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Contents
Contents
Preface 2
Section A. Sketching
Exercise 1a.
Exercise 2.
Ratchet Stop
Exercise 3.
Ratchet Wheel
Exercise 4.
Cover Plate
21
28
35
44
54
Exercise 6.
Exercise 7.
Yoke
Exercise 8.
Support
Exercise 8a.
Exercise 9.
Wheel
Exercise 10.
Pipe
Exercise 11.
C-Bar Dynamometer
Exercise 11a.
Exercise 12.
Threaded Shaft
Exercise 13.
Lifting Fork
Exercise 14.
Caster Frame
64
72
79
88
94
98
106
111
119
124
130
144
Exercise 16.
Universal Joint
152
Exercise 16a.
Exercise 17.
Clamping Mechanism
Exercise 17a.
165
176
197
215
Exercise 18a.
219
Exercise 19.
Exercise 19a.
Exercise 20.
Exercise 20a.
225
234
240
230
2
Preface
Preface
Use of the Book
This book is designed for those who want to learn how to create parts and assembly models using ANSYS
DesignModeler. The author assumes no previous CAD/CAE experiences to begin with the book.
This book is mainly designed as an auxiliary tutorial in a course using ANSYS as a CAE platform. In particular,
this book can serve as a preparation to the author's another book Finite Element Simulations with ANSYS Workbench 14,
which emphasizes on finite element simulations rather than geometry modeling such that the exercises on geometry
modeling (especially assembly modeling) may not be adequate.
ANSYS DesignModeler
ANSYS DesignModeler is a CAD program running under ANSYS Workbench environment. The DesignModeler can
create geometries as sophisticated as any other CAD programs. Yet, many engineers choose to create geometry
models using other CAD programs (e.g., Pro/Engineer, SolidWorks) and then import them into an ANSYS simulation
module (such as Mechanical) for simulations. One of the reasons may be that, other than the training materials
provided by the ANSYS Inc., there exist no tutorials in the bookstore. That is the main reason that I created this book.
The DesignModeler is designed specifically for creating models which can be seamlessly imported into an ANSYS
simulation modules (such as Mechanical). Therefore, if a geometry model is solely used for ANSYS simulations, I
strongly suggest that we create the model from scratch using DesignModeler, rather than other CAD programs, to
avoid any unnecessary incompatibilities.
An assembly consists of two or more parts. Each part can be viewed as boolean operations (union, subtraction,
etc.) of simpler 3D bodies. Each of the 3D bodies usually can be created by a two-step operation: drawing a 2D sketch
on a 2D plane and then generate the 3D body by extrusion, revolution, sweeping, or skin/lofting.
The book is divided into 4 sections. Section A lets students familiarize with sketching techniques. Section B
contains exercises of part modeling. Section C consists of exercises of assembly modeling. The last section introduces
the creations of concept models, including 2D models, surface models, and line models. A concept model is a
simplification of a 3D models, and is usually easier to create and more efficient to be simulated.
Preface
Companion Webpage
A webpage dedicated to this book is maintained by the author:
http://myweb.ncku.edu.tw/~hhlee/Myweb_at_NCKU/ADM14.html
The webpage contains links to finished project files of each exercise and appendix. If everything works smoothly, you
do not need them at all. Every model can be built from scratch according to the steps described in the book. The
author provides these project files just in some cases you need them. For examples, if you have troubles to follow the
geometry details in the textbook, you may need to look up the geometry details from the project files.
Huei-Huang Lee
Associate Professor
Department of Engineering Science
National Cheng Kung University
Tainan, Taiwan
hhlee@mail.ncku.edu.tw
myweb.ncku.edu.tw/~hhlee
4
Section A. Sketching
Section A
Sketching
An assembly is a combination of parts. From manufacture point of view, a part is a basic unit for manufacturing
process. Many parts can be created by a two-step operation: drawing a 2D sketch on a plane and then generate a 3D
body by extrusion, revolution, sweeping, or skin/lofting.
The exercises in Section A are designed to introduce the 2D sketching techniques provided by the
DesignModeler. Each part created in Section A involves drawing a sketch and then extrude to generate a 3D solid
body representing the part.
Although it can be used as a general purpose CAD software, the DesignModeler is particularly designed for
creating geometric models to be analyzed (simulated) under the ANSYS environment. To let the readers understand
what it means by analysis (simulation) as early as possible, an exercise (Exercise 1a) is appended right after Exercise 1
to perform a structural analysis for the part created in Exercise 1. However, the reader has option to skip Exercise 1a
without affect the subsequent learning of geometric modeling.
6
Exercise 1. Arm
Exercise 1
Arm
1-1 Introduction
In this exercise, we will create a 3D
solid model for an arm, which is a
part of a clamping mechanism [1].
The clamping mechanism will be
introduced in Exercise 17 and
simulated in Exercise 17a.
The arm model consists of a
single solid body, which can be
generated by extruding a sketch by a
thickness of 0.125 inches [2].
Before creating a geometry
model, we must set up a global
coordinate system. For this exercise,
we arbitrarily choose the global
coordinate system as shown [3].
Note that the origin is on the back
surface of the part.
R0.313
1.375
R0.313
X
3 D0.25
2.25
R0.25
[2] Details of
the arm.
Unit: in.
Thickness: 0.125 in.
R0.5
Exercise 1. Arm
[7] Double-click
<Geometry> to start
up the DesignModeler.
8
Exercise 1. Arm
Speech Bubbles
1. In this book, each exercise is divided into subsections (e.g., 1-1, 1-2). In each subsection, speech bubbles are
ordered with numbers, which are enclosed by pairs of square brackets (e.g., [1], [2]). When you read, please follow
the order of speech bubble; the order is significant.
2. The square-bracket numbers also serve as reference numbers when referred in other text. When in the same
subsection, we simply refer to a speech bubble by its number (e.g., [1], [2]). When in the other subsections, we refer
to a speech bubble by its subsection identifier and its bubble number (e.g., 1-2[1]).
3. When a circle is used with a speech bubble, it is to indicate that mouse or keyboard ACTIONS are needed in that
step [1, 3, 4, 7, 9, 10]. A circle may be filled with white color [1, 4, 7] or unfilled [3, 9, 10]. A speech bubble without a
circle [2, 8] or with a rectangle [6] is used for commentary only, i.e., no mouse or keyboard actions are needed.
Workbench Keywords
A pair of angle brackets is used to highlight an Workbench keyword (e.g., <Component Systems> in [3]).
Sometimes, if the angle brackets do not add any clarity, they may be dropped (e.g., DesignModeler).
Exercise 1. Arm
[1] By default,
<XYPlane> is the
current sketching
plane (active plane).
10
Exercise 1. Arm
[1] Select
<Circle> tool.
[7] Select
<Dimension>
toolbox.
[8] Select
<Diameter> tool.
Exercise 1. Arm
11
12
Exercise 1. Arm
[3] Select
<Circle> tool.
