ANSYS Mechanical Tutorials r170

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ANSYS Mechanical Tutorials

Release 17.0 ANSYS, Inc. January 2016 Southpointe 2600 ANSYS Drive

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Tutorials

This section includes step-by-step tutorials that represent some of the basic analyses you can perform in the Mechanical Application. The tutorials are designed to be self-paced and each have associated geometry input files. You will need to download all of these input files before starting any of the tutorials.

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Actuator Mechanism using Rigid Body Dynamics

This example problem demonstrates the use of a Rigid Dynamic analysis to examine the kinematic behavior of an actuator after moment force is applied to the flywheel.

Features Demonstrated

• Joints • Joint loads • Springs

• Coordinate system definition • Body view

• Joint probes

Setting Up the Analysis System

1. Create the analysis system.

Start by creating a Rigid Dynamics analysis system and importing geometry. a. Start ANSYS Workbench.

b. In the Workbench Project page, drag a Rigid Dynamics system from the Toolbox into the Project

Schematic.

c. Right-click the Geometry cell of the Rigid Dynamics system, and select Import Geometry>Browse. d. Browse to open the Actuator.agdb file. A check mark appears next to the Geometry cell in the

Project Schematic when the geometry is loaded. This file is available on the ANSYS Customer Portal;

go to http://support.ansys.com/training.

2. Continue preparing the analysis in the Mechanical Application.

a. In the Rigid Dynamics system schematic, right-click the Model cell, and select Edit. The Mechanical Application opens and displays the model.

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The actuator mechanism model consists of four parts: (from left to right) the drive, link, actuator, and guide.

b. From the Menu bar, select Units>Metric (mm, kg, N, s, mV, mA).

Note

Stiffness behavior for all geometries are rigid by default.

3. Remove surface-to-surface contact.

Rigid dynamic models use joints to describe the relationships between parts in an assembly. As such, the surface-to-surface contacts that were transferred from the geometry model are not needed in this case. To remove surface-to-surface contact:

a. Expand the Connections branch in the Outline, then expand the Contacts branch. Highlight all of the contact regions in the Contacts branch.

b. Right-click the highlighted contact regions, then select Delete.

Note that this step is not needed if your Mechanical options are configured so that automatic contact detection is not performed upon attachment.

4. Define joints.

Joints will be defined in the model from left to right as shown below, using Body-Ground and

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Prior to defining joints, it is useful to select the Body Views button in the Connections toolbar. The

Body Views button splits the graphics window into three sections: the main window, the reference

body window, and the mobile body window. Each window can be manipulated independently. This makes it easier to select desired regions on the model when scoping joints.

To define joints:

a. Select the drive pin face and link center hole face as shown below, then select Body-Body>Revolute in the Connections toolbar.

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c. Select the link face and actuator center hole face as shown below, then select Body-Body>Revolute in the Connections toolbar.

d. Select the actuator face and the guide face as shown below, then select Body-Body>Translational in the Connections toolbar.

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e. Select the guide top face as shown below, then select Body-Ground>Fixed in the Connections toolbar.

5. Define joint coordinate systems.

The coordinate systems for each new joint must be properly defined to ensure correct joint motion. Realign each joint coordinate system so that they match the corresponding systems pictured in step 4 (p. 2). To specify a joint coordinate system:

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d. Click the desired new axis to realign the joint coordinate system.

e. Select Apply in the Details view once the desired alignment is achieved. 6. Define a local coordinate system.

A local coordinate system must be created that will be used to define a spring that will be added to the actuator.

a. Right-click the Coordinate Systems branch in the Outline, then select Insert>Coordinate System. b. Right-click the new coordinate system, then select Rename. Enter Spring_fix as the name. c. In the Spring_fix Details view, define the Origin fields using the values shown below:

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7. Add a spring to the actuator.

a. Select the bottom face of the actuator as shown below, then select Body-Ground>Spring in the

Connections toolbar.

b. In the Reference section of the spring Details view, set the Coordinate System to Spring_fix. c. In the Definition section of the spring Details view, specify:

Longitudinal Stiffness = 0.005 N/mm Longitudinal Damping = 0.01 N*s/mm

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8. Define analysis settings.

To define the length of the analysis:

a. Select the Analysis Settings branch in the Outline.

b. In the Analysis Settings Details view, specify Step End Time = 60. s 9. Define a joint load.

A joint load must be defined to apply a kinematic driving condition to the joint object. To define a joint load:

a. Right-click the Transient branch in the Outline, then select Insert>Joint Load. b. In the Joint Load Details view, specify:

Joint = Revolute - Ground To Drive Type = Moment

Magnitude = Tabular (Time)

Graph and Tabular Data windows will appear.

c. In the Tabular Data window, specify that Moment = 5000 at Time = 60, as shown below.

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a. Select Solution in the Outline, then select Deformation>Total in the Solution toolbar.

b. In the Outline, click and drag the link to actuator revolute joint to the Solution branch. Joint Probe will appear under the Solution branch.

This is a shortcut for creating a joint probe that is already scoped to the joint in question. Because we want to find the forces acting on this joint, the default settings in the details of the joint probe are used.

c. Click the Solve button in the main toolbar. 11. Analyze the results

a. After the solution is complete, select Total Deformation under the Solution branch in the Outline. A timeline animation of max/min deformation vs. time appears in the Graph window.

b. In the Graph window, select the Distributed animation type button, and specify 100 frames and 4 seconds, as shown below. (These values have been chosen for efficiency purposes, but they can be adjusted to user preference.)

c. Click the Play button to view the animation. d. Select the Joint Probe branch in the Outline,

e. In the Joint Probe Details view, specify X Axis in the Result Selection field. f. Right-click the Joint Probe branch, then select Evaluate All Results.

The results from the analysis show that the spring-based actuator is adding energy in to the system that is reducing the cycle time.

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Nonlinear Static Structural Analysis of a Rubber Boot Seal

Problem Description

This is the same problem demonstrated in Chapter 29: Nonlinear Analysis of a Rubber Boot Seal in the Mechanical APDL Technology Demonstration Guide. The following example is provided only to demonstrate the steps to setup and analyze the same model using Mechanical.

This rubber boot seal example demonstrates geometric nonlinearities (large strain and large deformation), nonlinear material behavior (rubber), and changing status nonlinearities (contact). The objective of this example is to show the advantages of the surface-projection-based contact method and to determine the displacement behavior of the rubber boot seal, stress results.

