Week - 5 - Modelling Spotwelds

CAR CRASH SIMULATION USING ANSYS WORKBENCH OBJECTIVE 1. To simulate car crash for different thickness of car body, Case-1: Thickness=0.3 mm. Case-2: Thickness=0.7 mm. Case-3: Thickness=1.5 mm. 2. To find out Total deformation and Equivalent stress developed in car body for each case and compare the results. 1. THEORY 1.1…

SIMULATION OF BULLET PENETRATING INTO A BUCKET USING ANSYS WORKBENCH OBJECTIVE To simulate bullet penetrating into a bucket for different cases of bucket material, Case-1: Aluminium Alloy NL Case-2: Copper Alloy NL Case-3: Stainless Steel NL To find out Total deformation and Equivalent stress developed in bucket for…

SIMULATION OF TENSION AND TORSION TEST ON A SPECIMEN USING ANSYS WORKBENCH OBJECTIVE To perform the tension and torsion test simulation on the specimen by following the necessary boundary conditions, For the tension test, one end of the specimen has to be displaced to 18mm while keeping the other end fixed. For the torsion…

EXPLICIT DYNAMIC ANALYSIS OF MACHINING WITH PLANER USING ANSYS WORKBENCH OBJECTIVE To perform explicit dynamic analysis of machining with planer for the following two different cases of cutting velocity, Case-1: Cutting velocity=20000 mm/s Case-2: Cutting velocity=15000 mm/s To find out Directional Deformation, Equivalent…

TRANSIENT STRUCTURAL ANALYSIS ON WORM GEAR USING ANSYS WORKBENCH OBJECTIVE To perform transient structural analysis on a worm gear assembly. To find out Total Deformation, Equivalent Stress, and Equivalent Elastic Strain in the model. 1. THEORY 1.1 Worm Gear: Worm gear drives are mechanical drives with skewed axes which…

TRANSIENT STRUCTURAL ANALYSIS ON A DOUBLE UNIVERSAL JOINT USING ANSYS WORKBENCH OBJECTIVE 1. To perform transient structural analysis on a double universal joint with spring for the following three different cases of materials, Case-1: Structural steel Case-2: Stainless steel Case-3: Titanium alloy 2. To find out Total…

TRANSIENT STRUCTURAL ANALYSIS ON A PISTON AND CAM MECHANISM USING ANSYS WORKBENCH OBJECTIVE 1. To perform transient structural analysis on a piston and cam mechanism for the following case study, Case-1: Frictionless contact. Case-2: Frictional contact, coefficient of friction=0.1. Case-3: Frictional contact, coefficient…

SIMULATION OF IPHONE BENDING USING ANSYS WORKBENCH OBJECTIVE To simulate the bending of iPhone for the following case study, Case (1): To simulate the model with bottom fingers in their pre-defined position. Case (2): To move the bottom fingers from their defined position to the given position X= 22.5mm & Z= 10mm and…

SIMULATION OF SPHERE PRESSING OVER A FLAT PLATE USING ANSYS WORKBENCH OBJECTIVE To simulate a sphere pressing on a flat plate by following the required conditions. To use Structural Steel for both sphere and plate but the material of the plate is Non-Linear. To press the sphere onto plate 4mm downwards and…

SIMULATION OF WIRE BENDING USING ANSYS WORKBENCH OBJECTIVE 1. To simulate bending of wire for different cases of wire material, Case-1: Copper Alloy NL Case-2: Aluminium Alloy NL Case-3: Magnesium Alloy NL 2. To find out Equivalent stress and Equivalent strain developed in wire for each case and compare the results. 1.…

SIMULATION OF ROLLING OPERATION USING ANSYS WORKBENCH OBJECTIVE To simulate the rolling operation on a workpiece made of copper by increasing the length of the workpiece by 60 mm and decreasing its size on both sides by 8 mm. Run the simulation for 14 steps by ensuring that the edge of the workpiece is displaced by 90mm.…