Exercise 1. Arm
13
[7] Select
<Dimension> toolbox
and then select
<Horizontal> tool.
[11] In the <Details
View>, type 1.375 for
the horizontal
dimension.
[13] Select
<Vertical> tool.
14
Exercise 1. Arm
Exercise 1. Arm
15
16
Exercise 1. Arm
Exercise 1. Arm
17
18
Exercise 1. Arm
[2] It automatically
switches to
<Modeling Mode>, in
which a <Tree
Outline> is
displayed, which will
be explained later.
Exercise 1. Arm
19
1-12 Review
Global Coordinate System
Before creating a geometry model, you must set up a global coordinate system (1-1[3], 1-3[6]).
Workbench GUI
In the <Workbench GUI> (1-2[2]), you can create a system (1-2[4]) and start up DesignModeler (1-2[7]). Other
capabilities will be introduced later.
Project Schematic
Created systems appear on the <Project Schematic>, an area in the <Workbench GUI>.
DesignModeler GUI
Geometries are created entirely within the <DesignModeler GUI> (1-2[8]).
Length Unit
Before creating a model in the DesignModeler, you must choose a length unit (1-2[9, 10]). The length unit cannot be
changed thereafter.
Mouse Operations
Click
-- Left-click the mouse button.
Select
-- Left-click the mouse button.
Double-Click -- Left-click the mouse button twice.
Zoom In/Out -- Scroll the mouse wheel
Pan
-- Move the mouse while holding control-left-button.
Other mouse operations will be introduced later.
Look At Face/Plane/Sketch
Clicking this tool to rotate the view angle so that you look at the current sketching plane (1-3[3]).
Ruler
The ruler (1-3[4, 5]) is to help you obtain a better feeling of the drawing scale. In this book, we always leave the ruler
off to make more sketching space.
20
Exercise 1. Arm
Scrolling
In case you don't see a tool in a toolbox, scroll down/up to reveal the tool (1-4[2]). There is also a scrolling controller
for the <Details View>.
-- Draw a circle, giving the center and the radius (1-4[1, 3-5]).
-- Draw a line tangent to two curves (including circles and arcs) (1-7[1, 2]).
--
--
--
--
--
--
--
Auto Constraints
P -- The mouse cursor snaps to a point (or the origin) (1-4[4]).
R -- The radius is the same as another circle (or arc) (1-4[5]).
C -- The mouse cursor is coincident to a line (or an axis) (1-5[4, 6]).
Other auto constraint features will be introduced later.
Color Codes
Greenish-blue --
Blue
--
Red
--
Under-constrained (1-8[2])
Fully constrained (fixed in the space) (1-4[9], 1-5[10,14]).
Over-constrained
Zoom To Fit
Click this tool to fit the entire sketch (in the <Sketching> mode) or entire model (in the <Modeling> mode) into the
graphics window (1-4[14]).
Extrude
This tool extrude a sketch by a specified depth to create a 3D body (1-10[1-5]). More exercises will be given later.
Isometric View
Click the little cyan sphere of the triad will rotate the view into an isometric view (1-10[3]). Other view controls will
be introduced later.
Display Plane
This tool is to toggle the display of current sketching plane and the sketches it contains (1-10[6]).
Appendix:
Exercise 1a
Structural Analysis of the Arm
1a-1 Introduction
Although it can be used as a general purpose
CAD software, the DesignModeler is
particularly designed for creating geometric
models to be analyzed (simulated) under the
ANSYS environment. The purpose of this
exercise is to let the readers understand what
it means by analysis (simulation). However, the
reader has option to skip this exercise without
affect the subsequent learning of geometric
modeling.
In this exercise, we will perform a static
structural analysis for the arm created in
Exercise 1. The objective is to find the
deformation and stresses under the working
loads.
The clamping mechanism is entirely
made of steel and is designed to withstand a
clamping force of 450 lbf [1]. After a
structural analysis of the entire mechanism [2]
(also see Exercise 17a), the results show
shows that, to withstand a clamping force of
450 lbf, the arm is subject to external forces as
shown [3] (also see 17a-13). Note that the
external forces are in a state of static
equilibrium.
The analysis for the entire clamping
mechanism will be perform in Exercise 17a. In
this exercise, we will only perform a analysis
on the arm. The purpose is to make sure the
stresses are within the allowable stress of the
steel, which is 30,000 psi.
The analysis task cannot not be
performed in DesignModeler. Rather, it is
carried out with <Mechanical>, another
Workbench application program.
281 lbf
264 lbf
77 lbf
407 lbf
126 lbf
187 lbf
21
22
[6] Double-click to
start up the
<Mechanical>.
23
24
[4] Click
<Apply>.
25
26
[5] Undeformed
shape.
[2] Click the Z-axis
to rotate the view so
that you look into the
<XYPlane>.
27
28
Exercise 2
Ratchet Stop
2-1 Introduction
R0.56
p:
Slo
Y
[3] Details
of the
ratchet stop.
40
0.125
0.1
X
R0.34
Unit: in.
Thickness: 0.125 in.
R0.188
0.57
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit (1-2[9, 10]).
[3] Draw a
circle centered at
the plane origin
(1-4[1-5]).
[1] Switch to
<Sketching
Mode> (1-3[2]).
[2] Rotate to
XYPlane view
(1-3[3])
29
30
[1] To specify an angle dimension, you need to select two lines (or axes).
When you select a line (or axis), the end near where you click become
the "arrow end" of the line. The angle is then measured from the first
line to the second line in a counter-clockwise fashion.
[5] If you made mistakes (click on wrong ends or in a wrong order) and the
angle is not what you meant, right-click anywhere in the graphics window to
bring up a <Context Menu> and choose <Alternate Angle>. Repeat this before
you click to locate the angle dimension until the correct angle appears.
31
32
33
Wrap Up
Close DesignModeler, save the project as "Stop," and exit the
Workbench (1-11[1-3]).
34
2-9 Review
Context Menu
When you right-click the mouse, a menu pops up. The contents of the menu
depends on when and where you right-click the mouse. The menu is thus
called the <Context Menu> (2-5[5]). Try to right-click anywhere in the
graphics area, <Details View>, or <Tree Outline> (1-10[2]), to see the
contents of the <Context Menu>.
<Dimension/General> Tool
This tool can be used for any type of dimension. For a line, the default is to
create a <Length> dimension (2-4[2]). For a circle or arc, the default is to
create a diameter dimension. If the default is not what you want, right-click
anywhere in the graphics window to bring up the <Context Menu> [1] and
choose a dimension type.
<Dimension/Angle> Tool
To specify an angle dimension, you need to select two lines (or axes). When
you select a line (or axis), the end near where you click become the "arrow
end" of the line. The angle is then measured from the first line to the second
line in a counter-clockwise fashion (2-5[1-4]).
If you made mistakes (click on wrong ends or in a wrong order) and
the angle is not what you meant, right-click anywhere in the graphics window
to bring up the <Context Menu> [2] and choose <Alternate Angle>. Repeat
this until the correct angle appears before you click to locate the angle
dimension (2-5[5]).
