TCL/TK PROJECT 1: Creating a master GUI for Hypermesh

AIM: To perform dynamic explicit analysis of a car crash simulation using ANSYS Workbench.   PROCEDURE:   The reduced car model along with a rigid wall was imported into ANSYS and the geometry is shown below:     A symmetric condition normal to x-axis was given to the two bodies as shown below:…

AIM: To conduct an explicit dynamic analysis of a bullet penetrating a bucket using ANSYS Workbench.   PROCEDURE:   Initially, the model consisting of bullet and bucket was imported into Hypermesh and the geometry is shown below:     The two geometries were meshed for 25 mm element size as shown…

AIM: To perform explicit dynamic analysis of a machining operation using planer in ANSYS Workbench.   PROCEDURE:   Initially, the machining tool along with workpiece was imported into ANSYS and the geometry is shown below:     The tool was given a rigid behavior with material structural steel assigned.…

AIM: To perform structural analysis on a railwheel and track setup using ANSYS Workbench.   PROCEDURE:   Initially the model consisting of the railwheel and track setup was imported into ANSYS and the geometry is shown below:     A mesh of size 50 mm with face sizing of 35 mm element length at…

AIM: To perform tension and torsion test of a simple test specimen using explicit dynamics of ANSYS Workbench.   PROCEDURE:   The following geometry is imported into ANSYS :     The two edges of the specimen are given 3mm size mesh as shown below:     One end of the specimen is given…

AIM: To conduct a transient structural analysis of a universal joint with a spring using ANSYS Workbench.   PROCEDURE:   The universal joint with spring attached was imported into ANSYS and the geometry of the assembly is shown below:     The unattached end of the spring is fixed using fixed joint…

AIM: To perform transient structural analysis on a piston and cam mechanism using ANSYS Workbench.   PROCEDURE:    Initially, the piston and cam mechanism model was imported to ANSYS workbench and is shown below:     The geometry consists of a barrel, barrel cam and cam follower. The contacts…

AIM: To perform a bend test on an iPhone model using ANSYS Workbench.   History:   One of the biggest PR disasters was the bending of the iPhone 6 Plus which was demonstrated by the Youtube channel "Unbox Therapy". The video went viral and resulted in mobile phone companies having to rethink the way in which…

AIM: To perform structural analysis on rolling operation of copper using ANSYS Workbench.   PROCEDURE: The model was initially imported into ANSYS as shown below:       The length of the workpiece was increased by 60 mm and the width decreased by 8 mm on both sides. The final geometry is shown…

AIM: To perform structural analysis of wire bending of copper, aluminium and magnesium alloy wires using ANSYS workbench.   PROCEDURE:    Initially, the wire bending machine geometry is imported into ANSYS. It consists of wire, wheel and lever as shown below:     Materials Aluminium, Copper…

AIM: To verify weld joints using structural analysis in ANSYS Workbench.   PROCEDURE:   The given geometry with weld joints was imported into ANSYS and is shown below:     The geometry consists of two plates, two ribs and 20 welds. The materials used for this assignment are Aluminium, Bronze, Copper…

AIM: To perform structural analysis on bevel gears for different mesh sizes and compare the results using ANSYS Workbench.   GRID DEPENDENCY TEST: It is the process in which structural analysis is conducted using varying sizes of meshes until a suitable level of accuracy i.e required convergence is achieved.…

Aim: To simulate two Spur gears using three different materials namely Cast Iron, Cast Steel and Cast Bronze using ANSYS and discuss the different results obtained from the three cases.   PROCEDURE:   The .step file containing the geometry of the two gears was imported into ANSYS and is shown below:  …

AIM: To create a plate with one hole and another plate with three holes. To compare the tensile behaviour of the two plates using ANSYS Workbench.   PROCEDURE:   The geometry is created by creating a rectangle of size 120mm x 300mm and creating a hole at the center with a diameter 60mm. This geometry is…