STATIC STRUCTURAL ANALYSIS ON SHEET METAL BENDING USING ANSYS WORKBENCH OBJECTIVE To perform static structural analysis on sheet metal bending for different materials mentioned in the following case study, Case 1: The material of the sheet for analysis are i.e., i) Aluminium Alloy 1199, ii) Copper Alloy NL, iii) Magnesium…

VERIFICATION OF WELD JOINTS USING ANSYS OBJECTIVE 1. To simulate three different types of welding using three different weld materials, Case 1: Weld Material used is Stainless Steel. The material of plates and ribs are also Stainless Steel. Case 2: Weld Material used is Aluminium Alloy (high strength, wrought).…

STATIC STRUCTURAL ANALYSIS ON THE RAILWHEEL AND TRACK USING ANSYS OBJECTIVE To perform a static structural analysis on the Railwheel and Track setup for the following case study, Case 1: To multiply the bearing load by 5 times and compare the results with the load of 100000 N. Compare the Total Deformation, Equivalent…

GRID DEPENDENCY TEST FOR BEVEL GEAR SIMULATION USING ANSYS OBJECTIVE To perform a grid dependency test for the Bevel gear simulation for the following mesh sizes, Case-1: Mesh size is 6 mm Case-2: Mesh size is 5 mm Case-3: Mesh size is 4 mm To find and compare the results of Total Deformation, Von-Mises Stress and Equivalent…

STATIC STRUCTURAL ANALYSIS ON SPUR GEAR USING ANSYS OBJECTIVE To carry out a static structural analysis on spur gear with following type of materials, Case-1: Cast Iron Case-2: Cast Bronze Case-3: Cast Steel To find and compare the results of Equivalent stress, Total deformation, Stress intensity for all the cases. To…

STRESS CONCENTRATION IN A PLATE WITH HOLE OBJECTIVE 1. To design a plate with hole for the following cases, Case(1): Length=300mm, height=120mm, thickness=30mm, circular hole at the center with diameter=60mm. Case(2): The dimensions are similar to case 1, but additional two smaller holes of diameter=30mm away from center.…

BIRD STRIKE SIMULATION ON AN AERO ENGINE USING LS-DYNA AIM To create the simulation of bird strike on the Aero Engine from the given FE model. Following are the information and conditions required to model the phenomenon The blades should rotate at a constant velocity but the casing should remain stationary. The cylindrical…

JOINT CREATION AND DEMONSTRATION IN LS-DYNA AIM To demonstrate spherical, revolute, cylindrical, and translational joints between two rigid bodies and two deformable bodies.  THEORY A distinguishing feature of multibody systems is the presence of joints that impose constraints on the relative motion of the various…

Hyperelastic Material Modelling using LS-DYNA AIM: To calculate the Mooney Rivlin and Ogden material constants and compare the both using stress-strain data from a Dogbone specimen tensile test with 100 percent strain. The given material data is the engineering stress-strain in MPa/(mm/mm). The comparison should be shown…

MATERIAL MODELING FROM RAW DATA USING LS-DYNA AIM: To create a material model using the data extracted from the given true stress-strain curve of graphite iron casting and validate it using the dogbone specimen. Note: The unit system used is kg-mm-ms. PROCEDURE: 1. Data Extraction: The given image file of true stress-strain…

MASS SCALING IN LS-DYNA AIM: To reduce the runtime required to run the analysis of the given model using mass scaling technique and stability has to be completely intact. To plot a histogram to compare the runtime with mass scaling trials. To optimize both the DT and TSSFAC parameters.  To run the same model using…

PEDESTRAIN HEAD IMPACT SIMULATION USING LS-DYNA AIM: To perform the Head Impact Simulation and calculate the Head Impact Criterion (HIC) value for the following cases. Simple head model impacting against rigid wall Child headform dummy model impacting against rigid wall Child headform dummy model impacting against…

