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ANSYS Report - Project Project Author ANSYS Workbench User Subject Design Study Prepared For My Company Project

Created Wednesday, April 02, 2003 at 5:27:32 PM Project Last Modified Thursday, May 15, 2003 at 10:16:02 AM Report Created Thursday, May 15, 2003 at 10:35:13 AM Software Used ANSYS 7.1 Database D:\My Documents\Models\Workbench Projects\Parametric Wheel\Parametric Wheel.dsdb

1. Summary This report documents design and analysis information created and maintained using the ANSYS engineering software program. Each scenario listed below represents one complete engineering simulation. Scenario 1 Based on the Inventor assembly "D:\My Documents\Models\Workbench Projects\Parametric Wheel\Brake Disc Assembly.iam". Considered the effect of body-to-body contact, structural loads and structural supports. Calculated safety factors and margins based on maximum equivalent stress along with structural results. No convergence criteria defined. No alert criteria defined. See Scenario 1 below for supporting details and Appendix A1 for corresponding figures.

2. Introduction The ANSYS CAE (Computer-Aided Engineering) software program was used in conjunction with 3-D CAD (Computer-Aided Design) solid geometry to simulate the behavior of mechanical bodies under thermal/structural loading conditions. ANSYS automated FEA (Finite Element Analysis) technologies from ANSYS, Inc. to generate the results listed in this report. Each scenario presented below represents one complete engineering simulation. The definition of a simulation includes known factors about a design such as material properties per body, contact behavior between bodies (in an assembly), and types and magnitudes of loading conditions. The results of a simulation provide insight into how the bodies may perform and how the design might be improved. Multiple scenarios allow comparison of results given different loading

conditions, materials or geometric configurations. Convergence and alert criteria may be defined for any of the results and can serve as guides for evaluating the quality of calculated results and the acceptability of values in the context of known design requirements. Solution history provides a means of assessing the quality of results by examining how values change during successive iterations of solution refinement. Convergence criteria sets a specific limit on the allowable change in a result between iterations. A result meeting this criteria is said to be "converged". Alert criteria define "allowable" ranges for result values. Alert ranges typically represent known aspects of the design specification. The discussions below follow the organization of information in the ANSYS "Explorer" user interface. Each scenario corresponds to a unique branch in the Explorer "Outline". Names emphasized in "double quotes" match preferences set in the user interface. All values are presented in the "Metric (mm, kg, MPa, C, s)" unit system. Notice Do not accept or reject a design based solely on the data presented in this report. Evaluate designs by considering this information in conjunction with experimental test data and the practical experience of design engineers and analysts. A quality approach to engineering design usually mandates physical testing as the final means of validating structural integrity to a measured precision.

3. Scenario 1 3.1. "Model" "Model" obtains geometry from the Inventor assembly "D:\My Documents\Models\Workbench Projects\Parametric Wheel\Brake Disc Assembly.iam". The bounding box for all positioned bodies in the model measures 314.18 by 314.18 by 130.0 mm along the global x, y and z axes, respectively. The model weighs a total of 9.32 kg. Table 3.1.1. BodiesNameMaterialBounding Box (mm)Mass (kg)Volume (mm)NodesElements "Disk:1""Structural Steel" 314.18, 314.18, 40.0 6.66848,365.562914516277 "Hub:1""Structural Steel" 230.51, 230.51, 80.0 2.01256,642.245492106 "bolt:1""Structural Steel" 21.8, 16.55, 35.0 2.5810-23,285.44373169 "bolt:2""Structural Steel" 21.84, 16.83, 35.0 2.5810-23,285.44366166 "bolt:3""Structural Steel" 16.55, 21.8, 35.0 2.5810-23,285.44377173 "bolt:4""Structural Steel" 16.83, 21.84, 35.0 2.5810-23,285.44383177 "bolt:5""Structural Steel" 21.8, 16.55, 35.0 2.5810-23,285.44374168 "bolt:6""Structural Steel" 21.84, 16.83, 35.0 2.5810-23,285.44371169 "bolt:7""Structural Steel" 16.55, 21.8, 35.0 2.5810-23,285.44368165 "bolt:8""Structural Steel" 16.83, 21.84, 35.0 2.5810-23,285.44363163 "Pad:1""Structural Steel" 107.75, 34.99, 10.0 0.2228,108.1541448 "Pad:2""Structural Steel" 107.75, 34.99, 10.0 0.2228,108.1537943 3.1.1. Contact "Contact" uses a tolerance of 0.0 for automatic detection. "Contact" is set to use symmetric contact. Table 3.1.1.1. Contact ConditionsNameTypeAssociated BodiesNormal StiffnessScope ModeBehaviorFormulationInitial Interface TreatmentThermal Conductance "Contact Region"Bonded"Hub:1" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled

"Contact Region 2"Bonded"bolt:1" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 3"Bonded"bolt:2" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 4"Bonded"bolt:3" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 5"Bonded"bolt:4" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 6"Bonded"bolt:5" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 7"Bonded"bolt:6" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 8"Bonded"bolt:7" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 9"Bonded"bolt:8" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 10"Bonded"Pad:1" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 11"Bonded"Pad:2" and "Disk:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 12"Bonded"bolt:1" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 13"Bonded"bolt:2" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 14"Bonded"bolt:3" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 15"Bonded"bolt:4" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 16"Bonded"bolt:5" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 17"Bonded"bolt:6" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 18"Bonded"bolt:7" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled "Contact Region 19"Bonded"bolt:8" and "Hub:1"Program ControlledAutomaticSymmetricPure PenaltyAdjusted to TouchProgram Controlled 3.1.2. Mesh "Mesh"(Figure A1.2 to A1.3) , associated with "Model" has an overall relevance of 0. "Mesh" contains 37462 nodes and 19824 elements.

No mesh controls specified. 3.2. "Environment" "Environment"(Figure A1.4 to A1.5) contains all loading conditions defined for "Model" in this scenario. The following tables list local loads and supports applied to specific geometry. 3.2.1. Structural Loading Table 3.2.1.1. Structural LoadsNameTypeMagnitudeVectorReaction ForceReaction Force VectorReaction MomentReaction Moment VectorAssociated Bodies "Moment"Surface Moment1,000,000.0 Nmm[-2.9610-10 Nmm x, 5.7510-11 Nmm y,-1,000,000.0 Nmm z] N/AN/AN/AN/A"Hub:1" "Pressure"Surface Pressure14.0 MPaN/AN/AN/AN/AN/A"Pad:1" 3.2.2. Structural Supports Table 3.2.2.1. Structural SupportsNameTypeReaction ForceReaction Force VectorReaction MomentReaction Moment VectorAssociated Bodies "Cylindrical Support"Fixed Cylinder2,473.27 N[2,460.49 N x, -215.32 N y, -129.12 N z]532,022.17 Nmm[2,908.24 Nmm x, 86,879.21 Nmm y, 524,872.49 Nmm z]"Hub:1" "Fixed Support"Fixed Surface39,299.0 N[-2,460.49 N x, 215.31 N y, -39,221.31 N z]288,902.74 Nmm[-50,420.79 Nmm x, 232,656.4 Nmm y, 163,687.32 Nmm z]"Pad:2" 3.3. "Solution" "Solution" contains the calculated response for "Model" given loading conditions defined in "Environment". It was selected that the program would choose the solver used in this solution. 3.3.1. Structural Results Table 3.3.1.1. ValuesNameFigureScopeMinimumMaximumAlert Criteria "Equivalent Stress"A1.6, A1.7All Bodies In "Model"0.05 MPa61.75 MPaNone "Total Deformation"A1.8All Bodies In "Model"0.0 mm5.5310-2 mmNone Convergence tracking not enabled. 3.3.2. Equivalent Stress Safety Table 3.3.2.1. DefinitionNameStress Limit "Stress Tool"Yield strength per material. Table 3.3.2.2. ResultsNameFigureScopeTypeMinimumAlert Criteria "Stress Tool"A1.9, A1.10All Bodies In "Model" Safety Factor4.05 None Convergence tracking not enabled.

