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Simulation of Machining with Planer using ANSYS Workbench

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…

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    Read more Projects by Ashwen Venkatesh (58)

    Project - 2 - Meshing on the suspension Assembly

    Objective:

    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…

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    28 Jun 2021 11:11 AM IST

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    Project 1 - 2D meshing on the instrumental Panel

    Objective:

    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 …

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    24 Jun 2021 11:46 AM IST

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    Tool Test 1

    Objective:

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

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    16 Jun 2021 02:54 PM IST

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      Week - 4 - 2D meshing for Plastic components

      Objective:

      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…

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      15 Jun 2021 06:06 AM IST

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      Tool Test-2

      Objective:

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

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      09 Jun 2021 07:50 AM IST

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        Week- 5 - Solid meshing

        Objective:

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

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        08 Jun 2021 06:14 AM IST

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        Week 6 - Creating connection for Rear door

        Objective:

        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…

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        07 Jun 2021 08:11 AM IST

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        Week - 8 - Morphing

        Objective:

        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…

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        04 Jun 2021 06:27 AM IST

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        Week 5 Bending of iPhone

        Objective:

        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…

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        20 Jan 2021 08:01 AM IST

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          Week 7-Long Piston With Cam

          Objective:

          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…

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          29 Dec 2020 07:20 AM IST

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            Week 3 Verification of Weld Joints

            Objective:

            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…

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            29 Dec 2020 05:43 AM IST

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              Week 11 Car Crash simulation

              Objective:

              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…

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              28 Dec 2020 12:07 PM IST

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                Week 2 Bevel Gear Challenge

                Objective:

                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…

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                28 Dec 2020 07:39 AM IST

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                  Simulation of Worm Gear using ANSYS Workbench

                  Objective:

                  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…

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                  28 Dec 2020 04:06 AM IST

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                    Simulation of Sheet metal Bending using ANSYS Workbench

                    Objective:

                    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…

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                    28 Dec 2020 04:06 AM IST

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                      Railwheel and Track simulation using ANSYS Workbench

                      Objective:

                      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…

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                      28 Dec 2020 04:06 AM IST

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                        Simulation of Bullet penetrating a Bucket using ANSYS Workbench

                        Objective:

                        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.…

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                        28 Dec 2020 04:05 AM IST

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                          Universal Joint simulation using ANSYS Workbench

                          Objective:

                          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…

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                          28 Dec 2020 04:05 AM IST

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                            Simulation of Machining with Planer using ANSYS Workbench

                            Objective:

                            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…

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                            28 Dec 2020 04:05 AM IST

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                              Simulation of Tension and Torsion test using ANSYS Workbench

                              Objective:

                              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…

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                              28 Dec 2020 04:04 AM IST

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                                Simulation of sphere pressing on a plate using ANSYS Workbench

                                Objective:

                                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 >>…

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                                28 Dec 2020 04:04 AM IST

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                                  Simulation of Rolling operation using ANSYS Workbench

                                  Objective:

                                  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…

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                                  28 Dec 2020 04:04 AM IST

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                                    Wire Bending Simulation using ANSYS Workbench

                                    Objective:

                                    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…

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                                    28 Dec 2020 04:03 AM IST

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                                      Simulation of Spur Gear using ANSYS Workbench

                                      Objective:

                                      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…

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                                      28 Dec 2020 04:03 AM IST

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                                        Analysis of Stress Concentration on a Plate with hole using ANSYS Workbench

                                        Objective:

                                        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…

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                                        28 Dec 2020 04:03 AM IST

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                                          Simulation of Bird Strike in aero-engine using LS-Dyna

                                          Objective:

                                          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…

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                                          28 Dec 2020 04:01 AM IST

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                                            Joint creation and Demonstration using LS-Dyna

                                            Objective:

                                            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…

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                                            28 Dec 2020 04:01 AM IST

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                                              Hyperelastic Material Modelling using LS-Dyna

                                              Objective:

                                              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…

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                                              28 Dec 2020 04:01 AM IST

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                                                Material modeling from raw data using LS-Dyna

                                                Objective:

                                                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…

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                                                28 Dec 2020 04:01 AM IST

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                                                  Head Impact Simulation using LS-Dyna

                                                  Objective:

                                                  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…

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                                                  28 Dec 2020 04:00 AM IST

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                                                    Study of Mass Scaling using LS-Dyna

                                                    Objective:

                                                    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…

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                                                    28 Dec 2020 04:00 AM IST

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                                                      Calculating the Stretch Ratio by comparing the ELFORM (-2,-1,1,2) with Ogden_Material Model using LS-Dyna