<Draw/Line> Tool
This tool draws a line by defining two end points (2-4[1])).
<Constraints/Tangent> Tool
This tool impose a <Tangent> constraint between two curves or between a
line and a curve (2-6[6, 12]).
Exercise 3. Ratchet
35
Exercise 3
Ratchet Wheel
3-1 Introduction
In this exercise, we'll create a 3D
solid model for the ratchet wheel
mentioned in Exercise 2 [1]. The
details of the ratchet wheel are
shown in the figure below [2].
60
15
1.00
[2] Details of
the ratchet
wheel.
X
D0.25
Unit: in.
Thickness: 0.25 in.
36
Exercise 3. Ratchet
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit.
Exercise 3. Ratchet
37
[3] Draw
another line like
this.
[4] Specify an angle
dimension of 60
degrees.
38
Exercise 3. Ratchet
[3] After
trimming, a single
tooth remains.
Exercise 3. Ratchet
39
[1] Select
<Modify/Copy>.
[3] Right-click
anywhere in the
graphics window to
bring up the
<Context Menu>, and
select <End/Use Plane
Origin as Handle>.
Now the tooth has
been copied to a
"clipboard."
40
Exercise 3. Ratchet
Exercise 3. Ratchet
[10] Type 90
(degrees) for the
rotating angle.
[11] Repeat
steps [5, 6].
41
42
Exercise 3. Ratchet
Wrap Up
Close DesignModeler, save the project as "Ratchet," and exit
the Workbench.
Exercise 3. Ratchet
43
3-8 Review
Selection of Multiple Entities
There are several ways to select multiple entities. Two of them are <Control-Select> and <Sweep Select>.
Control-Select -- Click the entities sequentially while holding the Control key.
Sweep Select -- Hold the left mouse button and sweep through the entities.
Box Select
-- Select <Select Mode/Box Select> [1], and use mouse to define a box.
All entities inside the box are selected.
<Modify/Replicate> Tool
<Replicate> is equivalent to a <Copy> followed by a <Paste>.
Ending a Tool
You can press <Esc> to end a tool (3-6[8, 12]). Besides, the <Context Menu> often provides an <End> option to end
a tool (3-6[5, 6]).
44
Exercise 4
Cover Plate
4-1 Introduction
In this exercise, we'll create a 3D solid model
for a cover plate, of which the details are
shown in the figure below [2].
2 R0.188
2 D0.201
8 R0.15
0.25
0.376
0.312
2.00
0.312
1.25
[1] Details of
the cover plate.
0.25
0.75
6 R0.06
X
Unit: in.
Thickness: 0.046 in.
0.562
1.50
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit.
45
46
47
48
[1] Select
<Modify/Fillet>
and type 0.06 (in.)
for the <Radius>.
[4] Select
<Modify/Fillet>
again and type 0.15
(in.) for the
<Radius>.
49
50
51
52
Wrap Up
Close DesignModeler, save the project as "Cover," and exit the
Workbench.
4-8 Review
<Draw/Rectangle>
Draws a rectangle by defining two diagonally opposite points. The edges of the rectangle are either horizontal or
vertical. To draw a rectangle at an arbitrary orientation, please use <Draw/Rectangle by 3 Points>.
<Draw/Polyline>
This tool allows you to draw a series of connected lines, called a polyline. The polyline can be closed or open. After
defining the last point, choose <Open End> or <Closed End> from the <Context Menu>.
Auto Constraints
H
V
--
--
Horizontal
Vertical
Note:
For a comprehensive description of sketching tools, please refer to the following ANSYS on-line reference:
ANSYS Help System//DesignModeler User Guide//2D Sketching
53
54
Section B
Part Modeling
As mentioned in the opening of Section A, many parts can be created by a two-step operation: drawing a 2D sketch on
a plane and then generate a 3D body by extrusion, revolution, sweeping, or skin/lofting.
A more complicated part often can be viewed as a series of the two-step operations; each two-step operation
either add material to the existing body or cut material from the existing body. The exercises in Section B are
designed to introduce the 3D modeling techniques for more complicated parts.
Exercise 5. Crank
55
Exercise 5
Crank
5-1 Introduction
In this exercise, we'll create a 3D solid model for a crank, of which the details are shown in the figure below. Note
that a global coordinate system is set up and shown in the figure.
The crank model can be viewed as a series of three two-step operations; each involves drawing a sketch on
XYPlane and then extrude the sketch to generate a material. The materials are either add to the existing body or cut
from the existing body.
Y
2 D10
2 R10
75
Unit: mm.
R10
R22
D30
D20
65
8
20
56
Exercise 5. Crank
[2] Double-click
<Geometry> cell to start
up DesignModeler.
Exercise 5. Crank
57
58
Exercise 5. Crank
[10] Click
<Display Plane>
to turn off the
plane display.
[9] Click
<Generate>.
[3] Click
<Extrude>.
[5] An <Extrude1>
object is inserted in
the model tree.
[4] It automatically
switches to
<Modeling Mode>.
[14] The
<Extrude1> uses
<Sketch1> as the
base geometry.
[12] Click all the
plus signs <+> to
expand the model
tree.
Exercise 5. Crank
59
[2] A new sketch (Sketch2) is created. Note that, for the first
sketch of a plane, you don't need to explicitly click <New
Sketch>. However, for additional sketches on the same plane,
you need to click <New Sketch>. Remember that the
drawing entities always belong to the active sketch.
60
Exercise 5. Crank
[1] Click
<Extrude>.
[3] Type 20
(mm).
[5] Click
<Generate>.
[7] <Sketch2> is
added under
XYPlane.
[9] <Extrude2>
uses <Sketch2> as
the base
geometry. The
<Extrude2> is
simply a cylinder.
Exercise 5. Crank
61
62
Exercise 5. Crank
[1] Click
<Extrude>.
[4] Select
<Through All>.
[5] Click
<Generate>.
[7] <Sketch3> is
added under
XYPlane.
Wrap Up
Close DesignModeler, save the project as "Crank," and exit the
Workbench.
[9] <Extrude3>
uses <Sketch3> as
the base
geometry. The
<Extrude3> is
simply a cylinder.
Exercise 5. Crank
63
5-9 Review
<Plane> and <Sketch>
A sketch must be created on a plane; each plane, however, may contain multiple sketches. In the beginning of a
DesignModeler session, three planes are automatically created: XYPlane,YZPlane, and ZXPlane. You can create new
planes and new sketches as many as needed.
Modeling Mode
In the modeling mode (5-4[4]), several modeling tools become available, including Extrude, Revolve, Sweep, Skin/Loft,
Thin/Surface, Blend, Chamfer, Point, etc. In addition, a <Tree Outline> is displayed.
Model Tree
<Tree Outline> (5-4[11]) contains an outline of the model tree, the data structure of the geometric model. Each branch
of the tree is called an object, which may contain one or more objects. At the bottom of the model tree is a part
branch, which is the only object that will be exported to <Mechanical>. By right-clicking an object and selecting a tool
from the context menu, you can operate on the object, such as delete, rename, duplicate, etc.
