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ABAQUS CAE FORKLIFT TINE TUTOR ANALYSIS OF A FORKLI Problem Description: This tutorial analyzes the fork tine o and the maximum Von Misses stres deflection at the tip of the fork, and influence of AISI 4140 Alloy Steel (Y as the fork material. This analysis w meters. A comparison of maximum distributed/pressure load of 1000 N analysis are illustrated in Figure 1 sh Figure 1: Loading RIAL 1 IFT TINE USING 8-NODED BRICK E on a forklift, and used Abaqus to analyze the deflect ss caused by a distributed/pressure load. The magni d the location and magnitude of the largest stress ar Young's Modulus of 190 GPa; Poisson's Ratio of 0.27 will look at a single fork tine for two cases of lengths: m Von Mises stress and vertical tip deflection will be m N/m 2 . A sketch of the loading and boundary conditio hown below. and Boundary Conditions of a Single Forklift Fo Class: MECH5130, Spring 2016 Final Project Tutorial Author(s): Christy Cavaleri and Benjam Programs used: ABAQUS/CAE- Version 6.14 REV 04.25.2016 ELEMENTS tion of the fork itude of the re of interest. The 7) will be analyzed : 1 meter and 1.5 made under a ons for this ork min Salisbury 4-2

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Page 1: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

ANALYSIS OF A FORKLIFT Problem Description: This tutorial analyzes the fork tine on a forklift, and used Abaqus to analyze the deflection of the fork and the maximum Von Misses stress caused by a distributed/pressure load. The magnitude of the deflection at the tip of the fork, and the location and influence of AISI 4140 Alloy Steel (Young's Modulus of 190 GPa; Poisson's Ratio of 0.27) will be analyzed as the fork material. This analysis will look at a single fork tinemeters. A comparison of maximum Von Mises stress and vertical tip deflection will be made under a distributed/pressure load of 1000 Nanalysis are illustrated in Figure 1 shown below

Figure 1: Loading and Boundary Conditions of a Single Forklift Fork

TUTORIAL 1

LIFT TINE USING 8-NODED BRICK ELEMENTS

This tutorial analyzes the fork tine on a forklift, and used Abaqus to analyze the deflection of the fork and the maximum Von Misses stress caused by a distributed/pressure load. The magnitude of the deflection at the tip of the fork, and the location and magnitude of the largest stress are of interest. The influence of AISI 4140 Alloy Steel (Young's Modulus of 190 GPa; Poisson's Ratio of 0.27) will be analyzed

s will look at a single fork tine for two cases of lengths: 1 mmeters. A comparison of maximum Von Mises stress and vertical tip deflection will be made under a

load of 1000 N/m2. A sketch of the loading and boundary conditions for this analysis are illustrated in Figure 1 shown below.

Figure 1: Loading and Boundary Conditions of a Single Forklift Fork

Class: MECH5130, Spring 2016 Final Project Tutorial Author(s): Christy Cavaleri and Benjamin SalisburyPrograms used: ABAQUS/CAE- Version 6.14

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NODED BRICK ELEMENTS

This tutorial analyzes the fork tine on a forklift, and used Abaqus to analyze the deflection of the fork and the maximum Von Misses stress caused by a distributed/pressure load. The magnitude of the

magnitude of the largest stress are of interest. The influence of AISI 4140 Alloy Steel (Young's Modulus of 190 GPa; Poisson's Ratio of 0.27) will be analyzed

for two cases of lengths: 1 meter and 1.5 meters. A comparison of maximum Von Mises stress and vertical tip deflection will be made under a

. A sketch of the loading and boundary conditions for this

Figure 1: Loading and Boundary Conditions of a Single Forklift Fork

Christy Cavaleri and Benjamin Salisbury Version 6.14-2

Page 2: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Tutorial steps: Creating the Model Geometry

Go to the Start Menu and open You may be prompted with an

box by clicking the X in the top right hand corner.

Figure 1:Abaqus/CAE 6.1

TUTORIAL 2

and open Abaqus/CAE You may be prompted with an Abaqus/CAE 6.14-2 Start Session dialog box (Figure 1). Close this

in the top right hand corner.

Abaqus/CAE 6.14-2 Start Session Dialog Box.

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dialog box (Figure 1). Close this

Page 3: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Once the Start Session box is exited, the Abaqus/CAE Viewport should look similar to Figure 2.

(Please note the model tree while the module is the list of icons to the right of the model tree)

To create the model geometry of the Using the left mouse button, double click

dialog box appears. Enter a new name for the part (to 10. The Create Part dialog box should look identical to Figure 3b.

Click Continue… and the graphics window will change to a set of gridlines.

TUTORIAL 3

box is exited, the Abaqus/CAE Viewport should look similar to Figure 2. model tree is the series of functions listed on the left hand side of the viewport,

is the list of icons to the right of the model tree)

Figure 2: Abaqus/CAE Viewport

To create the model geometry of the tine, a sketch of the profile of the part must be generated. Using the left mouse button, double click Parts in the model tree and the Create Part dialog box appears. Enter a new name for the part (TINE). Change the approximate size option

dialog box should look identical to Figure 3b. … and the graphics window will change to a set of gridlines.

