate than two linear elements having a total of three nodes across the same dimension.
In nonlinear analysis, a finer mesh of linear elements is computationally more efficient, robust,
stable and more accurate than a coarser quadratic mesh with a comparable number of nodes.
How can a 2D element be a solid? First, they are considered solid because they are not a shell or a
beam element. Secondly, they are solids because they fully represent a solid chunky part by modeling
a cross section of that part. There are three main kinds of 2D solid elements:
Plane Strain: In a plane strain analysis we are modeling something that is so long that there is no
strain in the thickness direction. A cross section of a long beam or a dam holding back water would be
examples of this kind of behavior. Stresses in the thickness direction are significant.
Axisymmetric: In this type of analysis we are modeling a cross section of a structure that is fully
defined by rotating the cross section around a central axis. A pressure vessel or bottle would be
examples of this kind of structure. The thickness direction here represents the circumferential (hoop)
direction and those out-of-plane stresses are very significant (picture a tank under pressure).
Plane Stress: This is not really a solid element per say but still falls into this category (since it
doesnt really fit anywhere else). A plane stress analysis is a 2D model of a thin sheet with a small
thickness and in-plane loading.
All 2D solid elements can be any one of these three types by changing the element key options.
PLANE42: Basic 2D solid element.
PLANE82: 8 noded version of PLANE42. Also has a triangular option.
PLANE182: Similar to PLANE42 except has capability for simulating deformations of nearly
incompressible elastoplastic materials, and fully incompressible hyperelastic materials.
PLANE183: 8 noded version of PLANE182.
3D Solid Elements:
These types of elements have their geometry fully defined by the element nodes. They are elements
used to mesh volumes in ANSYS. These volumes could be created in the ANSYS pre-processor or
imported from a CAD system. Hexahedral elements (bricks) can be used to mesh regularly shaped
rectangular type volumes, while tetrahedral elements (tets) can be used to mesh any volume. Even
linear bricks (if they are not distorted much) can model a thin plate in out-of-plane bending with one
element through the thickness since they all by default have the extra shapes turned on.
SOLID45: Basic linear brick.

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SOLID95: 20 noded version of SOLID45. It can tolerate irregular shapes without as much loss of
accuracy. Well suited to model curved boundaries. These elements can also be tetrahedral and can
automatically transition between hexahedral and tetrahedral using pyramids.
SOLID185: Newer version of SOLID45. Also has mixed formulation capability for simulating
deformations of nearly incompressible elastoplastic materials, and fully incompressible hyperelastic
materials.
SOLID186: Newer version of SOLID95. Also has mixed formulation capability for simulating
deformations of nearly incompressible elastoplastic materials, and fully incompressible hyperelastic
materials.
SOLID92: Tetrahedral only element (10 noded quadratic).
SOLID187: Newer version of SOLID92. Similarly to other 18x elements also has mixed formulation
capability for simulating deformations of nearly incompressible elastoplastic materials, and fully
incompressible hyperelastic materials.
3D Shell Elements:
A shell element is a surface type element. It is really a 2D element that is called 3D because it is not
restricted to the XY plane like a 2D solid element; it can be located anywhere in three-dimensional
space and it can deform out-of-plane. Shell elements are engineering abstractions because a
geometric surface has no physical thickness. An ANSYS real constant is used to assign a thickness
to a shell element. Shell elements are also called plate elements, and are used to model panel type
structures where the thickness is small compared to the other dimensions of the part. They can carry
in-plane loads (also called membrane loads) and also out-of-plane bending moments and twisting.
SHELL63: This is an older but still very widely used shell element. It can analyze large deflections but
not plasticity.
SHELL93: Quadratic version of SHELL63. In addition it can analyze plasticity.
SHELL181: Newest linear shell element. Has plasticity and can also be used to model laminated
composites and sandwich panels. Note: There is no eight noded 18x series shell element.
Line Elements:
Line elements are a further engineering abstraction from shells; they are physically idealized as a
simple line, which represents a long slender structure that can carry axial, bending, shear and twisting
forces. Real constants define the cross sectional properties of the beam element.
BEAM3: Simple 2D beam element. Must be created in XY plane.
BEAM4: Beam element that can be modeled in 3D space. Has large deflection.
BEAM44: Tapered beam element. Can use the beam tool to define a section and have real constants
automatically calculated.
BEAM188: Timoshenko beam that includes shear deformation. Can handle plasticity and can define a
section with the beam tool. Can have a built-up cross section with more than one material. By default
this is a true linear element. You need a lot of them to give the same results as one BEAM3/4/44/189.
In release 8.0 turn on KEYOPT(3) = 2 to give an internal quadratic shape function to eliminate this
problem. Can display stresses on the actual beam shape like it was solid.
BEAM189: Three noded quadratic version of BEAM188. This is pretty much the ultimate beam
element that can do everything well.