The order of the objects is relevant. <DesignModeler> renders the geometry according to the order of objects
in the model tree. New objects are normally added one after another. If you want to insert a new object BEFORE an
existing object, right-click the existing object and select <Insert/...> from the context menu. After insertion,
<DesignModeler> will re-render the geometry.
64
Exercise 6
Geneva Gear Index
6-1 Introduction
In this exercise, we'll create a 3D solid model for a Geneva gear index, of which the details are shown in the figure
below. Note that a global coordinate system is set up and shown in the figure.
5 0
5 R0.63
.2
Unit: in.
29
1.5
D0.25
D0.5
D2.47
D1.25
0.25
0.44
65
66
[8] Apply a
<Constraints/Tangent>
on the lower circle and
the horizontal line.
67
68
69
[10] Click
<Generate>.
70
[9] Click
<Generate>.
[5] Select <Create/
Primitive/Cylinder> again.
Wrap Up
Close DesignModeler, save the project as
"Geneva," and exit the Workbench.
71
6-7 Review
Auto Constraints: <//>
It is applicable to a line, indicating that the line is parallel to another line in the same plane (6-3[7]).
<Create/Pattern>
This tool allows you to create copies bodies in three types of pattern: Linear, Circular, and Rectangular (6-5).
<Create/Primitive/Cylinder>
This tool creates a cylinder by specifying its origin, axis, and radius (6-6). The origin and axis are defined by referring to
the active plane coordinate system (1-12).
72
Exercise 7. Yoke
Exercise 7
Yoke
7-1 Introduction
The yoke is a part of a universal joint [1]. In this exercise, we'll create a 3D
solid model for the yoke, of which the details are shown in the multiview
drawings below. Note that a global coordinate system is also shown in the
figure.
D1.20
Y
Unit: in.
3.55
R1.00
Z
1.50
D0.75
2 0.75
R1.00
Exercise 7. Yoke
[6] Use
<Dimensions/
General> to
specify a length of
2.50 (in.).
[3] Click the second
point. Make sure the
first segment is vertical.
73
74
Exercise 7. Yoke
[12] Click
<Generate>.
[9] Click
<Extrude>.
Exercise 7. Yoke
[5] Click
<Generate>.
[3] Click
<Apply>.
[3] Click
<Generate>.
75
76
Exercise 7. Yoke
[6] Click
<Generate>.
Exercise 7. Yoke
[5] Click
<Extrude>.
[6] Select
<Reversed> for
<Direction>. Now,
the extrusion
direction is the -Z
direction.
Wrap Up
Close DesignModeler, save the project as "Yoke," and exit the Workbench.
77
[8] Click
<Generate>.
78
Exercise 7. Yoke
7-7 Review
Extrude Direction
There are four options you can choose for the extrusion direction: <Normal>, <Reversed>, <Both -- Symmetric>, and
<Both -- Asymmetric>. In <Normal> case, the extrusion direction is the Z-direction of the sketching plane. When
<Reversed> is selected, the extrusion direction reverses to the -Z-direction (7-6[6]). For <Both -- Symmetric>, the
extrusion is along both +Z and -Z directions with the same depth (defined by <Depth>) (7-3[10]). For <Both -Asymmetric>, the extrusion is along both +Z and -Z directions with the different depths (defined by <Depth> and
<Depth 2>).
<Blend/Fixed Radius>
This tool can be used to place rounds or fillets on a body (7-4). The fillets are specified on edges, while the rounds
can be specified on edges or faces. When faces are specified for rounds, the rounds are placed on the enclosing edges.
Exercise 8. Support
79
Exercise 8
Support
8-1 Introduction
The support is a part of the clamping
mechanism mentioned in Exercise 1 [1]. In
this exercise, we'll create a 3D solid model
for the support, of which the details are
shown in the multiview drawings below.
Note that a global coordinate system is also
shown in the figure.
X
[1] The support is a
part of a clamping
mechanism.
0.125
0.375
0.375
0.375
1.250
0.219
0.250
0.750
R0.313
Unit: in.
2 R0.100
0.250
:4
pe
Slo
1.250
R0.156
6 D0.25
0.375
1.250
0.625
0.875
2.500
0.125
1.000
R0.100
80
Exercise 8. Support
[2] Specify a
diameter of 0.25
in. for any one of
the circles.
Exercise 8. Support
81
82
Exercise 8. Support
[11] Click
<Extrude>.
[13] Click
<Generate>.
Exercise 8. Support
[2] Select
<From Face>.
83
84
Exercise 8. Support
[13] Click
<Extrude>.
[15] Click
<Generate>.
[2] Select
<From Face>.
Exercise 8. Support
[10] This is
<Plane5>; it
includes an
outline.
[16] Click
<Generate>.
[12] Click
<Extrude>.
[15] Select
<Through All>.
85
86
Exercise 8. Support
[5] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Support,"
and exit the Workbench.
Exercise 8. Support
87
8-7 Review
Create New Planes From Faces
You can create a new plane from an existing face (8-4[1-7]). There are subtypes to choose: <Outline Plane> and
<Tangent Plane>. The only difference is that a <Tangent Plane> doesn't include the outline of the face. In either
subtype, the plane coordinate system is determined according to how you click the face. The origin is usually located
at the closest corner point or the center of a circle (or an arc); The Z-axis always points out of the face; The X-axis is
usually parallel to the closest edge.
An outline plane include the outline of the face (8-4[11]). The outline is not part of a sketch but can be used as
references (datum). Without the outline, the only references are two exes (X-axis and Y-axis of the plane). However,
you can copy the outline (or part of the outline) into a sketch, using the sketching tool <Modify/Duplicate>.
88
Appendix:
Exercise 8a
Structural Analysis of the Support
8a-1 Introduction
In this exercise, we will perform a static
structural analysis for the support created
in Exercise 8. The objective is to find the
deformation and the stresses under the
working loads, and make sure the stresses
are within the allowable level (30,000 psi).
As mentioned in Exercise 1a, the
clamping mechanism is entirely made of
steel and is designed to withstand a
clamping force of 450 lbf [1]. After a
structural analysis of the entire
mechanism [2] (which is performed in
Exercise 17a), the results show shows
that, to withstand a clamping force of 450
lbf, the support is subject to external
forces as shown [3] (also see 17a-4).
Note that the holes on the horizontal
plates are fixed to the ground [4].
The analysis task will be carried out
with <Mechanical>.
380 lbf
62 lbf
163 lbf
380 lbf
[4] The horizontal
plates are fixed to
the ground.
[6] Double-click to
start up the
<Mechanical>.
89
90
[9] Click
<Apply>.
[10] Select <Components>.
[2] Control-select
the three cylindrical
faces on the
horizontal plate.
[3] And
control-select
this face.
91
92
[7] Click
<Apply>.
[8] Type 0
(in.) for <Z
Component>.