AIM: To create a macro for Hypermesh using TCL/TK which automatically creates an excel report which includes information about the user, profile used, components, materials, properties and elements. To also highlight failed and duplicate elements and empty components, unused properties and unused materials.  …

AIM: To create a master GUI which includes all the macros created in previous assignments such as quality checks, creating welds, auto reflecting, etc using TCL/TK.   PROCEDURE: The code for creating the master GUI is given below: *clearmarkall 1; *clearmarkall 2 *setnormalsdisplaytype 1 *setsurfacenormalsdisplaytype…

AIM: To create a macro for Hypermesh using TCL/TK to create a GUI for element quality check of 2D and 3D elements.   PROCEDURE:   The macro created should have the following features:   1. Button for each criteria 2. Entry box to accept quality criteria value 3. Button presses should highlight failed…

AIM: To create macros for Hypermesh using TCL/TK to create midlines between two line lists and spot welds between two node lists.   PROCEDURE:   PART A: Midlines:   To create midlines, the following code was prepared:   *clearmarkall 1; *clearmarkall 2 *createlistbypathpanel lines 1 "Select source…

AIM: To create a macro in TCL/TK to autoreflect elements from given FE part in Hypermesh.   PROCEDURE:   The macro for auto reflecting elements must do the following:   1. Ask for name of new component in which reflected elements will be stored 2. Ask the user for original and target geometries 3. Create…

AIM: To create a code in TCL/TK to display free and T-edges for displayed elements and make all the components transparent.    PROCEDURE:   Part A: Display free and T edges and automatically create nodes on free nodes for tolerance value of 0.01   The following code was built for the purpose of…

AIM: To create a graphical user interface (GUI) in tcl/tk for deleting displayed entities, empty entities, reordering and renumbering entities alphabetically and to create a master button to execute all the aforementioned commands in Hypermesh.   PROCEDURE:   The code created for the present assignment is…

AIM: To create a widget containing buttons for toggling normals display and for reversing the normals in Hypermesh using tcl/tk.   PROCEDURE:  The code prepared in tcl/tk for creating the required widget is given below:   *setnormalsdisplaytype 1 *setsurfacenormalsdisplaytype 1 *createmark elems 1 "displayed"…

AIM: To simulate a bird strike on the blades of an aeroplane engine using LS-DYNA.   PROCEDURE:   The model which consists of the engine blades, casing, hub and a simplified model of a bird are shown below:     The casing, blades and bird are made of shell elements and the hub is made of solid…

AIM: To simulate various joints, namely spherical, cylindrical, translational and revolute joints for rigid and deformable bodies using LS-PrePost.   PROCEDURE:   1. Spherical joint:   To simulate a spherical joint, initially an outer and inner spherical shell elements were created by going to Elements…

AIM: To model a material in LS-DYNA using data obtained from experiments. To use the material model to simulate a tensile test of a simple dogbone specimen and compare the results to the experimental results.   PROCEDURE:    The experimental data which constitutes true stress and true strain of a material…

AIM: To simulate the crash of a pedestrian's head on the hood of a car and to discuss the Stress-Strain results obtained using LS-PrePost and LS-DYNA.   PROCEDURE:   Initially, before simulating a headform of a child onto the hood, simple impact tests are done as a prelude. A simple sphere is modelled in LS-PrePost…

Aim: To simulate a crash test of the given component by welding the two parts using beam elements and solid elements by using LS-DYNA and LS-PrePost. To compare the results obtained by using the two different spotweld types.   Procedure:   Initially, the model is imported into LS-PrePost and is shown below:…

Aim: To simulate the crash of a crash box onto a rigid wall using LS-PrePost and LS-DYNA. To generate output blocks for global and cross-sections for shell thickness of 1.2 mm and 1.5 mm and to compare the obtained results.   PROCEDURE:   1. Import the keyword file into LS-PrePost:   The keyword file…

