Week - 5 - Modelling Spotwelds

OBJECTIVE:                 To run the simulation with different element formulation 1,-1,2,-2 and compare the stretch ratio vs Stress for all the cases Steps carried out: Initially open the LS Dyna keyword file which is containing only the ogden material card, like shown in below…

AIM:                 Create Spotwelds between the given two parts with the beam element as case 1 and use Hexa element in case2, now comparet the results of both the case and conclude the same Steps Followed:  Create section and material for parts:- Import the model to the LS pre post Check for the available keywords from…

AIM: To create a complete simulation file for Crash box with required keyword   Procedure:  Open the keyword file and look for the available keywords Create a SHELL section of 1.2mm and 1.5mm for both cases Go to keyword manager> Section> SHELL Create a linear plasticity Material go to keyword manager>MAT>…

AIM: To Create a complete input deck filr from scratch with all required cards for drop test simulation STEPS: Create Material and Section:- Open the model in LS Prepost which contains only mesh From the above image we can see there are no sufficient cards to carry on the simulation Now we have to create required cards…

AIM:  Solve the above given equation in both Implicit and Explicit method and compare the result with exact result IMPLICIT Method:- This method is mostly used in static analysis Acceleration will vary linearly within given time step Time step is more compared to explicit method It needs a numerical solver to invert…

UNIT CONVERSION from Kg m ms to g mm ms Mass 1Kg = 1000gm Length 1m =1000mm Time 1 sec =1000 milli seconds Force F= mass*acceleration = kg * (m/s^2)    =kg*(m/s^2)    =`10^3`g* (1000mm/1000*10^3 `ms^2`)1N=1g`(mm)/(ms^2)` Stress Stress = Force/ Unit area 1Pa = 1N/m^2      = 1g*`((mm)/(ms^2))/(10^6mm^2)` 1Pa= `10^-6`*`(g)/(mm*ms^2)`…

OBJECTIVE:- To set the Car crash simulation in explicit dynamics analysis system with different surface thickness Steps:- Import model:- Import the model from saved location and open it in space module check for abnormalities In this case we will be using stainless steel non linear material for car body Mechanical module:-…

OBJECTIVE:- To set up the Model for Bullet penetrating Bucket challenge with different materials and observing the change in the results Steps:- Import Materials:- In this challenge we will be using explicit dynamics analysis system As mentioned above let us import any three nonlinear materials from engineer data I am…

OBJECTIVE: To set up the model for Explicit Analysis and obtain the mentioned Results Steps: Import Model and Material:- We will be using Explicit Analysis system in this challenge Import the model from the saved location Check for any abnormalities in model opening it in space claim Import Steel 1100 material from explicit…

OBJECTIVE: To Set up the model for Tension and Torsional test by Explicit dynamics analysis system Steps for Tension test: Import geometry:- Open the Explicit Dynamics Analysis system Import Steel 1006 material from engineering data resources>Explicit materials Open the model in Space claim to see for any abnormalities…

OBJECTIVE: To set up the Worm Gear model for Transient Structural analysis Steps: Import Geometry:- Import the geometry and cut half of the gear to avoid the node limits error for academic version   Define Contact:- Rename the parts to our convinience Let the material be default one Define the contact between parts…

OBJECTIVE: To set the Universal joint with a spring in Transient Analysis system Steps: Import Geometry:- Import the geometry from the saved location Import the required materials from engineer data madule Open the imported model in space claim and look for any abnormality in Geometry Mechanical Workbench:- Rename the…

OBJECTIVE: To set up a Piston and Cam mechanism model in Transient Analysis with different case setup and comparing the results Steps: Import Geometry:- Import the geometry from the saved location Open the Geometry in space claim and check for any abnormalties in the model In this set up we will be using the default material…

OBJECTIVE: Setting up the model for bending and compare the results with different marterials and different cases Steps: Import material:- First import the required materials like Aluminium alloy NL, Polyethelene Duplicate Polyethelene and rename i as glass, edit the properties like shown below Duplicate aluminium alloy…