Appendixes A1. Scenario 1 Figures Figure A1.1. "Geometry" Geometry Figure A1.2. "Mesh" Geometry Figure A1.3. "Mesh" Geometry Figure A1.4. "Environment" Geometry

Figure A1.5. "Environment" Geometry Figure A1.6. "Equivalent Stress" Contours Figure A1.7. "Equivalent Stress" Contours Figure A1.8. "Total Deformation" Contours Figure A1.9. "Safety Factor" Contours Figure A1.10. "Safety Factor" Contours A2. Definition of "Structural Steel" Table A2.1. "Structural Steel" PropertiesNameTypeValue Modulus of ElasticityTemperature-Independent200,000.0 MPa Poisson's RatioTemperature-Independent0.3 Mass DensityTemperature-Independent7.8510-6 kg/mm Coefficient of Thermal ExpansionTemperature-Independent1.210-5 1/C Thermal ConductivityTemperature-Independent0.06 W/mmC Specific HeatTemperature-Independent434.0 J/kgC Table A2.2. "Structural Steel" Stress LimitsNameTypeValue Tensile Yield StrengthTemperature-Independent250.0 MPa Tensile Ultimate StrengthTemperature-Independent460.0 MPa Compressive Yield StrengthTemperature-Independent250.0 MPa Compressive Ultimate StrengthTemperature-Independent0.0 MPa Description: "Fatigue Data at zero mean stress comes from 1998 ASME BPV Code, Section 8, Div 2, Table 5-110.1" Material data file: "C:\Program Files\ANSYS Inc\v71\AISOL\CommonFiles\Language\en-us\EngineeringData\Materials\Structural_ Steel.xml" Table A2.1. Thermal Conductivity vs. Temperature Table A2.2. Alternating Stress vs. Cycles A3. Definition of "Aluminum Alloy" Table A3.1. "Aluminum Alloy" PropertiesNameTypeValueTemperature Modulus of ElasticityTemperature-Independent71,000.0 MPa Poisson's RatioTemperature-Independent0.33 Mass DensityTemperature-Independent2.7710-6 kg/mm Coefficient of Thermal ExpansionTemperature-Independent1.710-5 1/C Thermal ConductivityTemperature-Dependent0.11 W/mmC-100.0 C Thermal ConductivityTemperature-Dependent0.14 W/mmC0.0 C Thermal ConductivityTemperature-Dependent0.17 W/mmC100.0 C Thermal ConductivityTemperature-Dependent0.18 W/mmC200.0 C Specific HeatTemperature-Independent875.0 J/kgC Table A3.2. "Aluminum Alloy" Stress LimitsNameTypeValue Tensile Yield StrengthTemperature-Independent280.0 MPa Tensile Ultimate StrengthTemperature-Independent310.0 MPa Compressive Yield StrengthTemperature-Independent280.0 MPa Compressive Ultimate StrengthTemperature-Independent0.0 MPa Description: "6061-T6 aluminum. Fatigue properties come from MIL-HDBK-5H, page 3-277." "Aluminum Alloy" contains nonlinear data for thermal conductivity. Thermal