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box is exited, the Abaqus/CAE Viewport should look similar to Figure 2. is the series of functions listed on the left hand side of the viewport,

, a sketch of the profile of the part must be generated. Create Part (Figure 3a)

). Change the approximate size option

Page 4: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 3a: Create Part Dialog Box

The first step in generating the model geometry, an outline of the profile of the

created. Click the Create Isolated Point At the bottom of the viewport the

the tine geometry are entered using X,Y coordinates. listed in Table 1. After each entry press the enter key on the keyboard. If done successfully, a different point should appear in the viewport each time the e

TUTORIAL 4

Create Part Dialog Box Figure 3b: Create Part Dialog Box (

The first step in generating the model geometry, an outline of the profile of the

Create Isolated Point icon in the module. At the bottom of the viewport the Pick a point - - or enter X,Y: option should appear. Points of

geometry are entered using X,Y coordinates. Enter the X,Y coordinates for each point . After each entry press the enter key on the keyboard. If done successfully, a

different point should appear in the viewport each time the enter button is pressed.

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Create Part Dialog Box (TINE)

The first step in generating the model geometry, an outline of the profile of the tine will be

option should appear. Points of Enter the X,Y coordinates for each point

. After each entry press the enter key on the keyboard. If done successfully, a nter button is pressed.

Page 5: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Press F6 to automatically scale the points to fit the screen. If all the points have been entered correctly, the viewport should look similar to

TUTORIAL 5

Table 1: Points for Geometry

to automatically scale the points to fit the screen. If all the points have been entered correctly, the viewport should look similar to Figure 4.

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to automatically scale the points to fit the screen. If all the points have been entered

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Click the Create Lines: Connected points 1&2. After this first line has been created click the center scroll wheel on the mouse to exit the creation of this segment of lines.

Next, create lines between points 15&16, 16&17, 17&18, 18&19, 19&20, 20&6Lines: Connected tool. If done correctly, the viewport should look similar to

TUTORIAL 6

Figure 4: Geometry Points

Create Lines: Connected icon in the module. Click and create lines between . After this first line has been created click the center scroll wheel on the mouse to

exit the creation of this segment of lines. ate lines between points 5&7, 7&8, 8&9, 9&10, 10&11, 11&12, 12&13, 13&14, 14&15,

15&16, 16&17, 17&18, 18&19, 19&20, 20&6. Press Esc on the keyboard to exit the tool. If done correctly, the viewport should look similar to Figure 5

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in the module. Click and create lines between . After this first line has been created click the center scroll wheel on the mouse to

5&7, 7&8, 8&9, 9&10, 10&11, 11&12, 12&13, 13&14, 14&15, on the keyboard to exit the Create

Figure 5.

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Next, the two fillets must be created. Click the the module. To set the center point of the first fillet, left click starting point of the arc. Select

To select the center of the second fillet, again leftpoint of the arc. Select point6

If done correctly, the geometry should look similar to

TUTORIAL 7

Figure 5: Geometry Lines

Next, the two fillets must be created. Click the Create Arc: Center and 2 Endpointsthe module. To set the center point of the first fillet, left click point 3. Next, click starting point of the arc. Select point5 as the end point of the arc to finish creating the fillet.To select the center of the second fillet, again left-click point 3. Next, click point

point6 as the end point of the arc to finish creating finalIf done correctly, the geometry should look similar to Figure 6.

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Create Arc: Center and 2 Endpoints icon in . Next, click point 2as the

as the end point of the arc to finish creating the fillet. point4 as the starting final fillet.

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Next, the inside angle for the tip of the

Construction: Oblique Line Thru 2 Points

Construction: Line at an Angle At the bottom of the viewport, the

tine tip angle should be enterefield and press Enter on the keyboard. A red line of infinite length with a downward slope from left to right should now follow the cursor in the viewport.

Left-click point 1 and then pr If done correctly, the geometry in the viewport should match that illustrated in

TUTORIAL 8

Figure 6: Geometry Fillets

Next, the inside angle for the tip of the tine must be established. Click and hold

lique Line Thru 2 Points icon in the module. Then select the

Construction: Line at an Angle icon from the expanded menu. At the bottom of the viewport, the Angle: option should appear. Angle measurements for the

tip angle should be entered as degrees relative to the X-axis. Enter a value of on the keyboard. A red line of infinite length with a downward slope from

left to right should now follow the cursor in the viewport. and then press Esc to exit the Create Construction: Line at an Angle

If done correctly, the geometry in the viewport should match that illustrated in

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and hold the Create

. Then select the Create

icon from the expanded menu. Angle measurements for the Enter a value of -5.0 into this

on the keyboard. A red line of infinite length with a downward slope from

Create Construction: Line at an Angle tool. If done correctly, the geometry in the viewport should match that illustrated in Figure 7:

Page 9: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 7:

The final step in drawing the profile of the

4. Once again, click the Create Lines: Connected starting point for the line. Next, drag the cursor in a horizontal line until it intersects with the construction line. When done correctly, an seen in Figure 8. (note: if the marker is a

