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Structural Model Simulation Workshop: Basics & Environment Setup

Learn to set up and solve a stress and deflection model using Workbench Simulation, with details on goals, assumptions, and preprocessing steps. Understand frictionless supports and weak springs to ensure accurate results.

jclifford
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Structural Model Simulation Workshop: Basics & Environment Setup

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  1. Workshop 2 Workbench - Simulation Basics

  2. Notes on Workshop 2 • The first workshop is extensively documented. As this course progresses, students will become more familiar with basic Workbench Simulation functionality (menu locations etc.), thus subsequent workshops will contain less details. • Throughout these workshops menu paths are documented as: “First pick > Second pick > etc.”. • Workshops begin with a goals section followed by an assumptions section. August 26, 2005 Inventory #002266 WS2-2

  3. Workshop 2 - Goals • Using the Stress Wizard, set up and solve a structural model for stress, deflection and safety factor. • Problem statement: • The model consists of a Parasolid file representing a control box cover (see figure). The cover is intended to be used in an external pressure application (1 Mpa/145 psi). • The cover is to be made from aluminum alloy. • Our goal is to verify that the part will function in its intended environment. August 26, 2005 Inventory #002266 WS2-3

  4. Workshop 2 - Assumptions • We will represent the constrains on the counter bores, bottom contact area and inner sides using frictionless supports. • Frictionless supports place a normal constraint on an entire surface. Translational displacement is allowed in all directions except into and out of the supported plane. Since we would expect frictional forces to at contact areas this is a conservative approach. August 26, 2005 Inventory #002266 WS2-4

  5. Workshop 2 - Start Page • From the launcher start Simulation. • Choose “Geometry > From File . . . “ and browse to the file “Cap_fillets.x_t”. • When Workbench - Simulation starts choose “Structural Branch” under Outline Branch Macros, “Ductile Materials” under “New Structural Simulation” and click Run. August 26, 2005 Inventory #002266 WS2-5

  6. Workshop 2 - Environment • Loads: the load consists of a 1 MPa pressure applied to the 17 exterior surfaces of the cover. August 26, 2005 Inventory #002266 WS2-6

  7. . . . Workshop 2 - Environment • Supports: As described earlier frictionless supports are applied on 3 different regions of the model. • Note: the use of all frictionless surfaces will trigger the message shown here: • Workbench Simulation automatically places weak springs on structural models where the potential of rigid body motion exists. An inspection of the boundary conditions on this model should confirm that rigid body motion is prevented. In this case the weak springs have no effect on the results. • This is an informational warning that the model should be inspected. It does NOT indicate the solution is invalid. • The weak spring feature can be configured on/off by the user. August 26, 2005 Inventory #002266 WS2-7

  8. Workshop 2 - Preprocessing Setup working unit system: • From the main menu go to “Units > Metric (mm, Kg, N, °C, s). August 26, 2005 Inventory #002266 WS2-8

  9. . . . Workshop 2 - Preprocessing • From the Simulation Wizard choose “Verify Material”. Locate the “Material” detail field and choose to “Import…” > “Aluminum Alloy”. • Notice that verifying and changing material automatically highlighted the part branch in the tree. August 26, 2005 Inventory #002266 WS2-9

  10. . . . Workshop 2 - Preprocessing Loads: Select the 17 exterior surfaces of the cover. To simplify selection • Select 1 surface (choice is arbitrary). • Click “Extend to Limits” to select the remaining 16 surfaces. 4 3 August 26, 2005 Inventory #002266 WS2-10

  11. 7 6 5 . . . Workshop 2 - Preprocessing Loads Continued: • Choose “Insert Loads” from the SimWiz. • Structural > Pressure. • Enter a Magnitude of 1 Mpa in the Details window. August 26, 2005 Inventory #002266 WS2-11

  12. . . . Workshop 2 - Preprocessing Supports (counter bores): • Select the 4 counter bore surfaces (figure below shows 1). • Choose “Insert Supports” from the SimWiz. • Structural > Frictionless Support 10 9 8 August 26, 2005 Inventory #002266 WS2-12

  13. . . . Workshop 2 - Preprocessing Supports (inner sides): • Select one of the inside surfaces of the bottom recess. Click the “Extend to Limits” button to add the remaining 7 surfaces to the selection set (8 total). • Choose “Insert Supports” from the SimWiz. • Structural > Frictionless Support 11 13 12 August 26, 2005 Inventory #002266 WS2-13

  14. 14 16 15 . . . Workshop 2 - Preprocessing Supports (bottom): • Select the surface at the bottom of the recess. • Choose “Insert Supports” from the SimWiz. • Structural > Frictionless Support August 26, 2005 Inventory #002266 WS2-14

  15. Workshop 2 - Solution • From the SimWiz choose “Solve”. The callout will direct you to the solve icon at the top of the GUI. Alternately you could right click on any branch in the tree and choose “solve”. 17 August 26, 2005 Inventory #002266 WS2-15

  16. Workshop 2 - Results • From the SimWiz choose “View Results”. The call out will direct you to the Solution branch. Selecting various results branches will cause that result to be plotted (see next page). 18 August 26, 2005 Inventory #002266 WS2-16

  17. . . . Workshop 2 - Results • Plotting a model’s deformation often provides a “reality check” in structural analysis. Verifying the general nature (direction and amount) of deflection can help avoid obvious mistakes in model setup. Animations are often used as well. August 26, 2005 Inventory #002266 WS2-17

  18. . . . Workshop 2 - Results • After reviewing stress results expand the safety tools and plot safety factors and margins. Notice both failure theories predict a minimum safety factor of < 1. August 26, 2005 Inventory #002266 WS2-18

  19. Workshop 2 - Report • To create an html report first click the “Report Preview” tab. The customization page allows you to set up the report. • At this point simply choose “Generate Report” to review the default setup. August 26, 2005 Inventory #002266 WS2-19

  20. . . . Workshop 2 - Report • When the report generation is complete scroll through the report and review its contents. • Notice at this point there are no graphic images. Return to the “Geometry” tab to insert figures. August 26, 2005 Inventory #002266 WS2-20

  21. . . . Workshop 2 - Report • Choose the graphical items you wish to include in your report by first highlighting the branch and orienting the plot. • Next right click and insert a figure. • The next time the report is generated the figures will be included. August 26, 2005 Inventory #002266 WS2-21

  22. . . . Workshop 2 - Report Notes on Figures: • Figures are not limited to results items. Adding a plot of the environment branch, for example, will include an image of model boundary conditions in the Report. • Figures are independent. You may set up individual figures and have their orientation, zoom level, etc. retained regardless of the active model orientation or other figures. • Individual branches can have multiple figures associated with them. August 26, 2005 Inventory #002266 WS2-22

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