Chapter 1 Introduction

Chapter 1
Introduction
1.1
Case Study: Pneumatically Actuated PDMS Fingers
1.2
Structural Mechanics: A Quick Review
1.3
Finite Element Methods: A Conceptual Introduction
1.4
Failure Criteria of Materials
1.5
Review

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Section 1.1
Case Study: Pneumatically Actuated
PDMS Fingers
Problem Description
[2] A single
finger is studied in
this case.

[1] The pneumatic

fingers are part of a
surgical parallel robot
system remotely
controlled by a surgeon
through the Internet.

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

5
[4] The strain-stress
curve of the PDMS
elastomer used in
this case.

4
Stress (MPa)

[3]
Geometric
model.

3
2
1
0

0.2

0.4

0.6

Strain (Dimensionless)

[6] Undeformed
shape.
[5] As air pressure
applies, the finger bends
downward.

0.8

1.0

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Static Structural Simulations

[1] Prepare
material
properties.

[4] Set up loads

and supports.

[2] Create
geometric model.

[5] Solve the

model.

[3] Generate finite

element mesh.

[6] View the

results.

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

[8] Strains.

[7] Displacements.

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Buckling and Stress-Stiffening

Stress-stiffening: bending stiffness increases with increasing axial tensile stress, e.g., guitar string.
The opposite also holds: bending stiffness decreases with increasing axial compressive stress.
Buckling: phenomenon when bending stiffness reduces to zero, i.e., the structure is unstable.
Usually occurs in slender columns, thin walls, etc.

Purpose of a buckling analysis is to find buckling loads and buckling modes.

[2] The upper surface would

undergo compressive stress.
It in turn reduces the bending
stiffness.

[1] If we apply
an upward
force here...

Chapter 1 Introduction

Dynamic Simulations

When the bodies move and

deform very fast, inertia effect
and damping effect must be
considered.

When including these

dynamic effects, it is called a
dynamic simulation.

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Modal Analysis

A special case of dynamic

simulations is the simulation of free
vibrations, the vibrations of a
structure without any loading.

It is called a modal analysis.

Purpose of a modal analysis is to
find natural frequencies and mode
shapes.

Chapter 1 Introduction

Section 1.1 Case Study: Pneumatically Actuated PDMS Fingers

Structural Nonlinearities

the response is linearly

proportional to the loading.

When the solution deviates from
the reality, a nonlinear simulation
is needed.

Structural nonlinearities come

-5
Deflection (mm)

[2] Solution of the

linear simulation pf
the PDMS finger.

Linear simulations assume that

-10
-15

from large deformation, topology

-25

changes, nonlinear stress-strain

-30

relationship, etc.

[1] Solution of the

nonlinear simulation
of the PDMS finger.

-20

40

80

120

Pressure (kPa)

160

200

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

Section 1.2
Structural Mechanics: A Quick Review

Engineering simulation: finding the responses of a problem domain subject to

environmental conditions.

Structural simulation: finding the responses of bodies subject to

environmental conditions.

The bodies are described by geometries and materials.

Environment conditions include support and loading conditions.
Responses can be described by displacements, strains, and stresses.

10

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

Displacements
{u} = {

uX

uY

uZ

[3] An arbitrary particle

of position (X,Y, Z), before
the deformation.

[1] The body before

deformation.

[2] The body after

deformation.

[5] The displacement

vector {u} of the particle is
formed by connecting the
positions before and after
the deformation.

[4] After the

deformation, the
particle moves to a
new position.

11

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

12

Stresses

X
= YX

ZX

{ }

[3] This face is called

negative X-face.

XZ

YZ

XY
Y
ZY

[2] This face is

called X-face, since the
X-direction is normal
to this face.

XY = YX , YZ = ZY , XZ = ZX

{ } = {

XY

YZ

ZX

ZY

[5] The Ycomponent of the

stress on X-face.

ZX

YX

XY
X

[4] The X-component

of the stress on X-face.

XZ

YZ

[1] The reference

frame XYZ.

[6] The Z-component

of the stress on X-face.

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

Strains
[5] Translate AB C so
that A coincides with A.
The new configuration is
AB C . Now CC is the
amount of stretch of ABC in
Y-face.