Figure 8: Proper Intersection of New Line and Construction Line Indicated by “X”

Select this intersection as the second point of the new line. Finally, create a line between the intersection point and

geometry of the tine. Press If done correctly, the geometry in the viewport will match that viewed in

TUTORIAL 9

Figure 7: Tip Angle Construction Line

The final step in drawing the profile of the tine is to close the border between point 1 and point

Create Lines: Connected icon in the module. Select starting point for the line. Next, drag the cursor in a horizontal line until it intersects with the

e. When done correctly, an X will appear at the intersection of the two lines, (note: if the marker is a O and not an X, the new line is not horizontal)

Proper Intersection of New Line and Construction Line Indicated by “X”

Select this intersection as the second point of the new line. Finally, create a line between the intersection point and point 1 to complete the profile

. Press Esc on the keyboard to exit the Create Lines: Connectedne correctly, the geometry in the viewport will match that viewed in Figure 9

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close the border between point 1 and point

in the module. Select point 4 as the starting point for the line. Next, drag the cursor in a horizontal line until it intersects with the

will appear at the intersection of the two lines, , the new line is not horizontal)

Proper Intersection of New Line and Construction Line Indicated by “X” Marker

to complete the profile Create Lines: Connected tool.

Figure 9.

Page 10: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 9:

The geometry of the tine is now complete. Click sketching viewport.

The Edit Base Extrusion (Figure 10a) dialog box should appear. In the Edit Base Extrusion dialog box should be identical to

Figure 10a: Edit Base Extrusion dialog box

Click Okay. The part should turn a solid grey color and rotate into an isometric view similar to Figure 11.

TUTORIAL 10

Figure 9: Completed Fork Profile Geometry

is now complete. Click Doneat the bottom of the viewport to exit the

(Figure 10a) dialog box should appear. In the Depth field enter dialog box should be identical to Figure 10b.

Edit Base Extrusion dialog box Figure 10b: Edit Base Extrusion dialog box (

. The part should turn a solid grey color and rotate into an isometric view similar to

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at the bottom of the viewport to exit the

field enter 0.1. The

Edit Base Extrusion dialog box (TINE)

. The part should turn a solid grey color and rotate into an isometric view similar to

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 11:

Defining Material Properties

To define material properties for this model, double click on Edit Material dialog box will appear (Alloy Steel), and click the Mechanical Young’s Modulus = 190E09 GPabeen entered, the Edit Material

Click Ok.

TUTORIAL 11

Figure 11:Completed Model of Individual Forklift Tine

To define material properties for this model, double click on Materials in the model tree and the dialog box will appear (Figure 12a). Enter a Name for the material (

Mechanical tab, highlight Elasticity and click Elastic. = 190E09 GPa, and Poisson’s Ratio = 0.27. After the material properties have Edit Material dialog box should look identical to Figure 12b.

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in the model tree and the for the material (AISI 4140

Elastic. Enter values of = 0.27. After the material properties have

.

Page 12: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 12a: Edit Material Dialog Box

It should be noted that there is no feature in ABAQUS that sets specific units. All dimensions used in this tutorial have been entered in meters. Because of this, Young’s Modulus must be entered in Pa (Pascals) in order to maintain consistency.

Creating Sections

To create a solid section in ABAQUS, double click (Figure 13a) dialog box will appear. In the dialog box should look identical to

Click Continue…

TUTORIAL 12

Edit Material Dialog Box Figure 12b: Edit Material Dialog Box (Alloy Steel)

It should be noted that there is no feature in ABAQUS that sets specific units. All dimensions used in entered in meters. Because of this, Young’s Modulus must be entered in Pa

(Pascals) in order to maintain consistency.

To create a solid section in ABAQUS, double click Sections in the model tree and the ) dialog box will appear. In the Name field, enter SOLID. The complete

dialog box should look identical to Figure 13b.

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Edit Material Dialog Box (AISI 4140

It should be noted that there is no feature in ABAQUS that sets specific units. All dimensions used in entered in meters. Because of this, Young’s Modulus must be entered in Pa

in the model tree and the Create Section field, enter SOLID. The complete Create Section

Page 13: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 13a: Create Section Dialog Box

The Edit Section (Figure 14) dialog box will appear.

Figure 14:

Click OK to accept the default values.

Assigning Sections

To assign sections to the model, expand the next to Part.

Next, expand the TINE branch. Double click the Section Assignments

TUTORIAL 13

Create Section Dialog Box Figure 13b: Create Section Dialog Box (SOLID)

) dialog box will appear.

Figure 14: Edit Section Dialog Box (SOLID)

to accept the default values.

To assign sections to the model, expand the Part branch of the model tree by pressing the

Assignmentsicon, seen in Figure 15.

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Create Section Dialog Box (SOLID)

branch of the model tree by pressing the + symbol

Page 14: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 15: Expanded Model Tree Showing Section Assignment icon

Left click in the viewport and drag a box across the entirety of the model. If the section has been chosen correctly all edges should change from black to red (

Uncheck the box below the view Click Done.