A rubber boot seal with half symmetry is considered for this analysis. There are three contact pairs defined; one is rigid-flexible contact between the rubber boot and cylindrical shaft, and the remaining two are self contact pairs on the inside and outside surfaces of the boot.

Features Demonstrated

• Hyperelastic Material Creation • Remote Point

• Named Selection

• Manual Contact Generation • Large Deflection

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b. On the Workbench Project page, drag a Static Structural system from the Toolbox to the Project

Schematic.

2. Create Materials.

For this tutorial, we are going to create a material to use during the analysis.

a. In the Static Structural schematic, right-click the Engineering Data cell and choose Edit. The Engineering Data tab opens. Structural Steel is the default material.

b. From the Engineering Data tab, place your cursor in the Click here to add new material field and then enter "Rubber Material".

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c. Expand the Hyperelastic Toolbox menu:

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ii. Enter 1.5 for the Initial Shear Modulus (μ) Value and then select MPa for the Unit.

iii. Enter .026 for the Incompressibility Parameter D1 Value and then select MPa^-1 for the Unit.

d. Click the Return to Project toolbar button to return to the Project Schematic. 3. Attach Geometry.

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b. Browse to the proper folder location and open the file BootSeal_Cylinder.agdb. This file is available on the ANSYS Customer Portal; go to http://support.ansys.com/training.

Define the Model

The steps to define the model in preparation for analysis are described below. You may wish to refer to the Modeling section of Chapter 29: Nonlinear Analysis of a Rubber Boot Seal in the Mechanical

APDL Technology Demonstration Guide to see the steps taken in the Mechanical APDL Application.

1. Launch Mechanical by right-clicking the Model cell and then choosing Edit. (Tip: You can also double-click the Model cell to launch Mechanical).

2. Define Unit System: from the Menu bar, select Units> Metric (mm, kg, N, s, mV, mA). Also select Radians as the angular unit.

3. Define stiffness behavior and thickness: expand the Geometry folder and select the Surface Body object. Set the Stiffness Behavior to Rigid and enter a Thickness value of 0.01 mm.

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4. In the Geometry folder, select the Solid geometry object. In the Details under the Material category, open the Assignment property drop-down list and select Rubber Material.

5. Create a Cylindrical Coordinate System: Right-click the Coordinate Systems folder and select

Insert>Co-ordinate System. Highlight the new CoInsert>Co-ordinate System object, right-click, and rename it to "Cylindrical

Coordinate System".

Specify properties of the Cylindrical Coordinate System:

a. Under the Details view Definition category, change Type to Cylindrical and Coordinate System to

Manual.

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c. Under Principal Axis select Z as the Axis value and set the Define By property to Global Y Axis. d. Under Orientation About Principal Axis, select X as the Axis value and select Global Z Axis for the

Define By property.

6. Insert Remote Point: Right-click on the Model object and select Insert>Remote Point.

7. In Details view, scope the Geometry to cylinder’s exterior surface, set X Coordinate, Y Coordinate, and

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8. Define Named Selections:

a. Right-click on the Model object and select Insert>Named Selection.

b. Select the exterior surface of the cylinder, Apply it as the Geometry, right-click, and Rename it to

Cylinder_Outer_Surface.

c. Right-click on the Surface Body object under the Geometry folder and select Hide Body. This step eases the selection of the boot’s inner surfaces.

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d. Highlight the Named Selection object and select Insert>Named Selection.

e. Select all of the inner faces of the boot seal as illustrated below and scope the faces as the Geometry selection. Make sure that the Geometry property indicates that 24 Faces are selected.

Press the Ctrl key to select multiple surfaces individually or you can hold down the mouse button and methodically drag the cursor across all of the interior surfaces. Note that the status bar at the bottom of the graphics window displays the number of selected surfaces (highlighted in green in the following image).

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g. Again highlight the Named Selection object and select Insert>Named Selection.

h. Reorient your model and select all of the outer faces of the boot seal as illustrated below and scope the faces as the Geometry selection. Make sure that the Geometry property indicates that 27 Faces are selected.

The selection process is the same. Press the Ctrl key to select multiple surfaces individually or you can hold down the mouse button and methodically drag the cursor across all of the surfaces (except the top surface of the boot).

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i. Right-click the new Selection object and Rename it to Boot_Seal_Outer_Surfaces.

9. Insert a Connection Group and Manual Contacts:

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b. Right-click on the Connections Group and select Insert>Manual Contact Region. Notice that Connec-tion Group is automatically renamed to Contacts and that the new contact region requires definiConnec-tion.

c. Create a Rigid-Flexible contact between the rubber boot and cylindrical shaft by defining the following Details view properties of the newly added Bonded-No Selection To No Selection.

• Scoping Method set to Named Selections.

• Contact set to Boot_Seal_Inner_Surfaces from drop-down list of Named Selections. • Target set to Cylinder_Outer_Surface from drop-down list of Named Selections. • Target Shell Face set to Top.

• Type set to Frictional.

• Frictional Coefficient Value equal to 0.2. • Set Behavior set to Asymmetric.

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Note

The name of the contact, Bonded-No Selection To No Selection, is automatically renamed to Frictional - Boot_Seal_Inner_Surfaces To Cylinder_Outer_Surface.

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d. Right-click the Contacts folder object and select Insert>Manual Contact Region. Set Contact at inner surface of the boot seal. In details view of the newly added Bonded-No Selection To No Selection, change the following properties:

• Scope set to Named Selection.

• Contact and Target set to Boot_Seal_Inner_Surfaces. • Type set to Frictional.

• Frictional Coefficient value equal to 0.2.

• Detection Method set to Nodal-Projected Normal From Contact.

Note

The Bonded-No Selection To No Selection is automatically renamed to Frictional

- Boot_Seal_Inner_Surfaces To Boot_Seal_Inner_Surfaces.

e. Right-click the Contacts folder object and select Insert>Manual Contact Region. Set Contact at inner surface of the boot seal. Self Contact at outer surface of the boot seal. In details view of the newly added

Bonded-No Selection To No Selection, specify the following properties:

• Scoping Method set to Named Selection.

• Contact and Target set to Boot_Seal_Outer_Surfaces. • Type set to Frictional.

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Note

BondedNo Selection To No Selection is automatically renamed to Frictional -Boot_Seal_Outer_Surfaces To -Boot_Seal_Outer_Surfaces.

