fea applications i - pennsylvania state university · 2017-09-12 · fea applications i met 415...
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FEA Applications I MET 415 Review
• Course Structure:
• 15 week course
• Weekly Schedule
• 50 minute lecture
• 2.5 hour laboratory
• 50 minute lecture
9/6/17, David Johnson P.E. (Thank you) & PAJ 1
The Mechanical Engineering Technology Students are
required to take FEA Applications II (MET 425)
Goal: Obtain feedback from
“Industry Users” on course
presentation and content
Lectures • Focused on Applications
• User Manual Construction Required
• Matrix manipulations are only discussed (no exercises)
• Weekly quizzes (MC and T/F)
• 3 Exams (MC, T/F, Practical's)
9/6/17, David Johnson P.E. (Thank you) & PAJ 2
• Focused on Applications
• Worksheet Provided
• “Turn In” 1. Table of results comparisons (include the model size, i.e., the number of nodes and elements used in each case). At least three FEA
analyses are required; more than three may be needed.
Results to list: element type, maximum deflection, Fx, maximum SX stress, mesh error SEPC
2. Hand calculation of stress concentration (Include your reference for the formula, etc.)
Make a statement comparing the FEA results to the hand calc. Calculate % difference.
3. Hand calculation of the total elongation of the plate in the direction of loading.
Make a statement comparing the FEA results to the hand calc. Calculate % difference.
4. An annotated, color (or gray shades) plot of x-direction stress results, SX, from any ONE of your solutions.
5. An annotated, color (or gray shades) plot of vonMises stress results, SEQV, from any ONE of your solutions.
Write a note comparing the maximum normal stress (SX) to the maximum vonMises stress (SEQV) - what makes the max. equivalent
stress so similar to the max. normal stress, SX for this problem ? Why might they be different (in other problems)?
6. [HINT: How is Mohr's circle used in computing vonMises or equiv. stress?]
Labs
FEA Applications I Review
9/6/17, David Johnson P.E. (Thank you) & PAJ 3
FEA Applications I Review
ANSYS Mechanical APDL: 5 weeks
#1: 2D Plate
• Geometry Construction
• 1 Mesh control
• Boundary Conditions
• Plane Stress
• Model simplification
• Post Processing
#2A: Window Latch
• Work Planes
• Boolean Ops
• Plane Strain
• Commands (AOVLP)
#2B: Concrete Dam
• Varying Loads
• Gravity & Mass in ANSYS
• Plane Strain
9/6/17, David Johnson P.E. (Thank you) & PAJ 4
FEA Applications I Review
ANSYS Mechanical APDL: 5 weeks (cont)
#3A: Ceramic Magnet
• Geometry Import
• Multiple Materials
• Axi-symmetric
#3B: Brake Drum
• Geometry modification
• Angular velocity
• Axi-symmetric
• Multiple load steps
#4: Plastic Snap Fit
• Geometry Import and Modification
• Large Deformation
• Contact Wizard
9/6/17, David Johnson P.E. (Thank you) & PAJ 5
FEA Applications I Review
ANSYS Mechanical APDL: 5 weeks (cont)
#4A: Interference Fit
• Statically Indeterminate
• Contact Wizard
• Multiple Materials
#4B: Pipe Clamp
• Symmetry
• Contact Wizard
• Multiple Materials
9/6/17, David Johnson P.E. (Thank you) & PAJ 6
FEA Applications I Review
ANSYS Mechanical Workbench: 10 weeks
#5: Plastic Plate
• SCDM
• Symmetry
• Multiple Materials
#6A: Lawn Tractor Steering Link
• Combined Loading
• Symmetry?
• 3D Solids
• Singularities
#6B: Triangular Plate
• Singularities
• Symmetry?
9/6/17, David Johnson P.E. (Thank you) & PAJ 7
FEA Applications I Review
ANSYS Mechanical Workbench: 10 weeks (cont)
#7A: Pump Assembly
• Contacts
• Scoping Assemblies
• Multiple Materials
• Contact Behavior
• Bearing Loads
#7B: Machining Vise
• Contacts
• Boundary Conditions
• Contact Behavior
• Scoping Assemblies
• Mesh Controls
#8A: Allen Wrench
• Non-linear behavior
• Boundary Conditions
• Scoping
• Mesh Controls
9/6/17, David Johnson P.E. (Thank you) & PAJ 8
FEA Applications I Review
ANSYS Mechanical Workbench: 10 weeks (cont)
#8B: Elastomer
• Hyper-elastic behavior
• Boundary Conditions
• Scoping
• Mesh Controls
#9A: Lawn Tractor Hood
• 2D Shells
• SCDM
• Virtual Topology
#9B: Welded Plate
• 2D Shells
• Rotated Coordinate
Systems
• Post Processing
9/6/17, David Johnson P.E. (Thank you) & PAJ 9
FEA Applications I Review
ANSYS Mechanical Workbench: 10 weeks (cont)
#10: Punch Die
• 2D Shells & 3D Solids
• Large Deformation
• Contact Behavior
• Symmetry
#11A: Back-hoe
• Beam Elements
• Section Properties
• Joints
#11B: Bridge (APDL)
• Truss Elements
• Boundary Conditions
• Varying Sections
9/6/17, David Johnson P.E. (Thank you) & PAJ 10
Laboratory Teams will be assigned as shown
1 2 3 4 5 6 7 8 9 10 11 12
1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4 4 4 4 4 4
5 5 5 5 5 5 5 5 5 5 5 5 5