[3] After
deformation,
ABC moves to
AB C .

[4] To compare with

original configuration,
rotate AB C to a new
configuration AB C .
C

C
C

[1] The reference

frame.

X =

BD
DB
, XY =
AB
AB

B
B

BB
AB

Strain on X-face =

13

[7] And the vector

DB describes the twist
of ABC in X-face.

[2] Original
configuration ABC.
[6] The vector BD
describes the stretch of
ABC in X-face.

Chapter 1 Introduction

Physical meaning of strains:

The normal strain X is the
percentage of stretch of a fiber which
lies along X-direction.
The shear strain XY is the angle
change (in radian) of two fibers lying
on XY-plane and originally forming a
right angle.
We can define other strain components
in a similar way.

Section 1.2 Structural Mechanics: A Quick Review

X
= YX

ZX

{}

XY
Y
ZY

XZ

YZ

XY = YX , YZ = ZY , XZ = ZX

{ } = {

XY

YZ

ZX

14

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

Governing Equations
{u} = {
{ } = {
{ } = {

uX

uY

uZ

XY
XY

}
YZ

ZX

YZ

ZX

Totally 15 quantities

Equilibrium Equations (3 Equations)

Strain-Displacement Relations (6 Equations)
Stress-Strain Relations (6 Equations)

15

Chapter 1 Introduction

Section 1.2 Structural Mechanics: A Quick Review

Stress-Strain Relations: Hooke's Law

X

Y Z
E
E
E
Y
Z
X
Y =

E
E
E
Z
X
Y
Z =

E
E
E

= XY , YZ = YZ , ZX = ZX
G
G
G
X =

XY

For isotropic, linearly elastic materials,

Young's modulus (E) and Poisson's ratio ( )
can be used to fully describe the stressstrain relations.

The Hooke's law is called a material

model.

The Young's modulus and the Poisson's

ratio are called the material parameters

G=

E
2(1+ )

of the material model.

16

Chapter 1 Introduction

Y Z + T
E
E
E
Y
Z
X
Y =

+ T
E
E
E

Z = Z X Y + T
E
E
E

XY = XY , YZ = YZ , ZX = ZX
G
G
G
X =

Section 1.2 Structural Mechanics: A Quick Review

If temperature changes (thermal loads)

are involved, the coefficient of thermal
expansion, (CTE, ) must be included.

If inertia forces (e.g., dynamic

simulations) are involved, the mass
density must be included.

17

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

Section 1.3
Finite Element Methods: A Conceptual
Introduction
Basic Ideas

A basic idea of finite element methods is to divide the structural body into small and
geometrically simple bodies, called elements, so that equilibrium equations of each
element can be written, and all the equilibrium equations are solved simultaneously

The elements are assumed to be connected by nodes located on the elements' edges
and vertices.

18

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

19

Another idea is to solve unknown

discrete values (displacements at the
nodes) rather than to solve unknown
functions (displacement fields).

Since the displacement on each node

is a vector and has three components
(in 3D cases), the number of total
unknown quantities to be solved is
three times the number of nodes.

The nodal displacement components

are called the degrees of freedom
(DOF's) of the structure.

In case of the pneumatic finger, the

structural body is divided into 3122
elements. The elements are connected by
17142 nodes. There are 3x17142 unknown
displacement values to be solved.

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

In static cases, the system of equilibrium equations has following form:

{ } {}

K D = F

The displacement vector {D} contains displacements of all degrees of

freedom.

The force vector {F} contains forces acting on all degrees of freedom.
The matrix [K] is called the stiffness matrix of the structure. In a special
case when the structure is a spring, {F} as external force, and {D} as the
deformation of the spring, then [K] is the spring constant.

20

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

Basic Procedure of Finite Element Method

1. Given the bodies' geometries, material properties, support conditions, and loading
conditions.
2. Divide the bodies into elements.
3. Establish the equilibrium equation: [K] {D} = {F}
3.1 Construct the [K] matrix, according to the elements' geometries and the material
properties.
3.2 Most of components in {F} can be calculated, according to the loading conditions.
3.3 Most of components in {D} are unknown. Some component, however, are known,
according to the support conditions.
3.4 The total number of unknowns in {D} and {F} should be equal to the total number
of degrees of freedom of the structure.