results for bodies using this material usually require several iterations to converge. Material data file: "C:\Program Files\ANSYS Inc\v71\AISOL\CommonFiles\Language\en-us\EngineeringData\Materials\Aluminum_Al loy.xml" Table A3.1. Thermal Conductivity vs. Temperature Table A3.2. Alternating Stress vs. Cycles Table A3.3. Alternating Stress vs. Cycles Table A3.4. Alternating Stress vs. Cycles Table A3.5. Alternating Stress vs. Cycles A4. Definition of "Titanium Alloy" Table A4.1. "Titanium Alloy" PropertiesNameTypeValue Modulus of ElasticityTemperature-Independent96,000.0 MPa Poisson's RatioTemperature-Independent0.36 Mass DensityTemperature-Independent4.6210-6 kg/mm Coefficient of Thermal ExpansionTemperature-Independent9.410-6 1/C Thermal ConductivityTemperature-Independent0.02 W/mmC Specific HeatTemperature-Independent522.0 J/kgC Table A4.2. "Titanium Alloy" Stress LimitsNameTypeValue Tensile Yield StrengthTemperature-Independent930.0 MPa Tensile Ultimate StrengthTemperature-Independent1,070.0 MPa Compressive Yield StrengthTemperature-Independent930.0 MPa Compressive Ultimate StrengthTemperature-Independent0.0 MPa Material data file: "C:\Program Files\ANSYS Inc\v71\AISOL\CommonFiles\Language\en-us\EngineeringData\Materials\Titanium_Al loy.xml" Table A4.1. Thermal Conductivity vs. Temperature A5. Glossary Alert Criteria Alerts cause ANSYS to flag results that exceed minimum or maximum allowable values. Bonded Contact Prevents contacting regions on selected faces from sliding or separating. "Glues" the faces together. Bounding Box A three-dimensional cube aligned to the global x, y and z axes that exactly contains a body or assembly. Convergence Tracking Convergence tracking causes ANSYS to iteratively refine the solution until the criteria for allowable change in the result is met or the maximum number of loops is exhausted. Frictionless Contact Models standard nonlinear unilateral contact. Allows free sliding and gaps to form at contact interface. No Separation Prevents contacting regions on selected faces from separating. Frictionless sliding may occur. Relevance Defines the acceptable accuracy for a body and valuates the importance of

bodies in an assembly. The relevance range extends from -100 to +100, where -100 implies maximum software speed and +100 implies maximum accuracy in calculating results. Rough Contact Nonlinear contact that allows gaps to form at contact interface but does not allow sliding (infinite coefficient of friction). Scope Filters a result to selected geometry. If combined with convergence tracking, focuses refinement activity on the selected geometry. Visible A user preference that controls the visibility of bodies in figures in this report. Unlike suppressed bodies, invisible bodies are fully considered in the calculation of results. A6. Distributing This Report The following table lists the files that you need to include for posting this report to an Internet or Intranet web server or for moving this report to a different location. Store all files in the same folder as the HTML page. This report was originally generated in the folder "W:\ansys\designspace\report2\". Table A6.1. Files Included In This ReportFile NameDescription "brake_rotor.htm"This HTML page. "StyleSheet.css"The Cascading Style Sheet used to format the HTML page. "AnsCompanyLogo.gif"The ANSYS image displayed at the top of the title page. "DS0001.png"Figure A1.1. "Geometry" Geometry "DS0002.png"Figure A1.2. "Mesh" Geometry "DS0003.png"Figure A1.3. "Mesh" Geometry "DS0004.png"Figure A1.4. "Environment" Geometry "DS0005.png"Figure A1.5. "Environment" Geometry "DS0006.png"Figure A1.6. "Equivalent Stress" Contours "DS0007.png"Figure A1.7. "Equivalent Stress" Contours "DS0008.png"Figure A1.8. "Total Deformation" Contours "DS0009.png"Figure A1.9. "Safety Factor" Contours "DS0010.png"Figure A1.10. "Safety Factor" Contours "Table0001.jpg"Table A2.1. "Thermal Conductivity vs. Temperature" Thermal Conductivity vs. Temperature "Table0002.jpg"Table A2.2. "Alternating Stress vs. Cycles" Alternating Stress vs. Cycles "Table0003.jpg"Table A3.1. "Thermal Conductivity vs. Temperature" Thermal Conductivity vs. Temperature "Table0004.jpg"Table A3.2. "Alternating Stress vs. Cycles" Alternating Stress vs. Cycles "Table0005.jpg"Table A3.3. "Alternating Stress vs. Cycles" Alternating Stress vs. Cycles "Table0006.jpg"Table A3.4. "Alternating Stress vs. Cycles" Alternating Stress vs. Cycles "Table0007.jpg"Table A3.5. "Alternating Stress vs. Cycles" Alternating Stress vs. Cycles "Table0008.jpg"Table A4.1. "Thermal Conductivity vs. Temperature" Thermal Conductivity vs. Temperature

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