Figure 16:

The Edit Section Assignment (Figure 17

TUTORIAL 14

Expanded Model Tree Showing Section Assignment icon

Left click in the viewport and drag a box across the entirety of the model. If the section has been chosen correctly all edges should change from black to red (Figure 16). Uncheck the box below the viewport next to “Create Set:”

Figure 16: Section Assignment Selection

Figure 17) dialog box will then appear.

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Left click in the viewport and drag a box across the entirety of the model. If the section has been

Page 15: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 17:

Click OK. The geometry should now turn

Creating an Instance

The part must be brought into the assembly before it is able to be meshed. This process is started by left clicking the + to the left of the branch is seen in Figure 18.

Double click Instances.

Figure 18:

The Create Instance (Figure 19) dialog box will appear. Under the that Dependent (mesh on part)

TUTORIAL 15

Figure 17: Edit Section Assignment (SOLID)

The geometry should now turn a light blue/green color.

The part must be brought into the assembly before it is able to be meshed. This process is started to the left of the Assembly icon in the model tree. The expanded

Figure 18: Expanded Assembly Branch

) dialog box will appear. Under the Instance Type Option be sure Dependent (mesh on part) is selected.

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The part must be brought into the assembly before it is able to be meshed. This process is started icon in the model tree. The expanded Assembly

Option be sure

Page 16: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 19:

Click OK. If done correctly, the model will turn blue (

TUTORIAL 16

Figure 19: Create Instance Dialog Box

done correctly, the model will turn blue (Figure 20).

Figure 20: Instance Tine

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Page 17: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Creating a Mesh

Since the Instance Type is set to established through the part tree. Under the Figure 21. If done correctly, the geometry should change color to yellow.

The geometry must be partitioned before creating the mesh. Click the icon in the module.

At the top of the screen, click View

The Views Toolbar

From the views toolbar, select the now be visible.Click the front face of the model. If done correctly, t

Click Done. You will be prompted to select an edge or axis. In the dropof the viewport, select horizontal and on the bottom

Use the Create Lines: Connectedidentical to that in Figure 22.

TUTORIAL 17

is set to Dependent (mesh on part), the mesh for the model will be established through the part tree. Under the TINE branch, double click Mesh (Empty)

. If done correctly, the geometry should change color to yellow.

Figure 21: Expanded Part Branch

The geometry must be partitioned before creating the mesh. Click the Partition Face: Sketch

View and in the dropdown menu select Toolbars, then click

will appear.

toolbar, select the Apply Front View icon. The front face of the model should front face of the model. If done correctly, the face will turn red.

. You will be prompted to select an edge or axis. In the drop-down menu at the bottom horizontal and on the bottom, then click the bottom edge of the face.

Create Lines: Connected icon in the module and create lines such that the geometry is

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, the mesh for the model will be Mesh (Empty), seen in

Partition Face: Sketch

, then click Views.

will appear.

face of the model should he face will turn red.

down menu at the bottom om edge of the face.

icon in the module and create lines such that the geometry is

Page 18: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Click Done. If done correctly, the model should turn yellow.

The next step in creating the mesh is to seedmodule, seed the edges listed in order to seed by number of elements, the option Window (Figure 24). Select the edges one at a time, click doneto the desired amount, then click ok. Click the next edge and repeat,

Figure 23: Selected Edges

TUTORIAL 18

Figure 22: Partitioned Geometry If done correctly, the model should turn yellow.

p in creating the mesh is to seed the part. Using the Seed Edges icon in the module, seed the edges listed in Figure 23 with their respective values shown in Table 2order to seed by number of elements, the option By Number should be selected in the

Select the edges one at a time, click done, and change the number of elements to the desired amount, then click ok. Click the next edge and repeat, through edge 32.

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icon in the Table 2. (Note: In

should be selected in the Local Seeds , and change the number of elements

through edge 32.

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ABAQUS CAE FORKLIFT TINE TUTORIAL 19 REV 04.25.2016

Table 2: Elements per Edge

Edge # of Elements1 252 253 174 175 36 67 88 69 210 311 212 113 114 115 116 1817 418 1219 220 321 222 123 124 125 126 227 228 229 230 231 232 2

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ABAQUS CAE FORKLIFT TINE TUTORIAL

From the views toolbar, select the should now be visible.

Hold Shift and drag a line bisecting the model through the center, from left to rigcorrectly, the viewport will appear identical to

TUTORIAL 20

Figure 24: Local Seeds Dialog Box

toolbar, select the Apply Bottom View icon. The bottom face of the model

Hold Shift and drag a line bisecting the model through the center, from left to right. If done correctly, the viewport will appear identical to Figure 25.

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face of the model

ht. If done

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Click Done. Under Sizing Controls, enter 4 as the number of elements. The window should look identical to

Figure 26.

TUTORIAL 21

Figure 25: Depth Edge Selection

as the number of elements. The window should look identical to

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as the number of elements. The window should look identical to

Page 22: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 26:

Click OK. Click Done.