AIM: To simulate the drop test of a phone onto the floor using LS-Prepost and LS-DYNA.   PROCEDURE: To simulate a drop test of a phone the following steps were followed:   1. Import the meshed keyword file into LS-Prepost:   The drop test model was imported into LS-PrePost and is shown below:  …

AIM: To perform mathematical implicit and explicit analysis on the given cubic force-displacement equation for a tensile operation and discuss the difference in results obtained.   Problem description: The present problem is related to a tensile expansion of a simple bar as shown below:      …

OBJECTIVE: To simulate a roof crush of an impactor on a reduced BIW model of Neon Dodge car. To plot a force vs displacement graph and discuss the results obtained.   PROCEDURE:  To simulate a roof crush, the following steps have to be followed:   1. Import the impactor and reduced-BIW car model onto…

OBJECTIVE: To perform a side-crash test on a Neon Dodge model with reduced BIW components against a rigid pole. To compare the resultant forces acting upon cross-sections of critical components as well as intrusions and velocities of critical points in the car.   PROCEDURE: To complete the analysis of a…

OBJECTIVE: To simulate a frontal car crash onto a rigid wall using Hypermesh and RADIOSS. To compare the forces being applied onto various sections of the car due to the crash. To detect the accelerations and intrusions occurring at various parts of the car.   PROCEDURE:  To complete the simulation of a…

OBJECTIVE: To perform analysis of crush tube crashing on rigid wall using different parameters. To compare and contrast the variation in results occurring due to change in parameters. To perform mesh on given bumper model.   PROCEDURE:  To complete the meshing of the bumper model, the following steps have…

OBJECTIVES: To create 1D elements (Rod, Beam and Bar) at appropriate locations, define degrees of freedom on the given CAD model and to join the two components using spring element.   PROCEDURE: The CAD model of the two components is given below.                  …

OBJECTIVE: To simulate the given case for 7 different simulation conditions. To compare and contrast the various simulation cases.    PROCEDURE: In order to complete the given simulation, the following steps have to be taken: 1. Import the .rad file and give the appropriate material properties and failure…

OBJECTIVE: To clean the geometry of the given models and to remove any unnecessary free edge. To extract midsurface and perform geometric cleanup. To create 2D mesh on the midsurface and cleanup elements according to required quality criteria. To assign proper thickness to the mesh.   PROCEDURE:   …

OBJECTIVE: To extract midsurface of the sheet metal component and to perform 2D meshing on the midsurface according to the given quality criteria.   PROCEDURE: In order to successfully mesh the given component, the following steps have to be followed:   1. Import geometry into Hypermesh 2. Extract mid-surface…

OBJECTIVE: To extract midsurface of the plastic component and mesh it according to the required quality parameters and assign thickness values.   PROCEDURE: In order to successfully mesh the plastic component, the following steps have to be followed: 1. Import geometry into Hypermesh. 2. Perform geometric…

OBJECTIVES: To perform 3D meshing of given models and to check for given quality parameters such as element size and tet collapse values.   PROCEDURE: To ensure good quality of 3D mesh of the given models, the following steps have to be taken: 1. Import geometry into Hypermesh 3. Perform 3D meshing on the components…

OBJECTIVE: To apply connectors between various parts of the given frame assembly model.   PROCEDURE: In order to apply connectors between the various parts of the model, the following steps have to be followed: 1. Import geometry into Hypermesh. 2. Extract midsurface from the components and cleanup geometry 3.…

OBJECTIVE: To extract midsurface of backdoor of a car and perform geometric cleanup. To mesh the midsurface of the backdoor and to cleanup the elements according to the given quality parameters.   PROCEDURE: In order to complete the meshing of the backdoor according to the required quality parameters, the following…

OBJECTIVE: To extract midsurface from the CAD model of a hood and to perform geometric clean-up. The midsurface is then to be meshed to the necessary quality criteria. PROCEDURE: In order to completely mesh the hood, the following steps have to be completed: 1. Import the geometry into Hypermesh 2. Extract the midsurface…