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Example 1.
Perform an finite-element method (FEM) analysis of a 2-D cantilever beam shown in Figure below
and calculate the deflection of the beam at the loading point and the longitudinal stress distribution in
the beam.
Geometry: length l =90 mm, height h=5 mm, thickness b=10mm

Material: mild steel having Youngs modulus E =210 GPa and Poissons ratio =0.3.
Boundary conditions: The beam is clamped to a rigid wall at the left end and loaded
at x =80mm by a point load of P =100 N.
REVIEW OF THE SOLUTIONS OBTAINED BY THE ELEMENTARY BEAM THEORY
Before proceeding to the FEM analysis of the beam, let us review the solutions to the example
problem obtained by the elementary beam theory. The maximum deflection of the beam max can be
calculated by the following equation:
where l1 (=80mm) is the distance of the application point of the load from the rigid wall and l2 =l l1.
The maximum tensile stress max(x) at x in the longitudinal direction appears at the upper surface of
the beam in a cross section at x from the wall;
where l (=90mm) is the length, h (=5mm) the height, b (=10mm) the thickness, E (=210 GPa) Youngs
modulus and I the area moment of inertia of the cross section of the beam. For a beam having a
rectangular cross section of a height h by a thickness b, the value of I can be calculated by the
following equation:

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Flow chart of the structural analysis using ANSYS
CREATION OF AN ANALYTICAL MODEL

[1] Creation of a beam shape to analyze
Here we will analyze a rectangular slender beam of 5mm (0.005 m) in height by 90mm (0.09 m) in
length by 10mm (0.01 m) in width as illustrated in Figure given in the problem.
Figure below shows the ANSYS Main Menu window where we can find layered command options
imitating folders and files in the Microsoft Explorer folder window.
In order to prepare for creating the beam, the following operations should be made:
(1) Click [A] Preprocessor to open its sub-menus in ANSYSMainMenu window.
(2) Click [B] Modeling to open its sub-menus and select Create menu.
(3) Click [C] Areas to open its sub-menus and select Rectangle menu.
(4) Click to select [D] By 2 corners menu.

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After carrying out the operations above, a window called Rectangle by 2 corners as
shown in figure below appears for the input of the geometry of a 2-D rectangular beam.
[2] Input of the beam geometry to analyze

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The Rectangle by 2 corners window has four boxes for inputting the coordinates of the lower left
corner point of the rectangular beam and the width and height of the beam to create. The following
operations complete the creation procedure of the beam:
(1) Input two 0s into [A] WP X and [B] WP Y to determine the lower left corner
point of the beam on the Cartesian coordinates of the working plane.
(2) Input 0.09 and 0.005 (m) into [C] Width and [D] Height, respectively to
determine the shape of the beam model.
(3) Click [E] OK button to create the rectangular area, or beam on the ANSYS
Graphics window as shown in Figure below
INPUT OF THE ELASTIC PROPERTIES OF THE BEAM MATERIAL.

Command ANSYSMainMenuPreprocessorMaterial PropsMaterialModels
Then the Define Material Model Behavior window opens as shown in Figure below:
(1) Double-click [A] Structural, Linear, Elastic, and Isotropic buttons one after another.
(2) Input the value of Youngs modulus, 2.1e11 (Pa), and that of Poissons ratio, 0.3, into [B] EX and
[C] PRXY boxes, and click [D]OK button of the Linear Isotropic Properties for Material Number 1
as shown in Figure below

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.
(3) Exit from the Define Material Model Behavior window by selecting Exit in [E] Material menu of
the window
FINITE-ELEMENT DISCRETIZATION OF THE BEAM AREA
Here we will divide the beam area into finite elements. The procedures for finite element discretization
are firstly to select the element type, secondly to input the element thickness and finally to divide the
beam area into elements.
[1] Selection of the element type
Command ANSYSMainMenuPreprocessorElement TypeAdd/ Edit/Delete
Then the Element Types window opens:
(1) Click [A] Add . . .button to open the Library of Element Types window as shown in Figure below
and select the element type to use.