Click the Apply Iso Viewmodel.

Click the Assign Element Type The Element Type (Figure 27a

option. The Element Type

TUTORIAL 22

Figure 26: Local Seeds Window for Depth Edges

icon in the Views Toolbar to return to the isometric view of the

Assign Element Type icon in the module. Figure 27a) dialog box will appear. Uncheck the Reduced Integration

Element Type dialog box should be identical to Figure 27b.

Figure 27a: Element Type Dialog Box

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to return to the isometric view of the

Reduced Integration

Page 23: FEA Final Project

ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 27b:

Click OK.

Next, click the Mesh Part mesh the part? Click Yes. If done correctly, the model should appear similar to

TUTORIAL 23

Figure 27b: Element Type Dialog Box (TINE)

icon in the module. At the bottom of the viewport, next to . If done correctly, the model should appear similar to

Figure 28: Meshed Model

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e viewport, next to OK to . If done correctly, the model should appear similar to Figure 28.

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Creating a Step

A step is used to define the type of loading and boundary conditions. In the model tree, double click the

appear. In the Name field, enter choose General. Next, select should look identical to Figure 29b

Figure 29a: Create Step Dialog Box

Click Continue….The Edit Step

TUTORIAL 24

A step is used to define the type of loading and boundary conditions. In the model tree, double click the Steps (1) icon. The Create Step (Figure 29a

field, enter LOADING STEP. In the dropdown menu for Procedure type. Next, select Static, General in the menu below. The Create Step

Figure 29b.

Create Step Dialog Box Figure 29b: Create Step Dialog Box (LOADING STEP)

Edit Step (Figure 30)dialog box will immediately appear.

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Figure 29a) dialog box will Procedure type,

Create Step dialog box

Create Step Dialog Box (LOADING STEP)

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Click OK to accept the default values.

Apply Boundary Conditions

Boundary conditions will be defined to simulate the forklift tine while in use. The underside of the mounting brackets will be fixed and a distributed load will be appltine.

Double click BCs in the model tree and the will appear. Enter Fixed in the Be sure under Category the optionSymmetry/Antisymmetry/Encastre

The Create Boundary Condition

TUTORIAL 25

Figure 30: Edit Step Dialog Box

to accept the default values.

Boundary conditions will be defined to simulate the forklift tine while in use. The underside of the mounting brackets will be fixed and a distributed load will be applied along the length of the

in the model tree and the Create Boundary Condition (Figure 31ain the Name field, and under the Step drop down menu select the option for Mechanical is selected. Additionally,

Symmetry/Antisymmetry/Encastre should be selected under Types for Selected StepCreate Boundary Condition window should look identical to Figure 31b.

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Boundary conditions will be defined to simulate the forklift tine while in use. The underside of ied along the length of the

Figure 31a) dialog box drop down menu select Initial.

Types for Selected Step.

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 31a: Create Boundary Condition Dialog Box

Click Continue….

At the top of the screen select the rotate the model so that the undersides of both brackets are visible.

If done correctly the viewport should look similar to

Figure 32: Rotated View of Model Exposing Undersides of Brackets

TUTORIAL 26

Create Boundary Condition Dialog Box Figure 31b: Create Boundary Condition Dialog Box (FIXED)

At the top of the screen select the Rotate View icon. Click inside the circle in the viewport and rotate the model so that the undersides of both brackets are visible.

ectly the viewport should look similar to Figure 32.

Rotated View of Model Exposing Undersides of Brackets

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Create Boundary Condition Dialog

icon. Click inside the circle in the viewport and

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Click the X in the bottom left corner Hold Shift and left click the two visible faces

bracket. Uncheck the Create Set: The Edit Boundary Condition (Figure 33

Figure 33:

Select ENCASTRE (U1=U2=U3=UR1=UR2=UR3=0) If done correctly, the model should look identical to

Figure 34: Model with Proper Boundary Conditions Applied

TUTORIAL 27

bottom left corner of the screen. the two visible faces that create a right angle, (see Figure 32

Create Set: box at the bottom and click Done. Figure 33) dialog box will appear.

Figure 33: Edit Boundary Condition Dialog Box

ENCASTRE (U1=U2=U3=UR1=UR2=UR3=0) option and click OK. If done correctly, the model should look identical to Figure 34.

Model with Proper Boundary Conditions Applied

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32) under each

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Click the Apply Iso View icon in the model.

Applying a Pressure Load to the Model

A uniform pressure load of 1000 NLoads in the model tree and the for the load called PRESSURE, and ensuAdditionally, the Category should be set to have Pressure selected. The Create Load

Figure 35a: Create Load Dialog Box

Click Continue…. Left click the largest visible surface parallel with the Create surface option at the bottom and click red and the Edit Load (Figure 36a

In the Magnitude field, enter 1000

TUTORIAL 28

icon in the Views Toolbar to return to the isometric view of the

Pressure Load to the Model

uniform pressure load of 1000 N/m2 will be applied to the length of the model. Double click in the model tree and the Create Load (Figure 35a) dialog box will appear. Create a

, and ensure that the Step option is set to LOADING STEPshould be set to Mechanical and the Types for Selected Step

Create Load dialog box should appear identical to Figure 35b

Create Load Dialog Box Figure 35b: Create Load Dialog Box (PRESSURE)

. Left click the largest visible surface parallel with the XZ-Plane. Uncheck the option at the bottom and click Done. The selected face of the model sh

Figure 36a) dialog box will immediately appear. 1000. The Edit Load dialog box should be identical to

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to return to the isometric view of the

will be applied to the length of the model. Double click ) dialog box will appear. Create a Name

LOADING STEP. Types for Selected Step should

Figure 35b.