21

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

4. Solve the equilibrium equation. Now, the nodal displacements {d} of each element are
known.
5. For each element:
5.1 Calculate displacement fields {u}, using an interpolating method, {u} = [N] {d}. The
interpolating functions in [N] are called the shape functions.
5.2 Calculate strain fields according to the strain-displacement relations.
5.3 Calculate stress fields according to the stress-strain relations (Hooke's law).

22

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

23

Shape Functions

[1] A 2D 4-node
quadrilateral element

Shape functions serve as interpolating

d6

functions, allowing the calculation of

d5

d8

displacement fields (functions of X, Y,

d7

Z) from nodal displacements (discrete

values).

{u} = N {d}

For elements with nodes at vertices,

the interpolation must be linear and
thus the shape functions are linear (of
X,Y, Z).

d4
d2
X

d3
d1
[2] This element's
nodes locate at
vertices.

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

For elements with nodes at vertices as well as at middles of edges, the interpolation
must be quadratic and thus the shape functions are quadratic (of X,Y, Z).

Elements with linear shape functions are called linear elements, first-order elements, or
lower-order elements.

Elements with quadratic shape functions are called quadratic elements, second-order
elements, or higher-order elements.

ANSYS Workbench supports only first-order and second-order elements.

24

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

Workbench Elements
3D Solid Bodies

[1] 3D 20-node
structural solid.
Each node has 3
translational
degrees of
freedom: DX, DY,
and DZ.

[4] Tetrahedron.

[3] Quadrilateralbased pyramid.

[2] Triangle-based
prism.

25

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

2D Solid Bodies

[5] 2D 8-node
structural solid.
Each node has 2
translational
degrees of
freedom: DX and
DY.

[6] Degenerated
Triangle.

26

Chapter 1 Introduction

Section 1.3 Finite Element Methods: A Conceptual Introduction

3D Surface Bodies
[8] Degenerated
Triangle

[7] 3D 4-node
structural shell.
Each node has 3
translational and 3
rotational degrees
of freedom: DX, DY,
DZ, RX, RY, and RZ.

3D Line Bodies
[9] 3D 2-Node
beam. Each node has
3 translational and 3
rotational degrees of
freedom: DX, DY, DZ,
RX, RY, RZ.

27

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Section 1.4
Failure Criteria of Materials
Ductile versus Brittle Materials

A Ductile material exhibits a large amount of strain before it

fractures.

The fracture strain of a brittle material is relatively small.

Fracture strain is a measure of ductility.

28

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Failure Points for Ductile Materials

Mild steel is a typical ductile material.

For ductile materials, there often exists an
obvious yield point, beyond which the
deformation would be too large so that the
the failure is accompanied by excess
deformation.

Therefore, for these materials, we are most

concerned about whether the material
reaches the yield point y .

y
Stress

material is no longer reliable or functional;

[2] Fracture
point.

[3] Yield
point.

[1] Stress-strain curve

for a ductile material.
Strain

29

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Failure Points for Brittle Materials

[2] Fracture
point.

Cast iron and ceramics are two examples

For brittle materials, there usually doesn't

exist obvious yield point, and we are

Stress

of brittle materials.

concerned about their fracture point f .

[1] Stress-strain
curve for a
brittle material.
Strain

30

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Failure Modes

The fracture of brittle materials is mostly due to

tensile failure.

The yielding of ductile materials is mostly due to shear

failure

31

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Principal Stresses

A direction in which the shear

stress vanishes is called a

[5]
Mohr's
circle.

principal direction.

The corresponding normal stress

is called a principle stress.

[8] Point of
maximum
shear stress.

[4] Other stress

pairs could be
drawn.

[2] Stress in
the base
direction.

[7] Point of
minimum
normal
stress.

( X , XY )

( Y , XY )

[1] Stress
state.

XY
XY
X

XY
XY
Y

[3] Stress in
the direction that
forms 90o with
the base
direction.

[9] Another
Point of
maximum shear
stress.

[6] Point of
maximum
normal
stress.

32

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

At any point of a 3D solid, there are three principal directions and

three principal stresses.

The maximum normal stress is called the maximum principal stress

and denoted by 1 .

The minimum normal stress is called the minimum principal stress and
denoted by 3 .

