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.

3.1.1. Contact

• "Contact" uses a tolerance of 0.0 for automatic detection.
• "Contact" is set to use symmetric contact.

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

3.2.2. Structural Supports

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

• Convergence tracking not enabled.

3.3.2. Equivalent Stress Safety

• 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"

• 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"

• 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_Alloy.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"

• Material data file: "C:\Program Files\ANSYS Inc\v71\AISOL\CommonFiles\Language\en-us\EngineeringData\Materials\Titanium_Alloy.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\".