Wrap Up
Close <Mechanical>, save the project as "Support-a," and exit the
Workbench.
93
94
Exercise 9. Wheel
Exercise 9
Wheel
9-1 Introduction
The main purpose of this exercise is to introduce another modeling tool (than <Extrude>): <Revolve>, which takes a
sketch as the profile and revolves about an axis to create a 3D solid body.
We'll create a 3D solid model for a wheel, of which the details are shown in the multiview drawings below. A
global coordinate system is also shown in the figure.
Note that the wheel is axisymmetric. An axisymmetric body can be created by drawing a profile then revolting
about its axis to generate the 3D solid body.
Y
45
Unit: in.
D1.00
D1.50
D3.50
D4.00
0.25
0.50
0.75
Exercise 9. Wheel
95
96
Exercise 9. Wheel
Exercise 9. Wheel
97
[5] Click
<Generate>.
[2] Rotate to an
isometric view.
Wrap Up
Close DesignModeler, save the project as "Wheel," and exit the Workbench.
9-5 Review
Modeling Tool <Revolve>
It takes a sketch as the profile and revolves about an axis to create a 3D solid body (9-4[1-5]). The angle of revolution
can be specified.
98
Exercise 10
Transition Pipe
10-1 Introduction
The transition pipe is used to connect two pipe segments. In this exercise, we'll create a 3D solid model for the
transition pipe, of which the details are shown in the multiview drawings below. A global coordinate system is also
shown in the figure.
The main purpose of this exercise is to introduce another modeling tool: <Sweep>, which takes a sketch as the
path and another sketch as the profile; the profile then "sweeps" along the path to create a 3D solid body.
Note that it is possible to create the curved pipe by using of <Revolve> tool (Exercise 9), however, as an
exercise, we decide to create the curved pipe by using <Sweep>.
R1/16"
2 D3.50
2 D2.50
8 D0.25
R3.50
Unit: in.
D1.00
R1/8"
R2.50
2 0.25
X
[1] Select
<ZXPlane> (or
click ZXPlane in
the model tree).
99
100
[3] Click
<Generate>.
[1] Click
<Sweep> on the
<Toolbar>.
[5] Click
<Apply>
[6] Click
<Generate>.
[4] Click
<Extrude>.
[6] Click
<Generate>.
101
102
[5] Click
<Apply>.
[6] Click
<Generate>.
<Plane5> is
created.
[8] Select
<Move>.
[9] Select the
existing end plate.
103
[4] Click
<Generate>.
[1] Select <Create/
Boolean>.
[4] Click
<Generate>.
104
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Pipe," and exit
the Workbench.
105
10-13 Review
Modeling Tool <Sweep>
The <Sweep> can be thought of a generalization of the <Extrude>. <Sweep> takes a sketch as the path and another
sketch as the profile; the profile then "sweeps" along the path to create a 3D solid body (10-5). The <Sweep> also can
be used to create spiral shapes, which will be demonstrated in Exercise 12.
Add Frozon
A body is either in a state of active or frozen. The default state is active. Two overlapped active bodies would
automatically join together to form a single body. If either of them is frozen, they wouldn't join together. Therefore,
the only way to avoid overlapped bodies joining together is to make at least one of them frozen. In 10-7, we create the
end plate as frozen body (separating it from the curved pipe), so that, in 10-8, we can copy the end plate alone without
the curved pipe.
<Body Operation/Move>
This tool moves a body (or a group of bodies) to another position and orientation in the same way that the source
plane is move to coincide with the destination plane (10-8). If the <Reserve Bodies?> option is <Yes>, it essentially
copies the bodies. This tool is useful for "assembling" parts together to form an assembly.
<Create/Boolean>
Using boolean operations, bodies can be united, intersected, and subtracted.
106
Exercise 11
C-Bar
P
11-1 Introduction
Y
P
100
70
D10
20
30
Unit: mm.
20
Y
40
R50
40
120
R10
107
[1] Select
<YZPlane> (or
click YZPlane in
the model tree).
108
[1] Select
<XYPlane>
[3] Right-click
<Sketch1> and select
<Hide Sketch> from
the context menu.
[5] Click
<Extrude>.
[7] Click
<Generate>.
[2] Control-select
these two edges.
[4] Click
<Generate>.
109
110
[4] Select
<ZXPlane> from the
model tree.
Wrap Up
Close DesignModeler, save the project as "CBar," and exit the Workbench.
[5] Click
<Generate>.
111
Appendix:
Exercise 11a
Deformation of the C-Bar
P
11a-1 Introduction
As described in Exercise 11, the C-shaped steel bar is used to measure the
magnitude of a force P [1]. A strain gauge is bonded to the surface of the location as
shown [2]. The location is chosen because the strain is relatively large and
distributed quite uniformly, so that the measured strain is not sensitive to the
variation of the location of the strain gauge. The measured strain is then used to
calculate the force P. The idea also relies on the fact that the strain is linearly
proportional to the force P, which is true when the deformation is small enough. In
other words, if the measured strain is doubled, then the force must be doubled.
In this section, we will assume a force of P = 2,000 N, and perform a simulation
to establish a relation between the force P and the strain .
11a-2 Start Up
[1]
Applied
force P.
[5] The two systems
share the same
<Geometry>. You can
edit up-stream cell
but not the downstream cell.
[2] Strain
gauge.
[6] Double-click
<Model> to start up
<Mechanical>
application.
[4] A <Static
Structural>
system is created.
112
113
114
Meshing
The process of dividing a body into small bodies is call meshing. The small bodies are called elements, or finite elements.
The simulation method is thus called finite element simulation. The basic idea of finite element methods is to divide a
body of rather complicated geometry into smaller elements of simple geometry, and the elements are assumed to be
connected to each other through nodes. The element's geometry is so simple that a set of equations may be
established easily for each element. All equations are then solve simultaneously for the displacements. Strains are then
calculated from the displacements. And stresses are in turn calculated from the strains.
In general, the finer the mesh, the more accurate the solution (and more computing time). In this exercise, we
control the mesh size by simply adjusting <Relevance Center> and <Relevance>.
Also, note that the Workbench will automatically generate a mesh right before it solves the problem if a mesh
doesn't exist.
[1] Highlight
<Static Structural>.
[2] Select
<Supports/Fixed
Support>.
115
116
[1] Highlight
<Solution>.
[4] Click
<Probe>.
117
118
11a-7 Conclusion
The simulation results show that a force of P = 2,000 N produces a strain = 0.000296. We may establish a relation
between the force P and the strain as follows:
P=
2000
0.000296
For example, if the measured strain in the strain gauge is 1 = 0.0001, then the force P1 is
P1 =
2000
0.0001= 676 N
0.000296
Wrap Up
Close <Mechanical>, save the project ("CBar"), and exit the Workbench.
119
Exercise 12
Threaded Shaft
12-1 Introduction
Unit: in.
[2] Major
diameter
d = .375 in.
[3] Pitch
p = 1/16 in.