                                                      Objective:

                                                      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…

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                                                      28 Dec 2020 03:59 AM IST

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                                                        Phone Drop test using LS-Dyna

                                                        Objective:

                                                        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…

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                                                        28 Dec 2020 03:59 AM IST

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                                                          Explicit and Implicit Analysis

                                                          Objective:

                                                           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…

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                                                          28 Dec 2020 03:58 AM IST

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                                                            Midsurface and meshing in accordance with the quality criteria using ANSA

                                                            Objective:

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

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                                                            28 Dec 2020 03:58 AM IST

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                                                            Data analysis using Python

                                                            Objective:

                                                            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…

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                                                            28 Dec 2020 03:56 AM IST

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                                                              Side Crash Analysis in the given BIW model using Radioss

                                                              Objective:

                                                              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…

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                                                              28 Dec 2020 03:56 AM IST

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                                                                Frontal Crash Analysis in the given BIW model using Radioss

                                                                Objective:

                                                                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…

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                                                                28 Dec 2020 03:55 AM IST

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                                                                  Curve fitting using Python

                                                                  Objective:

                                                                  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…

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                                                                  28 Dec 2020 03:55 AM IST

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                                                                    Crash Tube Analysis using Radioss

                                                                    Objective:

                                                                    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…

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                                                                    28 Dec 2020 03:54 AM IST

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                                                                      Solving second order ODEs using Python

                                                                      Objective:

                                                                      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)          …

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                                                                      28 Dec 2020 03:53 AM IST

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                                                                        Air standard Cycle using Python

                                                                        Objective:

                                                                        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…

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                                                                        28 Dec 2020 03:53 AM IST

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                                                                          To compare the different material failure property cards using Radioss

                                                                          Objective:

                                                                          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…

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                                                                          28 Dec 2020 03:53 AM IST

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                                                                            Study of different shell element properties using Radioss

                                                                            Objective:

                                                                            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…

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                                                                            28 Dec 2020 03:52 AM IST

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                                                                              3D Hexa Meshing using Hypermesh

                                                                              Objective:

                                                                              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…

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                                                                              28 Dec 2020 03:51 AM IST

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                                                                                Geometric cleaning, mid surface extraction and meshing using Hypermesh

                                                                                Objective:

                                                                                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…

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                                                                                28 Dec 2020 03:50 AM IST

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                                                                                  Consistency of units in LS-Dyna

                                                                                  Objective:

                                                                                  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…

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                                                                                  28 Dec 2020 03:49 AM IST

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                                                                                    Modal Analysis using Optistruct

                                                                                    Objective:

                                                                                    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…

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                                                                                    15 Nov 2020 06:03 AM IST

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                                                                                      Roof crush simulation

                                                                                      Objective:

                                                                                      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…

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                                                                                      27 Oct 2020 02:36 AM IST

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                                                                                        Morphing and writing macro for the given side body

                                                                                        Objective:

                                                                                        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…

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                                                                                        27 Oct 2020 02:31 AM IST

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                                                                                          Week - 5 - Modelling Spotwelds

                                                                                          Objective:

                                                                                          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…

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                                                                                          20 Oct 2020 07:08 AM IST

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                                                                                            Week - 4 - crash box simulation

                                                                                            Objective:

                                                                                            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…

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                                                                                            08 Oct 2020 05:20 AM IST

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                                                                                              Week 12 - Project-1

                                                                                              Objective:

                                                                                              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…

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                                                                                              06 Jun 2020 07:46 AM IST

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                                                                                                Batch Meshing in accordance with the given Quality Criteria

                                                                                                Objective:

                                                                                                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…

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                                                                                                10 May 2020 02:36 PM IST

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                                                                                                  Frame Assembly Welding using Connectors

                                                                                                  Objective:

                                                                                                  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…

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                                                                                                  07 May 2020 12:24 AM IST

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                                                                                                    Meshing of Chassis Assembly Housing and Crank Housing using 3D Tetra Mesh Element

                                                                                                    Objective:

                                                                                                    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:…

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                                                                                                    02 May 2020 02:27 PM IST

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                                                                                                      Meshing the given component in accordance with the quality criteria given

                                                                                                      Objective:

                                                                                                      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…

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                                                                                                      12 Apr 2020 03:27 PM IST

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                                                                                                        Creating different types of 1D elements with given cross section and DOF s in Hypermesh

                                                                                                        Objective:

                                                                                                        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                            …

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                                                                                                        29 Mar 2020 11:51 PM IST

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