Analysis Settings

The problem is solved in three load steps, which include: • Initial interference between the cylinder and boot.

• Vertical displacement of the cylinder (axial compression in the rubber boot). • Rotation of the cylinder (bending of the rubber boot).

Load steps are specified through the properties of the Analysis Settings object. 1. Highlight the Analysis Settings object.

2. Define the following properties: • Number of Steps equals 3.

• Auto Time Stepping set to On (from Program Controlled). • Define By set to Substeps.

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• Initial Substeps and Minimum Substeps set to 5. • Maximum Substeps set to 1000.

• Large Deflection set to On.

3. For the second load step, define the properties as follows: • Current Step Number to 2.

• Auto Time Stepping set to On (from Program Controlled). • Initial Substeps and Minimum Substeps set to 10. • Maximum Substeps set to 1000.

4. For the third load step, define the properties as follows: • Current Step Number to 3.

• Auto Time Stepping set to On (from Program Controlled). • Initial Substeps and Minimum Substeps set to 20.

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Boundary Conditions

The model is constrained at the symmetry plane by restricting the out-of-plane rotation (in Cylindrical Coordinate System). The bottom portion of the rubber boot is restricted in axial (Y axis) and radial dir-ections (in Cylindrical Coordinate System).

1. Highlight the Static Structural (A5) object and:

• select the two faces (press the Ctrl key and then select each face) of the rubber boot seal as illustrated here.

• right-click and select Insert>Displacement.

2. Set the Coordinate System property to Cylindrical Coordinate System and the Y Component property to 0.

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3. Highlight the Static Structural (A5) object and select the face illustrated here. Insert another Displacement and set the Y Component to 0 (Coordinate System should equal Global Coordinate System).

4. Insert another Displacement scoped as illustrated here and set the Coordinate System property to

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5. Insert a Remote Displacement from the Support drop-down menu on the Environment toolbar.

6. Specify Remote Point as the Scoping Method.

7. Select the Remote Point created earlier (only option) for the Remote Points property.

8. Change the X Component, Y Component, Z Component, Rotation X, Rotation Y, and Rotation Z prop-erties to Tabular (Time) as illustrated below.

9. In the Tabular Data specify:

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• RZ value for Step 3 as 0.55 [rad].

Results and Solution

1. Highlight the Solution and then select Deformation>Total Deformation from the Solution toolbar.

2. Specify the Geometry as the boot body only, and set the Definition category property By as Time and the

Display Time property as Last.

3. Highlight the Solution and then select Stress>Equivalent (von-Mises) from the Solution toolbar. 4. Specify the Geometry as the boot body only, and set the Definition category property By as Time and

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7. Click the Solve button.

Note

• The default mesh settings mesh keep mid-side nodes in elements creating SOLID186 elements (See Solution Information). You can drop mid-side nodes in Mesh Details view under the Advanced group. This allows you to mesh and solve faster with lower order elements.

• Although very close, the mesh generated in this example may be slightly different than the one generated in Chapter 29: Nonlinear Analysis of a Rubber Boot Seal in the Mechanical APDL

Technology Demonstration Guide.

Review Results

The solution objects should appear as illustrated below. You can ignore any warning messages.

For a more detailed examination and explanation of the results, see the Results and Discussion section of Chapter 29: Nonlinear Analysis of a Rubber Boot Seal in the Mechanical APDL Technology

Demonstration Guide.

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Equivalent Elastic Strain at Maximum Shaft Angle (at the end of 3 seconds)

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Cyclic Symmetry Analysis of a Rotor - Brake Assembly

Program Description

This tutorial demonstrates the use of cyclic symmetry analysis features in the Mechanical Application to study a sector model consisting of a rotor and brake assembly in frictional contact. With increased loading of the brake, the contact status between the pad and the rotor changes from “near”, to “sliding”, to “sticking”. Each of these contact states affects the natural frequencies and resulting mode shapes of the assembly. Three pre-stress modal analyses are used to verify this phenomenon.

Features Demonstrated

• Cyclic Regions

• Named Selections based on Criteria

• Thermal Steady-State Analysis with Cyclic Symmetry • Static Structural Analysis with Cyclic Symmetry • Modal Analysis with Cyclic Symmetry

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running the tutorial: “Steady-State and Transient Thermal Analysis of a Circuit Board” before attempting to run this tutorial.

Analysis System Layout

We will tour the different analysis systems that can leverage cyclic symmetry functionality. These comprise thermal, static structural and modal analyses:

• A steady-state thermal analysis will be used to calculate the temperature distribution for the evaluation of any temperature-dependent material properties or thermal expansions in subsequent analyses.

• A nonlinear static structural analysis is configured to represent the mechanical loading of the brake onto the rotor. Nonlinearities from large deformation and changes in contact status are included.

• Modal analyses, each at different stages of frictional contact status, are established to compare the free vi-bration responses of the model.

1. Create the analysis systems.

You need to establish a static structural analysis that is linked to a steady-state thermal analysis, then establish three modal analyses that are linked to the static structural analysis.

a. Start ANSYS Workbench.

b. From the Toolbox, drag a Steady-State Thermal system onto the Project Schematic.

c. From the Toolbox, drag and drop a Static Structural system onto the Steady-State Thermal system such that cells 2, 3, 4, and 6 are highlighted in red.

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e. To measure the free vibration response, go to the Toolbox, drag and drop a Modal system onto the

Static Structural system such that cells 2, 3, 4, and 6 are highlighted in red.

f. Repeat step e (p. 37) two more times to complete adding the remaining analysis systems. The layout of the analysis systems and interconnections in the Project Schematic should appear as shown below.

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a. In the Steady-State Thermal schematic, right-click the Geometry cell, and then choose Import

Geo-metry.

b. Browse to open the file Rotor_Brake.agdb. This file is available on the ANSYS Customer Portal; go to http://support.ansys.com/training.

Define the Cyclic Symmetry Model

We now specify the cyclic symmetry for our quarter sector model (N = 4, 90 degrees) and prepare other general aspects of modeling in the Mechanical application. To setup a cyclic symmetry analysis, Mech-anical uses a Cyclic Region object. This object requires selection of the sector boundaries, together with a cylindrical coordinate system whose Z axis is colinear with the axis of symmetry, and whose Y axis distinguishes the low and high boundaries.