[4] Thread
form: Unified
national coarse
Y
D0.625
D0.266
.375-16UNC
D0.250
0.438
3.750
0.875
Pitch p
H 4
Major diameter d
60
60
Slo
pe:
pe:
Slo
H = ( 3 2)p = 0.0541266 in
H
p = 0.0557342 in
8
H
= 0.0135316 in
4
H = ( 3 2)p
pH 8
H 8
120
[2] Click
<Revolve>.
[4] Click
<Generate>.
121
[3] Click
<Generate>.
[2] Right-click
<Sketch1> and select
<Hide Sketch>.
[3] Click <Sketch2>
to make it active.
122
[10] Click
<Sweep>.
[11] Select
<Sketch2> (from the
model tree) as the
<Profile>.
[12] Select
<Sketch3> (from the
model tree) as the
<Path>.
[13] Select <Pitch>
for <Twisting
Specification>.
Wrap Up
Close DesignModeler, save the project as "Shaft," and exit the Workbench.
[15] Click
<Generate>.
123
124
Exercise 13
Lift Fork
13-1 Introduction
The lifting fork is used in an LCD (liquid crystal display) manufacturing factory to handle glass panels. In this section,
we will create a 3D solid model for the lift fork, of which the details are shown below.
The cross sections of the prongs (fingers) are not uniform along the length [1-3]. The tools <Extrude> or
<Sweep> cannot be used to created the prongs. This exercise introduces a modeling tool, <Skin/Loft>, which takes a
series of profiles from different planes and creates a 3D solid that fits through these profiles
160
200
X
240
Unit: mm.
125
126
Skin/Loft
Now we want to create a single prong, or finger. The prong is then duplicated to create other prongs. The prong's
cross section is not uniform. You cannot create the prong using <Extrude> or <Sweep>. A more general way to
create a solid or surface of different cross sections along its path is using <Skin/Loft>. <Skin/Loft> takes a series of
profiles from different planes and creates a solid that fits through these profiles.
You may view <Sweep> as a generalization of <Extrude>, and <Skin/Loft> as a generalization of <Sweep>.
[4] Create
<Plane5>, see [5].
[6] Create
<Plane6>, see [7].
[7] Details of
<Plane6>.
[5] Details of
<Plane5>.
[3] Details of
<Plane4>.
127
[1] Click
<Skin/Loft> on
the toolbar.
128
[8] Click
<Apply>.
[1] Select
<Create/
Pattern>.
[5] Select this
edge.
[10] Click
<Generate>.
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Fork," and exit the Workbench.
129
130
Exercise 14
Caster Frame
14-1 Introduction
In this exercise, we'll create a 3D solid model for a caster frame, of which the details are shown in the multiview
drawings below. A coordinate system is also shown in the figure.
64
X
10
D17.5
D25
Unit: mm.
Fillets and rounds: R3
D35
50
R10
28
R15
10
X
10
92
10
76
126
10
13
D32
D21.5
131
132
[6] And
click
<Apply>.
[11] Click
<Generate>.
[14] Click
<Generate>.
133
134
[20] Click
<Generate>.
[23] Click
<Generate>.
135
136
[26] Click
<Generate>.
137
138
139
140
[2] Control-select
these four edges.
[6] Control-select
these two edges.
141
142
[7] Click
<Generate>.
143
[4] Click
<Generate>.
[6] Select <View/
Shaded Exterior> to
hide all edges.
Wrap Up
Close DesignModeler, save the project as "Caster," and exit the Workbench.
144
Section C
Assembly Modeling
An assembly consists of two or more parts. The DesignModeler assigns a color for each part in an assembly. Creating
a simple assembly is straightforward, but you have to take case so that parts are not bonded together. This usually can
be done by freezing the existing parts. Exercise 15 is an example of creating a simple assembly. Creating complex
assemblies involves transformations (translations, rotations, etc.) of parts to appropriate positions. Exercises 16 and 17
demonstrate these techniques.
Exercise 15
Threaded Shaft Assembly
15-1 Introduction
0.3
75
D0
.75
Unit: in.
0.1
875
0.7
D0
.75
.25
D0
0.1
25
3.0
00
5
0.2
63
5.0
6
.26
D0
00
2.0
19
0.2
145
146
[2] Double-click
<Geometry> to start
up DesignModeler. Due
to the complexity of
the threads, it may take
a while to open the
model.
[3] Right-click
<Solid> and select
<Rename> from the
context menu.
[2] A <Freeze1>
object is inserted.
147
148
[10] Click
<Generate>.
[11] Right-click
"EndHinge" and select
<Hide All Other Bodies>
from the context menu.
[13] Right-click
anywhere in the graphics
window and select
<Show All Bodies> from
the context menu.
149
150
[9] Click
<Generate>.
[10] Hide all bodies
except the
"MidHinge."
Wrap Up
Close DesignModeler, save the project ("Shaft"), and exit
the Workbench.
151
152
Exercise 16
Universal Joint
16-1 Introduction
In this exercise, we'll create a universal joint shown in the figure below. The assembly consists of four kinds of parts
[1-4], of which the yoke [1] was created in Exercise 7. A coordinate system for the assembly is also shown in the
figure [5]. The assembly created in this exercise is simple enough that we will create all parts in a single <Geometry>
system. For more complicated cases (eg., Exercises 17), multiple <Geometry> systems may be a better management
scheme.
The universal joint is adapted from a working drawing in the book Technical Graphics Communication, by G. R.
Bertoline, E. N. Wiebe, C. L. Miller, and J. L. Mohler.
Y
Unit: in.
[5] Coordinate
system for the
assembly.
[4] 4 x Pin.
D0.50, L1.35.
X
[2] Swivel.
OD1.00,
ID0.50, L2.15.
[3] 4 x Bushing.
OD0.75, ID0.50,
L0.60.
[1] 2 x Yoke
(created in
Exercise 7).
153
[3] Double-click
<Geometry> to start
up DesignModeler.
Coordinate Systems
There is a coordinate system for
the entire assembly, called a global
coordinate system; each part has
its own coordinate system, called a
local coordinate system.
Here, the coordinate system
set up in 16-1 is the global
coordinate system [4], and the
coordinate system defined in 7-1,
used to create the yoke, is a local
coordinate system [5].
In order to position the yoke
in the global coordinate system, we
need to move the yoke upward (in
Y direction) by 1.50 in.
Y ,Y
[5] The
coordinate
system of the
part.
[4] The
coordinate
system of the
assembly.
154
[2] Select
"UpperYoke,"
either from the
model tree or
from the graphics
window.
155
[13] Click
<Generate>.
[6] Select
<Rotate>.
[7] Select
"LowerYoke."
[8] Type 90
(degrees).
Selection Filters
By activating a selection filter [9],
you can make one of four types of
entities (points, edges, faces, and
bodies) selectable. By rightclicking the graphic area, selection
filters can also be accessed
through the context menu, where
additional filters are available [15].
Multiple filters can be activated at
the same time.