The medium principal stress is denoted by 2 .

The maximum principal stress is usually a positive value, a tension;
the minimum principal stress is often a negative value, a
compression.

33

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Failure Criterion for Brittle Materials

The failure of brittle materials is a tensile failure. In other words, a

brittle material fractures because its tensile stress reaches the
fracture strength f .

We may state a failure criterion for brittle materials as follows: At a

certain point of a body, if the maximum principal stress reaches the
fracture strength of the material, it will fail.

In short, a point of material fails if

1 f

34

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Tresca Criterion for Ductile Materials

The failure of ductile materials is a shear

It is easy to show (using

Mohr's circle) that

failure. In other words, a ductile material yields

because its shear stress reaches the shear

max =

strength y of the material.

We may state a failure criterion for ductile

y =

materials as follows: At a certain point of a

body, if the maximum shear stress reaches the

y
2

Thus, the material yields if

1 3 y

shear strength of the material, it will fail.

1 3
2

In short, a point of material fails if

max y

(1 3 ) is called the stress

intensity.

35

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

Von Mises Criterion for Ductile Materials

In 1913, Richard von Mises proposed a theory for predicting the yielding of ductile
materials. The theory states that the yielding occurs when the deviatoric strain energy
density reaches a critical value, i.e.,

w d w yd

It can be shown that the yielding deviatoric energy in uniaxial test is

w yd =

(1+ ) y2
3E

And the deviatoric energy in general 3D cases is

wd =

2
2
2
1+
1 2 + 2 3 + 3 1

6E

) (

) (

36

Chapter 1 Introduction

Section 1.4 Failure Criteria of Materials

After substitution and simplification, the criterion reduces to that the yielding
occurs when

) (

) (

2
2
2
1
1 2 + 2 3 + 3 1 y

The quantity on the left-hand-side is termed von Mises stress or effective stress, and
denoted by e ; in ANSYS, it is also referred to as equivalent stress,

e =

) (

) (

2
2
2
1
1 2 + 2 3 + 3 1

37

Chapter 2 Sketching

Chapter 2
Sketching
2.1
Step-by-Step: W16x50 Beam
2.2
Step-by-Step: Triangular Plate
2.3
More Details
2.4
More Exercise: M20x2.5 Threaded Bolt
2.5
More Exercise: Spur Gears
2.6
More Exercise: Microgripper
2.7
Review

Chapter 2 Sketching

Section 2.1 W16x50 Beam

Section 2.1
W16x50 Beam
7.07 "

Problem Description

.380 "

[1] Wide-flange
I-shape section.

[2] Nominal
depth 16 in.

W16x50

16.25"

.628 "

[3] Weight 50
lb/ft.

R.375"

Chapter 2 Sketching

Techniques/Concepts

Section 2.1 W16x50 Beam

Start up <DesignModeler>
Sketching/Modeling modes
Draw>Rectangle
Draw>Polyline
Dimensions>General
Dimension>Horizontal
Dimensions>Display
Dimensions>Move
Modify>Copy/Paste
Modify>Trim
Modify>Fillet
Constraints>Symmetry
Auto Constraints
Constraint Status
Extrude

Chapter 2 Sketching

Section 2.1 W16x50 Beam

Basic Mouse Operations

[7] Middle-click-drag:
rotation.

[6] Scroll-wheel: zoom

in/out.

[1] Click: single

selection

[2] Control-click: add/

remove selection

[3] Click-sweep:
continuous selection.

[5] Right-click-drag:
box zoom.

[4] Right-click: open

context menu.

Chapter 2 Sketching

Section 2.2 Triangular Plate

Section 2.2
Triangular Plate

40 mm

Problem Description

[2] Radii of
the fillets
are 10 mm.

[1] The plate

has three
planes of
symmetry.
30 mm
300 mm

Chapter 2 Sketching

Section 2.2 Triangular Plate

Techniques/Concepts

Draw>Arc by Center
Dimensions> Radius
Modify>Replicate
Modify>Offset
Constraints>Equal Length
Weak/Strong Dimensions
Weak/Strong Constraints
Selection Filter
Single/Box Selection

Chapter 2 Sketching

Section 2.2 Triangular Plate

2D Graphics Controls
[3] <Pan>.