Create Load Dialog Box (PRESSURE)

. Uncheck the . The selected face of the model should turn

dialog box should be identical to Figure 36b.

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ABAQUS CAE FORKLIFT TINE TUTORIAL

Figure 36a: Edit Load Dialog Box

Click OK. If done correctly, the viewport should be similar to

Figure 37:

Creating a Job

To create a job for this model, start by double clicking the The Create Job (Figure 38) dialog box will appear. In the

TUTORIAL 29

Edit Load Dialog Box Figure 36b: Edit Load Dialog Box (PRESSURE)

If done correctly, the viewport should be similar to Figure 37.

Figure 37: Model with Pressure Load Applied

To create a job for this model, start by double clicking the Jobs icon in the model tre) dialog box will appear. In the Name field, enter Case_1

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Edit Load Dialog Box (PRESSURE)

icon in the model tree. Case_1.

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Figure 38:

Click Continue…. The Edit Job

Click OK to accept the default settings.

Model Analysis

Click the + next to Jobs to view your newly created job. Right clickCase_1 and select Submit If you see a warning (Figure 40

unintentionally overwriting a previously completed analysis with the same name.

TUTORIAL 30

Figure 38: Create Job Dialog Box (Case_1)

Edit Job (Figure 39) dialog box will immediately appear.

Figure 39: Edit Job Dialog Box

accept the default settings.

to view your newly created job. Submit from the menu.

Figure 40), click OK. The intent of the warning is to prevent the user from entionally overwriting a previously completed analysis with the same name.

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. The intent of the warning is to prevent the user from

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The model is now submitted for analysis by Abaqus

Postprocessing using Abaqus/CAE

When ready, right click the Case_1 (Completed) If this selection was done correctly, the model will turn green and the geometry will remain in an

isometric view. This is illustrated in

To plot the deformed shape of ththe Visualization module. The model should look similar to

TUTORIAL 31

Figure 40: Submission Warning

The model is now submitted for analysis by Abaqus.

Case_1 (Completed) icon in the model tree and select If this selection was done correctly, the model will turn green and the geometry will remain in an isometric view. This is illustrated in Figure 41.

Figure 41: Results Viewport

To plot the deformed shape of the model, click the Plot Contours on Deformed Shapemodule. The model should look similar to Figure 42.

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icon in the model tree and select Results. If this selection was done correctly, the model will turn green and the geometry will remain in an

Plot Contours on Deformed Shape icon in

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Figure 42:

In the toolbar at the top of the screen, select Output… The Report Field Output

Figure 43:

TUTORIAL 32

Figure 42: View of Deformed Model

In the toolbar at the top of the screen, select Report and in the dropdown menu click Report Field Output (Figure 43) dialog box will appear.

Figure 43: Report Field Output Dialog Box

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and in the dropdown menu click Field

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Select the Setup tab. In the Name At the bottom of the window, uncheck The Report Field Output Setup Tab

Figure 44:

Return to the Variable tab and click the arrow next to Mises. The Variable tab should look identical to

TUTORIAL 33

Name field, replace abaqus.rpt with Case_1.rpt At the bottom of the window, uncheck Column totals.

Field Output Setup Tab dialog box should look identical to Figure 44.

Figure 44: Report Field Output Setup Tab

tab and click the arrow next to S: Stress components. Click the box next to tab should look identical to Figure 45.

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. Click the box next to

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Figure 45:

Click Apply. Next, uncheck the box next to In the dropdown menu next to Scroll down to the bottom of the list and click the arrow next to Check the box next to U2. The Variable tab should now look identical to

Figure 46:

Click OK.

TUTORIAL 34

Figure 45: Report Field Output Von Mises Stress

. Next, uncheck the box next to S: Stress components. In the dropdown menu next to Position, select Unique Nodal. Scroll down to the bottom of the list and click the arrow next to U: Spatial displacement

tab should now look identical to Figure 46.

Figure 46: Report Field Output Tip Deflection

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U: Spatial displacement

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The maximum Von Mises stress and maximum deflection (located at the tip of the tine) can now be viewed in Case_1.rpt located in the

Changing the Geometry to Satisfy Case 2

This task requires an analysis of a forklift tine at two separate lengths in order to makcomparison. Rather than creating an entirely new model, it is possible to modify the existing geometry to satisfy this requirement.

The previous model should be saved first before any modifications are made. Save the file by

either clicking File > Save or by clicking the screen.

