Analysis Run Exercise In this exercise you will setup and run an analysis on the original design and the optimized design to compare the results. The exercise follows very closely the video in the See It portion of the exercise. If you run into issues or get lost you can refer to the video.

Step 1: Open the Model 1. Click the Open icon.

2. Browse and select Exercise_4.x_t from the download location.

The model opens into session and appears as in the image.

Step 2: Apply the Forces 1. Click the Structure page to open the ribbon.

2. Select Forces on the Load icon.

3. Apply an 810N Force in the +Y-direction on the right upper pivot boss.

4. Select the other upper pivot boss for a second 810N force in the Y-direction.

5. Apply a 2435N Force on the right upper pivot boss.

6. Click the Move Force icon to rotate the model from the Y-Axis.

7. Select the rotation icon and enter -45 in the dialog.

8. Right click to exit the Move Force tool.

9. Repeat the process for the other upper pivot boss.

10. Right click to exit the tool when complete.

Step 3: Add Fasteners, Joints, and Contacts 1. Click the Fasteners Icon to activate the tool.

2. On the guide bar, left click the drop-down menu, which says Aligned Holes, and

select Single Holes.

3. Left click on the right hand hole on the fork.

The fastener is created in the hole, in this example a Nut and Bolt.

4. In this case we need the bolt to be a support. Click the type pull down to open it.

5. Select Grounded Bolt from the list.

The bolt now has a support attached to it.

6. Follow the steps to create a grounded bolt on the other hole.

7. Click +/- to rotate the bolt in the hole so the nut is on the inside and the bolt head is on the outside.

The grounded bolt is now oriented correctly.

8. Right click to exit the tool.

Step 4: Add Joints 1. Select the Joints icon.

2. Rotate the model to get a better view of the suspension rocker.

3. Select the hole representing the joint between the rocker and seat tube.

A pin joint is created in the hole.

4. Create a second pin at the joint between the fork and the rocker.

The pins have been created at the rotation points for the rocker.

5. Right click to exit the tool.

Step 5: Check and Set the Contacts 1. Select the Contacts icon.

2. Left click on the red flat surface at the pin joint where the rocker the fork.

3. Select Contacting to redefine the contact type.

The surface changes color to show it is a contacting contact.

4. Repeat the process for the contact at the joint between the seat tube and rocker.

The model will appear as in the image.

5. Right click to exit the tool.

The connections are now setup on the model.

Step 6: Add Supports to the Model 6. Select Supports in the Load icon.

7. Apply a support to the cylindrical hole through the seat tube.

8. Apply a second support to the surface at the end of the seat tube.

9. If necessary click the Apply to… icon to change the type of support to apply to a face surface support.

10. In the list of types, select Apply to Face.

The support is now attached to the face as indicated by the icon.

11. Right click to exit the tool.

Step 5: Create the Load Case and Add the Forces and Supports Since we have two sets of forces in different directions we need to create a second load case for the optimization. Force 3 and 4 will be placed in the new load case. All of the supports will be in both load cases.

1. Right-click Load Case 1 and select New>Load Case.

The new load case, Load Case 2 appears in the Model Browser.

2. Select Forces 3 and 4 in the Model Browser.

3. Right click on Force 3 and mouse over the Include/Exclude from menu.

4. Active Load Case 2 and deactivate Load Case 1.

5. Select Support 1, Support 2, Fastener 1, and Fastener 2 in the Model Browser.

6. Right click and mouse over the Include/Exclude from menu.

7. Click All Load Cases from the menu.

Step 6: Assign Materials to the Parts 1. Right click on the Fork part to open the menu.

2. Select Material > Aluminum (7075).

3. Assign aluminum to the Seat Post part and the Seat Post Gusset.

4. Assign Titanium (Ti-17) to the Pins.

Step 7: Run the Analysis on the Initial Design and Review the Results 1. Select the Run Analysis icon.

2. Set the element size to 0.003 m.

3. Click Run to run the analysis.

When the run is complete a green flag appears on the icon.

4. Click the green flag on the icon to import the results.

5. Right click on the Rocker part in the Model Browser to open the menu.

6. Click Isolate to isolate the part to see the analysis results just on that part.

7. Click von Mises Stress to see the stress results for load case 1.

8. Click Load Case 2 to see the stress results for it.

Note the maximum stress for each one.

Step 8: Open the Optimized Model 1. Click the Open icon.

2. Browse and select rocker_optimized.stmod from the download location.

The model opens into session and appears as in the image.

Step 9: Run the Analysis and Review the Results 1. Click the radio button next Min Mass SF 1.2 (5) in the Model Browser.

2. Double click the design space to open the Shape Explorer.

3. Ensure the Topology Slider is placed as in the image.

4. Click the Analyze button to run the analysis.

When the run is finished the green flag will appear on the icon.

5. Click the green flag to import the results.

6. Right click on the rocker part in the Model Browser and click Isolate. 7. Click von Mises Stress to see the stress results.

8. Review the results of the analysis for Load Case 1.

9. Click Load Case 2 to see the results.

Note the results the stress results of the optimized design.

Step 10: Create Geometry to be Exported 1. Exit the Analysis Explorer by clicking the exit icon at the top right corner.

2. Double click the design space to enter the Shape Explorer and ensure the Topology Slider is in the same position as before.

3. Click the Fit button to create surfaces around the optimized results.

When complete the green flag will appear on the Optimize icon.

4. Click the green flag to import the results.

The model will appear as below when finished.

5. Click File > Save As to save the results to the appropriate file type.