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(2) To select the 8-node iso-parametric element, select [B] Structural Mass Solid.
(3) Select [C] Quad 8node 82 and click [D] OK button to choose the 8-node iso-parametric element.
(4) Click [E] Options . . . button in the Element Types window as to open the PLANE82 element
type options window as depicted in
Figure below
Select [F] Plane strs w/thk item in the Element behavior box and click [G] OK button to return to
the Element Types window. Click [H] Close button to close the window.
The 8-node iso-parametric element is a rectangular element which has four corner nodal points and
four middle points as shown in Figure below and can realize the finite-element analysis with higher
accuracy than the 4-node linear rectangular element. The beam area is divided into these 8-node
rectangular PLANE 82 finite elements.
[2] Input of the element thickness

Command ANSYSMainMenuPreprocessorReal Constants
Select [A] Real Constants in the ANSYS Main Menu as shown in Figure below.

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(1) Click [A] Add/Edit/Delete button to open the Real Constants window as shown in Figure below
and click [B] Addbutton.
(2) Then the Element Type for Real Constants window opens (see Figure below). Click [C] OK
button.
(3) The Element Type for Real Constants window vanishes and the Real Constants Set Number
1. for PLANE82 window appears instead as shown in Figure below.

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Input a plate thickness of 0.01 (m) in [D] Thickness box and click [E] OK button.
(4) The Real Constants window returns with the display of the Defined Real Constants Sets box
changed to Set 1 as shown in Figure below. Click [F] Close button, which makes the operation of
setting the plate thickness completed.
[3] Sizing of the elements

Command
ANSYSMainMenuPreprocessor
SizeGlobalSize
MeshingSize
CntrlsManual
The Global Element Sizes window opens as shown in Figure below:
(1) Input 0.002 (m) in [A] SIZE box and click [B] OK button.
By the operations above the element size of 0.002, i.e., 0.002 m, or 2mmis specified and the beam of
5mm by 90mm is divided into rectangular finite-elements with one side 2mm and the other side 3mm
in length.

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[4] Meshing
Command ANSYSMainMenuPreprocessorMeshingMeshAreasFree
The Mesh Areas window opens as shown in Figure below:
(1) An upward arrow () appears in the ANSYS Graphics window. Move this arrow
to the beam area and click this area to mesh.
(2) The colour of the area turns from light blue into pink. Click [A] OK button to see
the area meshed by 8-node rectangular iso-parametric finite elements as shown in
Figure below
INPUT OF BOUNDARY CONDITIONS

Here we will impose constraint and loading conditions on nodes of the beam model.
Display the nodes first to define the constraint and loading conditions.
[1] Nodes display
Command ANSYS Utility MenuPlotNodes

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The nodes are plotted in the ANSYS Graphics window opens as shown in Figure below.
[2] Zoom in the nodes display

Enlarged view of the models is often convenient when imposing constraint and loading conditions on
the nodes. In order to zoom in the node display, execute the following commands:
Command ANSYS UtilityMenuPlotCtrlsPan Zoom Rotate . . .
The Pan-Zoom-Rotate window opens as shown in Figure below:

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(1) Click [A] Box Zoom button.
(2) The shape of the mouse cursor turns into a magnifying glass in the ANSYS Graphics window.
Click the upper left point and then the lower right point which enclose a portion of the beam area to
enlarge as shown in Figure below. Zoom in the left end of the beam.
(3) In order to display the whole view of the beam, click [B] Fit button in the Pan-Zoom-Rotate
window.
[3] Definition of constraint conditions
Selection of nodes
Command
ANSYSMainMenuSolutionDefine
DisplacementOn Nodes
LoadsApplyStructural
The Apply U. ROT on Nodes window opens as shown in Figure below.

