Week 2 Bevel Gear Challenge

OBJECTIVE: To mesh and create connections in the given suspension assembly as per the quality criteria given below using ANSA. PROCEDURE: 1. The given model is imported into the ANSA software and the geometry checks are run. This is shown in the figure below. 2. The errors are fixed using the auto-fix option. If the errors…

OBJECTIVE: To extract the mid surface and perform meshing in the given geometry as per quality criteria given below using ANSA. S.No  Quality Criteria  Value  1 Target/Average length   4 2 Minimum Length  2 3 Maximum Length  6 4 Aspect  3 5 Warpage 15 6 Skewness 45 7 Jacobian …

PFA the models. Time Taken: Model 1: 4.5 hours Model 2: 1.5 hours

OBJECTIVE: To extract mid surface and perform meshing as per the quality criteria given below using ANSA. S.No  Quality Criteria  Value  1 Target/Average length   1 2 Minimum Length  0.5 3 Maximum Length  3 4 Aspect  3 5 Warpage 15 6 Skewness 45 7 Jacobian  0.7 8 Minimum Quad…

PFA the model for Tool Test - 2.  Total time taken: 4 hours

OBJECTIVE: To perform solid meshing in the given rearview mirror component as per the quality criteria given below using ANSA. 2D Element Quality Criteria:                                               …

OBJECTIVE: To set PID and perform connections for the given rear door model with different connection techniques using ANSA. PROCEDURE: 1. The given model is imported into the ANSA software. It is observed that a default PID is set for the model. The imported model is shown in the figure below. 2. Now go to Mesh>>Macros>>Set…

OBJECTIVE: To perform the morphing techniques in the models shown below and to increase the size of doghouses and ribs using ANSA. Model-1 Model-2 PROCEDURE: Model-1 1. The given model is imported into the ANSA software. The imported CAD model after using the orient option is shown in the figure below. 2. After importing…

OBJECTIVE: To simulate the bending of iPhone using ANSYS Workbench. The following objectives have to be satisfied. Case 1: To simulate the material using the default aluminum alloy material available in the library. Case 2: To move the bottom fingers to the given position X= 22.5mm & Z= 10mm and to obtain the life of aluminum…

OBJECTIVE: To perform a transient analysis on a piston and cam mechanism using ANSYS Workbench. The following objectives have to be satisfied. Case 1: To run the analysis with frictionless contact Case 2: To run the analysis with frictional contact with 0.1 Case 3: To run the analysis with frictional contact with 0.2 PROCEDURE…

OBJECTIVE: To perform spur gear simulation using three different materials given in the problem using ANSYS Workbench. The equivalent stress, total deformation, and stress intensity have to be compared between all the materials and possible fracture location must be identified. PROCEDURE FOR CASE SETUP: 1. Open ANSYS>>Drag…

OBJECTIVE: To perform a car crash simulation (explicit analysis) using ANSYS Workbench. The analysis has to be carried out using different thicknesses for the car body.   PROCEDURE FOR CASE SETUP: 1. Open ANSYS >> Drag and drop explicit analysis in the project schematic window. 2. Go to engineering data for…

OBJECTIVE: To perform bevel gear simulation using ANSYS Workbench. The grid dependency test has to be carried out for the mesh sizes of 6,5 and 4 mm. GRID DEPENDENCY TEST: Mesh size is one of the governing factors in determining the accuracy of the solution. The grid dependency test is essentially used to investigate how…

OBJECTIVE: To perform transient structural simulation in the given worm gear assembly using ANSYS Workbench. The following objectives have to be satisfied. 1. To cut the model to half to bring it within academic limits 2. The worm should be rotated to the end of the half cut.  3. The equivalent stress, equivalent…

OBJECTIVE: Sheet metal bending has to be performed for 3 different materials using ANSYS Workbench. For the following cases, case setup and comparison of results should be done. Case 1: To simulate using three different materials for sheet namely Aluminum alloy 1199, Copper Alloy NL, and Magnesium Alloy NL, and to compare…