6 6 6 6 6 6 6 6 6 6 6 6 6
7 1 1 1 1 2 2 2 2 3 3 3 3
8 2 2 2 2 3 3 3 3 4 4 4 4
9 3 3 3 3 4 4 4 4 5 5 5 5
10 4 4 4 4 5 5 5 5 6 6 6 6
11 5 5 5 5 6 6 6 6 1 1 1 1
12 6 6 6 6 1 1 1 1 2 2 2 2
13 1 1 1 1 2 2 2 2 3 3 3 3
Student to submit electronically for the team
Lab #
Student
2 Member Teams Below for "A" labs (in class)
"B" Lab Teams can be chosen by individuals (always document who and who did what)
# Best Practice/Lesson Learned Benefits
1
2
3
4
5
6
7
Lab _____________________________________ Best Practices/Lessons Learned
9/6/17, David Johnson P.E. (Thank you) & PAJ 11
Applied FEA ME 467 Review
• Course Structure:
• 15 week course
• Weekly Schedule
• 50 minute recitation
• 50 minute lecture
• 2 hour laboratory
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 12
The Mechanical Engineering Students are NOT
required to take Applied FEA (ME 467). There is not
FEA II Course
Goal: Obtain feedback from
“Industry Users” on course
presentation and content
Lectures • Focused on Applications
• Matrix manipulations are only discussed (no exercises) – more in depth
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 13
• Workbench
• SCDM
• Focused on Applications
• “Turn In” (due weekly) 1. Results: deflection, stress, mesh error
2. Hand calculation of stress/deflection (Include your reference for the formula, etc.)
Make a statement comparing the FEA results to the hand calc.
Labs
ME 467 Applied FEA Review
HW: • Additional activities, similar to labs
• Individual assignemnts
• Due bi-weekly
Also: • Two exams (in lab, practical)
• Final Project
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 14
ME 467 Applied FEA Review
Lab #1: 2D Plate
• Geometry Construction
• 1 Mesh control
• Boundary Conditions
• Plane Stress
• Model simplification
• Post Processing
Lab#2: Window Frame
• Plane Strain
• BCs
HW#1: Concrete Dam
• Varying Loads
• Gravity & Mass in ANSYS
• Plane Strain
• Hand Calcs
• Singularities
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 15
ME 467 Applied FEA Review
HW #2: Brake Drum
• Angular velocity
• Axi-symmetric
• Multiple load steps
Lab #3: Lawn Tractor Steering Link
• Combined Loading
• Symmetry?
• 3D Solids
• Singularities
HW #3: Plastic Latch
• 3D Modeling
• Tetrahedral (free) meshing
• Element size control
• Concentrated Displacement
Loading
• 3D Stress State evaluation
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 16
ME 467 Applied FEA Review
Lab #4: Lawn Tractor Hood • 3D Modeling: Shell Elements • Introduction to Contact • Postprocessing of Shells • Mesh Error for non-Planer Surfaces
Lab 3a: SCDM Repair Tools • IGES file import and repair of somebody else's sloppy model • additional model construction after an IGES geometry import
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 17
ME 467 Applied FEA Review
Lab #5: Pump Assembly
• Contacts
• Scoping Assemblies
• Multiple Materials
• Contact Behavior
• Bearing Loads
HW#4: Gear Box • Combined Shell and Solid Models • Model Repair • Revising and Adding Contact Pairs • Scoping results
Lab #6: Backhoe
• Beam & Link
Elements
• SCDM Beams
• Boundary Conditions
• Varying Sections
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 18
ME 467 Applied FEA Review
Lab #7: Allen Wrench
• Non-linear behavior
• Boundary Conditions
• Scoping
• Mesh Controls
HW #5: Bolt Bracket
• Bolt Preload
• Load steps (sequenced analysis)
• Small or Large Deformation ?
• Material Nonlinearity ?
• Iterative, Non-linear analysis options and controls
• Ramped loading, automatic time stepping,
convergence issues
Lab #8: Sheet Metal Fan
• Modal Analysis by FEA
• symmetry in dynamic analysis
• constraints in dynamic analysis
• animation of mode shapes
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 19
ME 467 Applied FEA Review
HW #6: Machinery Skid
• Modal Analysis of Assemblies
• Using Beams and Shell
elements in Workbench
Lab #9: Tacoma Narrows
• Pre-stressed Modal Analysis
• Harmonic Analysis
• Mode Superposition Method
• "frequency" domain vs. "time"
domain analysis
Lab #10: Thermal Stress
• Conduction and Convection
• Steady-state Conditions
• Convection Film Coefficients
• Symmetry conditions for heat
transfer analyses
• Mesh error measure in thermal
analysis (TEPC)
9/10/17, David Johnson P.E. (Thank you) & PAJ & JMJ 20
ME 467 Applied FEA Review
HW #7: Heat Sink
• Heat Transfer Analysis by FEA
• Conduction
• Convection
• Internal Heat Generation Load
• 2D Model in ANSYS
Mechanical
• Thermal Mesh Error (TEPC)
Lab #11: Coffee Cup • Heat Transfer Analysis by FEA
• Conduction, Convection, and
Radiation
• Transient Conditions
• Symmetry conditions for heat
transfer analyses
• Nonlinear film coefficient data
table