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CrankDemoInventor

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CrankDemoInventor

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

Introduction

    The term “ANSYS Workbench Environment” (AWE)* used here is interchangeable with DesignSpace, as

    the functionality level used in this demo does not exceed that of DesignSpace Optima.

The most effective way to promote the DesignSpace and the Workbench Environment is to simply show

    what it can do. This demonstration can be run using either DesignSpace or ANSYS running the AWE. It

    shows how fast and painless our tools are for performing analysis on a 7 part, real world automotive

    assembly. These demonstration steps may be adapted to any part/assembly; feel free to substitute your

    normal demonstration parts for this assembly but practice beforehand to ensure the solution times are

    reasonable during a demo. Indeed, the most effective demos are done with customer parts and you are

    encouraged to do this; the customer will relate much more readily and be far more impressed. Simply

    follow this flow but use an appropriate loading scenario for whatever part/assembly used.

An alternate assembly is also included in this demo set: LeverAssembly.iam. Within this assembly, the

    part Lever.ipt has both a suppressed cutout that may be unsuppressed just as it is in this demo as well as a

    couple of parametric dimensions that may be changed within DesignSpace (expand the Geometry level,

    click on Lever, look in the Details View for the cad dimensions, make the change, and choose “Send

    parameters and Update CAD” option from the “Update” pull-down to make the change.) An example dsdb

    file is included for an example.

It is a matter of demonstration preference, but for a minimum of mouse clicks and minimum screen

    movement, using one of the simulation templates is most effective is incorporated in this script.

    * Starting at V7.0, ANSYS has the option of running with either the Classic interface (traditional

    FEA) or with the ANSYS Workbench Environment, the interface/GUI everyone has come to know

    as DesignSpace. When running ANSYS with the Workbench Environment (AWE), many additional

    engineering analysis options are made available to the user.

    Steps and Points to Convey Picture guide

    Setup: Required one time only and should be done

    prior to any demos.

    ? Set units to Inches (or your customary units,

    entry values given in both English and Metric).

    ? Open the Control Panel (found in Tools menu)

    and select Miscellaneous. Change the “Load

    Orientation Type” to “Component” in the drop-

    down box. This sets the data entry method of

    force loads to X, Y, Z values. ? If solution times seem slow, you may also adjust the Meshing value downward from the default

    of 0, but note that this might create very coarse

    elements that may turn-off experienced analysts.

    If there will be analysts in the room, avoid this.

    Also see the meshing demonstration section to

    address the needs and concerns of analysts.

    ? For the Convergence section of this demo, click

    on “Convergence” and set the default value to

    5% from 20%

    ? For the Fatigue section of this demo, set the

    default life expectancy and other appropriate

    values. The default Design Life is set to 1E9,

     Page 1 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

    setting it to 1E6 would be 1 million cycles. ? AWE and DesignSpace may be used

    interchangeably from time to time; AWE is the

    ANSYS Workbench Environment, a technology

    upon which DesignSpace is built and is capable

    of more advanced analysis functionality when

    used in conjunction with an ANSYS license.

NOTE: For practice purposes, setting the default

    mesh level to 100 can be much faster than running

    at the default of 0. This is usually suitable for demo

    purposes when there are no analysts in the audience who will want to see the mesh. Graphics/Selection shortcuts:

    ? When held down, the Middle Mouse Button

    (MMB) or wheel will temporarily place the

    graphics into rotate mode.

    ? When held down, the Right Mouse Button

    (RMB) will act as a zoom to region. Rubber

    band the region to zoom to.

    ? The RMB will present a context-sensitive menu

    dependent upon what level is currently active in

    the Project branch

    (Model/Environment/Solution) and will also

    provide the option to Fit the display (zoom

    all). Many experienced users will make

    extensive use of this capability to run their

    analysis.

    ? The Left Mouse Button (LMB) is used for

    selection. Holding it down while moving over

    the model will “paint select” everything under

    the pointer.

    ? The Control key used in conjunction with the

    LMB behaves just as it does in Windows

    Explorer (toggles selected entities). ? The Shift key used in conjunction with the LMB

    unconditionally adds to the current selection set.

    ? Once one or more surfaces are selected, the

    “Select Adjacent” icon will expand the selection

    set to include all tangent and adjacent faces.

    The selection set grows each time the “Select

    Adjacent” icon is pressed until there are no more

    faces tangent to the current selection set. Open the “slider_crank.iam” assembly in Inventor and then start DesignSpace from the ANSYS 7.1

    pull-down menu, choose “Design Simulation” to

    begin and attach the currently active Inventor part or

    assembly.

    If you need to open previously saved work, choose

    “Workbench” from the menu and you will be presented with the start page and be able to open

    previous work from there.

     Page 2 of 32

Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

     Page 3 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

NOTE: If you receive a message similar to this,

    answer “Yes” you will be running this demo from

    scratch and this message only means that these files

    were saved from a previous demo session. The

    “wbdb” file extension is new at V7.1 and is simply a

    project “Link” file connecting various geometry files

    and workbench applications together.

     From this point, those familiar with the interface can

    very quickly assign boundary conditions and choose what answers to solve for. For new and occasional

    users, a Wizard is available to guide them through

    the required steps and in this demonstration we will

    demonstrate how to use this wizard. Templates are a

    very powerful automation/learning/standardization tool and also a distinct competitive advantage over

    other systems.