OBJECTIVE: To set up the model for rolling operation and find the necessary solution STEPS: Import materials:- Import the required materials for the simulation Go to Engineering Data>Engineering Data sources>General Non linear materials>Copper alloy NL Import Gepmetry:- Import the model from saved loacation Open…

OBJECTIEVE: Set up the model for static analysis when sphere pressed over a plate We need to see the plastic strain occured in plate STEPS: Add materials:- Open static structural analysis system, select the material from engineering data Engineering data>Engineering data sources>General Non linear materials>Select…

OBJECTIVE: Set up the model for wire bending with different materials Compare the results with different cases Steps: Import the material First open the ansys workbench and import the materials Go to Engineering data>Engineering Data sources>Genral Non linear materials Select Copper alloy, Magnesium Alloy, Aluminum…

OBJECTIVE: Set up the model to verify how the weld behaves in load condition for different materials STEPS: Import materials:- Initally open the engineering data and import the materials mentioned above Add new materials with properties which is not in the library Bronze cast property Aluminim alloy property, high strength…

OBJECTIVE: Set up the model for sheet metal bending with respective contact and loads defined Compare the results of different materials See the results for same material with different mesh size and different friction co-efficient STEPS: Import material:- First import the material from engineering data sources Import…

OBJECTIVE: Set up the model for structural analysis and compae the results with different case Create a uder defines solution and compare it between both the cases STEPS Carried Out: Create contact:- Import the geometry and open it in mechanical module to set up the model First rename the contact based on definition for…

OBJECTIVE: Mesh the model with specified element size Compare the results between the cases Discuss about Grid dependency test Grid Dependency Test:- It is the test to check how the solution depends on grid size by running the simulation with refined mesh that is finer the mesh, higher is accuracy of result but with additional…

OBJECTIVE:  To perform the static analysis on the Spur gear, with three different materials in each case Case setup: Material creation:- Create a new static structural analysis project Firstly create the above mentioned material with the given parameters Cast iron(ductile) property is shown in below image Cast Steel…

OBJECTIVE: To Create the models and set up with the mentioned boundary conditions Compare the results and suggest the best model  Steps Followed: Case 1: Open the ANSYS workbench, select the analysis system as "Static Structural " New project will be created , rename it to convinience From project schematic we can…

OBJECTIVE: Intially set up the model for side crash, by creating rigid wall with given friction Create Interface with suitable parameters and friction = 0.2 Check for the penetration and intersections Check the model by Model checker Create sections and intrusion in mentioned place Create respective output blocks Steps…

OBJECTIVE: Objective of this project is to set the model for frontal car crash with mentioned time step Create rigid wall with specfied friction Create appropriate Interface, cross section for required output Balance the required mass and balance the COG to desired location Steps Carried out:  Import the rad file Import…

OBJECITVE: To mesh the given model and run the crush tube model in six different mentioned cases Steps to mesh Bumper:- Bumper model is .hm file , so directly open the model in the software Look for any geometry error of the model, auto cleanup the same Mesh the model with quad elements of 6mm size, like shown below Remesh…

OBJECTIVE: To run the Radioss engine file and compare the result between all the 7 cases Case Setup:  Case 1 (LAW2_epsmax_failure)  In this case let us import the Failure_johnson_0000.rad file In first case without aking any change to the model , run the file in Analysis>radiosss>save it in desired directory…

OBJECTIVE:  To run the given RADIOSS file and look for mass and energy error, if the error is acceptable, plot the above mentioned graph in hypergraph To run the Radioss file with change in properties and compare it with above crash beam file CASE 1 Procedure: First import the 0000.rad file into the software The creash…