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(1) Select [A] Box button and drag the mouse in the ANSYS Graphics window so as to enclose the
nodes on the left edge of the beam are with the yellow rectangular frame as shown in Figure below.
The Box button is selected to pick multiple nodes at once, whereas [B] the Single button is chosen
to pick a single node.
(2) After confirming that only the nodes to impose constraints on are selected, i.e., the nodes on the
left edge of the beam area, click [C] OK button.
Imposing constraint conditions on nodes
The Apply U. ROT on Nodes window (see Figure below) opens after clicking [C] OK button in the
procedure (2) in the subsection Selection of nodes above.
(1) In case of selecting [A] ALL DOF, the nodes are to be clamped, i.e., the displacements are set to
zero in the directions of the x- and y-axes. Similarly, the selection of UX makes the displacement in
the x-direction equal to zero and the selection of UY makes the displacement in the y-direction equal
to zero.
(2) Click [B] OK button and blue triangular symbols, which denote the clamping conditions, appear in
the ANSYS Graphics window as shown in Figure below. The upright triangles indicate that each
node to which the triangular symbol is attached is fixed in the y-direction, whereas the tilted triangles
indicate the fixed condition in the x-direction.

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[4] Imposing boundary conditions on nodes

Before imposing load conditions, click Fit button in the Pan-Zoom-Rotate window to get the whole
view of the area and then zoom in the right end of the beam area for ease of the following operations.
Selection of the nodes
(1) Pick the node at a point where x =0.08m and y =0.005m for this purpose, click
Command ANSYS Utility MenuPlot CtrlsNumbering . . .
Consecutively to open the Plot Numbering Controls window as shown in Figure below.
(2) Click [A] NODE_Off box to change it to_ On box.

(3) Click [B] OK button to display node numbers adjacent to corresponding node in the ANSYS
Graphics window as shown in Figure below.

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(4) To delete the node numbers, click [A] NODE_ On box again to change it to _Off box.
(5) Execute the following commands:
Command ANSYS UtilityMenuListNodes . . .
and the Sort NODE Listing window opens (see Figure below). Select [A] Coordinates only button
and then click [B] OK button.
(6) The NLIST Command window opens as shown in Figure below. Find the number of the node
having the coordinates x =0.08mand y =0.005 m, namely node #108 in Figure below.

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(7) Execute the following commands:

Command:
ANSYSMainMenuSolutionDefineLoadsApplyStructuralForce/ MomentOn Nodes to
open the Apply F/M on Nodes window (see Figure below)
]
(8) Pick only the #108 node having the coordinates x =0.08m and y =0.005m with
the upward arrow as shown in Figure below

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(9) After confirming that only the #108 node is enclosed with the yellow frame, click
[A] OK button in the Apply F/M on Nodes window.
Imposing load conditions on nodes
Click [A] OK in the Apply F/M on Nodes window to open another Apply F/M on Nodes window as
shown in Figure below.
(1) Choose [A] FY in the Lab Direction of force/mom box and input [B] 100 (N) in the VALUE box.
A positive value for load indicates load in the upward or rightward direction, whereas a negative value
load in the downward or leftward direction.
(2) Click [C] OK button to display the red downward arrow attached to the #108 node indicating the
downward load applied to that point as shown in Figure below.

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SOLUTION PROCEDURES
Command ANSYSMainMenuSolutionSolveCurrent LS
The Solve Current Load Step windows appear as shown in Figure below.
(1) Click [A] OK button in the Solve Current Load Step window as shown in
Figure above to begin the solution of the current load step.
(2) The STATUS Command window displays information on solution and load step options. Select
[B] File button to open the submenu and select Close button to
close the /STATUS Command window.
(3) When solution is completed, the Note window (see Figure below) appears. Click
[C] Close button to close the window
GRAPHICAL REPRESENTATION OF THE RESULTS

[1] Contour plot of displacements
Command ANSYSMainMenuGeneral PostprocPlot ResultsContour PlotNodal Solution
The Contour Nodal Solution Data window opens as shown in Figure below.

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(1) Select [A] DOF Solution and [B] Y-Component of displacement.

(2) Select [C] Deformed shape with undeformed edge in the Undisplaced shape
key box to compare the shapes of the beam before and after deformation.
(3) Click [D] OK button to display the contour of the y-component of displacement, or the deflection of
the beam in the ANSYS Graphics window (see Figure below). The DMX value shown in the Graphics
window indicates the maximum deflection of the beam.
[2] Contour plot of stresses

(1) Select [A] Stress and [B] X-Component of stress as shown in Figure below.

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(2) Click [C] OK button to display the contour of the x-component of stress, or the bending stress in
the beam in the ANSYS Graphics window (see Figure below). The
SMX and SMN values shown in the Graphics window indicate the maximum and the minimum
stresses in the beam, respectively.
(3) Click [D] Additional Options bar to open additional option items to choose. Select [E] All
applicable in the Number of facets per element edge box to calculate stresses and strains at
middle points of the elements.