1. Enter the Mechanical Application and set unit systems.

a. In the Steady-State Thermal schematic, right-click the Model cell, and then choose Edit.... The Mechanical Application opens and displays the model.

b. From the Menu bar, choose Units> Metric (mm, kg, N, s, mV, mA) . 2. Define the Coordinate System to specify the axis of symmetry.

a. Right-click Coordinate Systems in the tree and choose Insert> Coordinate System.

b. In the Details view of the newly-created Coordinate System, set Type to Cylindrical and Define By to Global Coordinates.

3. Define the Cyclic Region object.

a. Right-click Model in the tree and choose Insert> Symmetry.

b. Right-click Symmetry and choose Insert> Cyclic Region. The direction of the Y-axis should be compat-ible with the selection of low and high boundaries. The low boundary is designated as the one with a lower value of Y or azimuth.

c. Select the three faces that have lower azimuth for the low boundary. These faces are highlighted in blue in the figure below.

d. Select the three matching faces on the opposite end of the sector for the high boundary. These faces are highlighted in red in the figure below

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4. Define Connections. Frictional contact exists between the rotor and brake pad, whereas bonded contact exists between the wall and the rotor.

a. Expand the Connections folder in the tree, then expand the Contacts folder. Within the Contacts folder, two contact regions were detected automatically and displayed as Contact Region and Contact

Region 2.

b. Right-click the Contacts folder and choose Renamed Based on Definition. The contact region names automatically change to Bonded - Pad to Rotor and Bonded - Blade to Wall respectively.

c. Highlight Bonded - Pad to Rotor and in the Details view, set Type to Frictional. Note that the name of the object changes accordingly.

d. In the Friction Coefficient field, type 0.2 and press Enter.

Note

For higher values of contact friction coefficient a damped modal analysis would be needed. At a level of 0.2 damping effects are being neglected.

Generate the Mesh

In the following section we’ll use mesh controls to obtain a mesh of regular hexahedral elements. The Cyclic Region object will guarantee that matching meshes are generated on the low and high boundaries of the cyclic sector.

Taking advantage of the shape and dimensions of the model, Named Selections will be used to choose the edge selections for each mesh control.

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coordinate system, keeping those in the z-axis range [1mm, 6 mm] (to remove the thickness of the wall). To add rows to the Worksheet, right-click in the table and select the option from the flyout menus. d. Click the Generate button. You should see 11 edges.

e. Rename the object to Edges for Wall Rotor Pad Sector Boundary. The selection should display as follows:

Note

It may be useful to undock the Worksheet window and tile it with the Geometry view as shown above.

2. Insert a Mesh Sizing control.

a. Right-click on Mesh and choose Insert> Sizing. b. Set Scoping Method to Named Selection.

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d. Set its Element Size to 0.5 mm. e. Set Behavior to Soft.

Mesh control: Number of Divisions on Pad-Rotor:

1. Create a Named Selection to pick the circular edges in the orifice of the pad and rotor.

This Named Selection will pick the circular edges in the orifice of the pad and rotor, which is within a radius of 5 mm.

a. Right-click on Model and choose Insert> Named Selection.

b. Highlight the Selection object, and set Scoping Method to Worksheet. c. Rename the object to Edges for Rotor Pad Orifice.

d. Program the Worksheet, as shown below.

e. Click the Generate button. You should see 4 edges.

2. Insert a Mesh Sizing Control as before to select this Named Selection. a. Right-click on Mesh and choose Insert> Sizing.

b. Set Scoping Method to Named Selection.

c. Choose the named selection defined in the previous step. d. Set its Type to Number of Divisions and specify 9. e. Set Behavior to Hard.

Mesh control: Element Size on Wall-Blade

1. Create a Named Selection object to pick the thicknesses of the Wall and Blade. a. Right-click on Model and choose Insert> Named Selection.

b. Highlight the Selection object, and set Scoping Method to Worksheet. c. Rename the object to Edges for Wall Blade Thicknesses.

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c. Choose the named selection defined in the previous step. d. Set its Element Size to 1 mm.

e. Set Behavior to Hard.

Mesh Control: Number of Divisions on Blade - Longer Edges

1. Create a Named Selection object to pick the longer edges of the Blade. a. Right-click on Model and choose Insert> Named Selection.

b. Highlight the Selection object, and set Scoping Method to Worksheet. c. Rename the object to Edges for Blade.

d. Program the Worksheet as shown below.

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1. Create a Named Selection object to pick the shorter edges of the Blade. a. Right-click on Model and choose Insert> Named Selection.

b. Highlight the Selection object, and set Scoping Method to Worksheet. c. Rename the object to Edges for Blade 2.

d. Program the Worksheet as shown below.

Mesh Control: Method on Pad-Rotor-Wall-Blade

1. Insert a Sweep Method control.

a. Right-click Mesh in the tree and choose Insert> Method.

b. Select all the bodies by choosing Edit> Select All from the toolbar, then click the Apply button. c. In the Details view, set Method to Sweep.

d. Set Free Face Mesh Type to All Quad.

Generate the Mesh

• For convenience, select all 6 mesh controls defined, right-click and choose Rename Based on Definition. • Right-click Mesh in the tree and choose Generate Mesh. The mesh should appear as shown below:

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Steady-State Thermal Analysis

We now proceed to define the boundary conditions for a thermal analysis featuring cyclic symmetry. Thermal boundary conditions are prescribed throughout the model while steering clear of the faces comprising the sector boundaries since temperature constraints are already implied there.

1. Define a convection interface.

a. Right-click Steady-State Thermal in the tree and choose Insert> Convection. b. Select the outer faces of the Wall and the Blade as shown in the figure (8 faces).

c. Specify a Film Coefficient of air by right-clicking on the property and choosing Import Temperature

Dependent upon which you choose Stagnant Air - Simplified Case.

2. Insulate the upper and lower faces of the Wall.

• Select the upper and lower faces of the Wall, then right-click and choose Insert> Perfectly Insulated. 3. Apply a temperature load to the Pad and Rotor.

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a. Select the remaining faces on the assembly on the Pad and the Rotor, then right-click and choose Insert>

Temperature. Exclude any faces on the sector boundaries or in the frictional contact.

b. Type 100°C as the Magnitude and press Enter. 4. Solve and review the temperature distribution.

a. Right-click Solution under Steady-State Thermal and choose Insert> Thermal> Temperature. b. Solve the steady-state thermal analysis.

c. Review the temperature result by highlighting the Temperature result object.