[5] <Zoom>.

[2] <Zoom to Fit>.

[4] <Box Zoom>.

[7] <Next View>.

[6] <Previous View>.

[8] <Undo>.
[9] <Redo>.

[1] <Look At Face/

Plane/Sketch>.

Chapter 2 Sketching

Section 2.3

Pull-down Menus
and Toolbars

Mode Tabs
Tree Outline
Sketching
Toolboxes

Graphics area
Details View
Status Bar
Separators

Section 2.3 More Details

More Details

Chapter 2 Sketching

Section 2.3 More Details

Sketching Planes

A sketch must be created on a

[1] Currently
active plane.

[2] To create a
new plane,
click <New
Plane>.

sketching plane; each plane may

contain multiple sketches.

In the very beginning of a

<DesignModeler> session, three
planes are automatically created:
<XYPlane>, <YZPlane>, and
<ZXPlane>.

[3] There are many ways

of creating new planes.

Chapter 2 Sketching

Section 2.3 More Details

Sketches

A sketch consists of points and edges; edges may be straight lines or curves.
Multiple sketches may be created on a plane.

[2] Currently
active sketch.

[1] To create a new sketch on

the active sketching plane,
click <New Sketch>.

10

Chapter 2 Sketching

Section 2.3 More Details

Auto Constraints

- The cursor is coincident with a line.

- The cursor is coincident with another point.

- The cursor is a tangent point.

- The cursor is a perpendicular foot.

- The line is horizontal.

- The line is vertical.

//

- The line is parallel to another line.

- The radius is equal to another radius.

[1] You can turn

on/off <Auto
Constraints>.

11

Chapter 2 Sketching

Sketching Toolboxes

Section 2.3 More Details

12

Chapter 2 Sketching

Section 2.4 M20x2.5 Threaded Bolt

Section 2.4
M20x2.5 Threaded Bolt
Problem Description
[1] Metric
system.

[2] Nominal
diameter
d = 20 mm.

M20x2.5

[3] Pitch
p = 2.5 mm.

13

Chapter 2 Sketching

Section 2.4 M20x2.5 Threaded Bolt

H
H
4

d
d1

p
11 p = 27.5

H
8
p

32

External
threads
(bolt)
Internal
threads
(nut)

H = ( 3 2)p = 2.165 mm
d1 = d (5 8)H 2 =17.294 mm

Minor diameter of internal thread d1

Nominal diameter d

14

Chapter 2 Sketching

Techniques/Concepts

Dimensions>Angle
Modify>Replicate
Revolve

Section 2.4 M20x2.5 Threaded Bolt

15

Chapter 2 Sketching

Section 2.5
Spur Gears
Problem Description

To satisfy the fundamental law

of gearing, the gear profiles
are cut to an involute curve.

Section 2.5 Spur Gears

16

Chapter 2 Sketching

Section 2.5 Spur Gears

[1] The driving

gear rotates
clockwise.

[8] Line of action (common

normal of contacting gears).
The pressure angle is 20o.

[2] The driven

gear rotates
counterclockwise.

[3] Pitch circle

rp = 2.5 in.

[4] Pitch
circle of the
driving gear.
[6] Contact
point (pitch
point).
[5] Line of
centers.

[7] Common
tangent of the
pitch circles.

[9] Addendum
ra = 2.75 in.
[12] The fillet
has a radius of
0.1 in.
[10]
Dedendum
rd = 2.2 in.

[11] The shaft has

a radius of 1.25 in.

17

Chapter 2 Sketching

Techniques/Concepts

Draw>Construction Point
Draw>Spline
Modify>Replicate
Constraints>Perpendicular

Section 2.5 Spur Gears

18

Chapter 2 Sketching

Section 2.6 Microgripper

Section 2.6
Microgripper
Problem Description
[1] Gripping
direction.

[2] Actuation
direction.

[3] SMA
actuator.

[4] Glass
bead.