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Exercise Problems
1. Change the point of load application and the intensity of the applied load in the cantilever beam
model shown in the example and calculate the maximum deflection.
2. Calculate the maximum deflection in a beam clamped at the both ends as shown in Figure below
where the thickness of the beam in the direction perpendicular to the
page surface is 10 mm.
3. Calculate the maximum deflection in a beam simply supported at the both ends as
shown in Figure below where the thickness of the beam in the direction perpendicular to the page
surface is 10 mm.
4. Calculate the maximum value of the von-Mises stress or equivalent stress in the stepped beam as
shown in Figure below where Youngs modulus E =210 GPa, Poissons ratio =0.3, the element size
is 2mm and the beam thickness is 10 mm.
5. Calculate the maximum value of the von Mises stress in the stepped beam with a rounded fillet as
shown in Figure below where Youngs modulus E =210 GPa, Poissons ratio =0.3, the element size
is 2mm and the beam thickness is 10 mm.

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Structural Analysis of a 3D solid object
Example 1
Problem Description:
Model the object using solid Tetrahedral 10 node element.

Material: Assume the structure is made of steel with modulus of elasticity E=200 GPa.
Boundary conditions: The object is fixed around the inner surface of the hole.
Loading: The object is loaded uniformly (1000 N/cm2) along the top surface of the extended
beam.
Objective:
To plot deformed shape.
To determine the principal stress and the von Mises stress. (Use the stress plots to determine
these.)
What is the maximum load the object can take. Clearly mention the yield stress that you have
assumed for steel. Also assume factor of safety of 1.25.
Structural #6: Analysis of a 3D solid object

Introduction: In this example you will learn to use the Solid element in ANSYS. Also you will learn
some basic 3D modeling.
Physical Problem: See figure.

We will model the object using solid Tetrahedral 10 node element.

Material: Assume the structure is made of steel with modulus of elasticity E=200 GPa.
Boundary conditions: The object is fixed around the inner surface of the hole.
Loading: The object is loaded uniformly (1000 N/cm2) along the top surface of the extended beam.
Objective:
To determine the principal stress and the von Mises stress. (Use the stress plots to determine these. Do
not print the stress list)
What is the maximum load the object can take. Clearly mention the yield stress that you have assumed
for steel. Also assume factor of safety of 1.25.
You are required to hand in print outs for the above.
Figure:

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STARTING ANSYS:
Click on ANSYS 6.1 in the programs menu.

Select Interactive.
The following menu that comes up. Enter the working directory. All your files will be stored in this
directory. Also enter 64 for Total Workspace and 32 for Database.
Click on Run.

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MODELING THE STRUCTURE:

Go to the ANSYS Utility Menu.
Click Workplane>WP Settings.
The following window comes up:

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Check the Cartesian and Grid Only buttons.

Enter the values shown in the figure above.
We will model the object as four seperate volumes and then add them up.
Go to the ANSYS Main Menu Preprocessor>Modeling>Create>Volumes>Blocks>By 2 corners & Z.
Select the two corners and enter the depth in the "depth " field so as to create the first rectangular part
of the figure. The isometric view looks like the figure below.

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Now create two cylinders representing the holes. Use the

Preprocessor>Modeling>Create>Volumes>Cylinder>Solid Cylinder, and select the center and the radius
and the depth of the cylinder.
Now subtract these two cylinders from the main rectangular block. Use the Preprocessor>Modeling
>Operate>Booleans>Subtract>Volumes menu. Select the base area first (the rectangular block). Then
select the volumes to be subtracted (the two cylinders). Click OK. The isometric view of the figure looks
like the figure below.

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Now we will create the extended portion of the object.

Go to Utility Menu>WorkPlane>Offset Workplane by Increments. The following window will come up.

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Now offset the workplane in the +Z direction by an amount equal to the thickness of the previous
rectangular block we made. This thickness is 0.01 m which is 4 times of the snap (0.0025). So we set the
'snaps' to 4 and click on the +Z once. The workplane looks like this from the left side view.

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Now create the first extended rectangular block. The figure will look like the one below in isometric view.

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Now offset the workplane further along the +Z axis by an amount equal to the length of the extended
block (0.06 meter).
So the workplane looks like this from the left side view.