Note

Although insignificant in this model, temperature variations and their effect on the structural material properties are generally important to the formulation of physically accurate models.

Static Structural Analysis

In this analysis, the brake is loaded onto the rotor in a single load step. The contact status is monitored at various stages of loading and three points are selected as pre-stress conditions for subsequent

modal analyses. Because both contact and geometric nonlinearities are present, each pre-stress condition will present a different effective stiffness matrix to its corresponding modal analysis.

The solver uses restart points, generated in the static analysis, to record the snapshot of the nonlinear tangent stiffness matrices and transfers them into the subsequent linear systems. This technique is re-ferred to as Linear Perturbation.

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c. Set up the frictionless supports on the faces of Blade, Wall and Pad as shown below.

2. Configure the Analysis Settings. a. Set Auto Time Stepping to On. b. Set Define By to Substeps. c. Set Initial Substeps to 30. d. Set Minimum Substeps to 10. e. Set Maximum Substeps to 30.

f. Set Large Deflection to On to activate geometric nonlinearities.

g. To ensure that Restart Points are generated, under Restart Controls, set Generate Restart Points to

Manual, and request to retain All Files for load steps and substeps. Maximum Points to Save should

also be set to All.

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Reviewing the contact status changes during the course of the load application

The contact status will change with increasing loads from Near, to Sliding, to Sticking. A status change from Near to Sliding reflects the engagement of contact impenetrability conditions (normal direction). A change from Sliding to Sticking, reflects additional engagement of contact friction conditions (tangential direction). This progression will generally reflect an increased effective stiffness in the tangent stiffness matrix, which can be illustrated by a Force-deflection curve:

To review the contact status, insert a Contact Tool in the Solution folder. To display only the contact results at the frictional contact, unselect Bonded - Wall To Blade in the Contact Tool Worksheet. Insert three different Contact Status results with display times at 0.03, 0.5 and 0.8 seconds, which should reveal the progression in contact status as shown below (from left to right):

The legend for these contact status plots is as follows: • Yellow - Near

• Light Orange - Sliding • Dark Orange - Sticking

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Settings object of the Static Structural analysis is selected after solving. Restart points are denoted as

blue triangle marks atop the graph:

To select the restart point of interest, go to the Pre-Stress (Static Structural) object under each Modal

Analysis. Make sure Pre-Stress Define By is set to Time and specify the time. The object will

acknow-ledge the restart point in the Reported Loadstep, Reported Substep and Reported Time fields. Configure the Modal analyses as follows:

• In Modal 1 set Pre-Stress Time to 0.033 seconds. • In Modal 2 set Pre-Stress Time to 0.5 seconds. • In Modal 3 set Pre-Stress Time to 0.8 seconds.

Because the boundary conditions (that is, the frictionless supports) are automatically imported from the static analysis, we can proceed directly to solve.

Solving and Reviewing Modal Results

We'll monitor the lowest frequencies of vibration which belong to Harmonic Indices 0 (symmetric) and 2 (anti-symmetric).

1. Right-click on the Solution folder of each Modal analysis and choose Solve.

2. When the solutions complete, go to the Tabular Data window of each modal analysis. You can inspect the listing of modes and their frequencies. Because our structure has a symmetry of N=4, there will be three solutions, namely for Harmonic Indices 0, 1 and 2.

3. In the Tabular Data window of each modal analysis, select the two rows for Harmonic Index 0 - Mode 1 and Harmonic Index 2 - Mode 1. Right-click and choose Create Mode Shape Results.

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An interesting alternative to this view is to see the sorted frequency spectrum. You may review this by setting the X-Axis to Frequency on any of the Total Deformation results in each modal analysis:

At this point, each modal analysis should have two results for Total Deformation to inspect the first Mode of Harmonic Indices 0 and 2.

Recall the meaning of Harmonic Index solutions and how they apply to the model. Harmonic Index 0 represents the constant offset in the discrete Fourier Series representation of the model and cor-responds to equal values of every transformed quantity, for example, displacements in X, Y and Z directions, in consecutive sectors. Thus deformations that are axially positive in one sector will have the same axially positive value in the next. The following picture compiles, from left to right, the mode shapes for the Near, Sliding and Sticking status at Harmonic Index 0:

Notice how increased engagement of the frictional contact in the assembly has the effect of producing higher frequency vibrations. Also, the mode of vibration goes from being localized at the contact interface when the contact is Near, but is forced to distribute throughout the wall of the rotor as the contact sticks.

Note

You may need to specify Auto Scale on the Results toolbar so the mode shapes are plotted as shown.

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The lowest mode shows nearly independent vibration of the rotor relative to the blade. On the highest mode, sticking reduces this relative movement.

For a continued discussion on post-processing for Cyclic Symmetry and especially on features for postprocessing degenerate Harmonic Indices (those between 0 and N/2), see Reviewing Results

for Cyclic Symmetry in a Modal Analysis in the Mechanical help. End of tutorial.

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Steady-State and Transient Thermal Analysis of a Circuit Board

Problem Description

The circuit board shown below includes three chips that produce heat during normal operation. One chip stays energized as long as power is applied to the board, and two others energize and de-energize periodically at different times and for different durations. A Steady-State Thermal analysis and Transient Thermal analysis are used to study the resulting temperatures caused by the heat developed in these chips.

Features Illustrated

• Linked analyses • Attaching geometry • Model manipulation

• Mesh method and sizing controls • Constant and time-varying loads • Solving

• Time-history results • Result probes • Charts

Procedure

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that cells 2, 3, 4, and 6 are highlighted in red.

d. Release the mouse button to define the linked analysis system.

2. Attach geometry.

a. In the Steady-State Thermal schematic, right-click the Geometry cell, and then choose Import

Geo-metry.

b. Browse to open the file BoardWithChips.x_t. This file is available on the ANSYS Customer Portal; go to http://support.ansys.com/training.

3. Continue preparing the analysis in the Mechanical Application.

a. In the Steady-State Thermal schematic, right-click the Model cell, and then choose Edit. The Mechan-ical Application opens and displays the model.

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Note

You can perform the same model manipulations by holding down the mouse wheel or middle button while dragging the mouse.

c. From the Menu bar, choose Units> Metric (m, kg, N, s, V, A) . 4. Set mesh controls and generate mesh.