156
157
[10] Right-click
anywhere in the
graphics window and
select <Show All
Bodies>.
158
159
160
161
162
163
164
[15] Control-select
the last 10 objects
and right-clickselect <Suppress>.
Wrap Up
Close DesignModeler, save the project ("Joint"), and exit the Workbench.
165
Appendix:
Exercise 16a
Dynamic Simulation of the
Universal Joint
16a-1 Introduction
Y
In this exercise, we'll perform a dynamics simulation for
the assembly created in Exercise 11. The assembly is
entirely made of steel, which is the default material used
in <Mechanical>.
We assume a hinge set up at the top of the upper
yoke, such that the whole assembly can swing in the XY
plane and behaves like a double-pendulum [1]. Initially, the
lower yoke is raised to form an angle of 30 degrees with
the vertical axis, and then released [2]. The only external
force, other than the reaction forces at the hinge, acting
on the assembly is the gravitational force. We want to
observe the double-pendulum behavior of the assembly.
Since our concern is the double-pendulum behavior
of the assembly, the body deformation can be neglected.
Therefore, we assume all bodies are rigid. We'll use a
built-in system in the Workbench, called <Rigid
Dynamics>, which assumes all bodies are rigid and has
capabilities of performing rigid-body dynamic simulations.
We'll further assume that the combination of the
swivel, four bushings, and four pins is an integrated part,
i.e., they are bonded together. This assumption should be
reasonable as long as the double-pendulum behavior is
the only concern. This assumption not only simplifies the
model setup in <Mechanical> but also reduces
computation time.
30
166
[1] Lunch
Workbench and
open the project
"Joint," which was
saved in Exercise 16.
[2] Double-click
<Geometry> to start
up <DesignModeler>.
167
[2] A <Rigid
Dynamics>
system is created.
[4] Double-click
<Model> to start
up <Mechanical>.
168
[3] A revolute
joint is created.
[10] A revolute
joint allows the
mobile body rotates
in Z direction.
[8] Click
anywhere on the
upper yoke.
[11] Click
<Apply>.
[15] Click
<Apply>.
169
170
171
172
[4] Click
<Apply>.
[4] Click
<Configure>.
[2] Select <Revolute LowerYoke to
Bushing1>.
173
174
[3] An environment
condition is inserted.
[2] Select
<Deformation/
Total>.
175
[1] Click
<Solve>.
[3] Click
<Result
Sets>.
Wrap Up
Close <Mechanical>, save the project ("Joint"), and exit the Workbench.
[7] By clicking
<Export Video File>,
the animation can be
save as an AVI file.
176
Exercise 17
Clamping Mechanism
17-1 Introduction
0.375
0.3
75
0.375
0.75
1.375
Part Name: Grip
D0.25
D0.312
0.375
0.75
Part Name: Pin A
Unit: in.
0.2
D0.312
D0.25
0.7
5
Grip
0.75
1.125
Part Name: Pin B
Pin A
Pin C
Pin B
D0.312
D0.25
D0.312
0.375
1.125
Part Name: Pin C
[2] Double-click
<Geometry> to start
up DesignModeler.
[3] In DesignModeler,
select <File/Export...>.
177
178
[10] Double-click
<Geometry> to start
up DesignModeler.
[8] Click <No>.
[11] In DesignModeler,
select <File/Export...>.
[15] Click
<New>.
[18] Double-click
<Geometry> to start
up DesignModeler.
[16] Click <No>.
[19] In DesignModeler,
select <File/Export...>.
179
180
181
[4] Click
<Generate>.
[3] The <Base Plane>
determines how the imported
geometry positions in the current
global coordinate system. Here,
<XYPlane> means the imported
geometry's coordinate system is
to be coincident with the current
XYPlane.
[5] Click
<Display Plane>.
182
[2] Select
"Support1."
[3] Select
<XYPlane> from the
model tree and click
<Generate>.
[5] Rename the
body as "Support2."
183
184
185
9.273
46.775
186
[4] Bring up
<Apply/Cancel>
[7] Click to
reverse the
direction.
187
188
[4] Bring up
<Apply/Cancel>
[7] If necessary,
click here to
reverse the
direction.
189
[3] Select
<XYPlane> from the
model tree and click
<Generate>.
190
[5] Click
<Apply>.
[6] Select <Align X-Axis with
Global> for <Transform 1>.
191
192
[4] Pin A.
[4] Pin B.
193
194
[6] Select<Yes>
for <Preserve
Bodies?>
[4] Pin A.
195
196
Wrap Up
Close DesignModeler, save the project ("Clamp") and exit the Workbench.
197
Appendix:
Exercise 17a
Simulation of the Clamping
Mechanism
17a-1 Introduction
The clamping mechanism created in Exercise 17 is designed to provide clamping forces up to 450 lbf [1]. In this
exercise, we'll perform a simulation to make sure that, under the clamping force of 450 lbf, the stresses everywhere are
within the allowable stress of the steel, which is 30,000 psi. Remember that the clamping mechanism is entirely made
of steel, which is the default material used in <Mechanical>.
We'll assume an initial configuration such that the grip merely contacts the clamped object and the clamping
force is zero [2, 3]. As the handle rotates to increase the distance between two hinges, the clamping force also
increases, until the clamping force reaches 450 lbf [4-6].
198
[2] Double-click
<Geometry> to start
up DesignModeler.
[5] In DesignModeler,
select <File/Export...>.
199
200
[13] Select
<Import2>, which is
the shaft assembly.
[14] Double-click
<Source>.
201
[19] Control-select
"Support1," "Support2,"
"PinB1," "PinB2," and
"PinC," and right-clickselect <Form New Part>.
[17] Control-select
"Shaft," "Handle," and
"EndHinge," and
right-click-select
<Form New Part>.
[21] Control-select
"Grip" and "PinA," and
right-click-select <Form
New Part>.
[23] Close
DesignModeler.
202
[2] A <Static
Structural>
system is created.
[4] Double-click
<Model> to start
up <Mechanical>.
203
204
[12] While
<Connections> is
highlighted, click to
activate <Body Views>.
205
206
207
208
209
[2] Select
<Translational MidHinge to Shaft>.
[3] Select
<Displacement>.
210
211
212
[1] Highlight
<Equivalent Stress>.
213
56.048
225.04
379.94
163.13
214
379.94
62.045
163.13
379.94
Wrap Up
Close <Mechanical>, save the project as "Clamp-a", and exit the Workbench.
215
Section D
Concept Modeling
As mentioned, although it can be used as a general purpose CAD software, the DesignModeler is particularly designed
for creating geometric models to be analyzed (simulated) under the ANSYS environment. So far, we've created many
3D solid models; each can be imported into an analysis application, such as <ANSYS Mechanical>. 3D solid models are
not the only models that <ANSYS Mechanical> can analyze. Often, due to the efficiency (computing time and solution
accuracy), we prefer using simplified models, such as 2D solid models, surface models, or line models. This section
provides exercises for creating such simplified model.