Click the Model tab above the In the Tine branch, click the + Right click the Solid extrude-1

appear. Click the Edit Section Sketch

The viewport should now look similar to

TUTORIAL 35

ress and maximum deflection (located at the tip of the tine) can now be located in the Working Directory.

Changing the Geometry to Satisfy Case 2

This task requires an analysis of a forklift tine at two separate lengths in order to makcomparison. Rather than creating an entirely new model, it is possible to modify the existing geometry to satisfy this requirement. The previous model should be saved first before any modifications are made. Save the file by

or by clicking the Save Model Database icon in the top left of the

tab above the Results Tree to return to the model tree. next to the Features (2) icon.

1 icon and select Edit. The Edit Feature (Figure 47) dialog box will

Edit Section Sketch icon to modify the current geometry.

Figure 47: Edit Feature Dialog Box

The viewport should now look similar to Figure 48.

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ress and maximum deflection (located at the tip of the tine) can now be

This task requires an analysis of a forklift tine at two separate lengths in order to make a comparison. Rather than creating an entirely new model, it is possible to modify the existing

The previous model should be saved first before any modifications are made. Save the file by

icon in the top left of the

) dialog box will

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Using the scroll-wheel on the mouse, zoom out so that the geometry is about half as large in the window.

Next, click the Pan View icon and using the left mouse button, move the geometry to the center of the window.

When centered, press Esc on the keyboard to exit the

Click the Delete icon in the module. Next, click the construction linetip of the tine. If done correctly, the line will turn red.

Click Done. Press Esc on the keyboard to exit the In order to modify the geometry, the dimensions of certain edges will be altered. Before doing so it

is important to apply appropriate constraints. For example, in this case we want to extend the length of the top edge of the tine (where the presin the negative x direction, otherwise there would be unstable geometry.

Click the Add Constraint appear.

TUTORIAL 36

Figure 48: Edit Feature Viewport

wheel on the mouse, zoom out so that the geometry is about half as large in the

icon and using the left mouse button, move the geometry to the center

on the keyboard to exit the Pan View tool.

icon in the module. Next, click the construction line that passes through the . If done correctly, the line will turn red.

on the keyboard to exit the Delete tool. In order to modify the geometry, the dimensions of certain edges will be altered. Before doing so it is important to apply appropriate constraints. For example, in this case we want to extend the length of the top edge of the tine (where the pressure load is applied). This extension must occur

, otherwise there would be unstable geometry.

icon from the module. The Add Constraint (Figure 49

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wheel on the mouse, zoom out so that the geometry is about half as large in the

icon and using the left mouse button, move the geometry to the center

that passes through the

In order to modify the geometry, the dimensions of certain edges will be altered. Before doing so it is important to apply appropriate constraints. For example, in this case we want to extend the

sure load is applied). This extension must occur

Figure 49) window will

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Select Fixedand click on the point circled in red Click Done. Now select Horizontal in the Add Constraint

50a. The constraints should appear on the viewport si

Figure 50a:

TUTORIAL 37

Figure 49: Add Constraint Window

point circled in red from Figure 50a.

Add Constraint window and click the edge boxed in white

The constraints should appear on the viewport similar to Figure 50b.

Figure 50a: Added Constraint Locations

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edge boxed in whitefrom Figure

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Figure 50b:

Click the X in the bottom left cornermanually close the Add Constraint

The dimensions are now ready to be modified. Click the Next, click the angled edge circled in red

click again. You will be prompted tviewport. Press Enter on the keyboard to accept the original length as the dimension. (This step ensures that this edge will not change length when the top edge is extended.)

Click once on the top edge of the tine that is to be extended, the mouse above the edge and click again.

In the New Dimension field at the bottom of the viewport, Press Enter on the keyboard. If done correctly, the geometry of the model should be identical to

Figure 51b.

TUTORIAL 38

Figure 50b: Added Constraint Verification

bottom left corner to exit the Add Constraint tool. (You may also need to Add Constraint window by clicking the X in the corner of that window.

The dimensions are now ready to be modified. Click the Add Dimension icon in the module. edge circled in redin Figure 51a once. Drag the mouse down slightly and

click again. You will be prompted to input a value in the New Dimension field at the bottom of the on the keyboard to accept the original length as the dimension. (This step

ensures that this edge will not change length when the top edge is extended.) he top edge of the tine that is to be extended, circled in white in Figure 51a

the mouse above the edge and click again. field at the bottom of the viewport, type1.5

on the keyboard. If done correctly, the geometry of the model should be identical to

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tool. (You may also need to in the corner of that window.

icon in the module. once. Drag the mouse down slightly and

field at the bottom of the on the keyboard to accept the original length as the dimension. (This step

Figure 51a. Drag

on the keyboard. If done correctly, the geometry of the model should be identical to

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Figure 51b:

Press Esc on the keyboard to exit the

TUTORIAL 39

Figure 51a: Edges for Dimensioning

Figure 51b: Dimensioned Geometry

on the keyboard to exit the Add Dimension tool.

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Click Done. Click OK in the Edit Feature dialog box to finish editing the geometry. The model should appear

similar to Figure 52.

