Static Structural Analysis on the Buckle Clip

Static Structural Analysis on the Buckle Clip :

Aim -

• To perform static structural analysis on the Buckle Clip, and solve for Von Misses Equivalent stress, Equivalent Elastic Strain, and Total Deformation.

Objective :

• To perform a Structural Analysis on the Buckle and Clip for the two cases with the same material.
• To define the frictional contact between the buckle and clip.
• To give fixed support and displacement to the model.
• To solve and compare the results of the two cases for Total Deformation, Von-Mises Stress, and Equivalent Elastic Strain.
• Request outputs for Stress Tool, Contact Tool, and Force Reaction to the Model.

Procedure :

Phase 1- Material Set-Up :

• To set up the material for the Rail Wheel and Track Model. First, drag and drop the static structural analysis workspace into the project schematic from the analysis system. This is shown below in Figure 1.

Figure 1-Ansys Workbench Workspace.

• After deploying the static structural analysis system in the project schematic workspace.
• Define the Engineering Data and geometry, To define the Geometry and Engineering Data, Right Click on the Engineering Data and click to edit, it will take to the Engineering Tab.
• There Right Click on the Material Tab, A window will Pop-Up stating Engineering data sources.
• Click on the Engineering Data Sources, There go and select the material to define the engineering data. This is shown in Figure 2,3,4.

Figure 2-Right Click on the Engineering Data.

Figure 3-Right Click on the Material Tab.

Figure 4-Duplicate the Structural Steel Material Card and Rename it as POM (Polyoxymethylene) and Delete the Strain Life Parameters and Isotropic Secant Coefficient of Thermal Expansion.

Phase 2-Geometry Set-Up :

• Next set up the geometry. To set up the geometry, Right-Click on the Geometry option >> Import Geometry. This is shown in below Figure 5.

Figure 5-Importing Geometry.

Figure 6-Selecting the Geometry to Import.

• Next double click on the geometry to check, Whether the model imported, is Buckle and Clip Model or not. Space Claim Workspace will open. The model will be imported in the space claim, Which is shown in below Figure 7.

Figure 7-Buckle and Clip Model in the Space Claim.

Phase 3-Model Set-Up :

• Next, define the model, Double click on the model, The Mechanical Workspace will open, There go and define the material, set up the load case for the model.
• The Model loaded in the mechanical workspace is shown in below Figure 8.

Figure 8-Model Loaded in Mechanical Workspace.

3:1 Assign Material :

• Next, define the material as POM (Polyoxymethylene) for the Buckle and Clip Model which is shown in Figure 9.
• Similarly, define the POM (Polyoxymethylene) for the Buckle and Clip Model. The material properties are shown in Figures 10 and 11.
• To assign a material,Click on the Geometry >> Select the two Geometries >> Parameter Window >> Assignment >> Buckle and Clip.

Figure 9-Assign Material to the Buckle and Clip.

Figure 10-Mechanical Properties of POM (Polyoxymethylene).

3:2 Define Connections :

• For this Buckle and Clip Model, We have to create contact between the buckle and clip.

1) Contact between Buckle and Clip :

Figure 11-Defined Contact between Buckle and Clip.

3:3 Meshing :

• After defining the connections, We have to define mesh for the Buckle and Clip Model.
• There will be a default mesh created for the Buckle and Clip model.
• Give the mesh size as 5mm for the Buckle Clip Model.
• Change the Error Limits to Standard Mechanical, To change, Go to Quality >> Error Limits >> Standard Mechanical. This is shown in below Figure 12.

Figure 12-Final Meshed Model.

3:4 Analysis Settings :

• Here for this Rolling Operation Model, We are giving 4 steps to run the simulation.
• Auto Time Stepping-Program Controlled.
• Solver Type-Program Controlled.
• Weak Springs-Program Controlled.
• Large Deflection-ON
• Stabilization -Constant.
• Method-Energy.
• Energy Dissipation Ratio-0.1
• For the other parameters, Keep as it is the default.

Figure 13-Analaysis Settings.

3:5 Boundary Conditions :

• After giving some parameters in the analysis settings, We have to give boundary conditions.
• Here we have to create two boundary conditions.
• We have to give displacement and fixed support to the model.

Figure 14-Give Displacement to the Buckle and Clip Model.

1) Displacement :

• Here the clip should move, So we have to give displacement to the buckle in the negative Z direction. This is shown in below Figure 15.
• Give the displacement values in the tabular data from -13 to -49.7.