19

Chapter 2 Sketching

Section 2.6 Microgripper

92
32

D30

212

Unit: m
Thickness: 300 m
R45 R25

144
176
280

480

400

47

87

77

140

20

20

Chapter 2 Sketching

Techniques/Concepts

Constraints>Equal Radius
Copy bodies (Mirror)
Create new sketch
Constraints>Tangent
Multiple parts

Section 2.6 Microgripper

21

Chapter 3 2D Simulations

Chapter 3
2D Simulations
3.1
Step-by-Step: Triangular Plate
3.2
Step-by-Step: Threaded Bolt-and-Nut
3.3
More Details
3.4
More Exercise: Spur Gears
3.5
More Exercise: Filleted Bar
3.6
Review

Chapter 3 2D Simulations

Section 3.1
Triangular Plate
Problem Description

The plate is made of steel and designed to

withstand a tensile force of 20,000 N on each
of its three side faces.

We are concerned about the deformations

and the stresses.

Section 3.1 Triangular Plate

Chapter 3 2D Simulations

Techniques/Concepts

Section 3.1 Triangular Plate

Project Schematic
Concepts>Surface From Sketches
Analysis Type (2D)
Plane Stress Problems
Generate 2D Mesh
2D Solid Elements
<Relevance Center> and
<Relevance>

Loads>Pressure
Weak Springs
Solution>Total Deformation
Solution>Equivalent Stress
Tools>Symmetry
Coordinate System

Chapter 3 2D Simulations

Section 3.2 Threaded Bolt-and-Nut

Section 3.2
Threaded Bolt-and-Nut
Problem Description
[1] Bolt.

[3] Plates.

[2] Nut.

[4] Section
view.

Chapter 3 2D Simulations

Section 3.2 Threaded Bolt-and-Nut

17 mm

The axis of symmetry

The plane of symmetry

[1] The 2D
simulation
model.

[6] Frictionless
support.

Chapter 3 2D Simulations

Techniques/Concepts

Hide/Show Sketches
Display Model/Plane
Add Material/Frozen
Axisymmetric Problems
Contact/Target
Frictional Contacts
Edge Sizing
Loads>Force
Supports>Frictionless Support
Solution>Normal Stress
Radial/Axial/Hoop Stresses
Nonlinear Simulations

Section 3.2 Threaded Bolt-and-Nut

Chapter 3 2D Simulations

Section 3.3 More Details

Section 3.3

More Details

Plane stress condition:

Z = 0, ZY = 0, ZX = 0

The Hook's law becomes

X

Y
E
E

Y = Y X
E
E
X

Z =
Y
E
E

= XY , YZ = 0, ZX = 0
G
X =

Plane-Stress Problems

XY

XY

XY

X
XY

Y
X

XY
Stress state at a point
of a zero thickness
plate, subject to in-plane
forces.

A problem may assume the

plane-stress condition if its
thickness direction is not
restrained and thus free to
expand or contract.

Chapter 3 2D Simulations

Section 3.3 More Details

Plane-Strain Problems

Plane strain condition:

Z = 0, ZX = 0, ZY = 0

XY

XY

The Hook's law becomes

X =

E
(1 ) X + Y
(1+ )(1 2 )

Y =

E
(1 )Y + X
(1+ )(1 2 )

Z =

Y
X

E
+ Y
(1+ )(1 2 ) X

XY = G XY , YZ = 0, ZX = 0

A problem may assume the plane-strain

condition if its Z-direction is restrained
from expansion or contraction, all cross-

[2] Strain state at

a point of a planestrain structure.

sections perpendicular to the Z-direction

have the same geometry, and all
environment conditions are in the XY plane.

Chapter 3 2D Simulations

Section 3.3 More Details

Axisymmetric Problems

RZ

RZ

axisymmetric about the Z-axis,

then all response quantities are
independent of coordinate.

RZ

RZ

In such a case,
R = 0, Z = 0

Z
[2] Stress
state at a
point of a
axisymmetric
structure.

loading of a structure are

[1] Strain
state at a
point of a
axisymmetric
structure.

If the geometry, supports, and

R = 0, Z = 0

both and are generally not

zero. They are termed hoop

stress and hoop strain respectively.

Chapter 3 2D Simulations

Mechanical GUI

Pull-down Menus
and Toolbars

Outline of Project
Tree

Details View
Geometry
Graph
Tabular Data
Status Bar
Separators

Section 3.3 More Details

10

Chapter 3 2D Simulations

Project Tree

A project tree may contain one or more

simulation models.