1) Calculate the speed of sound in steel rail Sol: Formula for "Speed of sound" C=`root`E/`rho`       from the given 0000.rad file we can get the material properties of steel rail From the above image we can see the value of E=210000 Mpa(N/mm^2) ; `rho`=0.0078 g/mm^3, now using the above mentioned formula, we can substitute…

OBJECTIVE:  To Extract the mid surface of given model. To check the extracted mid surface for any Damaged surface or Duplicate surface or any type of other Geometrical errors. To mesh the Mid surface according to the given criteria. To check the elements for mesh flow , equivalance and any free edges.  PROCEDURE:…

AIM: To extract the mid surface and mesh the given model PROCEDURE:  Step 1:- Import the given model into the software Below image shows the initial CAD model  Look for any damaged surface and unstiched edges and correct the same by filling the surface or toggle edges Measure the thickness of the model Since…

AIM: TO Extract the mid surface and mesh the given model according to the mentioned quality criteria   PROCEDURE:   Step 1:- Import the cad model into the software Look for the missing surfaces, Damaged surfaces and Free edges correct them A missing surface is shown in below image We can toggle the edges…

AIM: To mesh given model and establish the mentioned connection to all the components   PROCEDURE: Step 1:- Import the model to the software and take look at any geometry error if present Rear truss component has a geometry error, as shown in below image In the above shown component edges are not stitched properly,…

AIM: To perform 3D tetra mesh on the given models PROCEDURE:   Model 1(Housing)     Step 1:- Import the given model and check for any geometry error In this model there are few missing surface like shown in the below image Fill the surface by Surface option or quick edit> filler surface option,…

AIM: To extract Mid surface and Mesh the given modelPROCEDURE:  Step 1:- Imoprt the model and check for number of components present Set current component as the component which you are working on Hide all the model and start extracting the mid surface one by one Firstly auto cleanup the model, so that geometry error are…

Aim: To mesh the model and assign the given cross section by 1D element Procedure:  Step 1:- Import the model to the software Extract mid surface of both the brackets by offset option, to capture the features properly. The first extracted mid surface will be stored under new model Create a new model id for other bracket…

AIM: To model the given component by Mid surface and Tetra mesh depending on the need and provide appropriate connection to the same PROCEDURE:  Step 1:- Once the model is imported into the software , firstly perform TOPO and check for the Geometry error The above image shows the number of geometry error present in…

AIM: To extract mid surface and mesh the given model according to the quality criteria   PROCEDURE:  Step 1:  First step is to perform TOPO on the model as soon it is imported into the software, in order to clear the transition error Below image represents the model befor performing TOPO, it is observed…

AIM:     Morphing is done to the given model   PROCEDURE: Step 1:- For the given model TOPO and Geometry check is done initially. New Morph Boxes are created selecting geometries Select the required points which has to be moved and change the features direction according to the direction Move the feature…

AIM: To establish the connection wherever is required in given component   PROCEDURE: Step 1:- The given is containing only FE model, so need of performing TOPO and geometry checks Firstly started the connection from the door's supporting to the B pillar portion Create points by On COG method from TOPO deck > Points…

Time taken:- 4 hours and 40 mins(Start time 6:35pm; End time:11:14 pm) Conclusion:- Given model is meshed with "Zero OFF elements"

AIM: To mesh the given solid component using tetra elements   PROCEDURE:  Step 1:- First step is to find how many volumes are given In this given model there 4 seperate solids We should define 4 seperate volumes Right click on one property isolate it by show only option, work on each solid seperately   Step 2:- First cleanup…

AIM: To extract manual mid surface of Bottle Cap and meshing the same by given quality criteria PROCEDURE:  Step 1:- Firstly perform TOPO on the model as soon as it is imported and do a check geometry for errors   fix errors by right click on the same and slect fix(Auto fix) if auto fix is not working then manually…

AIM : To check and clear the Geometrical error and to Mesh the given component.                                                                                     Procedure:  After importing the model to ANSA using property manager seperated different parts I have seprated the part as Bottom Hood(thickness=0.75mm), Top…