                                     CALCULATING THE STRETCH RATIO AND COMPARING THE ELFORM (-2, -1,1,2) WITH OGDEN MATERIAL MODEL USING LS-DYNA AIM: To Create a block of 10mmx10mmx10mm dimension with 10 elements for each…

                                                                               COMPARISON OF SPOTWELD MODELLED AS BEAM AND…

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PHONE DROP TEST AIM: To create a complete simulation file from the given file having just nodes and elements of two parts, a simplified cellphone and a plate mimicking ground to perform a drop test. Note: *INITIAL_VELOCITY card is used to give velocity specifications for the cellphone. The height of drop test is assumed…

Solving a given problem by using Explicit and implicit Analysis Aim: To solve the given problem using both explicit and implicit method and plot the results. Problem Statement: Consider the case of a simple bar in tension as shown in Figure 1. Suppose that the force in the bar is a nonlinear function of the displacement.…

Consistency of Units Aim: To convert the given measurement values to the following unit systems by showing the conversion factors. Measurement Values: Mass 1 kg Length 1 m Time 1 s Force 1 N Stress 1 Pa Energy 1 Nm Density 1 Kg/m3 Young’s Modulus 210 GPa Velocity 56.33 Km/hr Gravity 9.81 m/s2      …

Preprocessing Rear Suspension Assembly using ANSA. Aim: For the given assembly check for the geometrical errors and mesh with given element quality criteria. Assemble the components by deploying necessary connections. Methodology: Geometry cleanup Mid surface generation for parts with uniform thickness less than 5 mm.…

Mid Surface Extraction and Meshing of IP Substrate using ANSA. Aim: To extract the mid surface and generate 2D mesh for the given model according to the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 4 2 Minimum Length 2 3 Maximum Length 6 4 Aspect Ratio 3 5 Skewness 45 6 Warpage…

Basic Morphing Techniques in ANSA. Aim: To perform different morphing techniques for the given sheet metal component and mention its industrial applications. Procedure: The model provided in ‘.iges’ format is imported to ANSA as shown in fig.1. Fig.1. sheet metal component. Geometrical cleanup: The given model…

Creating connections on rear door using ANSA. Aim: To create necessary connections on the FE model of rear door using ANSA. Procedure: The given FE model of rear door was imported to ANSA is as shown in fig.1 Fig.1. FE model of rear door. The model was evaluated for necessary connections. Zone cut is created at the appropriate…

3D Meshing of Intake Manifold using ANSA. Objective: To clear the geometrical errors and perform 3D mesh using tetra elements for the given component by satisfying the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 5 2 Minimum Length 3 3 Maximum Length 7 4 Tet collapse 0.2 Introduction:…

3D Meshing of a rear-view mirror using ANSA. Objective: To clear the geometrical errors and perform 3D mesh using tetra elements for the given component by satisfying the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 1 2 Minimum Length 0.5 3 Maximum Length 2 4 Tet collapse 0.2…

Mid Surface Extraction and Meshing of a switch panel and sheet metal component using ANSA. Objective: To extract the midsurface and generate 2D mesh for the given models according to the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 4 2 Minimum Length 2 3 Maximum Length 6 4 Aspect…

Mid Surface Extraction and Meshing of a Bottle Cap Model using ANSA. Objective: To extract the midsurface and generate 2D mesh for the given bottle cap according to the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 1 2 Minimum Length 0.5 3 Maximum Length 3 4 Aspect Ratio 5 5 Skewness…

Objective: To extract the midsurface and generate 2D mesh for the given hood component of a car according to the given element quality criteria using ANSA. S. No Quality Criteria Value 1 Target Length 5 2 Minimum Length 3 3 Maximum Length 7 4 Aspect Ratio 5 5 Skewness 45 6 Warpage 15 7 Jacobian 0.7 8 Min. Quad Angle 45…