OBJECTIVE: To perform static structural analysis on the rail wheel and track setup for different load cases using ANSYS Workbench. The equivalent stress, total deformation, and life have to be compared for the different load cases and to calculate a user-defined result for total deformation and compare it with the inbuilt…

OBJECTIVE: To perform simulation of a bullet penetrating into a bucket (explicit analysis) using ANSYS Workbench. Three non-linear materials have to be used for the bucket and results should be compared. PROCEDURE FOR CASE SETUP: 1. Open ANSYS >> Drag and drop Explicit Dynamics module in the project schematic window.…

OBJECTIVE: To perform transient structural simulation on a double universal joint with a spring using ANSYS Workbench. The following objectives have to be satisfied. Case 1: For the joint with springs the material structural steel has to be used Case 2: For the joint with springs the material stainless steel has to…

OBJECTIVE: To perform machining using planar simulation (explicit analysis) using ANSYS Workbench. The following objectives have to be satisfied. Case 1: Cutting velocity of 20000 mm/s Case 2: Cutting velocity of 15000 mm/s PROCEDURE FOR CASE SETUP: 1. Open ANSYS >> Drag and drop Explicit Dynamics module in the project…

OBJECTIVE: To perform the tensile and torsion test on the specimen using ANSYS Workbench. The following objectives are to be satisfied. 1. To displace one end of the specimen to 18 mm while keeping the other end fixed for tension test. 2. To displace one end of the specimen to an angle of 1200 degrees while keeping the…

OBJECTIVE: To simulate a sphere pressing on a plate using ANSYS Workbench. The following objectives have to be satisfied. To simulate using the material structural steel for sphere and structural steel non-linear for the plate. The plastic deformation has to be captured. PROCEDURE FOR CASE SETUP: 1. Open ANSYS >>…

OBJECTIVE: To simulate the rolling operation on a workpiece made of copper using ANSYS Workbench. The following objectives have to be satisfied. 1. To find equivalent stress for the whole setup 2. To find the equivalent plastic strain for the workpiece 3. To find the directional deformation in the z-axis for the workpiece…

OBJECTIVE: Wire bending has to be performed for 3 different materials using ANSYS Workbench. For the following case, case setup and comparison of results should be done. To simulate using three different materials for wire namely Aluminum alloy (Non-Linear), Copper Alloy NL, and Magnesium Alloy NL, and to compare results…

OBJECTIVE: To perform spur gear simulation using three different materials given in the problem using ANSYS Workbench. The equivalent stress, total deformation, and stress intensity have to be compared between all the materials and possible fracture location must be identified. PROCEDURE FOR CASE SETUP: 1. Open ANSYS>>Drag…

OBJECTIVE: To design and simulate the given models of plates with the hole using ANSYS Workbench. The results of the simulation between the two cases must be compared with respect to deformation and maximum stress. PROCEDURE FOR CASE SETUP: For case 1: 1. Open ANSYS>>Drag and drop Static Structural module in the…

OBJECTIVE: To perform a bird strike in the given aero-engine model using LS-Dyna. The following objectives are to be satisfied. 1. To assign the given material for blades. To use elastic material for the bird(2000MPa) and the casing(200GPa). 2. To follow a consistent numbering approach. 3. The different parts of the file…

OBJECTIVE: To demonstrate spherical, revolute, spherical, and translational joints between two deformable bodies and two rigid bodies. The following objectives have to be satisfied. 1. The gif file has to be compiled for all the joints. 2.  *CONSTRAINED_EXTRA_NODES and *CONSTRAINED_NODAL_RIGID_BODY are to be…

OBJECTIVE: To calculate Mooney Rivlin and Ogden's material constants and compare both using stress-strain data from a Dogbone specimen tensile test with 100 percent strain. PROCEDURE: 1. The given engineering stress-strain values are tabulated in excel and the values are plotted as shown in the figure below. 2. The given…