Setting a specific mesh method control and mesh sizing controls will ensure a good quality mesh.

Mesh Method:

a. Right-click Mesh in the tree and choose Insert> Method.

b. Select all bodies by choosing Edit> Select All from the toolbar, then clicking the Apply button in the Details view.

c. In the Details view, set Method to Hex Dominant, and Free Face Mesh Type to All Quad.

Mesh Body Sizing – Board Components:

a. Right-click Mesh in the tree and choose Insert> Sizing.

b. Select all bodies except the board by first enabling the Body selection toolbar button, then holding the Ctrl keyboard button and clicking on the 15 individual bodies. Click the Apply button in the Details view when you are done selecting the bodies.

c. Change Element Size from Default to 0.0009 m.

Mesh Body Sizing – Board:

a. Right-click Mesh in the tree and choose Insert> Sizing.

b. Select the board only and change Element Size from Default to 0.002 m.

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5. Apply internal heat generation load to chip.

The chip on the board that is constantly energized represents an internal heat generation load of 5e7 W/m3.

a. Select the chip shown below by first enabling the Body selection toolbar button, then clicking on the chip.

b. Right-click Steady-State Thermal in the tree and choose Insert> Internal Heat Generation. c. Type 5e7 in the Magnitude field and press Enter.

General items to note:

• The applied loads are shown using color coded labels in the graphics. • Time is used even in a steady-state thermal analysis.

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• In a steady-state thermal analysis, the loads are ramped from zero. You can edit the table of load vs. time to modify the load behavior.

• You can also type in expressions that are functions of time for loads. 6. Apply a convection load to the entire circuit board.

The entire circuit board is subjected to a convection load representing Stagnant Air - Simplified Case.

a. Select all bodies by choosing Edit> Select All. b. Choose Convection from the Environment toolbar.

c. Import temperature dependent convection coefficient and choose Stagnant Air - Simplified Case. Note that the Ambient Temperature defaults to 22oC.

i. Click the flyout menu in the Film Coefficient field and choose Import Temperature Dependent (adjacent to the thermometer icon).

ii. Click the radio button for Stagnant Air - Simplified Case, then click OK. 7. Prepare for a temperature result.

The resulting temperature of the entire model will be reviewed.

• Right-click Solution in the tree under Steady-State Thermal and choose Insert> Thermal> Temperature. 8. Solve the steady-state thermal analysis.

• Choose Solve from the toolbar. 9. Review the temperature result.

• Highlight Temperature in the tree.

You have completed the steady-state thermal analysis, which is the first part of the overall objective for this tutorial. You will perform the transient thermal analysis in the remaining steps.

Items to note in preparation for the transient thermal analysis:

• If you highlight Initial Temperature under Transient Thermal in the tree, you will notice in the Details view, the read only displays of Initial Temperature and Initial Temperature Environment. In general, the initial temperature can be:

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By default the last set of results from the steady-state analysis will be used as the initial condition. You can specify a different set (different time point) if multiple result sets are available.

10. Specify a time duration for the transient analysis.

A time duration of the transient study will be 200 seconds.

• Under Transient Thermal, highlight the Analysis Settings object and enter 200 in either the Step End

Time field in the Details view or in the End Time column in the Tabular Data window. Also note and

accept the default initial, maximum, and minimum time step controls for this analysis.

11. Apply internal heat generation to simulate on/off switching on first chip.

A chip on the board is energized between 20 and 40 seconds and represents an internal heat gen-eration load of 5e7 W/m3 during this period.

a. Select the chip shown below by first enabling the selection toolbar button, then clicking on the chip.

b. Right-click Transient Thermal in the tree and choose Insert> Internal Heat Generation. c. Enter the following data in the Tabular Data window:

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• Time = 0; Internal Heat Generation = 0

Note

Enter each of the following sets of data in the row beneath the end time of 200 s.

• Time = 20; Internal Heat Generation = 0 • Time = 20.1; Internal Heat Generation = 5e7 • Time = 40; Internal Heat Generation = 5e7 • Time = 40.1; Internal Heat Generation = 0

The Graph window reflects the data that you entered.

General items to note:

• Loads can be specified as one of three types:

– Constant – remains constant throughout the time history of the transient. – Tabular (Time) – (as in this example) define a table of load vs. time.

– Function – enter a function such as “=10*sin(time)” to define a variation of load with respect to time. The function definition requires you to start with a ‘=‘ as the first character.

12. Apply internal heat generation to simulate on/off switching on second chip.

Another chip on the board is energized between 60 and 70 seconds and represents an internal heat generation load of 1e8 W/m3 during this period.

a. Select the chip shown below by first enabling the Body selection toolbar button, then clicking on the chip.

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b. Right-click Transient Thermal in the tree and choose Insert> Internal Heat Generation. c. Enter the following data in the Tabular Data window:

• Time = 0; Internal Heat Generation = 0

Note

Enter each of the following sets of data in the row beneath the end time of 200 s.

• Time = 60; Internal Heat Generation = 0 • Time = 60.1; Internal Heat Generation = 1e8 • Time = 70; Internal Heat Generation = 1e8 • Time = 70.1; Internal Heat Generation = 0

The Graph window reflects the data that you entered.

13. Prepare for a temperature result.

The resulting temperature of the entire model will be reviewed.

• Right-click Solution in the tree under Transient Thermal and choose Insert> Thermal> Temperature. 14. Solve the transient thermal analysis.

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• Click the right mouse button again on Solution and choose Solve. The solution is complete when green checks are displayed next to all of the objects. You can ignore the Warning message and click the Graph tab.

15. Review the time history of the temperature result for the entire model.

• Highlight the Temperature object. The time history of the temperature result for the entire model is evaluated and displayed.

– The Tabular Data window shows the min/max values of temperature at a time point.

– By moving the mouse, you can move the bar along the Graph as shown, to any time, click the right mouse button and Retrieve this Result to review the results at a particular time.

– You can also animate the solution.

16. Review the time history of the temperature result for each of the chips.

Temperature probes are used to obtain temperatures at specific locations on the model. a. Right-click Solution and choose Insert> Probe> Temperature.

b. Select the chip to which internal heat generation was applied in the steady state analysis and click the

Apply button in the Details view.

c. Follow the same procedure to insert two more probes for the two chips with internal heat generations in the transient thermal analysis.

d. Right-click Solution or Temperature Probe and choose Evaluate All Results.