Choose the type of analysis wizard/template by

    clicking from the list displayed on the right. Choose

    “Stress Branch Ductile Material” located at the

    bottom of the list. The solution folder level will be

    filled with a generic stress analysis answer set and

    the required steps wizard will be displayed.

These Templates can also be custom defined very

    easily, complete with figures and comments (simply

    RMB on any Solution and choose “Export Branch as

    Shortcut” it will then be available as a template).

    Consider creating your own template that already

    includes figures this can streamline your demo

    even more.

     Page 4 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

At this point, it is time to suppress unneeded

    components BLOCK, BASE, and CRANK by

    simply holding down the Left Mouse Button (LMB)

    and “paint selecting” at least one face of each

    component as shown on the right. Now Right Mouse

    Button (RMB) and choose “Suppress Body” from the

    menu. These parts will no longer be visible, will not be meshed, and will not be included in any results.

Another useful tool here is “Hide Body” which

    simply turns visibility of the selected bodies off yet

    will still mesh them and include them (but not show

    them) in the analysis results. (Do not do this for this demo, however.)

The “Go To” option will jump to the selected part(s)

    in the project branch so that you can change material

    properties, graphics properties, and other options,

    including suppress/hide.

     Page 5 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

    When an assembly is attached, surface-to-surface contact elements are automatically created to connect

    them to each other. The default behavior of these

    contact elements is “Bonded;” no movement will be

    allowed between parts. In this assembly the

    PISTONPIN is not, in reality, bonded to the

    connecting rod or to the piston head. As an example

    in this demo, we are going to change 1 of the contact

    conditions to “no-separation” which means

    “frictionless with no separation,” and leave the other

    2 as bonded. The contact regions with the “x” next to them belong to suppressed parts and are

    suppressed along with the other parts.

Expand the project branch item called “Contact,”

    choose “Region 8 (or whichever is between

    CON_ROD and PISTONPIN)” and then change its

    properties in the details view (lower-left of the screen) to “No Separation.” Notice the contact/target

    body names to ensure you have the correct contact

    pair. You may also turn the display to “wireframe”

    which is helpful when

    displaying/manipulating/creating contact elements.

When done changing the contact behavior, collapse the contact folder to keep the display un-cluttered.

Note: The last two contact behavior options,

    “Frictionless” and “Rough” are non-linear, will take considerably longer to solve, and, in this case, will not appreciably change the results.

     Page 6 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

By this point, the Required Steps Wizard will be

    displayed. Note the graphical status symbols

    indicating which step(s) have been completed, which

    remain to be done, and which steps have been done

    but should be verified (Informational).

From the Wizard Required Tasks list, notice that the

    “Insert Loads” and “Insert Supports” are yellowed

    which indicate that they must be completed.

As an example of how this tool works and how it

    instructs the user in how to run the software, Select

     “Verify Material” and “follow the bouncing balloon”

    as the wizard expands the geometry folder, selects all

    parts, and then displays an instructional balloon in

    the details view explaining where and how to change

    material properties. New users will learn this tool

    very quickly and occasional users will not forget

    how to use it; this software will not become shelfware.

We could browse for another material here but will

    stay with the default of Structural Steel for this

    demo. (NOTE: If planning to do a Fatigue analysis,

    the material must be either Structural Steel or

    Aluminum Alloy, unless you plan on entering

    Fatigue Material data for another material.)

When done, collapse the Geometry folder to keep the

    project branch uncluttered.

     Page 7 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

Next in the Required Steps list is “Insert Loads.”

    Select this item and again explain that the Wizard

    will change context to the appropriate location in the

    project branch (Environment) and then display a

    balloon at the appropriate location in the interface to accomplish the given task.

Make sure “Face Select” is active (it should be by

    default but can be changed by selecting vertex, edge,

    part, or any of the viewing modes.

     Page 8 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

Before taking the pull-down menu, select the top

    face of the piston head as indicated. Then select

    “Force” from the Structural pull-down menu and enter 500 LBF (-2200 N) in the Y Component

    direction located in the details view. By selecting

    the face before applying the boundary condition we

    are saving at least one mouse click.

Note: If at some later time you wish to modify the

    selection of a boundary condition, to change, add to,

    or delete from, simply click on the scope (# of

    faces/vertices/edges/parts) and the selection set for

    that boundary condition will be displayed and ready for modification.

If the geometry is not selected beforehand, select it

    and then hit “Apply” in the Scope Geometry section of the details view.

     Page 9 of 32

    Workbench Environment (DesignSpace) Crank Demonstration

    May 29, 2003

    A detailed guide for a Static Stress, Deformation, and Factor of Safety Analysis Using the ANSYS

    Workbench Environment or DesignSpace. Optional Mesh control and Fatigue demo included.

There are no more loads to apply so we must now

    constrain it in place. Remembering that the piston

    will travel along the bore and be attached to the

    crank, we will “Fix” the connecting rod where it

    attaches to the crank and apply a condition that

    would simulate the constraint of traveling the smooth

    bore (called a Frictionless Support).

    Apply the “Fixed Support.”

1) Select the geometry that would be attached to

    the crank (use paint select).

2) Select “Insert Supports” from the Required

    Tasks list on the right.

3) Select “Fixed Support” from the Structural pull-

    down menu.

     Page 10 of 32

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