216
Exercise 18
2D Solid Modeling (Arm)
18-1 Introduction
When the geometric characteristics in a certain dimension (e.g., the thickness in Z-dimension) can be parameterized
and the rest of the geometric characteristics (and the loads) can be expressed in a 2D space (in this example, XYspace), we often simplify the model into a 2D solid model, to facilitate the simulation task. The benefits of using a 2D
solid model (over a 3D solid model) include reduced modeling time, reduced computing time, increased accuracy,
increased post-processing efficiency.
In this exercise, we will create a 2D solid model for the arm, which has been modeled as s 3D solid model in
Exercise 1
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218
[5] Click
<Generate>.
[3] Select
<Sketch1> from
the model tree.
Wrap Up
Close DesignModeler, save the project as "Arm-2D" and exit the Workbench.
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Appendix:
Exercise 18a
Structural Analysis of the Arm
Using 2D Model
18a-1 Introduction
In this exercise, we will perform a static structural analysis for the 2D model created in Exercise 18. We'll use the
same boundary conditions (loads and supports) as in Exercise 1a (1a-1[3]). The results (stresses) should be the same
as those obtained in Exercise 1a, except that a 2D model is computationally much more efficient.
18a-2 Start Up
[3] Right-click
<Geometry> and
select <Properties>.
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[4] Click
<Apply>.
[6] Highlight
<Mesh>.
[7] There are 779 nodes in the model; that means a total
degrees of freedom is 1558 (2x779; for 2D problems, each
node has 2 degrees of freedom). The degrees of freedom
is an indication of problem size, and it is in turn an
indication of computing time.
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[2] Highlight
<Mesh>.
[7] There are 890 nodes in the model; that means a total
degrees of freedom is 2667 (3x890; for 3D problems,
each node has 3 degrees of freedom). The ratio of the
problem size between the 2D model and the 3D model
is 0.58 (1558/2667). That means, in this case, only
approximately 58% of computing time is need for the 2D
model, to achieve the same solution accuracy.
Wrap Up
Close <Mechanical> and exit the Workbench.
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Exercise 19
Surface Modeling (Support)
19-1 Introduction
When a body in 3D space is thin enough, we often simplify the body into a surface body, to facilitate the simulation
task. The benefits of using a 3D surface model (over a 3D solid model), similar to a 2D solid over 3D solid, include
reduced modeling time, reduced computing time, increased accuracy, increased post-processing efficiency.
In this exercise, we will create a 3D surface model for the support, which has been modeled as a 3D solid model
in Exercise 8.
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[2] Select
<Sketch1> from
the model tree.
[11] Click
<Generate>.
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[2] Switch to
<Sketching
Mode>.
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Support-Surface" and exit the Workbench.
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230
Appendix:
Exercise 19a
Structural Analysis of the
Support Using Surface Model
19a-1 Introduction
In this exercise, we will perform a static structural analysis for the surface model created in Exercise 19. We'll use the
same boundary conditions (loads and supports) as in Exercise 8a (8a-1[3, 4]).
19a-2 Start Up
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[4] Click
<Apply>.
[8] Click
<Apply>.
[9] Type 0
(in.) for <Z
Component>.
Wrap Up
Close <Mechanical>, save the project as "Support-Surface-a," and exit the Workbench.
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Exercise 20
Line Modeling (Space Truss)
20-1 Introduction
Consider a space truss subject to design loads as shown [1-4]. Note that each truss member and each connection
node (spherical joint) is given an identification number. This example is adapted from a problem in the book Vector
Mechanics for Engineers: Statics, by F. P. Beer, E. R. Johnston, and E. R. Eisenberg. The member forces calculated by the
textbook are shown in the table below [5]. Note that a plus sign is used to indicate a tensile member force and a
minus sign to indicate compressive member force.
The truss is a statically determinate structure, that is, the member forces can be solved using static equilibrium
equations without any cross-sectional information. Here, we assume that all members have a circular cross-section of
diameter 10 mm.
In this exercise, we'll create a line model for this space truss. In the Exercise 20a, as an appendix, we'll perform a
structural analysis to calculate the member forces using this line model.
Y
1m
[4] This node is
supported in Zdirection.
4
3
3
1
5
2
6
Z
0.5
200 N
0.5
1200 N
Member
Member
Force
+400 N
-600 N
-100 N
-200 N
-1342 N
+1500 N
+300 N
-566 N
1m
[5] Member
forces.
1m
[2] This node is
supported with a
hinge, i.e.,
displacements in all
directions are
restricted.
20-2 Start Up
[3] Double-click
<Geometry> to start
up <DesignModeler>.
Select <Meter> as
length unit.
[1] Launch
<Workbench> and
save the project as
"Truss."
[3] Type
coordinates.
[1] Select
<Create/Point>.
[4] Click
<Generate>.
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Point
X Coordinate
Y Coordinate
Z Coordinate
0m
0m
0m
1m
0m
0m
1m
1m
0m
0m
1m
0m
0.5 m
0m
1m
3
1
2
5
[1] Select
<Concept/Lines
From Points>.
Line
Start Point
End Point
Point1
Point2
Point2
Point3
Point3
Point4
Point4
Point1
Point1
Point5
Point2
Point5
Point3
Point5
Point4
Point5
Point1
Point3
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4
9
8
2
5
1
7
6
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20-5 Create and Assign Cross Section for the Line Bodies
[1] Select
<Concept/Cross
Section/Circular>.
Wrap Up
Close DesignModeler, save the project ("Truss") and exit the Workbench.
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Appendix:
Exercise 20a
Structural Analysis of the Space
Truss
20a-1 Introduction
In this exercise, we will perform a static structural analysis using the line model created in Exercise 20. We'll use the
boundary conditions (loads and supports) described in Exercise 20 (20-1[1-4]). The resulting member forces should
be consistent with those given by 20-1[5].
20a-2 Start Up
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[1] Highlight
<Connection>.
[2] Select <Body-Body/
Spherical>. A <Spherical>
joint allows the
connecting members to
independently rotate in
all directions.
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[3] Click
<Vertex>.
[4] Click this
node.
[5] Four "selection panes" show up;
each represents a vertex of a
connecting member. The currently
selected vertex is highlighted (redcolored) and arranged at the leftmost
position. Let's leave the leftmost vertex
selected.
[7] Select
<Deformable>.
[11] Select
<Deformable>.
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Now, we've set up a spherical joint at node 1. We'll repeat the above steps to set up the other spherical joints at
nodes 2, 3, 4, and 5. When you click a node, make sure all selection panes representing involved vertices show up; if
not, click again until all panes show up. Remember to leave the leftmost pane as <Reference> body and the other
panes as <Mobile> bodies.
[2] Select
<Vertex>.
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[11] Select
this node.
[1] Select
<Loads/Force>.
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[7] Click
<Probe>.
[3] Select <Auto
Scale>.
[6] Highlight
<Axial Force>.
Wrap Up
Close <Mechanical>, save the project as "Truss-a,"
and exit the Workbench.