17. Plot probe results on a chart.

a. Select the three temperature probes in the tree and select the New Chart and Table button from the toolbar.

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b. Right-click in the white space outside the chart in the Graph window and choose Show Legend.

c. In the Details view, you can change the X Axis variable as well as selectively omit data from being dis-played.

You have completed the transient thermal analysis and accomplished the second part of the overall objective for this tutorial.

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Thermal Induced Stresses on a PCB

Problem Description

This tutorial describes the steps to perform a thermal-structural simulation of a printed circuit board using ANSYS SpaceClaim and ANSYS Mechanical.

The tutorial shows you how to 1.) prepare a geometry in ANSYS SpaceClaim so that it works in cooper-ation with the Trace Mapping feature of ANSYS Mechanical and 2.) demonstrates the use of the Trace Import feature by examining the warpage (deformation) of a simply supported printed circuit board (PCB) as a result of uniform thermal loading.

Features Demonstrated

• Engineering Data/Materials • Static Structural Analysis

• Electronic Computer-Aided Design (ECAD) • Trace Mapping

Procedure

1. Set Up the Analysis.

a. Open ANSYS Workbench.

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b. Select and delete Structural Steel (right-click>Delete), the default material.

c. Select the Engineering Data Sources button on the toolbar.

d. From the General Material library, add FR4 (Dialectic Material) and Copper Alloy using the plus sign button in the Add column. A book icon displays in the Add column when you select the material.

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e. Select the Engineering Data Sources button. The new materials display in the Outline of Schematic

Pane and will now be available in Mechanical.

f. Return to the Workbench Project page. 3. Define Geometry.

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The SpaceClaim application opens. b. In SpaceClaim, select File>Open.

c. From the Open dialog box, select the Options button and verify that the Layer Topology option is se-lected under File Options>ECAD. Click Ok.

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d. From the Open dialog box, import the geometry file provided: file name ECAD_Tutorial.tgz. This file is available on the ANSYS Customer Portal.

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e. Uncheck the Components (STP) object in the tree. They will not be needed in Mechanical. Select and view the geometries as desired.

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g. Save the file as ECAD_Tutorial_File.scdoc. h. Return to the Workbench Project page.

4. Import the Geometry into Mechanical.

a. Place an External Data system into the project and drag it in front of the Static Structural system.

b. Right-click on the Setup cell and select Edit.

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d. Select the row for the file in the Outline to display the properties. As needed, specify ODB++TGZ for the Format Type. Note the default Identifier, File1.

e. Return to the Workbench Project page. f. Select the Update Project button.

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h. Right-click on the Geometry cell and browse (Import Geometry>Browse) to the geometry file you saved in SpaceClaim (ECAD_Tutorial_File.scdoc) and open it.

i. Right-click on the Model cell and select Edit to open the files in Mechanical.

5. Specifying Materials. In Mechanical you will note that the Geometry object is underdefined.

a. Open the STP object and select all of the child objects. Select FR-4 from the drop-down list of the

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b. Open the Imported Trace folder and select the Imported Trace object. c. Right-click in the Geometry window and select the option Select All.

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d. Click the Geometry property in the Details view and click Apply. Seven bodies are specified for the

Geometry property.

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f. In the Imported Trace Data View, select the Trace Material field and specify Copper Alloy.

g. Once specified, right-click on the field again and select Copy. Select the remaining Trace Material fields using the Shift key, right-click again, and select paste.

All of the remaining cells populate with the Copper Alloy material.

6. Define Trace Properties.

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b. Set the Display Source Points property to On to view the alignment of the source points provided by the trace layout files. Rotate the model and zoom in to view the points. Once you have finished, return the Display Source Points property to the Off setting.

Note

If you ever encounter misaligned source points in a simulation, you can use the Rigid Transformation controls in the External Data system to align the source mesh with the target.

7. Define Mesh Properties. a. Select the Mesh object.

b. Under the Sizing category, specify the Relevance Center property as Fine and the Element Size as

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c. Right-click on the Imported Trace object and select the Import Trace option. This mapping process will take several moments to complete. Once complete the mapping should appear as illustrated in the following image.

8. Specify Boundary Conditions.

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b. Apply Displacement boundary conditions to the bottom two corners illustrated below. Specify a 0mm

displacement for the Y Component and Z Component of the first displacement and a 0mm displacement for the Z Component of the second displacement.

c. Apply a Thermal Condition load to all bodies (Ctrl+A) of the model and specify a temperature mag-nitude of 50°.

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10. Generate Solution and Define Results.

a. Solve the analysis. This process will take several minutes. b. Apply results as desired.

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Delamination Analysis using Contact Based Debonding Capability

Problem Description

This tutorial demonstrates the use of Contact Debonding feature available in Mechanical by examining the displacement of two 2D parts on a double cantilever beam. This same problem is demonstrated in

VM255 in the ANSYS Mechanical APDL Verification Manual. The following example is provided to

demonstrate the steps to setup and analyze the same model using Mechanical.

As illustrated below, a two dimensional beam has a length of 100mm and an initial crack of length of 30mm at the free end that is subjected to a maximum vertical displacement (U_max) at the top and bottom of the free end nodes. Two vertical displacements, one positive and one negative, are applied to determine the vertical reaction at the end point. The point of fracture is at the vertex of the crack and the interface edges.

This tutorial also examines how to prepare the necessary materials that work in cooperation with the Contact Debonding feature.

Features Demonstrated

• Engineering Data/Materials • Static Structural Analysis

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a. Open ANSYS Workbench.

b. On the Workbench Project page, drag a Static Structural system from the Toolbox to the Project

Schematic. The Project Schematic should appear as follows. The properties window does not display

unless you have made the required selection; right-click a cell and select Properties.

2. Define materials.

a. In the Static Structural schematic, right-click the Engineering Data cell and choose Edit. The Engin-eering Data tab opens and displays Structural Steel as the default material.

b. Click the box below the field labeled "Click here to add new material" and enter the name "Interface Body Material".

c. Expand the Linear Elastic option in the Toolbox and right-click Orthotropic Elasticity. Select Include

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d. Define the new material by entering the following property values and units of measure into the cor-responding fields. Unit Value Property MPa 1.353E+05

Young’s Modulus X Direction

MPa 9000

Young’s Modulus Y Direction

MPa 9000

Young’s Modulus Z Direction

NA 0.24 Poisson’s Ratio XY NA 0.46 Poisson’s Ratio YZ NA 0.24 Poisson’s Ratio XZ MPa 5200 Shear Modulus XY MPa 0.0001 Shear Modulus YZ MPa 0.0001 Shear Modulus XZ

Once complete, the properties for the material should appear as follows.

e. Now you need to create a new Material that specifies the formulation used to introduce the fracture mechanism. For this tutorial, the Cohesive Zone Material (CZM) method is used. Click the field labeled "Click here to add new material" and enter the name “CZM Crack Material”.