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Now create another block (block 3) by

Preprocessor>Modeling>Create>Volumes>Blocks>By 2 corners & Z.
We make this block separately so that we can create the required fillet easily.

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Now create the block 4.

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Now glue parts together. Go to Preprocessor>Modeling>Operate>Booleans>Glue>Volumes.

In the window that comes up click Pick All and click OK.
Now we will create the fillet. Go to Preprocessor>Modeling>Create>Lines>Line Fillet
Select two lines on the "L" shape to create Fillet in between. Do this for both top and bottom sides. See
the Figure below:

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Now create two lines. Go to Preprocessor>Modeling>Create>Lines>Lines>Straight Line.

Pick keypoints to create lines as shown in the figure below:

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Now, create areas to close the fillet.

Go to Preprocessor>Modeling>Create>Areas>Arbitrary>By Lines
Create 3 areas of the fillet (Top, Bottom and Front) as shown in Figure below

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Two more areas are needed to define the fillet volume.

Go to Operate>Booleans>Divide>Area by Line.
Select the inner area of the "L" shape click OK.

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Then select the line as shown to divide the area into two pieces and click OK

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Repeat the dividing areas steps for the other inner area of the "L" shape
Now create the volume within the fillet by Preprocessor>Modeling>Create>Volumes>Arbitrary>By
Areas. Select the areas which enclose the fillet volume and click OK. The final model will look as follows.

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Now go to Preprocessor>Modeling>Operate>Booleans>Add>Volumes. Click on Pick All. So now we

have added all the volumes into a single volume.
MATERIAL PROPERTIES:
Go to the ANSYS Main Menu

Click Preprocessor>Material Properties>Material Models. In the window that comes up, select
Structural>Linear>Elastic>Isotropic.

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Material model 1 is automatically selected. The following window comes up
Fill in 2e11 for the Young's modulus and 0.3 for minor Poisson's Ratio. Click OK.
Now the material 1 has the properties defined in the above table. We will use this material for the
structure.
ELEMENT PROPERTIES:
SELECTING ELEMENT TYPE:

Click Preprocessor>Element Type>Add/Edit/Delete... In the 'Element Types' window that opens click on
Add... The following window opens:

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Type 1 in the Element type reference number.

Click on Structural Solid and select Tet 10node 92. Click OK. Close the 'Element types' window.
MESHING:
Go to Preprocessor>Meshing>Size Controls>Manual Size>Lines>Picked Lines. Pick all the lines on the

outer boundary of the figure and click OK.
In the menu that comes up type 0.005 in the field for 'Element edge length'.
Click on OK.
Now go to Preprocessor>Meshing>Mesh>Volumes>Free.
Click Pick All in the "Mesh Areas" dialog box. The meshed model looks like this.

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Now the object is divided into Solid Tetrahedral elements.
BOUNDARY CONDITIONS AND CONSTRAINTS:
APPLYING BOUNDARY CONDITIONS

The object is fixed around the inner faces of the holes.
Go to Main Menu Preprocessor>Loads>Define Loads>Apply>Structural>Displacement>On Areas.
Select the areas on the inner surface of the holes and click OK. The following window comes up.

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Select All DOF and click OK. The holes will look like the following after zooming in.
APPLYING FORCES
Go to the Main Menu
Click on Preprocessor>Loads>Define Loads>Apply>Structural>Pressure>On Area.
Select the top surface of the cantilever like arm.
Click on OK in the 'Apply PRES on areas' window. The following window will appear:

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Enter the value of the pressure as shown above.

Click OK.
The model should look like the one below.

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Now the Modeling of the problem is done.
SOLUTION:
Go to ANSYS Main Menu>Solution>Analysis Type>New Analysis.

Select Static and click on OK.
Go to Solution>Solve>Current LS.
Wait for ANSYS to solve the problem.
Click on OK and close the 'Information' window.
POST-PROCESSING:
You can also plot the displacements and stress.

Go to General Postprocessing>Plot Results>Deformed Shape. The following window comes up:

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Select Def+undef edge and click OK. The output will be like the figure below

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Select a stress (say von Mises) to be plotted and click OK. The output will be like this.

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Physical Problem: One day while using his hammer, Professor Shimada attempts to drive a
nail into the floor of his home. Unbenounced to him a layer of pure steel had been installed under the
wooden floor. The nail doesnt move and so a point force of 100N is exerted on the head of the
hammer. Plot the nodal solution of the deformation and stresses on the hammer.
We will model the object using solid Tetrahedral 10 node element.