This new model should be saved with a different name, so as not to lose the previous model. Click File>Save As… and create a save file with the name Click OK.

Redefining the Mesh

Because the geometry of the model changed, the original mesh will not fit the new model. Double click Mesh (Empty) in the model tree.

Click the Apply Front View

Next, click the Seed Edges replace the current number of elements with the appropriate values from edges not listed maintain their original number of seeds.)

A more in depth explanation of how to seed edges is found in the tutorial.

TUTORIAL 40

dialog box to finish editing the geometry. The model should appear

Figure 52: Case_2 Abaqus Model

This new model should be saved with a different name, so as not to lose the previous model. and create a save file with the name Case_2.cae

Because the geometry of the model changed, the original mesh will not fit the new model. in the model tree.

icon from the Views toolbar.

icon in the module. Based on the edge labels seen in Freplace the current number of elements with the appropriate values from Table 3edges not listed maintain their original number of seeds.) A more in depth explanation of how to seed edges is found in the Create a Mesh

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dialog box to finish editing the geometry. The model should appear

This new model should be saved with a different name, so as not to lose the previous model.

Because the geometry of the model changed, the original mesh will not fit the new model.

icon in the module. Based on the edge labels seen in Figure 53, 3. (Note: Any

section of this

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Figure 53:

Table 3:

When finished seeding the part, click

Next, click the Mesh Part mesh the part? Click Yes. If done correctly, the model should appear similar to

TUTORIAL 41

Figure 53: Labeled Edges for Assigning Local Seeds

Table 3: Adjusted Elements per Edge (Case_2)

When finished seeding the part, click Done.

icon in the module. At the bottom of the viewport, next to . If done correctly, the model should appear similar to Figure 54.

Edge # of Elements3 324 325 4

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icon in the module. At the bottom of the viewport, next to OK to Figure 54.

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Creating a Job, Running the Analysis, and Post Processing

Details on how to create a job for this model, perform an analysis, and how to post process the data are explained in the Create a Job using Abaqus/CAE (pgs 31-35) sections of this tutorial. steps that require a name entry,collected from the first half of

Conclusion:

Save the file by clicking the Save Model Database Close Abaqus/CAE: File>Exit or This completes the Finite AnalysisofaForklift

TUTORIAL 42

Figure 54: Case_2 Meshed Model

Creating a Job, Running the Analysis, and Post Processing

Details on how to create a job for this model, perform an analysis, and how to post process the Create a Job (pgs. 29-30), Modal Analysis (pgs 30-31), and

) sections of this tutorial. It should be noted, however, that for any steps that require a name entry, Case_2 should be entered instead of Case_1. Otherwise, data collected from the first half of this tutorial may be over written.

Save Model Database icon in the top left of the screen. or Ctrl+Q

nalysisofaForklift Tine Using 8-Noded Brick Elements

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Details on how to create a job for this model, perform an analysis, and how to post process the ), and Postprocessing

however, that for any . Otherwise, data

icon in the top left of the screen.

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Interpretation of the Results:

This tutorial analyzeda single fork tine on a forklift, and used Abaqus to build, run and postprocess the model. When the tutorial is run correctly, the deflection at the tip of the tine and the maximum Von Misses stress (caused by the pressure load of 1000 N/m2) are found. The program is run for two different cases: Case 1: L = 1.0 m, and Case 2: L = 1.5 m. The magnitude of the deflection at the tip of the tine for Case 1 was found to be 1.03043E-06 m, and was found to be 2.22711E-06 m for Case 2. The maximum Von Misses stress for Case 1 was found to be 1.11233 MPa, and was found to be 2.38622 MPa for Case 2. Comparing these results with hand calculations performed using beam theory; the Abaqus results yield an18% error between Maximum Von Mises stress for both cases. These results are tabulated below for easier viewing. This difference can be attributed to the element types used during analysis. The eight gauss points for the eight-noded brick element are located inside the element halfway between the centroid and the faces of the brick. Because the maximum stress in the model occurs due to bending; the highest stresses occur on the faces of the elements. In light of this, the analysis was run again for both cases using 20-noded bricks elements. The idea behind this theory was that due to the 20-noded brick having more gauss points, their locations would need to be closer to the face of the element. The closer the integration points are to the surface, the closer the recorded stress value will be to the surface stress. From this analysis, maximum Von Mises stresses of 1.43 Mpa and 3.08 Mpa were obtained for cases 1 and 2 respectively. When compared to the theoretical approach, these results show an average of 5.5% error, and are tabulated below. These results suggest that the 20-noded brick elements are better suited for this type of analysis.

8-Noded Brick σexp (Mpa) σtheory (Mpa) %error δexp(m) δtheory(m) %error Case 1 1112330 1359360 18.1725 -0.000159703 -0.000152 5.067763 Case 2 2386220 2910910 18.02495 -0.000584637 -0.000586 0.232594

20-Noded Brick σexp (Mpa) σtheory (Mpa) %error Case 1 1.43E+06 1359360 5.21 Case 2 3.08E+06 2910910 5.69