fea applications i - pennsylvania state university fea course review.pdf · fea applications i...

FEA Applications I MET 415 Review

• Course Structure:

• 15 week course

• Weekly Schedule

• 50 minute lecture

• 2.5 hour laboratory


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)


• 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



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



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



ANSYS Mechanical APDL: 5 weeks (cont)

#4A: Interference Fit

• Statically Indeterminate

• Contact Wizard


#4B: Pipe Clamp

• Symmetry

• Contact Wizard




ANSYS Mechanical Workbench: 10 weeks

#5: Plastic Plate

• SCDM

• Symmetry


#6A: Lawn Tractor Steering Link

• Combined Loading

• Symmetry?

• 3D Solids

• Singularities

#6B: Triangular Plate

• Singularities

• Symmetry?



ANSYS Mechanical Workbench: 10 weeks (cont)

#7A: Pump Assembly

• Contacts

• Scoping Assemblies


• Contact Behavior

• Bearing Loads

#7B: Machining Vise

• Contacts




• Mesh Controls

#8A: Allen Wrench

• Non-linear behavior


• Scoping

• Mesh Controls




#8B: Elastomer

• Hyper-elastic behavior


• Scoping

• Mesh Controls

#9A: Lawn Tractor Hood

• 2D Shells

• SCDM

• Virtual Topology

#9B: Welded Plate

• 2D Shells

• Rotated Coordinate

Systems

• Post Processing




#10: Punch Die

• 2D Shells & 3D Solids

• Large Deformation


• Symmetry

#11A: Back-hoe

• Beam Elements

• Section Properties

• Joints

#11B: Bridge (APDL)

• Truss Elements


• Varying Sections


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


Applied FEA ME 467 Review

• Course Structure:

• 15 week course

• Weekly Schedule

• 50 minute recitation


• 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


• 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



Lab #1: 2D Plate

• Geometry Construction

• 1 Mesh control


• 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



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



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



Lab #5: Pump Assembly

• Contacts




• 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


• Varying Sections



Lab #7: Allen Wrench

• Non-linear behavior


• 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



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)



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

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