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Ulf Sellgren KTH Machine Design School of Industrial Engineering and Management
MF2024 Robust and probabilistic design School of Industrial Engineering and Management November 2010
The exercise
The exercise requires (Ansys) Mechanical APDL 12.0 It is a group exercise (2 persons per group) Set up and run a probabilistic simulation of a simple snap fastener feature with Ansys Modify the probabilistic input parameters to make the output parameters satisfy the probabilistic requirements and constraints
nslk,s ! select node at point *get,nodnum,node,0,num,min DISP=abs(uy(nodnum)) W=Px ksel,all nsel,all finish
The FE model is a simple 2-D representation of a snap fastener mating feature (see figure 2). There are five design parameters (Length, Height, Width, Step, and Emod), which all are supposed to be randomly Gaussian distributed, and also the coefficient of friction (or Mu) and the mating height DELTA between the two mating features. is supposed to be uniformly distributed, while DELTA has a Gaussian distribution. The axial snap force W is searched for.
Figure2. The two snap fastener mating features (top), with the left one modeled and analyzed (bottom left).
2. Open Ansys 12 (Mechanical APDL) and execute Snaper.inp in the command window.
Start Mechanical APDL (Ansys Academic ) from the Mechanical APDL Product Launcher be sure to use the directory that contains the macro file as working directory (see figure 3).
Figure3. Open Ansys from the Mechanical APDL Product Launcher. The macro file Snaper.inp is executed by typing the command: /input,Snaper,inp
The macro file creates the FE model, defines the boundary conditions, performs a static simulation, plots the elastic strain in length direction (see figure 5) and stores the axial snap force and the maximum axial strain in the parameters W and STRAIN, respectively.
Figure 5. The strain results plotted as specified at the end of the macro Snaper.inp Scrutinize the input file and the results. Try to understand the simulated case.
3. Enter the Probabilistic Design module in Ansys and define the random input.
Select Random Input.in the Prob Definitns menu (see figure 6).
Figure 6. The Probabilistic Design module In the screen shots below, the geometric parameter LENGTH is defined as a random Gaussian variable with mean values 0.019 m and standard deviation 0.001 m. HEIGHT, WIDTH and STEP are also defined as random Gaussian variables, but with mean values 0.0035 m, 0.0095 m, and 0.0015 m, respectively and the standard deviations 0.0001 m. Furthermore, the ANGLE and EMOD (Youngs modulus) parameters are also defined as random Gaussian parameter with mean values 20 degrees and 2.2 GPa, respectively and the standard deviations 0.1 degrees and 0.1 GPa. The interaction parameter DELTA is defined as a random Gaussian variable with mean value 0.0015 m and standard deviation 0.0005 m. MU (coefficient of friction ) is defined as a random parameter with a uniform distribution between 0.54 and 0.66.
Figure 7. Add LENGTH as a random input variable Also add the other random input variables.
Figure 10. Chose the probabilistic design general options and output.
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Select Monte Carlo simulations as the probabilistic method, as shown in figure 11.
Figure 11. Define the options for the Monte Carlo simulations.
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Figure 12. Assign the Ansys input macro file, with the design parameter definitions removed.
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Figure 14. Sensitivity trends plotted for the random output snap force W.
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Figure 15. Sensitivity trends plotted for the random output axial strain STRAIN.
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Figure 16. Write the HTML report. In this case, the report SnapReport is create as a web-page in the subfolder SnapReport.
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11. Fill in the Exercise Word-template, pack the generated final HTML report folder and append them to an e-mail to mf2024@md.kth.se.
Add your results to the Exercise 2 Word-template, and zip the folder with the final Ansys HTML report for the Monte Carlo simulation where the reliability requirements are met, and append them both to an e-mail to mf2024@md.kth.se Your results should include 1. A table with the mean values of your input random variables and their standard deviation values. 2. The computed mean and standard deviation for the random output parameters. 3. Sensitivity plots for the two output parameters 4. A description of how the requirements for W and STRAIN and the cost constraint are satisfied. 5. A reflection on the model errors and how they could be addressed. 6. Dont forget to add your names on the front page. Your e-mail must include: 1. The subject: Exercise 2 2. Your exercise 2 results (in the Word-template) 3. A zip-file with your Ansys HTML report. 4. Your names.
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