OBJECTIVE: To model a material using the given true stress-strain curve of graphite casting and validate it using the given dogbone specimen. The following objectives has to be satisfied. 1. Extraction of data from the diagram. 2. Cleaning the data and matching it with the original data 3. Selecting a proper unit system…

OBJECTIVE: To perform head impact simulation in the given model. The following objectives are to be satisified. 1. The impact velocity should be between 20-40 kmph and the impact angle of pedestrian head should fall in the range of 35-75 degrees. 2. The HIC values should be calculated in post processing. 3. To perform impact…

OBJECTIVE: To use mass scaling to reduce the runtime of the given model. The simulation should satisfy the objectives stated below. 1. The limit on mass scaling is 8% and the mass scaling should not hinder the stability of the model. 2. Optimisation of both DT and TSSFAC has to be done. 3. Histogram should be plotted to…

OBJECTIVE: To compare the results obtained from simulation of solid block using elform -2, -1, 1, 2. The solid block parameters are given below. 1. To create solid block of dimensions 10mm*10mm*10mm with 10 elements for each direction. 2. To attach the given material model Ogden_Material.k extension file 3. To choose a…

AIM: To perform a drop test in the given LS-Dyna model and plot the results and contour obtained. PROCEDURE: 1. Open LS-Dyna program manager>>Start LS-PrePost>>Import the given model. 2. There are 3 parts shown in the figure below. The parts are renamed as per convenience. 3. Go to Part>>Select Shell…

 AIM: The aim of the challenge is to find solution for the function given below using both explicit and implicit methods. `F(u) = u^3+9u^2+4u` with a tolerance of `10^-2` EXPLANATION: IMPLICIT METHOD:  `{x}=[K]^-1({f}-([M]{x''}+[C]{x'}))` where, [K] is the stiffness matrix [M] is the mass matrix [C] is the…

OBJECTIVE: To extract midsurface and mesh the geometry using the given quality criteria given below. Suitable thickness has to be assigned.                                                   …

OBJECTIVE: To write a python script which satisfies the objectives given below: 1. The program should take the columns as input and plot the values in the chosen columns. 2. The plot should be saved by the name of the column. 3. The plot labels should be extracted from the file. 4. If a non-compatible file is given as…

OBJECTIVE: To perform side crash analysis in the given BIW model. The following parameters are to be done in the model. To check unit system and either follow [Mg mm s] or [Kg mm ms]. To create appropriate interface ,friction 0.2 and recommended parameters. To check for penetration and intersections. to create a rigid…

OBJECTIVE: To perform frontal crash analysis in the given BIW model. The following parameters are to be done in the model. To check unit system and either follow [Mg mm s] or [Kg mm ms]. To create appropriate interface ,friction 0.2 and recommended parameters. To check for penetration and intersections. to create a rigid…

OBJECTIVE: To perform curve fitting using python for the given Cp vs Temperature data file. THEORY: Curve fitting is the process of constructing a curve, or mathematical function, that has the best fit to a series of data points, possibly subject to constraints. It can involve either interpolation, where an exact fit to…

OBJECTIVE: To create a mesh for the given bumper assembly with a mesh size of 6mm. To compare the results obtained after simulation for the cases given below: 1. To run the crash tube model as it is 2. To change the Inacti to 6 and run 3. To create the TYPE 11 contact and run 4. Remove both notches and remove boundary…

OBJECTIVE: To write a program that solves the ODE given below and simulate the results obtained to create an animation.                              where θ = Angular displacement of the ball (in radians)          …

OBJECTIVE: To write a python code for an Otto cycle using the defined parameters and make plots. 1. To create a P-V diagram (Pressure Vs. Volume diagram) 2. To print the thermal efficiency of the cycle. PROBLEM STATEMENT:  An Otto cycle is an idealized thermodynamic cycle that describes the functioning of a typical…

OBJECTIVE: To study and compare the effect of different material failure property cards on the given rupture plate model. To compare the 7 cases given based on the following: 1. Total number of cycles, Energy error, mass error and simulation time 2. To notice the animation of all the 5 cases and to describe whether the…