A simulation model may contain one or more

<Environment> branches, along with other
objects. Default name for the <Environment>
branch is the name of the analysis system.

An <Environment> branch contains <Analysis

Settings>, environment conditions, and a
<Solution> branch.

A <Solution> branch contains <Solution

Information> and several results objects.

Section 3.3 More Details

11

Chapter 3 2D Simulations

Section 3.3 More Details

Unit Systems

[1] Built-in unit

systems.

[2] Unit system

for current
project.

Consistent versus Inconsistent

Unit Systems.

Built-in versus User-Defined Unit

Systems.

Project Unit System.

Length Unit in <DesignModeler>.
Unit System in <Mechanical>.
Internal Consistent Unit System.

[5] These, along with the

SI, are consistent unit
systems.

[4] Checked unit

systems won't be
available in the pulldown menu.

12

[3] Default
project unit
system.

Chapter 3 2D Simulations

Environment Conditions

Section 3.3 More Details

13

Chapter 3 2D Simulations

Section 3.3 More Details

Results Objects

View Results
[3] Label.

[4] You may

select the scale
of deformation.

[5] You can control

how the contour
displays.

[6] Some results

can display with
vectors.

[1] Click to turn on/

off the label of
maximum/minimum.

[2] Click to turn

on/off the probe.

14

Chapter 3 2D Simulations

Section 3.4 Spur Gears

15

Section 3.4
Spur Gears
Problem Description

[2] And the bending

stress here.

[1] What we are

concerned most is
the contact stress
here.

Chapter 3 2D Simulations

Techniques/Concepts

Copy bodies (Translate)

Contacts

Frictionless
Symmetric (Contact/Target)
Adjust to Touch

Loads>Moment
True Scale

Section 3.4 Spur Gears

16

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Section 3.5
Filleted Bar
Problem Description
[1] The bar is
made of steel.

100

100
[2] The bar has
a thickness of
10 mm.

50 kN

50 kN

50

100

R15

17

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Part A. Stress Discontinuity

Displacement field is
continuous over the
entire body.

18

Chapter 3 2D Simulations

[2] Original
calculated stresses
(unaveraged) are not
continuous across
element boundaries,
i.e., stress at boundary
has multiple values.

Section 3.5 Filleted Bar

[4] By default, stresses are

averaged on the nodes, and the
stress field is recalculated. That
way, the stress field is
continuous over the body.

19

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Part B. Structural Error

For an element, strain energies calculated using averaged stresses and unaveraged
stresses respectively are different. The difference between these two energy values is
called <Structural Error> of the element.

The finer the mesh, the smaller the structural error. Thus, the structural error can be
used as an indicator of mesh adequacy.

20

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Part C. Finite Element Convergence

[1] Quadrilateral
element.
0.0787
0.0786
Displacement (mm)

0.0785
[2] Triangular
element.

0.0784
0.0783
0.0782
0.0781

[3] Increasing
nodes.

0.0780
0.0779

2000

4000

6000

8000

Number of Nodes

10000

12000

14000

21

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Part D. Stress Concentration

[1] To accurately
evaluate the
concentrated stress,
finer mesh is needed,
particularly around the
corner.

[2] Stress
concentration.

22

Chapter 3 2D Simulations

Section 3.5 Filleted Bar

Part E. Stress Sigularity

The stress in this

zero-radius fillet
is theoretically
infinite.

Stress singularity is not limited

to sharp corners.

Any locations that have stress

of infinity are called singular
points.

Besides a concave fillet of zero

radius, a point of concentrated
forces is also a singular point.

23

Chapter 4 3D Solid Modeling

Chapter 4
3D Solid Modeling
4.1
Step-by-Step: Beam Bracket
4.2
Step-by-Step: Cover of Pressure Cylinder
4.3
Step-by-Step: Lifting Fork
4.4
More Details
4.5
More Exercise: LCD Display Support
4.6
Review

Chapter 4 3D Solid Modeling

Section 4.1 Beam Bracket

Section 4.1
Beam Bracket
Problem Description

Y
Z

The beam bracket is

made of WT8x25 steel.

