An In-Depth Look at Dynamic Simulation and Stress

Analysis Tools
Ravi Akella Autodesk, Inc.
Maxime Debono Autodesk, Inc.
In this session, we'll first explain Dynamic Simulation and Stress Analysis and some reminders about the physics
behind these tools. Well follow this with a discussion on how utilizing the simulation tools for Digital Protoyping can help
manufacturers get to market faster. Well explain how to adopt and use the digital prototyping philosophy, and study
workflows that solve classic engineering problems. Well finish the class with a Q&A session.

About the Speaker:

Ravi joined Autodesk in January 2006, and is a Product Manager for Inventor at the Manufacturing Solutions Division
(MSD). Formerly, Ravi was a Solutions Engineer with MSD sales team and a member of the Simulation Experts
Group. Ravi has experience presenting the capabilities of Autodesk Inventor to the CAD industry press, at Autodesk
University 2006 and at Autodesks annual training event for reseller engineers. Prior to joining Autodesk, Ravi worked
at LMS International, makers of engineering analysis software built to work with CATIA V5. While at LMS, he gained
considerable experience in kinematics and dynamics, FEA, and solid mechanics. Ravi earned a Master of Science
degree in Structural Mechanics from The University of Iowa in Iowa City in 2002.
ravi.akella@autodesk.com

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

What is Simulation?
The Merriam Webster dictionary defines simulation as the imitative representation of the functioning of one system or
process by means of the functioning of another <a computer simulation of an industrial process> or examination of a
problem often not subject to direct experimentation by means of a simulating device.
In the case of Autodesk Inventor Professional for Simulation, the intent is to imitatively represent the functioning of a
mechanical device being designed using the 3D CAD tools in Autodesk Inventor by adding aspects of the physical
world like gravity and friction to the model and applying the numerical methods of Multibody Dynamics.

Why do simulation?
We live in a physical world whose laws are described in Newtonian physics. However, in the past 3D CAD models
existed in an environment where a feather could move a brick and mechanisms could be driven without concern to the
forces and torques required to drive them in the real world.
In the spirit of functional design, Autodesk Inventor Professional for Simulation allows us to simulate reality. The key to
understanding simulation is the realization that the best investigative models are simplified representations of the real
thing where the simplifications hinge on valid assumptions.

Where did this technology come from?

The Dynamic Simulation functionality in Autodesk Inventor Professional for Simulation is a result of
Autodesk acquiring Solid Dynamics based in Roanne, France an established simulation software
developer and services provider in August 2005.
The company was founded in 1992 by Fabien Chojnowski and Laurent Chojnowski. The one focus of this
team has been to create the best in class kinematics and dynamics physics simulation software tools for
engineers and designers.

How does it all work?

Dynamic Simulation can help us answer the ultimate question that weve all been dying to answer; how
much time will it take for the DeLorean to get to 88 mph so that the lightning bolt can charge the flux
capacitor?

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

The key equation being Newtons 2nd law of motion

F = M.a = M.dv/dt
(sum of external forces = mass x acceleration)
where
M: mass
F: external force
A: acceleration
V: velocity
X: position
T: time
The acceleration is then:

a = dv/dt = F/M
The velocity is found by integrating the acceleration:

v = dx/dt = F/M.t
The position is found by integrating the velocities:

x = .F/M.t2
So at every timestep the Dynamic Simulation solver in Autodesk Inventor Professional is doing the following
calculations..

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

What is the relation between Dynamic Simulation and FEA?

Finite Element Analysis, as you might already be aware, is a method employed to determine the
strength of components when subjected to a given set of boundary conditions and applied
forces. The following is a simplified way to understand the relationship between the Dynamic
Simulation and FEA.
For FEA the structure, which in our case is a part, is segmented into elements and the singular
mass is divided into a mass matrix.

In Autodesk Inventor Professional for Simulation the part FEA analysis available assumes linear
elastic deformations so its based on Hookes Law. For systems that obey Hooke's law, the
extension produced is proportional to the load. So, the static equilibrium of each of the
elements, for the whole structure is calculated as:

K*X=F
where
K: stiffness matrix
X: displacement of nodes
F: external forces

In most FEA analyses, the force F is an educated guess, which makes the accuracy of the
resulting deformations only as good as the initial guess of the force.

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

Dynamic Simulation removes the dependence on educated guesses for applied forces in part
FEA analysis by introducing Newtons second law of motion into the mix.

Dynamic Simulation segments the time taken for a mechanical event to happen into individual
time steps.

Time

Time Step
The dynamic equilibrium of the mechanism at each time step is then calculated as:

M*A=F
where
M : mass matrix
A : articular accelerations
F : external forces
Hence, Dynamic Simulation now arms us with an accurate value of the force acting on the part
for part FEA analysis.

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

What are the hands-on exercises all about?

The lab exercises will allow you to experience creating and solving real world design problems using Autodesk Inventor
Professional for Simulation.

Exercise #1

Challenge: Given the desired motion of the follower, create the required cam.
Dynamic Simulation topics covered

Manual and automatic joint creation

Applying an imposed motion on a joints degree of freedom

Spline interpolation in the input grapher

Tracing the motion of point during the simulation

Export trace to sketch

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

Exercise #2

Challenge: Given the desired behavior of the bike suspension, create a spring that is
appropriately sized.
Dynamic Simulation topics covered

Changing the quantity along the x-axis in the input grapher

Use the Unknown Force feature

Determine the distance between two points at every time step of the simulation

Changing the quantity along the x-axis in the input grapher

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

Exercise #3

Challenge: Given that the desired effort applied by the gripper needs to be 1000 N, determine the
amount of force needed to be applied by the actuator/jack.
Dynamic Simulation topics covered

Redundant constraints: what, why and how

Applying an external force to the mechanism

Sizing the actuator

An In-Depth Look at Dynamic Simulation and Stress Analysis Tools

Exercise #4

Challenge: Ensure that the parts in the window lever mechanism are of adequate strength
Dynamic Simulation topics covered:

Tips & Tricks related to the new automatic constraint translation

Creating Rolling/Sliding joints

Tips & Tricks related to exporting motion loads to Stress Analysis

Perform FEA on desired part and check for strength and robustness

In Conclusion
This hands-on lab is intended to introduce some real-world examples where Dynamic Simulation can be used to
create and validate designs in an Inventor Digital Prototype and to explain some of the theory behind Dynamic
Simulation.
Our goal will be met if after the session you leave with a sense of understanding and confidence that allows you to
tackle your own design challenges using Dynamic Simulation in Autodesk Inventor Professional.