Figure 15-Displacement given to the Buckle.

2) Fixed Support :

• Give the fixed support to the buckle, Cause buckle should be fixed, which is shown in below Figure 16.

Figure 16-Given Fixed Support to the Buckle.

Phase 4-Request for the Outputs :

• Here we have to request outputs for the VonMisses Stress, Strain, and for Total Deformation.
• To request Output for Stress,Right Click on the Solution >> Insert >> Stress >> Equivalent Von Misses Stress.
• To request Output for Strain,Right Click on the Solution >> Insert >> Strain >> Equivalent Von Misses Strain.
• To request Output for Total Deformation,Right Click on the Solution >> Insert >> Deformation >> Total Deformation.
• This is shown in the below Figure 17.

Figure 17-Requesting Outputs for the Stress, Strain, and Deformation.

• Next request output for the contact.
• To request Contact Tool >> Right Click on the Solution >> Insert >> Contact Tool >> Pressure >> Status,Which is shown in below Figures 18 and 19.

Figure 18-Requesting Output for Contact.

Figure 19-Requesting Outputs for Contact Tool.

• Similarly request the output for the Force Reaction.
• The Output requested for the Sheet Metal bending Model is shown in Figure 20.
• After requesting all the outputs which are shown in Figure 20. Run the Simulation.

Figure 20-Required Outputs Requested.

Phase 5-Run the Simulation for all three Cases :

• To run the simulation, Right Click on the Solution >> Solve. This is shown in the below Figure 21.

Figure 21-Solve all the Outputs Requested.

• After solving the outputs requested, the simulation results for the two cases are shown below Figures.

Case-1: Equivalent Von Misses Stress :

Figure 22-Case-1 Equivalent Von Mises Stress.

Figure 23-Case-1 Equivalent Von Misses Stress Simulation Animation.

Case-2: Equivalent Von Misses Stress :

Figure 24-Case-2 Equivalent Von Mises Stress.

Figure 25-Case-2 Equivalent Von Misses Stress Simulation Animation.

Case-1: Equivalent Von Mises Stress of Clip:

Figure 26-Case-1 Equivalent Von Mises Stress of Clip.

Figure 27-Case-1 Equivalent Von Mises Stress of Clip Simulation Animation.

Case-2: Equivalent Von Mises Stress of Buckle:

Figure 28-Case-2 Equivalent Von Mises Stress of Buckle.

Figure 29-Case-2 Equivalent Von Mises Stress of Buckle Simulation Animation.

Case-1 Directional Deformation of Clip :

Figure 30-Case 1 Directional Deformation of Clip.

Figure 31-Case 1 Directional Deformation of Clip Simulation Animation.

Case-2 Directional Deformation of Buckle :

Figure 32-Case 2 Directional Deformation of Buckle.

Figure 33-Case 2 Directional Deformation of Buckle Simulation Animation.

Case-1 Total Deformation :

Figure 34-Case-1 Total Deformation.

Figure 35-Case-1 Total Deformation Simulation Animation.

Case-2 Total Deformation :

Figure 36-Case-2 Total Deformation.

Figure 37-Case-2 Total Deformation Simulation Animation.

Case-1 Saftey Factor :

Figure 38-Case 1 Saftey Factor.

Figure 39-Case 1 Saftey Factor Simulation Animation.

Case-2 Saftey Factor :

Figure 40-Case 2 Saftey Factor.

Figure 41-Case 2 Saftey Factor Simulation Animation.

Results :

Cases	Equivalent Von-Misses Stress of Clip and Buckle (MPa)		Equivalent Von-Misses Stress (MPa )		Directional Deformation (mm)		Total Deformation (mm)		Safety Factor
	Max.	Min.	Max.	Min.	Max.	Min.	Max.	Min.	Max.	Min.
Case-1	11.856 MPa	6.6126e-008 MPa	140.98 MPa	6.6126e-008 MPa	-49.697 mm	-49.704 mm	49.704 mm	0 mm	15	0.027358
Case-2	0.14492 MPa	5.5372e-006 MPa	9807.4 MPa	5.5372e-006 MPa	49.7 mm	49.7 mm	49.7 mm	0. mm	15	0.27962

Table-1

• Here the maximum stress has occurred at case-1, The maximum stress occurred is 11.856 MPa, Which is very high when compared to case-2, In case-1, The buckle is fixed and the displacement is given to the clip.
• In case-2, the clip is fixed, and the displacement is given to the buckle. The deformation and safety factors are almost similar in both cases.