ANSYS Guest Lecture by R Bhaskaran

24-March-2014

MAE 3272: Computational Modeling of Bicycle Crank using ANSYS

Rajesh Bhaskaran Mechanical & Aerospace Engineering
Cornell University

My Co-ordinates
Dr. Rajesh Bhaskaran Swanson Director of Engineering Simulation Mechanical & Aerospace Engineering E-mail: bhaskaran@cornell.edu Office: 102 Rhodes Hall Office hours (held in Swanson Lab, 163 Rhodes):
T 3-4 pm, W 3:30-4:30 pm Come for help with ANSYS

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Computer Labs with ANSYS

B7 Upson 318 Phillips ACCEL lab (Carpenter Hall) Swanson Lab (163 Rhodes)

Student Version of ANSYS (including Mechanical & FLUENT)

$25 for one-year license Provides access to all FEA, CFD and rigid-body dynamics capabilities
No CAD translators Limits on mesh size
Mesh size should be sufficient for MAE3272

Purchase instructions will be posted on Blackboard Student version is 15.0. Labs are at 14.5.
You can read 14.5 files into 15.0 but not vice versa

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

ANSYS Node Limits

Node limit for ANSYS Mechanical 32k

Student version

Version in 256k computer labs Research version No limit in Swanson lab

Get vague solution error when you exceed the node limit

Crank Arm Experiment

Strain Gage Rosette

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Testing Procedure
Static Test Dynamic Test

Static Test
Experimental Set-up ANSYS Model

Strain Gage Rosette

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Close-Up View of Sample Rosette Locations

Physical Model ANSYS Model

ANSYS Modeling Procedure for Static Test Case

1. Hand calculations using beam theory 2. Import CAD geometry 3. Mesh, Setup Physics and Solve 4. Check results 5. Add gauges to CAD geometry 6. Calculate strain values for gauges 7. Compare with measured values
Covered in MAE 3250

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Tutorials on ANSYS Modeling Procedure

Google cornell ansys URL: https://confluence.c ornell.edu/x/uhPpB Bike Crank Part 2: Covers ANSYS procedure for adding strain gages to the crank model

ANSYS Modeling Procedure for Static Test Case

1. Hand calculations using beam theory 2. Import CAD geometry 3. Mesh, Setup Physics and Solve 4. Check results 5. Add gauges to CAD geometry 6. Calculate strain values for gauges 7. Compare with measured values

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Hand Calculations
Use Euler-Bernoulli beam theory
See Pre-Analysis step in Bike Crank Part 2 tutorial

ANSYS Modeling Procedure for Static Test Case

1. Hand calculations using beam theory 2. Import CAD geometry 3. Mesh, Setup Physics and Solve 4. Check results 5. Add gauges to CAD geometry 6. Calculate strain values for gauges 7. Compare with measured values

Will focus on these steps

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Static Test: Comparing Strain Measurements to ANSYS Values

Need to extract average normal strain in the area covered by strain gage

Static Test Case: Post-Processing

ANSYS (Blackbox) Post-processing step
Color pictures & other results

User inputs

Mathematical model

Numerical Solution

Displacements at selected points

Postprocessing:
Nodal displacements > , , , , , , w, , > , etc. > , etc. Additional post-processing: , etc. > > average strain over area covered by strain gauge)
Transform and average

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Post-Processing in ANSYS
In ANSYS, use the post-processing capabilities of the shell181 element type to calculate
Model each gauge as one shell181 element
shell181: 4 nodes per element

Post-processing sequence:
Crank nodal displacements > ,w > shell181 nodal displacements shell181 post-processing: nodal displacements > , , w > etc. > > ,

Post-processing in ANSYS
Key point: shell181 nodal displacements are not added to the vector of nodal displacements
Stiffness of gauge is ignored
Thickness of shell181 element is ignored

Original stiffness matrix is not changed

ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Strain Gage Modeling: Procedure

Create surface on crank face
Plane > Sketch > Surface from sketch

Bond surface to crank face

Should happen automatically

Mesh surface with one shell181 element

Insert Commands Tell ANSYS to use shell181 purely for post-processing

Solve and view results

Use solution coordinate system to get strain component in direction
ANSYS will do the transformation and averaging to find

Strain Gage Modeling: Commands

See help for shell181 for more info

et: set element type keyopt: set keyoption to control element behavior

et, matid, 181: set element type to 181 (i.e. shell181) keyopt, matid, 1, 2: set keyoption #1 to 2 (use shell181 elements for post-processing only)

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ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Results: Solution Coordinate System

Local coordinate system for element

Verification of ANSYS Results

Check that:
Boundary conditions on displacement and traction are satisfied Equilibrium is satisfied: Reactions balance applied load ANSYS results are reasonably independent of the mesh ANSYS results compare well with EulerBenoulli beam theory

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ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Verification: Some Sample Results

(microstrains)

ANSYS (0.05 edge sizing) -1240

ANSYS (0.075 edge sizing) -1239

ANSYS (0.1 edge sizing) -1239

Beam Bending Theory -1228

ANSYS vs. Experiment vs. Theory: Sample Results

Strain gauge

Beam theory

ANSYS

Experiment

Rosette 1 Right Rosette 1 Center Rosette 1 Left Rosette 2 Right Rosette 2 Center Rosette 2 Left

12 317 172 -29 6 15

-6 311 206 -42 6 30

-10 4 351 6 274.5 4. -47.75 4 7.75 2 35.5 2

% difference between ANSYS & Expt. 40 11 25 12 22 15

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ANSYS Guest Lecture by R Bhaskaran

24-March-2014

ANSYS vs. Digital Image Correlation (DIC)

DIC: New measurement technique enabled by computers and digital cameras Procedure:
Paint random speckle pattern on surface of part Track the movement of the pattern as part is loaded Deduce displacements and strain

Digital Image Correlation:

ANSYS:

Figures provided by J. Borshoff

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ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Sources of Mismatch Between Measurements and ANSYS

Gauges are placed in regions of low strain
Place gauges away from the neutral axis

Uncertainty in the locations and orientation angles of the gauges

Results are particularly sensitive to the orientation of the gauges

Gauges not glued on correctly Wobble in support used in static test

Not modeled in ANSYS

Dynamic Test
Model as quasi-static since loading rates are low
Freeze-frame loads at any instant and analyze as static Ignores acceleration: Creates bonded contacts at interfaces between parts

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ANSYS Guest Lecture by R Bhaskaran

24-March-2014

Conclusion
Static test: Can get good comparison between ANSYS, strain gauge measurements & beam theory in regions of high strain Dynamic test: Might not get good comparison
Think about possible reasons

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