OBJECTIVE: To compare the results with base simulation and improved shell element properties as per the steps given below: 1. To change the run time to 55 ms 2. To change the number of animation steps during simulation to a minimum of 25 and a maximum of 60 3. To run the base simulation without modification in elemental…

OBJECTIVE: 1. To check the material properties of the rail component and calculate the speed of sound in steel rail using the given .rad file 2. The length of the rail is about 1000 mm. To calculate the time takes for a shock wave to travel from one end of the rail to the other. 3.Tp calculate the time for sound…

OBJECTIVE: To cleanup and extract the midsurface of the given gometries. To 2D mesh the given geometries in accordance with the quality criterias given below and to assign thickness by creating a generic property. Minimum Element Size: 3.5mm Target Element Size: 5mm Maximum Element Size: 7mm PROCEDURE: For part 1 1. Import…

AIM: To write the given measurements in different system of units. Also, to prepare consistent unit system table for different unit system EXPLANATION: Fundamental Quantities: These quantities are are independent of any other quantity. It includes mass, time and length.  Derived Quantities: All the quantities…

AIM: To carry out modal analysis in the given bracket using optistruct solver. PROCEDURE: 1. Open Hypermesh and select Optistruct as the solver. 2. Go to Import Solver Deck>>Import Geometry>>File type: IGES>>Import the necessary file. 3. Change the view to Topo Mode to check for the errors. 4. Now, go…

OBJECTIVE: To perform roof crush analysis in the given BIW model. The following case setup has to be done. 1. To do a transformation given below. • A 180° rotation about the global z-axis• A 5° rotation about the axis through axis AB• A 25° rotation about the axis through axis AC• A translation…

OBJECTIVE: To morph the given side body component to the desired shape as given in the image given below and to write macro for the same.             PROCEDURE: 1. Go to Import Solver Deck>>Import Model>>Select file>>Import 2. Go to components view tab>>Select component…

OBJECTIVE: To create and compare the simulation results of spotwelds using beams and solids elements. The following objectives are to be satisfied in the model. 1. To create 3-7 spotwelds in a symmetric manner. 2. To compare the axial and shear force for both the cases. 3. To describe the failure of spotweld at half of…

AIM AND OBJECTIVE: To simulate the given crash box using LS-Dyna. The following objectives are to be satisfied: 1. To create a rigid wall using *RIGIDWALL_Keyword 2. The material and thickness to be assigned for the crash tube is steel and 1.2 mm respectively. 3. Intial velocity of crash box is 50 kmph 4. The unit system…

OBJECTIVE: To mesh the given component in accordance with the quality criteria given below and to assign thickness. Target Element Length: 4mm S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2mm 6 Max. Length 6mm 7 Min angle Quad 45…

OBJECTIVE: To perform batch meshing on the given components with the given quality criteria and assigning non-linear material steel to them. Target Element Size: 5mm S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2mm 6 Max. Length 8mm…

OBJECTIVE: To create connector and Attach the various parts of the given model  1. Right_Rail_2 & Front_truss_1:- Seam-Quad (angled+capped+L) 2. Left_Rail_2 & Front_truss_1:- Quad elements 3. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 3 Layers and 5…

OBJECTIVE: 1. To create the tetramesh for housing model using the criteria given below: Target Element Size: 5mm Minimum element size: 2mm Maximum element size: 7mm Tet collapse: 0.15 2. To create tetramesh for chassis assembly and other model using the criteria given below: Target Element Size: 6mm Minimum element size:…

OBJECTIVE: To mesh the given components using the quality criteria given below and to assign the thickness. S.No Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2mm 6 Max. Length 8mm 7 Min angle Quad 45 8 Max angle Quad 135 9 Min angle Tria…

OBJECTIVE: Create 1D elements on the following component with given cross-section and DOF           a. Rod element:- with only translational DOF and RBE2 link Cross-Section: BOX- Dimension a= 12 mm                            …