Chapter 4 3D Solid Modeling

Section 4.1 Beam Bracket

Techniques/Concepts

Local coordinate systems

Sketching with plane view
versus in 3D view

Use of Triad
Add Material
Rounds/Fillets
Turn on/off edges display

Chapter 4 3D Solid Modeling

Section 4.2 Cover of Pressure Cylinder

Section 4.2
Cover of Pressure Cylinder
Problem Description
[1] Pressure
cylinder.

[3] Back view of

the cover.

[2] Cylinder
Cover.

Chapter 4 3D Solid Modeling

Section 4.2 Cover of Pressure Cylinder

30.3

62.0
2.3

1.6

7.4

Unit: mm.

25.3
21.0

1.3

7.4
R19.0
R8.5
R7.5

62.0

R14.5
R18.1

R3.2
R4.9
R9.0

31.0

R25.4
R27.8

R3.4

10.0

3.0

Chapter 4 3D Solid Modeling

Section 4.2 Cover of Pressure Cylinder

Techniques/Concepts

Create new planes

Set up local coordinate systems
Plane with boundary
Modify>Duplicate
Cut Material

Chapter 4 3D Solid Modeling

Section 4.3 Lifting Fork

Section 4.3
Lifting Fork
Problem Description
[1] Fork (steel).

[2] Glass panel (1.0

mm).

Chapter 4 3D Solid Modeling

[3] The cross

section here is
100x10 mm.

Section 4.3 Lifting Fork

[2] The cross

section here is
130x20 mm.

[1] The cross

section here is
160x40 mm.

200

2400
2500

200

2200

1600

Unit: mm.

Chapter 4 3D Solid Modeling

Techniques/Concepts

Skin/Loft
Lofting guide line
Add Frozen
Copy bodies (Pattern)
Boolean
Create 3D surface bodies

Section 4.3 Lifting Fork

Chapter 4 3D Solid Modeling

Section 4.4

Triad
Isometric View
Rotation
Selection Filters
Extend Selection
Selection Panes
Edge Display
Tools for 3D
features

Section 4.4 More Details

More Details

10

Chapter 4 3D Solid Modeling

Section 4.4 More Details

Triad
[1] Click an
arrow will
orient the
view normal
to that arrow.

[3] If the cyan sphere

coincides with the origin,
that means the view is an
isometric view.

[2] A black
arrow represents
a negative
direction.
[4] Click the
cyan sphere to
return to the
isometric view.

11

Chapter 4 3D Solid Modeling

Section 4.4 More Details

Rotations
[1] Hold the middle mouse button
down while moving around the graphic
area, you can rotate the model.

[3] Roll,
rotation about
screen Z-axis.

[5] Pitch,
rotation about
screen X-axis.

[2] Free
rotation.

[4] Yaw,
rotation about
screen
Y-axis.

[6] The type of rotation depends on

the location of the cursor.

12

Chapter 4 3D Solid Modeling

Selection Aides

Selection Filters
Extend Selectin
Selection Panes

Section 4.4 More Details

13

Chapter 4 3D Solid Modeling

Section 4.4 More Details

Bodies and Parts

A body is entirely made of one kind of

material and is the basic building
blocks of a model.
A 3D body is either a solid body, a
surface body, or a line body.
A part is a collection of same type of
bodies. All bodies in a part are
assumed to be bonded together with
one another.
In <Mechanical>, parts are meshed
independently
A model may consist of one or more
parts.
In <Mechanical>, connections
(contacts, joints) among parts must be
established to complete a model.

This is the only

geometric
entities that will
be attached to
<Mechanical> for
simulations.

14

Chapter 4 3D Solid Modeling

Features

Section 4.4 More Details

Features
Based Features
Extrude
Revolve
Sweep
Skin/Loft
Surface
Lines
Point
etc.
Placed Features
Thin/Surface
Blend
Chamfer
etc.
Planes
Operations
etc.

15

Chapter 4 3D Solid Modeling

Section 4.5
LCD Display Support
Problem Description

Section 4.5 LCD Display Support

16

Chapter 4 3D Solid Modeling

Section 4.5 LCD Display Support

42

17

Unit: mm

200
80

10

50

60

17

Chapter 4 3D Solid Modeling

Section 4.5 LCD Display Support

Techniques/Concepts

Revolve
Skin/loft
Thin/Surface

18