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f. Expand the Cohesive Zone option in the Toolbox and right-click Fracture-Energies based Debonding. Select Include Property. The required properties for the material are highlighted in yellow.

g. Define the new material by entering the following property values and units of measure into the cor-responding fields. Unit Value Property NA No

Tangential Slip Under Normal Compression

Pa 1.7E+06 Maximum Normal Contact Stress

J m^-2 280

Critical Fracture Energy for Normal Separation

Pa 1E-30 Maximum Equivalent Tangential Contact

Stress

J m^-2 1E-30

Critical Fracture Energy for Tangential Slip

s 1e-8 Artificial Damping Coefficient

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3. Attach geometry.

a. In the Static Structural schematic, right-click the Geometry cell and choose Import Geometry>Browse. b. Browse to the proper location and open the file 2D_Fracture_Geom.agdb. This file is available on

the ANSYS Customer Portal; go to http://support.ansys.com/training.

c. Right-click the Geometry cell and select Properties. In the Properties window, set the Analysis Type property to 2D.

The Project Schematic should appear as follows:

4. Launch Mechanical. Right-click the Model cell and then choose Edit. (Tip: You can also double-click the cell to launch Mechanical).

5. Define unit system. From the menu bar in Mechanical, select Units>Metric (mm, kg, N, s, mV, mA). 6. Define 2D behavior.

a. Select the Geometry folder.

b. In the Details pane, set the 2D Behavior property to Plane Strain. This constrains all of the UZ degrees of freedom. See the 2D Analyses section of the Mechanical User's Guide for additional information about this property.

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7. Apply material.

a. Expand the Geometry folder and select the Part 2 folder.

b. In the Details pane, set the Assignment property to Interface Body Material. Selecting the Part folder allows you to assign the material to both parts at the same time.

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a. Expand the Connections folder and the Contacts folder. A Contact Region object was automatically generated for the entire interface of the two parts.

b. Select the Edge selection filter (on the Graphics Toolbar) and highlight an edge in the center of the model. Using the Depth Picking tool, select the first rectangle in the stack, and then scope the edge as the geometry (Apply in the Contact property).

This tutorial employs the Depth Picking tool because of the close proximity of the two edges involved in the interface. As illustrated here, the graphics window displays a stack of rectangles in the lower left corner. The rectangles are stacked in appearance, with the topmost rectangle representing the visible (selected) geometry and subsequent rectangles representing additional geometry selections. For this example, the topmost geometry is the "high" edge.

c. Select the Edge selection filter and highlight an edge in the center of the model. Using the Depth Picking tool, select the second rectangle in the stack, and then scope the edge as the geometry (Apply in the Target property).

Verify that Bonded is selected as the contact Type and that Pure Penalty is set as the

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d. Rename the contact "Body".

9. Define Mesh Options and Controls.

a. Select the Mesh object. Define the following Mesh object properties: • Set Use Advanced Size Function (Sizing category) to Off.

• Enter an Element Size (Sizing category) of 0.750.

• Set Element Midside Nodes (Advanced category) to Kept.

b. Right-click the Mesh object and select Insert>Sizing. This mesh sizing control should be scoped to the four side edges.

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c. In the Details view, enter 0.75 mm as the Element Size.

d. Select the Edge selection filter (on the Graphics Toolbar) and highlight an edge in the center of the model. Use the Depth Picking tool and, holding the Ctrl key, select both rectangles in the lower left corner of the graphics window. Continue to hold the Ctrl key, and select an edge of the crack. Again, use the Depth Picking tool and select both rectangles in the lower left corner of the graphics window. Still holding the Ctrl key, select the top and bottom edges on the model.

e. Right-click the Mesh object and select Insert>Sizing. This mesh sizing control should be scoped to six (top and bottom and the four interface edges) edges.

f. In the Details view, enter 0.5 mm as the Element Size. g. Right-click the Mesh object and select Generate Mesh. 10. Specify Contact Debonding object.

a. Insert a Fracture folder into the tree by highlighting the Model object and then selecting the Fracture button on the Model Context Toolbar.

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b. Right-click and select Insert>Contact Debonding. You could also select the Contact Debonding button on the Fracture Context Toolbar.

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d. In the Details pane, set the Contact Region property to Body.

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11. Configure the Analysis Settings. a. Select the Analysis Settings object.

b. Set the Auto Time Setting property to On and then enter 100 for the Initial Substeps, Minimum

Substeps, and Maximum Substeps properties.

12. Apply boundary conditions.

a. Select the Edge selection filter and select the two edges on the side of the model that is opposite of the crack. Select one edge, press the Ctrl key, and then select the next edge.

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b. Highlight the Static Structural object, select the Supports menu on the Environment Context Toolbar, and then select Fixed Support.

c. Highlight the Static Structural object. With the Vertex selection filter active, select the vertex illustrated below, select the Supports menu and then select Displacement.

In the Details pane, enter 10 (mm in the positive Y direction) as the loading value for the Y

Component property.

d. Create another Displacement. With the Vertex selection filter active, select the bottom vertex, and then select Supports>Displacement. Enter -10 (mm in the negative Y direction) as the loading value for the Y Component property.

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13. Specify result objects and solve.

a. Highlight the Solution object, select the Deformation menu on the Solution Context Toolbar, and then select Directional Deformation.

b. Under the Definition category in the Details view, set the Orientation property to Y Axis.

c. Highlight the Solution object, select the Probe menu on the Solution Context Toolbar, and then select

Force Reaction.

d. Select Displacement for the Boundary Condition property of the probe. e. Click the Solve button.

14. Review the results. Highlight the Directional Deformation and Force Reaction objects. Results appear as follows:

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You may wish to validate results against those outlined in the verification test case (VM255 in the ANSYS

Mechanical APDL Verification Manual). This is most easily accomplished by creating User Defined Results

using the Worksheet.

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ANSYS Mechanical Tutorials r170