Material: Assume the structure is made of steel with modulus of elasticity E=200 GPa and a
Poisons Ratio of 0.3.
Boundary conditions: The hammer is fixed at the base..
Loading: The object is has a point force of 100N at the head.
Objective:
To determine the principal stress and the von Mises stress. (Use the stress plots to determine
these. Do not print the stress list)
What is the maximum load the object can take. Clearly mention the yield stress that you have
assumed for steel. Also assume factor of safety of 1.25.
You are required to hand in print outs for the above.
Figure:

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Dimensions:
10 cm hexagonal handle, radius 0.02m, theta=300 at (0,0)
15 cm circular solid, radius 0.015m at 0,0)
5 cm hexagonal head joint, radius 0.04m, theta=270 at (0,0)
18 cm top cone, radius=0.03m
Create the hexagonal solid defining the grip for the handle.
Shift the workplane the axial length of the hexagonal solid and create the circular solid defining the
section between the handle and the head of the hammer.
Shift the workplane again and create the hexagonal head of the hammer.
Now rotate the workplane and shift it such that the cone is created 0.09m in the correct direction
from the axial center of the handle.
Now overlap the conic section and the hexagonal volume defining the head of the hammer. Once
these are married into one volume, add the volumes together such that the hammer is one full
volume.
Define the Material Properties of the Steel hammer (Elastic Modulus and Poisons Ration are the
important qualities)
Define the Element Properties as a Tet 10 node Structural Solid.
Mesh the hammer. (Do so by picking all lines and setting the element edge length to 0.01.)
Apply the boundary conditions. (Structrual Displacement on the bottom face of the handle equal to
zero, and a structural force / moment on a node closest to the center of the hammer head as
possible equal to 100N in the X direction. If the hammer head is oriented properly then this value
should be directed perpendicularly into the face of the hammers head.)
Solve
List the nodal results of the solution with respect to all degrees of freedom.
Plot the nodal solution with respect to all degrees of freedom. Show both the deformed and
undeformed shape of the hammer.
(The output should be identical to the figure below)

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(Without the Undeformed Hammer it should look like this:)

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(Select a stress (say von Mises) to be plotted and click OK. The output will look like this.)

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CAD/CAM LAB

Engineering analysis with ANSYS software

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Geometry: length l =90 mm, height h=5 mm, thickness b=10mm

DEPARTMENT OF MECHANICAL ENGINEERING

CREATION OF AN ANALYTICAL MODEL

DEPARTMENT OF MECHANICAL ENGINEERING

[2] Input of the beam geometry to analyze

DEPARTMENT OF MECHANICAL ENGINEERING

INPUT OF THE ELASTIC PROPERTIES OF THE BEAM MATERIAL.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

[2] Input of the element thickness

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

[3] Sizing of the elements

The Global Element Sizes window opens as shown in Figure below:

DEPARTMENT OF MECHANICAL ENGINEERING

INPUT OF BOUNDARY CONDITIONS

DEPARTMENT OF MECHANICAL ENGINEERING

[2] Zoom in the nodes display

DEPARTMENT OF MECHANICAL ENGINEERING

The Apply U. ROT on Nodes window opens as shown in Figure below.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

[4] Imposing boundary conditions on nodes

(2) Click [A] NODE_Off box to change it to_ On box.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

(7) Execute the following commands:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

GRAPHICAL REPRESENTATION OF THE RESULTS

DEPARTMENT OF MECHANICAL ENGINEERING

(1) Select [A] DOF Solution and [B] Y-Component of displacement.

[2] Contour plot of stresses

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Model the object using solid Tetrahedral 10 node element.

Structural #6: Analysis of a 3D solid object

Physical Problem: See figure.

We will model the object using solid Tetrahedral 10 node element.

DEPARTMENT OF MECHANICAL ENGINEERING

Click on ANSYS 6.1 in the programs menu.

DEPARTMENT OF MECHANICAL ENGINEERING

MODELING THE STRUCTURE:

DEPARTMENT OF MECHANICAL ENGINEERING

Check the Cartesian and Grid Only buttons.

DEPARTMENT OF MECHANICAL ENGINEERING

Now create two cylinders representing the holes. Use the

DEPARTMENT OF MECHANICAL ENGINEERING

Now we will create the extended portion of the object.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING