Finite Element Analysis in Practice: Instructor Manual

Finite Element Analysis
in Practice
Instructor Manual
Based on: Autodesk Algor Simulation

Professional 2011
II FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
2010 Autodesk, Inc. All rights reserved.
Finite Element Analysis in Practice Instructor Manual

Based on: Autodesk Algor Simulation Professional 2011
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reproduced in any form, by any method, for any purpose.
Certain materials included in this publication are reprinted with the permission of the copyright
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FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 III
IV FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
TABLE OF CONTENTS
COURSE INTRODUCTION:
Overview .....................................................................................................VII
Software Installation, Services, and Support ..............................................VII
Installing and Running Autodesk Algor Simulation........................................VII
System Requirements....................................................................................VIII
Autodesk Algor Simulation Help ...................................................................... IX
Subscription Center ......................................................................................... X
Web Links ........................................................................................................ X
Tutorials .......................................................................................................... XI
Webcasts and Web Courses........................................................................... XI
How to Receive Technical Support ................................................................. XI
Updates ..........................................................................................................XII
Navigating the User Interface .....................................................................XII
Toolbars........................................................................................................ XIV
Using the Keyboard and Mouse ..................................................................... XV
Introduction to the ViewCube ........................................................................ XVI
Additional View Controls .............................................................................. XVII
Legacy View Controls in Autodesk Algor Simulation ................................... XVIII
Notes Concerning the Steps for Exercises Section .............................. XVIII
PRESENTATION SLIDESHOW:
Introduction ................................................................................................... 3
FEA Overview and Examples using Autodesk Algor Simulation................. 8
Introductory Example .................................................................................. 12
FEA Concepts............................................................................................. 16
Exercise A - FEA Example by Hand ..............................................................25
Analysis Options ......................................................................................... 30

Element Options ......................................................................................... 36
Meshing and Modeling ................................................................................ 37
Loads and Constraints ................................................................................ 41
Truss Elements ........................................................................................... 49
Exercise B - Truss Frame Model....................................................................50
Beam Elements .......................................................................................... 51

Exercise C - Support Beam Under Gravity .....................................................53
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 V
2-D Elements .............................................................................................. 54
Exercise D - Axisymmetric Thick-walled Cylinder ...........................................56
Plate/Shell Elements ................................................................................... 56

Exercise E - Plate Under Uniform Pressure ...................................................59
Brick Elements ............................................................................................ 59

Exercise F - Cantilever Beam Model ..............................................................60
Comparing Element Types ......................................................................... 61

Exercise G - Comparing Element Types ........................................................61
Mesh Convergence ..................................................................................... 62

Exercise H - Mesh Convergence....................................................................64
Meshing CAD Solid Models ........................................................................ 65

Exercise I - Bracket Model .............................................................................67
Exercise J - Hanger Assembly Model ............................................................69
Combining Element Types .......................................................................... 69

Contact ....................................................................................................... 71
Exercise K - Linear Contact Model.................................................................72
Solving Options ........................................................................................... 73

Results Evaluation ...................................................................................... 74
Presentation of Results ............................................................................... 77
Other Analysis Types .................................................................................. 80
Thermal Analysis ................................................................................... 81
Exercise L - Thermal Model .....................................................................85
Electrostatic Analysis ............................................................................. 86

Fluid Flow Analysis ................................................................................ 89
Mechanical Event Simulation (MES) ..................................................... 92
Exercise M - Nonlinear Material Model .................................................. 101
Combining Analysis Types (Multiphysics) ................................................. 103

Material Models ........................................................................................ 105
Exercise N - Mechanical Event Simulation, Geneva Mechanism ................ 107
STEPS FOR EXERCISES .......................................................... SE.1
VI FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
Overview
This course will introduce the students to the analysis products available within Autodesk
Algor Simulation Professional and the proper usage of these tools. The program
capabilities include static stress with linear and nonlinear material models, mechanical event
simulation, heat transfer, fluid flow, linear dynamics, natural frequency (modal) analysis with
nonlinear materials, transient mass transfer, and electrostatics analyses. The course will
utilize hand-built models and those originating from CAD solid modeling programs. The
students will learn basic Finite Element Analysis (FEA) theory, the various meshing options,
available load and constraint options, and how to create results presentations (including
images, animations, and HTML reports). The Finite Element Analysis in Action course
curriculum is organized into three main sections, as follows.
This Course Introduction section contains necessary prerequisite information concerning

software installation and configuration, how to obtain updates and technical support, and
basics concerning the user interface. The program emulates the view orientations and
mouse actions of many popular CAD packages. However, the procedures detailed within
this course are all based on the default Algor Simulation settings for the views and mouse
functions. Please ensure that all student workstations are set up accordingly so that the
software behavior will be consistent with the text.
The Presentation Slideshow is provided in two forms. Within the second section of this
Instructor Manual, the slides are presented in handout fashion, two per page. In addition, a
separate Microsoft PowerPoint presentation is included for classroom projection.
The Steps for Exercises section includes descriptions of all of the exercises included
within the slideshow presentation along with keystroke-specific procedures for correctly
completing the exercises.
Software Installation, Services, and Support
Installing and Running Autodesk Algor Simulation
The simulation software is distributed on DVDs with the exception of software for the Linux
platform, which is distributed on CDs. In addition, the software may be downloaded from the
Autodesk website. When you place the software DVD into a DVD-ROM drive, a launch
dialog having four options will appear. If you want to set up the software on a client
workstation, whether you will be using a license locked to a single computer or a network
license, press the "Install Products" button. If using a network license, you must already
have the license server software installed to a computer on the network. If you wish to create
pre-configured deployments for installing the product on multiple client workstations, choose
the "Create Deployments" command. If you want to set up the computer as a license server
to control the number of concurrent users through a network, or, if you wish to install optional
reporting tools, press the "Install Tools and Utilities" command. Finally, a fourth command
on the launch screen, "Read the Documentation," leads to a screen from which you can
access a ReadMe file and other installation and licensing guides.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 VII
Course Introduction
During the product installation process, you will need to specify your name, the name of your
organization. You will also need to enter the product serial number and the product key.
Otherwise, you will be limited to a 30-day trial period. To customize the installation location
on your computer, the components to be installed, and/or to specify a network license server,
you will have to press the "Configuration" button that appears on one of the screens during
the installation process. Then, follow the prompts, provide the required information, and click
the "Configuration Complete" button to continue the installation process.
Any time after the installation, you will be able to start the software by using the available
shortcut found in the "Start" menu folder, "All Programs: Autodesk: Autodesk Algor
Simulation." The version number is included in the start menu folder name and shortcut.
The name of the shortcut will depend upon which package has been purchased ("Simulation,"
"Simulation MES," "Simulation CFD," or "Simulation Professional"). In the dialog
that appears when the program is launched, you will be able to open an existing model or
begin a new model. The simulation software will be used to create, analyze, and review the
results of an analysis within a single user interface, regardless of the analysis type.
System Requirements
We recommend the following system specifications for a Microsoft Windows platform

running Autodesk Algor Simulation. These specifications will allow you to achieve the best
performance for large models and advanced analysis types.
32-Bit 64-Bit *
Dual Core or Dual Processor Intel 64 or Dual Core or Dual Processor Intel 64
AMD 64, 3 GHz or higher or AMD 64, 3 GHz or higher
2 GB RAM or higher (3 GB for MES and 8 GB RAM or higher
CFD applications)
100 GB of free disk space or higher
30 GB of free disk space or higher
512 MB or higher OpenGL
256 MB or higher OpenGL accelerated accelerated graphics card
graphics card
DVD-ROM drive
DVD-ROM drive
Supported Operating Systems:
Microsoft Windows 7 (32-bit and 64-bit editions)

Microsoft Vista (32-bit and 64-bit editions)
Microsoft Windows Server 2003 and Windows Server 2008
Microsoft Windows XP (32-bit and 64-bit editions)
Linux **
Other Requirements (All Platforms):
Mouse or pointing device

Sound card and speakers ***
Internet connection ***
Web browser with Adobe Flash Player 10 (or higher) plug-in ***
VIII FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
Notes Concerning System Requirements:
* We recommend usage of a 64-bit version of the operating system to run large models of any
analysis type and for Mechanical Event Simulation, CFD, and Multiphysics analyses.
While a 32-bit machine can be configured for larger system memory sizes, architectural
issues of the operating system limit the benefit of the additional memory.
** Linux may be used as a platform for running the solution phase of the analysis only. It
may be used for a distributed processing (or clustering) platform. However, pre- and
post-processing is done in the graphical user interface, which must be installed and run
on a Microsoft Windows platform.
*** These requirements are due to the use of multimedia in our product line and the
availability of distance learning webcasts, software demos, and related media.
Minimum system requirements and additional recommendations for Linux platforms may be
found on the Autodesk website. To navigate to the Autodesk Algor Simulation web page,
access the HELP pull-down menu within the user interface, select the "Web Links" pull-out
menu, and choose the "Autodesk Algor Simulation" link.
Autodesk Algor Simulation Help, often referred to as the Help files or users guide, contains
the following information:
Autodesk Algor Simulation Help
Documentation for all of the model creation options within the user interface
Documentation for all of the Autodesk Algor Simulation analysis types
Documentation for all of the result options available within the user interface
Step-by-step examples that illustrate many modeling and analysis options
How to Access the Help Files
From the user interface, access the HELP pull-down menu and select the "Contents"
command. The Autodesk Algor Simulation Help title page of will appear.
You can navigate through the user's guide via the table of contents to the left or by using
the "Search" or "Index" tabs.
Features of the Help Files
Autodesk Algor Simulation Help is a set of compiled help files that are installed with the
software but are also accessible from the Autodesk website.
Hyperlinks and a table of contents make it easy to move quickly from topic to topic.
The Help window contains a standard Internet browser toolbar, so you can move forward
and backward and print with ease.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 IX
Course Introduction
Figure 1: Autodesk Algor Simulation Users Guide
Search the Help Files using Keywords
All of the pages in the Help files can be searched based on keywords.
The keywords are entered at the top of the "Search" tab on the left side of the Users
Guide screen. Topics that match the search criteria are listed below.
Keywords are used to search the Help files. You may use single or multiple keywords.
Boolean operators (AND, OR, NEAR, and NOT) are available to enhance the search utility.
Also, phrases may be enclosed in quotes to search only for a specific series of words.
Subscription Center
Along with your Autodesk Algor Simulation software purchase, you have the option of
purchasing various levels of Subscription Center access and support. The Subscription Center
is accessible via the "key" icon near the right end of the program title bar and also via the
"Help: Web Links" menu.
Through the Subscription Center, you can download software updates, service packs, and add-
on applications. You can access training media, such as topical webcasts. Finally, you can
also submit technical support requests via the Subscription Center.
Web Links
Within the HELP pull-down menu of the Autodesk Algor Simulation user interface, there is a
"Web Links" pull-out menu. The following content can be accessed via the web links within
this menu:
Autodesk Algor Simulation product page

Subscription Center
Services and Support information
Discussion Group
X FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
Training course information

Autodesk Labs where you may obtain free tools and explore developing technologies
Manufacturing Community
Tutorials
Tutorials are available that demonstrate many of the capabilities of the Autodesk Algor
Simulation software. Each analysis is presented through step-by-step instructions with
illustrations to assist the user. The tutorials are accessed from the "Help: Tutorials"
command and the associated model files are in the "\Tutorials\Models" subdirectory within
the program installation folder. The tutorials will appear next to the user interface. You will
be able to follow the steps using the software without switching between the two windows.
Webcasts and Web Courses
Webcasts focus on the capabilities and features of the software, on new functionality, on
accuracy verification examples, and on interoperability with various CAD solid modeling
packages. These streaming media presentations are available for on-demand viewing from
the Subscription Center via your web browser. Similarly, web courses are also available for
on-demand viewing. Web courses are typically longer in duration than webcasts and focus on
more in-depth training regarding the effective usage of your simulation software. The topics
cover a wide variety of application scenarios.
For a list of available webcasts and web courses, follow the "Training" link from the home
page of the Subscription Center. Choose the "Autodesk Algor Simulation" product in the
"Browse the Catalog" list. This leads to the Autodesk Algor Simulation e-Learning page, in
which the available webcasts and web courses are listed according to topic.
How to Receive Technical Support
Technical support is reachable through several contact methods. The means you can use may
depend upon the level of support that was purchased. For example, customers with "Silver"
support must obtain their technical support from the reseller that sold them the software.
"Gold" subscription customers may obtain support directly from Autodesk.
Five ways to contact Technical Support:
Reseller: Obtain phone, fax, and/or e-mail information from your reseller.
Subscription Center: Access the Subscription Center from the link provided in the program
interface. Click the Tech Support link on the left side of the page
and then click on the "Request Support" link.
Autodesk Phone: (412) 967-2700 [or in USA/Canada: (800) 482-5467]
Autodesk Fax: (412) 967-2781
Autodesk E-mail: service.algor@autodesk.com
When contacting Technical Support:
Have your contract number ready before contacting Technical Support.

Know the current version number of your software.
Have specific questions ready.
Remember, Technical Support personnel cannot perform, comment on, or make
judgments regarding the validity of engineering work.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 XI
Course Introduction
Updates
The software is updated with new functionality on a continual basis. The following three
types of releases are provided:
1. A major version: Indicated by the four-digit year of the software release (based upon
the Autodesk fiscal year, not the calendar year)
2. A "subscription" version: Customers with a current maintenance subscription are
eligible for additional releases that may be made available between major product version
releases. These are designated by the addition of the word "Subscription" after the major
version number.
3. A service pack: Incorporates minor improvements to a major or subscription release and
is indicated by the letters "SP" and a service pack number after the major or subscription
version number.
How to Determine the Software Version
Access the HELP pull-down menu in the user interface and select the "About" command.
This dialog will display the version that you are using. In addition, the program title bar and
the splash screen that appears at each program launch will indicate the major version number
of the software. However, as with the start menu group name and program shortcut, it will
not indicate the subscription and service pack variants.
How to Obtain an Update
Update notifications are provided via the "Communication Center" within the user interface.
The Communication Center icon is located at the right end of the program window title bar.
The state of the Communication Center icon changes whenever new information is available.
The Communication Center provides up-to-date product support information, software
patches, subscription announcements, articles, and other product information through a
connection to the Internet. Users may specify how frequently the Live Update information
will be polledon-demand, daily, weekly, or monthly. When a program update notification
is received, the user will be given the option of downloading and installing it.
Navigating the User Interface
In this section, we will introduce you to the Autodesk Algor Simulation user interface. This
interface is the same for each of the available packages, including the foundational Algor
Simulation product and the Algor Simulation CFD, MES, and Professional products. The
only difference will be with regard to which advanced features or capabilities are enabled.
We will begin with an overview of the major components of the graphical user interface.
Then, we will discuss the toolbars, keyboard, mouse, ViewCube, and additional view
controls. Please note that the behavior of the keyboard, mouse, and ViewCube as discussed
within this manual are based on the default program settings for a clean installation of the
product. Many of the features to be discussed are customizable via tabs and settings within
the "Options" dialog, reachable via the "Tools: Options" pull-down menu command.
Figure 2 on the next page, along with the legend that follows it, introduces the major
components of the user interface. This manual is based on Autodesk Algor Simulation
Professional 2011. Users of other versions may encounter differences between their version
and the interface described herein.
XII FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
Figure 2: Autodesk Algor Simulation User Interface
Interface Legend:
A. Title Bar: The title bar displays the program name and version as well as providing links to the
Autodesk Subscription Center and Communication Center.
B. Menu Bar: The menu bar is located just below the title bar and contains the pull-down menus.
C. Toolbars: The toolbars provide the user with quick access to many commands.
D. Tree View: The tree view has unique contents for each environment of the user interface. For the
FEA Editor, it shows the parts list and the units, various properties, and loads that will be used for
the analysis. In the Results environment, you will see a list of results presentations and other post-
processing-specific content. The components of the analysis report will be listed in the tree view
within the Report environment.
E. ViewCube and Additional View Controls: These tools are used to manipulate the model display
position, rotation, zoom, display pivot point, and so on. There is also an optional Compass feature
that can be activated, providing a compass heading ring around the base of the ViewCube.
F. Display Area: The display area is where the modeling activity takes place. The title bar of the
window displays the current environment and the model name. The FEA Editor environment is used to
create the model, add the loads and constraints and perform the analysis. The Results environment is
used to view results and to create images, graphs, and animations. The Report environment will be
used to produce a formal report of the analysis, including desired results presentations.
G. Miniaxis and Scale Ruler: The miniaxis shows your viewpoint with respect to the three-
dimensional working area. The scale ruler gives you a sense of the model size,
H. Status Bar: The status bar displays important messages.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 XIII
Course Introduction
Toolbars
Autodesk Algor Simulation accesses program functions through pull-down menus, context
menus, and toolbars. The available toolbars and menus vary for each program environment
(FEA Editor, Results, and Report). By default, the toolbars are positioned at the top of the
screen, just under the pull-down menus. As is true for the menus, commands are logically
grouped into a number of different toolbars. For example, one toolbar includes predefined
view orientations, another includes various selection tools, still another includes structured
meshing tools, and so on. These may be displayed, hidden, or repositioned as desired.
Most of the toolbars and pull-down menus will not appear until an existing model is opened
or a new model is created. To see the toolbars of the FEA Editor at this time, start the
program. Dismiss the "What's New" screen if it appears, select the "New" icon in the initial
dialog ("Open" / "New"), and click the "New" button. Navigate to a working folder, type in
the name of your choice in the "File name:" field, and click the "Save" button.
How to Display or Hide Specific Toolbars
To display or hide toolbars or to adjust the icon size or style, access the TOOLS pull-down
menu and select the "View Toolbars..." command. To display another toolbar activate the
checkbox for that toolbar. Deactivate the checkbox for each toolbar that you prefer to hide.
Additional checkboxes are provided for the toolbar size and style options. Press the "Close"
button to exit the "Toolbars" screen.
How to Dock Toolbars
Toolbars can be docked on the top, bottom, and/or sides of the display area. To dock a
toolbar, first click on the title bar and drag it toward one of the edges of the display area.
Once you reach the edge, the shape will change to signify that you are at a location where the
toolbar may be docked. Release the mouse and the toolbar will dock at the location of the
mouse. That is, it will snap to the docked position and the title bar will disappear. This is
illustrated in the following images.
Figure 3: Steps to Dock a Toolbar
XIV FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
Using the Keyboard and Mouse
The keyboard and mouse will both be used to operate within the user interface. The keyboard
will be used to enter the required data for loads, constraints, material properties, and so on. It
will also be used to modify the behavior of particular mouse operations. That is, certain
keyboard keys, when held down, will change the behavior of the mouse.
The software supports a number of different mouse configurations. This document assumes
that the default template for a new installation is in effect. However, user settings, or those
retained from a prior Autodesk Algor Simulation installation, may cause the behavior to differ
from that described herein. To ensure that your mouse actions follow the descriptions in this
book, access the "Tools: Options: Mouse Options" dialog and choose the "Algor
Simulation" template.
The left mouse button will be used to select items. How items are selected will depend upon
the selection mode chosen in the "Selection: Shape" pull-out menu or toolbar. The type of
objects that are selected (such as lines, vertices, surfaces, parts, edges, or elements) will
depend upon the selection mode chosen in the "Selection: Select" pull-out menu or toolbar.
Hold down the <Ctrl> key while left-clicking an object to toggle the selection state of the
clicked object. That is, unselected objects will be added to the selection set and previously
selected items will be removed from the selection set. Holding down the <Shift> key while
left-clicking will only add clicked objects to the selection set (this will have no effect on
already selected items). Finally, holding both <Ctrl> and <Shift> while left-clicking will
only remove clicked objects from the selection set (this will have no effect on items that are
not already part of the current selection set).
Pressing the right mouse button with the cursor hovering over items in the tree view will
access a context menu with commands relevant to the item under the cursor. When items are
currently selected, either within the tree view or display area, the right-click context menu
will display commands and options that are specifically relevant to the selected items. For
example, if a surface is selected, only surface-based commands will appear in the context
menu. You may right-click anywhere in the display area when items are selected to access
the context menu. However, to access the context menu within the tree view area, you must
right-click with the cursor positioned on one of the selected headings.
If a mouse has a wheel, rolling the wheel will zoom in or out on the model. Holding down the
middle mouse button or wheel and dragging the mouse will rotate the model. Press the
<Ctrl> key while holding the middle button and dragging the mouse to pan the model,
moving it within the display area. Press the <Shift> key while dragging the mouse with the
middle button down to zoom in and out, making the model larger as the mouse is moved
upward and smaller as it is moved downward. You will likely find the use of the middle
mouse button and wheel to be more convenient than choosing a command like "Rotate" or
"Pan," clicking and dragging the mouse, and then pressing <Esc> to exit the command.
Finally, the X, Y, or Z key on the keyboard may be held down while dragging the mouse with
the middle button held down. Doing so will rotate the model, as before, but constraining the
rotation to be only about the corresponding X, Y, or Z global axis direction. You may also
use the left and right cursor keys on the keyboard while holding down X, Y, or Z to rotate
about these axes in fixed increments (15 degrees by default). The rotation increment is
customizable via the "Tools: Options: Graphics: Miscellaneous" dialog.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 XV
Course Introduction
Introduction to the ViewCube
As is true for the mouse, the software also supports a number of different view configurations.
This document assumes that the default view options template and view navigation settings
for a new installation are in effect. However, user settings, or settings retained from a prior
Autodesk Algor Simulation installation, may cause the view orientations and behavior to
differ from those described throughout this document. To ensure that your view commands
follow the descriptions in this book, access the "Tools: Options: Views Options" dialog and
choose the "Algor Simulation" template.
Next, access the "Graphics" tab of the same "Options" dialog, select "Navigation Tools" from
the items listed on the left side of the dialog, and click on the "View Cube" button. Click the
"Restore Defaults" button followed by OK to exit the "ViewCube Properties" dialog.
Finally, click the "Steering Wheel" button. Click the "Restore Defaults" button followed by
OK to exit the "SteeringWheels Properties" dialog. Click OK to exit the "Options" dialog.
The ViewCube will be located in the upper right corner of the display by default but may be
relocated. The appearance will change depending upon whether the view is aligned with a
global plane and whether the cursor is near the cube or not. The ViewCube, in its various
appearances, is shown in Figure 4.
(a) Cursor not near the

ViewCube
(b) Cursor on ViewCube
(view not aligned to a
standard face)
(c) Cursor on ViewCube
(standard face view)
Figure 4: ViewCube Appearance
The six standard view names, as labeled on the cube faces, are the Top, Bottom, Front, Back,
Left, and Right. These may be selected by clicking near visible face names on the cube, as
shown in Figure 4 (b) or by clicking the triangular arrows pointing towards the adjacent faces, as
shown in Figure 4 (c), which shows the cursor pointing to the arrow for the Bottom view.
In addition, there are clickable zones at each corner and along each edge of the ViewCube.
Clicking on a corner will produce an isometric view in which that particular corner is
positioned near the center and towards you. Clicking an edge will produce an oblique view,
rotated 45 degrees, half-way between the views represented by the two adjacent faces.
When the cursor is near the ViewCube, a "Home" icon will appear above it and to the left,
providing easy access to the home view. This is an isometric view having the corner between
the Front, Right, and Top Faces centrally positioned and towards you by default. The home
view may be redefined by right-clicking the Home icon and choosing the "Set Current View
as Home" command while viewing the model positioned as desired.
When one of the six standard views is active and the cursor is near the ViewCube, two curved
arrows will appear above and to the right of the cube, as seen in Figure 4 (c). These are used
to rotate the model to one of the four possible variants of the particular standard view. Each
click of an arrow will rotate the model 90 degrees in the selected direction.
XVI FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
Course Introduction
When the face being viewed is changed via the ViewCube, the model may move to the
selected view in the manner that requires the least amount of motion. For example, say we
are first looking at the Right view, with the word "Right" positioned upright (that is in the
normal reading position). Now, if we click the downward arrow above the cube, the model
will rotate 90 degrees to reveal the top face. The Top view will be rotated 90 degrees
clockwise from the upright orientation (that is, the word "Top" will read in the vertically
downward direction). Activating the "Keep scene upright" option will cause the Front,
Back, Left, and Right views to automatically be oriented in the upright position (Top above,
Bottom below) when changing to any of these views. You may, however, rotate the view
after initial selection, if desired. Go to "Tools: Options: Graphics: Navigation Tools:
View Cube" to locate the "Keep scene upright" setting. It is activated by default.
The point of this discussion is that whenever a new face is selected using the ViewCube, the
resultant view rotation may differ, depending upon the prior position of the model. If the resultant
orientation is not what is desired, simply click one of the curved arrows to rotate the view.
Additional View Controls
Immediately below the ViewCube is a pallet of additional view controls. This

consists of seven tools, each of which may be individually enabled or disabled.
Figure 5: Additional View Controls Pallet

All are on by default. Figure 5 shows the view control pallet.
From top to bottom, the seven tools are as follows:
SteeringWheels
Pan
Zoom
Orbit
Center
Previous View
Next View
Each of these icons, except for the Previous and Next commands, function as a
toggleclicking it once to activate a command and again to deactivate it.
Several of these tools, such as Pan, Previous, and Next are self-explanatory.
The "Zoom" tool includes a fly-out menu allowing the choice of one of four different zooming
modesZoom, Zoom (Fit All), Zoom (Selected), and Zoom (Window). The first of these
causes the model to become larger as the cursor is moved upward in the display area and smaller
when it is moved downward. The Fit (All) mode encloses the extents of the whole model. After
selecting objects in the display area, the Zoom (Selected) tool fits the selected items into the
display area. Finally, after selecting the Zoom (Window) tool, you can click and drag the mouse
to draw a window defining the area you wish to expand to fill the display area.
The "Orbit" tool has two variants, selectable via a fly-out menuOrbit, and Orbit
(Constrained). The former allows the model to be rotated freely in any direction. The
Constrained option causes the model to rotate only about the global Z-axis, similar to pressing
the Z key while dragging the mouse with the middle button depressed.
The "Center" tool is used to center a point on the model within the display area. Click with
the mouse to specify the desired center point after selecting the Center command. This point
also becomes the display pivot point, about which the model pivots when being rotated.
FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010 XVII
Course Introduction
The "SteeringWheels" tool is customizable and, in its default setting, produces the Full
Navigation Wheel shown in Figure 6. The full navigation wheel floats above the model view,
following the cursor position. It provides an additional access method for several functions
found elsewhere on the view tools pallet as well as a few additional functions.
Figure 6: Full Navigation Wheel
The "Rewind" button on the navigation wheel presents a timeline of thumbnails representing
various views that have been used during the modeling session. Simply release the mouse
button with the cursor positioned at the thumbnail representing the view to which you wish to
jump. This is more convenient than pressing the previous or next view buttons multiple times.
For additional information concerning these view controls, consult the User's Guide.
Legacy View Controls in Autodesk Algor Simulation
Traditional view controls and options are also provided via the pull-down menus and toolbars
at the top of the user interface window. Options for displaying or hiding the mesh or model
shading may be found here as well as eight pre-defined, standard view orientations. The
orientations will depend upon the currently active views options template (previously
discussed in the "Introduction to the ViewCube" section of this introduction).
There is also a "User-defined Views" dialog that may be used to save, modify, or restore
custom views. Additional capabilities include a local zoom feature and display toggles for the
scale ruler, miniaxis, and perspective mode.
The "Local Zoom" feature displays a small rectangle that represents the area to be
magnified. A larger rectangle shows an overlay of the magnified region. You may click on
and drag the local zoom window to position it anywhere on the model within the display area.
The size of the local zoom area and magnified overlay and also the zoom level can be
customized via the "Tools: Options: Graphics: Local Zoom" dialog.
For additional information concerning the legacy view controls, consult the Help files.
Notes Concerning the Steps for Exercises Section
Exercise descriptions and step-by-step solutions are provided in a separate section at the back
of this Instructor Manual. Excerpts from the Steps for Exercises section may be printed and
distributed to the students as desired.
In addition, please refer to the Forward portion of the Steps for Exercises section for detailed
information regarding the necessary program setup parameters. Using the specified
configuration at each workstation will ensure the expected software behavior for instructor
and student alike.
XVIII FEA in Practice Instructor Manual Autodesk Algor Simulation Professional 2011 4/30/2010
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Beam Elements (continued)
NOTE: For details concerning beam element

orientation, access the Contents tab of
the Help files, go to Autodesk Algor
Simulation: Setting Up and Performing
the Analysis: Setting Up Part 1: Linear:
Element Types and Parameters: Beam
Elements. Scroll down the resultant page,
and click on the Beam Element
Orientation heading.
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Other Analysis Types
Thermal
Analyses
Slide 158:
Thermal Analyses
The following two types of thermal analysis
are available:
Steady-State Heat Transfer

Transient Heat Transfer
Slide 159:
Thermal Elements
Thermal elements are geometrically
identical to the corresponding structural
elements. The available types are:
Rod (this is a line element)
2-D
Plate
Brick
Slide 160:
Thermal Nodal Loads

Initial Temperature
Specify the temperature of a node(s) at the
beginning of the analysis (transient analysis).
Applied Temperature
Specify a temperature at which a node(s) will be
held during the analysis. A stiffness value specifies
the amount of thermal energy (heat source or heat
sink) available for maintaining the temperature.
Slide 161:
Thermal Surface Loads

Convection
Assign a convection coefficient and the ambient
temperature.
Radiation
Assign the radiation function and the ambient
temperature.
Heat Flux
Assign the amount of heat added or removed per
unit area.
Slide 162:
Thermal Element Loads

Heat Generation
Enter the amount of volumetric heat generated in a
given part.
Slide 163:
Body-to-Body Radiation
Define the surfaces that will exchange heat
through radiation and assign emissivity
values.
Define body-to-body radiation enclosures
(i.e., groups of surfaces that will radiate
to/from each other).
The processor will automatically calculate
the view factors between elements.
Slide 164:
Thermal Contact
Used to simulate imperfect thermal conduction
between two parts or the resistance of a
substance that is not modeled (such as epoxy)
between two parts.
Define contact pairs in the FEA Editor
environment.
Define the resistance value between the
surfaces.
Applicable to 3D CAD, hand-built, and 2-D
models.
Slide 165:
Thermal Results
Temperature
Heat flux (energy / time / length2)
Heat rate of face (energy / time)
Slide 166:
Exercise L - Thermal Model

Objective: Analyze
the thermal effects of
a material containing
hot and cold water
passages. Use a mesh
size of 80% of default.
Material: Steel (ASTM - A514)
Loads:
in lbs
Largest Hole: Convection coefficient = 1.4 in 2 sec F
Ambient temperature= 65F
in lbs
Second Largest Hole: Convection coefficient = 2.8 in 2 sec F
Ambient temperature = 180F
Slide 167:
Electrostatic
Analyses
Slide 168:
Electrostatic Analyses
The following two types of electrostatic
analysis are available:
Electrostatic Field Strength and Voltage

Electrostatic Current and Coltage
Slide 169:
Electrostatic Elements
Electrostatic 2-D and brick elements are
geometrically identical to the analogous
structural elements.
Slide 170:
Electrostatic Nodal Loads

Applied Voltages
Specify a certain voltage at which a node(s) will
be held, due to a voltage source.
Temperatures
Specify the temperature of a node(s) to influence
the electrostatic results when temperature-
dependent material properties are being used.
Slide 171:
Electrostatic Results
Voltage (Volts or mV)
Current (Amps or mA / length2)
Current Rate of Face (Amps or mA)
Electric field (voltage/length)
Displacement field (force/voltage * length)
Electrostatic force
Electrostatic charge (current * time)
Slide 172:
Electrostatic Analysis Exercise
Refer to the softwares Help: Tutorials menu

command. Follow the Radial Comb Motor
Electrostatic Analysis tutorial listed under
Analyzing and Evaluating Results Tutorials
for further information on performing an
electrostatic analysis.
Slide 173:
Fluid Flow
Analyses
Slide 174:
Fluid Flow Analyses

The following four types of fluid flow analysis
are available:
Steady Fluid Flow

Unsteady Fluid Flow
Flow Through Porous Media
Open Channel Flow
Slide 175:
Fluid Flow Elements

The fluid flow 2-D and brick elements are
geometrically identical to the analogous
structural elements.
Slide 176:
Fluid Flow Loads

Prescribed Velocity
Can be used to specify an inlet velocity or zero
velocity along a wall.
Surface Prescribed Inlet/Outlet
Fan Curves
Can be used to model flow generated by intake,
exhaust or internal fans.
Rotating Frames of Reference
Can be used to model flow in rotating machinery.
Gravity
Slide 177:
Fluid Flow Loads (continued)

Pressure/Traction
Applied normal to the edge of 2-D elements (selected
as surfaces since the edges represent surfaces).
Applied normal to the face of 3-D elements.
Applied in a specified vector direction to the edge
surface of 2-D elements or the face of 3-D elements.
Buoyancy Force
Apply thermal results from a steady-state heat
transfer analysis to a steady fluid flow analysis.
Surface Prescribed Turbulence Condition
Surface Prescribed Wall Roughness
Slide 178:
Fluid Flow Results

Velocity (length/time)
Pressure (force/length2)
Stress tensors (force/length2)
Reaction forces
Slide 179:
Fluid Flow Analysis

command. Follow the Ball Valve Fluid Flow
Analysis tutorial listed under Analyzing and
Evaluating Results Tutorials for further
information on performing a fluid flow analysis.
Slide 180:
Mechanical
Event
Simulation
(MES)
Slide 181:
Mechanical Event Simulation (MES)

MES overcomes many limitations of static stress
analysis by accounting for
Geometric nonlinearity (large deformations that change

the load and/or constraint positions and directions)
Acceleration/inertia
Damping
Motion-enabled contact or impact (that is, surface-to-
surface contact that changes over time due to motion or
component deformation)
Nonlinear material behavior (such as plastic deformation
due to exceeding the material yield strength).
Slide 182:
Mechanical Event Simulation (MES)

(continued)
Other MES characteristics:
Loads and results are time-dependent, providing

many instantaneous results snapshots over a
user-defined period of time.
Load curves are used to define how the given
loads vary over time.
Multiple results time steps are provided for post-
processing.
Results may be graphed versus time. The integral
and first or second derivative of the results may
also be graphed.
Slide 183:
Comparison of Linear Static Stress and MES

Previously, we introduced the following governing
equation for static stress analysis:
{f} = [K] {d}
Where: {f} = force vector, [K] = stiffness matrix, {d} = displacement vector
For MES, additional terms are included, resulting

in the following equation:
{f } = [K ]{d}+ [c]{d }+ [m]{d}
Where: [c] = damping matrix, [m] = mass matrix,
{}
d = velocity vector (first derivative of displacement),
{}
= acceleration vector (second derivative of displacement)
d
Slide 184:
MES Shell Elements

MES shell elements are similar to
linear plate elements. They are
triangular or quadrilateral, are
planar (or nearly planar), and have
three or four corner nodes.
There are several available
formulations (consult the Help files
for more information).
Composites are a subset of shell
elements in MES, rather than a
separate element type.
Slide 185:
MES Kinematic Elements

Kinematic elements can be either 2-D or
3-D elements.
Kinematic elements do not experience strains
and do not report stresses. Otherwise, these
elements behave just like flexible brick
elements.
They have an advantage over conventional
brick elements because of their small
contribution to the size of the global stiffness
matrix. This results in faster run times.
Slide 186:
MES Contact Elements

Contact elements can have
different stiffness values in
compression and tension.
These elements can also have a
breaking stress at which point
the stiffness will be zero.
These elements can be used to
simulate cables.
Slide 187:
MES Coupling Elements

Coupling elements aid in the
simulation of parts that "couple"
at a known length.
This coupling is modeled by
introducing a stiffness when it
reaches this length. This
stiffness is calculated using the
modulus of elasticity, a coupling
area, and the length of the
element.
Slide 188:
MES Dashpot Elements

Dashpot elements can be used
to apply local damping to a
model.
You can specify a damping
coefficient that will control how
much these elements affect
motion.
Slide 189:
MES Actuator Elements

Actuator elements are line
elements whose lengths can
change over time.
They are used to simulate
defined movement of a part
(such as hydraulic cylinders or
solenoids).
Slide 190:
MES Slider Elements

A slider element consists of two
collinear lines connected at one
node.
The node in the middle will be
allowed to move along the line
defined by the other two points,
letting the node slide such as
if it were in a guide or slot.
Slide 191:
MES Pulley Elements

Pulley elements consist
of three nodes: driver,
pivot, and slack.
As the driver node
moves toward or away
from the pivot, the slack
node will move in the
opposite direction by a
set relationship.
Slide 192:
MES Pipe Elements

Pipe elements allow you to
model piping systems under
internal pressure loads.
The pipe elements can be either
straight sections or bends.
Slide 193:
MES Hydrodynamic Elements

Hydrodynamic elements
can be either 2-D or 3-D
elements.
These elements allow for
the simulation of the
interaction of fluids with
solids without considering
the details of the flow.
Slide 194:
MES Impact Planes

Specify a wall, floor, or ceiling parallel to
the global X, Y and Z axes.
Objects will not be able to pass through this
plane.
Slide 195:
MES Surface-to-Surface Contact

Specify two or more surfaces that may come
into contact during the event duration.
Can include static and dynamic friction effects.
A slide, no bounce option is available to
prevent objects from separating once theyve
come into contact.
Consult the Help files for more information
concerning the various surface contact options
and parameters.
Slide 196:
Mechanical Event Simulation Example
For an introductory level mechanical event

simulation (MES) example, refer to the
softwares Help: Tutorials menu command.
Follow the Piston Mechanical Event
Simulation tutorial listed under Analyzing
and Evaluating Results Tutorials.
Also, refer to Example M (next slide) for a
more complex and challenging MES example
involving surface number reassignment and
surface-to-surface contact.
Slide 197:
Exercise M MES, Geneva Mechanism
Center of Joint 1 (0, 0, -0.125) & Joint 2 (1.414214, 0, -0.125): Fixed except for Rz
Center of Joint 3 (0, 0, 0.875) & Joint 4 (1.414214, 0, 0.875): Tx, Ty, Rx & Ry constrained
Slide 1 of 4
Slide 198:
Exercise M (continued)
1. Before meshing, set the default contact = Free/No Contact and define a surface
contact pair between Part 1 and Part 2, which will prevent mesh matching
between the parts (this is desirable for MES contact surfaces).
2. Mesh the model at an absolute mesh size of 0.0625 (1/16th of an inch).
3. Modify line attributes to consolidate the contact surfaces. Use surface 100 for
the 1st contact pair, 101 for the 2nd, and 102 for the 3rd include chamfers. For
the drive wheel, surfaces 100 and 101 will each encompass about one-third of the
perimeter of the wheels C-shaped cylindrical contact surface.
4. From the General Surface-to-Surface Contact screen, redefine the first pair to
be Part 1/Surface 100 to Part 2/Surface 100. Create two more pairPart 1/
Surface 101 to Part 2/Surface 101 and Part 1/Surface 102 to Part 2/Surface 102.
Set the contact element Updating to Automatic. Set the contact parameters
for all three pair as follows
Contact problem type = High Speed Contact (Impact)
Contact type = Surface to Surface
User specified contact stiffness = 1000 lbf/in
User specified contact tolerance = 0.0011 (eliminates the effects of 0.001 part clearances
and prevents chatter, resulting in a quicker and more stable solution).
Slide 2 of 4
Slide 199:
5. Create four universal joints, one at each end face of the four stub shafts,
entering the specified vertex coordinates from the preceding diagram.
6. In the element definition screen for parts 1 and 2, set the analysis type to
Large Displacement. Set the material for the drive wheel to Brass, Red and
for the driven wheel to Plastic Nylon Type 6/6. For all four joints Change
the element type to Pipe In the element definition screen, set the OD to
0.1 and the wall thickness to 0.03 The material is to be custom defined,
E=100e6; all other values remain at zero.
7. Apply the nodal boundary conditions and loads specified on the preceding
diagram to the center points of the four joints. For Joint 4s lumped mass,
specify a uniform mass of 0.00088 lbfs2/in and a mass moment of inertia in the
Z-direction of 0.00135 lbfs2in. These values simulate a steel disk 1/8 thick
with a diameter of 3.5.
Use load curve 1 for the prescribed displacement (rotation) and load
curve 2 for the nodal moment. Load curve 1 ramps linearly from 0 to 1 in
1 second. Load curve 2 is constant at 1. Set a death time of 1 second in the
active range data dialog for the prescribed displacement.
Slide 3 of 4
Slide 200:
8. In the analysis parameters screen, set the event duration to 1 second and
the capture rate to 90. This will produce a time step for every two degrees
of drive wheel rotation.
9. Under the equilibrium tab of the advanced analysis parameters, uncheck the
Automatic box for the displacement tolerance and set the value to 0.02.
10. Run the Analysis and review the results. Generate a von Mises stress
animation and a plot of displacement magnitude vs. time for two
nodes one on the drive wheels indexing pin and one on the perimeter of
the driven wheel.
***
NOTE: Depending upon the computer hardware, this analysis may take several
hours to run. You may wish to allow several steps to converge, stop the
analysis, and then load the already completed model from the provided
archive file, Exercise M\Results Archive\Exercise M.ach.
Slide 4 of 4
Slide 201:
Finite Element Analysis in Practice
Combining
Analysis Types
(Multiphysics)
Slide 202:
Multiphysics
A multiphysics analysis combines the effects of
multiple analysis types.
The initial analysis is performed.
Another analysis is set up using the results from
the initial analysis as the loading in the
subsequent analysis.
For some analyses, iterations are required to
reach a converged solution.
Steady or unsteady coupled fluid flow and
thermal analyses solve for fluid and thermal
results simultaneously.
Slide 203:
Examples of Combining Analysis Types

Apply temperature results from a heat transfer
analysis to a stress analysis to analyze thermal
stress.
Apply boundary forces from a fluid flow analysis to
a stress analysis (fluid/structural interaction).
Apply velocity results from a fluid flow analysis to a
heat transfer analysis to analyze the effect of forced
convection on the temperature distribution (where
the temperature does not significantly influence the flow
pattern).
Apply temperature results from a heat transfer
analysis to a fluid flow analysis to drive natural
convection (where the flow does not significantly
influence the temperature distribution).
Slide 204:
Examples of Combining Analysis Types

(continued)
Apply current results from an electrostatic
analysis to a heat transfer analysis to analyze
Joule heating.
Apply electrostatic attraction/repulsion forces
from an electrostatic analysis to a stress
analysis to determine displacements and
stresses (commonly used in the analysis of
micro electromechanical systems MEMS).
Slide 205:
Multiphysics Example:
Analysis of Stresses due to
Electrostatic Forces
command. Follow the Radial Comb Motor
Static Stress Analysis tutorial listed under
Analyzing and Evaluating Results Tutorials
for further information on performing a
multiphysics analysis of structural stress and
displacement due to electrostatic forces.
Slide 206:
Finite Element Analysis in Practice
Material
Models
Slide 207:
Background on Material Models

Material models are subsets of the element
types.
These models allow you to make decisions
on what type of material properties will be
used for each part in the model.
For example, if a part will see the plastic
region of a stress versus strain curve, you
should select one of the von Mises material
models for an elastic/plastic analysis.
Slide 208:
Isotropic
This is the standard material model. The
material properties are independent of
direction.
Slide 209:
Orthotropic
This material model can have different
properties in the three orthogonal
directions.
The required properties are identical to the
isotropic material model. However, you
enter separate values for the three
directions.
Slide 210:
Temperature-Dependent
For some elements, the properties for both
isotropic and orthotropic materials can be
defined on a temperature-dependent basis.
The values are linearly interpolated between
the specified temperature points.
Slide 211:
Elastic-Plastic (von Mises)

von Mises: This material models is based on a bilinear
simplification of the stress-strain curve. The modulus
for the elastic region, the yield point, and the modulus
for the plastic region must be defined. If the material
library includes the elastic modulus, yield point,
ultimate strength, and elongation; the program will
automatically calculate the plastic modulus for you.
von Mises Curve: This material model uses either an
approximated stress-strain curve or actual stress-strain
data. As above, if the material library includes the
elastic modulus, yield point, ultimate strength, and
elongation; the approximated stress-strain curve will be
generated automatically. Alternately, you may define a
table of true stress-strain data (either within the material
library manager or the material application screen).
Slide 212:
Elastic-Plastic (von Mises)

(continued)
Isotropic hardening and kinematic hardening
variants of the von Mises material models are
available.
Use the von Mises with Isotropic Hardening model for
non-reversing load conditions.
The von Mises with Kinematic Hardening model is
recommended for greater accuracy when reversing
strain cycles will occur.
Slide 213:
Hyperelastic and Foam Material Models

The following rubber-like (hyperelastic)
material models are available:
Mooney-Rivlin Yeoh
Arruda-Boyce Neo-Hookean
Ogden Van der Waals
The following foam-like material models are
available:
Blatz-Ko
Hyperfoam (accounts for compressibility)
Slide 214:
Drucker-Prager
This material model is used to model rock
and concrete.
Slide 215:
Viscoelastic and Viscoplastic

These material models are used to account
for rate-dependent material behavior due to
dissipative losses from viscous effects.
The viscoelastic material models are
variants of the previously listed
hyperelastic material models.
A material model that can be used to model
thermal creep is also available (Thermal
Creep Viscoelastic).
Slide 216:
Thermoelastic and Thermoplastic

These material models are used for thermal
stress analyses. The Thermoplastic model
is used when stresses beyond the yield
point occur.
Slide 217:
Piezoelectric
This material model is for parts that
experience stress due to a voltage
distribution.
Slide 218:
Curve
This material model allows you to input a
bulk modulus versus strain curve to control
the behavior of the part.
Slide 219:
Reinforced Concrete
This material model allows different tensile
and compressive behaviors. It can simulate
cracking and crushing failure of concrete
under relatively monotonic loading. A
maximum of three independent directions
of rebar are allowed for the concrete
material. The rebar locations (in height or
depth) are not considered; they are treated
as "smeared" throughout the part.
Slide 220:
Exercise N - Nonlinear Material Model

Objective: Analyze a cantilever beam
using beam elements and an elastic
material model. Determine if yielding
occurs. If it does, reanalyze the beam
using a plastic material model.
Geometry: The beam is 10 long
and is 5 x 5 square.
Loads: 56,000 pounds in the Load curve:
-Y direction at the free end.
Constraints: The fixed end is fully
constrained.
Duration: 10 seconds.
Capture rate: 2 steps per second.
Finite Element Analysis
in Practice
Steps for Exercises
Based on Autodesk Algor Simulation

Professional 2011
SE.2 FEA in Practice Steps for Exercises Autodesk Algor Simulation Professional 2011 4/30/2010
STEPS FOR EXERCISES
TABLE OF CONTENTS
Foreword........................................... SE.5
Introductory Example Motor Mount .................................................................. SE.7
Exercise A FEA Example by Hand ................................................................... SE.17
Exercise B Truss Frame Model ........................................................................ SE.23
Exercise C Support Beam under Gravity ......................................................... SE.33
Exercise D Axisymmetric Thick-Walled Cylinder.............................................. SE.43
Exercise E Plate under Uniform Pressure ........................................................ SE.49
Exercise F Cantilever Beam Model .................................................................. SE.57
Exercise G Comparing Element Types ............................................................ SE.67
Exercise H Mesh Convergence ........................................................................ SE.79
Exercise I Bracket Model .................................................................................. SE.85
Exercise J Hanger Assembly Model ................................................................ SE.91
Exercise K Linear Contact Model ..................................................................... SE.97
Exercise L Thermal Model.............................................................................. SE.105
Exercise M Mechanical Event Simulation (MES), Geneva Mechanism ......... SE.111
Exercise N Nonlinear Material Model ............................................................. SE.129
FEA in Practice Steps for Exercises Autodesk Algor Simulation Professional 2011 4/30/2010 SE.3
Foreword
Starting Autodesk Algor Simulation
The software may be started by:
Accessing the Windows "Start" menu and selecting the "All Programs" pull-out menu,
followed by selecting the "Autodesk" group and the "Autodesk Algor Simulation" folder
within it. Select the "Autodesk Algor Simulation" command.
In addition, the program may be started by choosing the "Autodesk Algor Mesh" command
within supported CAD solid modeling applications. This method starts the program and transfers-
in the CAD solid model in one operation.
Defaults
Each exercise is written using the default program settings, as if the software has been opened for the first
time after installation. In this way, a user can work through the exercises in any order. If a user will be
working through several exercises during one session, some settings from one exercise may be retained,
creating incorrect or invalid steps in the following exercise. To minimize this possibility, exit the program
at the end of each exercise and reopen it to begin a new exercise. It is possible for an experienced user to
work through several exercises without this precaution, but extra care should be taken to review that input
is correct and appropriate.
It is important that the user access view commands exactly as described, except as otherwise indicated (that
is, from the pull-down menus or toolbars). These commands ensure a constant and repeatable view
orientation that is not ensured when using the ViewCube. Specifically, while the displayed plane will be
correct, the rotational position may not be as expected when using the ViewCube.
Several program settings are global. That is, once set, they will influence the program behavior for every
model until the settings are changed again. In particular, the solution steps in this manual may be
invalidated if a deviation is made from any of the settings listed below. These are the program settings
upon which the solution procedures are based:
"Tools: Options"
o "Analysis"
"Automate Analysis" Activated
"Ask to show mesh results after CAD meshing" Activated
"Default Modeling Units" = English (in)
o "CAD Import: Global CAD Import Options"
"Knit surfaces on import:" = No
Automatically generate contact pairs:" = No
o "Graphics: Navigation Tools: View Cube"
"Fit-to-View on view change" Activated
o "Mouse Options: Mouse settings templates" = Algor Simulation
o "Views Options: Views settings templates" = Algor Simulation
Forward
Input Files and Archives
The University Course Curriculum is distributed in the form of an executable, self-extracting archive and is
delivered electronically. Hardcopies of the curriculum are not available. When the downloaded archive is
extracted, various documents and folders will be created within the folder at the extraction location. Along
with the Instructor Manual (PDF file) and the presentation slides (PPT file), there is a set of folders
containing the example and exercise model input files and results archives. These are clearly identified by
the folder structure and naming convention. Discretion should be used with regard to which files and
folders are made available to the students via a shared network drive. It is recommended that the instructor
only shares the example and exercise model input files and results archives. The Instructor Manual and
presentation slideshow should not be shared. However, exercise handouts may be provided for the students
by selecting and printing the appropriate pages of the Instructor Manual or by printing excerpts as PDF
files and sharing these with the students on a per-assignment basis.
Many of the exercise input files are in the form of CAD universal formats. A number of the
input files, and all of the results files for the course examples and exercises, are in the form of
Algor Simulation archive files (*.ach). These input files and results archives must be copied
to the local computer workstations for each student before they are opened. Do not try to
open or run models directly from a shared network drive. This will produce excessive
network traffic, slow down the analyses, and some analyses may fail to run across a network
connection. For this reason, students who have their My Documents folders mapped to a
shared network drive, as is a common practice in university settings, should NOT place FEA
models in their My Documents folder. Instead, a folder for FEA models should be created
on each local workstation hard drive. Models can be archived to the shared folder for
portability during the setup process or after they have been solved.
Opening Archives
1. Copy the set of folders and files to your local computer from the class directory.
2. Start Autodesk Algor Simulation and select the "Open" icon at the left side of the dialog.
3. Select the "Algor Simulation Archive (*.ach)" option in the Autodesk Algor Files section of the
"Files of type:" drop-down box.
4. Double-click to open the desired folder, highlight the desired file, and press the "Open" button.
5. In the "Browse for Folder" screen, select a folder on the hard drive for the location of the
restored model files.
6. Click the OK button.
The model will be restored to the selected folder and automatically opened in the FEA Editor environment.
For exercises based on CAD solid models, the input files will be universal formats (such as STEP, IGES,
and so on), rather than Algor Simulation archives. These files should be placed in the desired working
folder prior to opening them. The FEA files will be created in the folder where the CAD file resides when it
is opened.
Printing of Exercise Descriptions and Solution Steps
Individual exercise descriptions and/or solution steps within this manual may be printed and distributed to
the students at the instructor's discretion. However, they are not to be distributed beyond or outside of the
current class of the university or trade school that owns the Autodesk Algor Simulation license.
Introductory Example
Motor Bracket Assembly Model
Brick Elements
Objective: To perform an analysis on a motor bracket that is loaded with surface forces.
Geometry: Use the file MotorMount.stp located in the "Introductory Example\Input File" directory
as the input file for this exercise. Mesh the model at the default mesh size.
Loads: Surface force loads of 75 lbf each will be applied to the top of the two brackets. The
direction of the load will be normal to the selected surfaces.
Constraints: The two holes at the ends of the shaft will be fully constrained.
Elements: Brick
Material: Steel (ASTM-A36) All Parts
Solution
Meshing the Model
Start Autodesk Algor Simulation from the Windows Start menu.
"Open" Select the "Open" icon at the left side of the dialog.
Mouse If the desired analysis type is not already set, click on the
arrow button next to the "Choose analysis type:" field,
"Linear: Static Stress with select the "Linear" pull-out menu, and choose "Static
Linear Material Models " Stress with Linear Material Models."
Select the "STEP (*.stp, *.ste, *.step)" option in the CAD
"STEP (*.stp, *.ste, *.step)" Files section of the "Files of type" drop-down box.
Navigate to the directory where the model is located.
Select the MotorMount.stp file in the "Introductory
MotorMount.stp
Example\Input File" directory.
"Open" Press the "Open" button.
A "Select Length Units" dialog will appear. Choose the
"Use STEP file units"
"Use STEP file units" option from the pull-down menu if
OK
it is not already selected and click the OK button.
A dialog will appear asking you to choose the analysis type for
this model. Click the OK button to accept the default of
OK
"Static Stress with Linear Material Models". The model
will be displayed in the FEA Editor as shown in Figure 0.1.
Figure 0.1: Model in the FEA Editor Environment
Access the MESH pull-down menu and select the "Model

Mouse
Mesh Settings" command.
Mouse Move the slider in the "Mesh size" section to 75%.
Press the "Mesh model" button in the "Model Mesh
"Mesh model"
Settings" dialog.
Press the "No" button when asked to view the mesh results. A
"No"
mesh will be displayed on the model as shown in Figure 0.2).
Figure 0.2: Meshed Model
Defining the Material Data
Mouse Click on the "Material" heading for Part 1 in the tree view.
Holding down the <Ctrl> key, click on the "Material"
<Ctrl>Mouse
heading for Part 2 in the tree view.
<Ctrl>Mouse
Mouse Right-click on one of the selected headings.
"Modify Material" Select the "Modify Material" command.
Within the "Element Material Specification dialog, expand
the "Steel" branch of the Autodesk Algor Material Library,
"Steel (ASTM - A36)"
scroll down towards the bottom of the list, and select the
material, "Steel (ASTM - A36)," as shown in Figure 0.3.
Figure 0.3: Defining the Materials
Click the OK button to accept this material for all three

OK
parts.
Adding Loads and Constraints
Click and hold the middle mouse button to rotate the model
view. Drag the mouse to position the model for clear
Mouse
visibility of the top surfaces of the brackets and then release
the mouse button.
Access the SELECTION pull-down menu and choose the
"Selection: Select: Surfaces"
"Select" pull-out menu. Select the "Surfaces" command.
Mouse Click on the top surface of one of the brackets.
Holding down the <Ctrl> key, click on the top surface of
<Ctrl>Mouse
the other bracket.
Mouse Right-click in the display area.
Select the "Add" pull-out menu and select the "Surface
"Add: Surface Forces"
Forces" command (see Figure 0.4).
Figure 0.4: Applying Surface Loads
Type "75" in the "Magnitude" field. This is the force

75
applied per selected surface.
OK Click the OK button to accept this load.
Click and hold the middle mouse button to rotate the model
Mouse view. Drag the mouse to position the model for clear
visibility of the holes at each end of the shaft.
Click on one of the inner surfaces of one of the holes in the
Mouse
shaft.
Holding down the <Ctrl> key, click on the remaining three
<Ctrl>Mouse
inner surfaces of the two holes.
"Add: Surface Boundary Select the "Add" pull-out menu and select the "Surface
Conditions" Boundary Conditions" command.
"Fixed" Press the "Fixed" button in the "Predefined" section.
OK Press OK to accept these surface boundary conditions.
Running the Analysis
Access the ANALYSIS pull-down menu and select the

"Analysis: Perform "Perform Analysis" command to run the analysis. At
Analysis" the completion of the analysis, the program will
automatically transfer to the Results environment.
Viewing the Results
The von Mises stress contour on the displaced shape will appear as shown in Figure 0.5.
Figure 0.5: von Mises Stress Results
Other types of results can be displayed by accessing the RESULTS pull-down menu and selecting from among the
various available results. In addition, the amount of displacement exaggeration may be altered and the
undisplaced shape can be overlaid on the displaced shape plot.
Access the RESULTS pull-down menu, then the

"Results: Displacement:
"Displacement" pull-out menu, and select the "Magnitude"
Magnitude"
command. Note the maximum displacement magnitude.
Access the RESULTS OPTIONS pull-down menu and
"Results Options: Displaced
select the "Displaced Model Options" command to
Model Options"
access the "Displaced Model Options" dialog.
Increase the displacement scale from 5% to 10% by dragging
the slider towards the right. The displaced plot will now be
Mouse
exaggerated so that the displacement is approximately 10% of
the overall model size.
Under the Scale Factor heading, activate the "As an
Mouse Absolute Value" radio button. The scale factor field will
now show the actual displacement multiplier.
Select the "Transparent" radio button in the "Show
"Transparent"
Undisplaced Model As" section.
Mouse Press the button in the upper right corner of the

"Displaced Model Options" dialog.
We will now capture a screen image of the displacement results for inclusion within the analysis report.
Access the FILE pull-down menu, select the "Export"

File: Export: Image
pull-out menu, and choose the "Image" command.
Click once in the display area to make this window active
and press <Enter> to automatically select the entire display
Mouse area and open the Save image as dialog. (Note that it is
also possible to click and drag to select only a portion of the
display for capture.)
Portable network graphics Choose Portable network graphics file (*.png) from the
file (*.png) drop-down list in the Save as type: field.
Motor Mount Type Motor Mount Displacement in the File
Displacement name: field.
Save Click the Save button.
Generating an HTML Report
Access the TOOLS pull-down menu and select the

"Tools: Report"
"Report" command to change to the Report environment.
Mouse Right-click on the "HTML Report" heading in the tree view.
"Configure Report" Select the "Configure Report" command.

Activate the Logo checkbox. Drag the horizontal scroll
Mouse bar towards the right to see the full logo. The Configure
Report dialog will now appear as shown in Figure 0.6.
Figure 0.6: Report Configuration Utility
NOTE: When selecting portions of the report to modify, click on the item name and not on the checkbox. Clicking
on the checkbox will toggle the inclusion state of the item (that is, whether it is to be included or excluded
from the HTML report).
Mouse Select the "Project Name" heading.

Mouse: Click and drag the mouse to select the text "Design
Introductory Exercise Analysis" and type "Introductory Exercise" to replace it.
Mouse:
Click and drag the mouse to select the text "Project Title
Analysis of a Motor
Here" and replace this text by typing "Analysis of a Motor
Mount under a 150 lbf
Load. Mount under a 150 lbf Load".
Mouse Select the "Title and Author" heading.

Your Name Type your name into the "Author" field.
Your Department Type your department name into the "Department" field.
Deselect the "Executive Summary" item by clicking on
Mouse the associated checkbox. This item will be excluded from
the report.
NOTES: Text can be added as desired within the "Executive Summary" section using the built-in word processor
features. A variety of font and paragraph styles are included, such as bullet or numbered lists, tables, tabs,
and various text justification settings.
The following sections are automatically generated and cannot be modified. The analyst may only include
or exclude these items or alter their order of appearance within the report:
Summary
Analysis Parameters
Parts
Element
Material
Loads
Constraints
Probes
Rotating Frames (applicable to fluid flow analysis)
Results Presentations
Processor Log Files Group
Code Checking General
Code Checking Detailed
We will now deactivate the default results presentation image and instead add the displacement image that
we captured previously. We will position the image within the report just before the processor log files.
Deselect the "Results Presentation" item by clicking on

Mouse
the associated checkbox to exclude it from the report.
Access the TREE pull-down menu and choose the Add
Tree: Add Image File(s)
Image File(s) command.
Portable Network Graphics Choose Portable Network Graphics (.png) from the
(.png) drop-down list to the right of the File name: field.
Motor Mount Browse to and select the file, Motor Mount
Displacement.png Displacement.png that was previously created.
Click the Open button. A heading matching the image
Open name will appear at the bottom of the report tree view.
Also, the default header text will match the filename.
Click on the Motor Mount Displacement heading and

drag it upward in the tree view to reposition this item within
Mouse the report. Release the button with the cursor over the
Processor Log Files heading. The image will now
precede the log files.
Press the "Generate Report" button. This will automatically
"Generate Report" bring up the report, which will appear as shown in Figure 0.7.
You can scroll through and review the full report.
Figure 0.7: Completed Report
NOTES: The default title image is the model as it currently appears within the FEA Editor environment.
A different image may be substituted for this one and/or the image may be resized using the
report configuration utility. To resize the image, click and drag the handles that appear around
the image border while it is selected within the report configuration utility.
Within the folder where any given model resides there will be a subfolder named
"modelname.ds_data" (in this case, "MotorMount.ds_data"). Within this folder, there will be one
numbered subfolder for each design scenario that was built and analyzed. In this case, only the
folder ("1") will exist, since only the first design scenario was used. Finally, within the numbered
design scenario folder there will be a subfolder named "ds_rpt." This folder contains the HTML
report and all of its attachments, style sheet, and table of contents. This folder may be zipped and
sent to anyone who wishes to review the report. They do not need to have the Algor Simulation
software installed on the system in order to review the report. The HTML document may be
opened in a web browser (like Internet Explorer). Merely extract the report and double-click on
the file "modelname.htm" to open it in the default web browser. Note that the report can also be
saved in a variety of other formatsWord 97, Word 2007, PDF (Adobe portable document
format), and RTF (rich text format).
To review a completed archive of this exercise, refer to the file MotorMount.ach in the "Introductory
Example\Results Archive" directory.
Exercise A
FEA Example by Hand
Truss Elements
Objective: Construct and analyze a system of three trusses supporting a vertical load.
Geometry: Draw the trusses in the XY plane (Top View).

L = 10 feet
Cross-sectional area = 2 in2
= 45
Loads: F = 10,000 pounds
Constraints: Fully fixed at nodes 2, 3 and 4.

Constrain translation in the Z direction at point 1.
Elements: Truss
Material: Modulus of elasticity = 30e6 psi
Exercise A FEA Example by Hand
Solution
Building the Model
"New" Select the "New" icon at the left side of the dialog.
"New" Press the "New" button.
Type "Exercise A" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise A
analysis files will be created. This location can be changed
by navigating to an alternate working folder if desired.
"Save" Press the "Save" button.
Access the GEOMETRY pull-down menu and select the
"Geometry: Add: Line"
"Add" pull-out menu. Select the "Line" command.
Mouse Deactivate the "Use as Construction" checkbox.
Type "120" in the "Y:" field in the "Vertex" section of
120<Enter> the "Define Geometry" dialog and press <Enter> to define
the point (0, 120, 0) as the first vertex.
<Enter> Press <Enter> to define the origin as the next vertex.
Type "120" in the "X:" field in the "Vertex" section of
120<Enter> the "Define Geometry" dialog and press <Enter> to define
the point (120, 0, 0) as the next vertex.
<Esc> Press <Esc> to begin a new line.
<Enter> Press <Enter> to define the origin as the first vertex.
Type "120" in the "X:" field in the "Vertex" section of
the "Define Geometry" dialog, press <Tab>, type "120"
120<Tab>120<Enter>
and press <Enter> to define the point (120, 120, 0) as the
final coordinate.
Press the button in the upper right corner of the "Define
Mouse
Geometry" dialog to close it.
Access the VIEW pull-down menu and select the
"View: Orientation: Top
"Orientation" pull-out menu. Select the "Top View"
View"
command.
Defining the Element and Material Data
Right-click on the "Element Type" heading for Part 1 in

Mouse
the tree view.
"Truss" Select the "Truss" command.
Right-click on the "Element Definition" heading for Part 1

Mouse
in the tree view.
"Modify Element
Select the "Modify Element Definition" command.
Definition"
2 Type "2" in the "Cross-Sectional Area" field.
OK Click the OK button.
Right-click on the "Material" heading for Part 1 in the tree
Mouse
view.
"Edit Properties" Press the "Edit Properties" button.
30e6 Type "30e6" in the "Modulus of Elasticity" field.
Click the OK button to close the Element Material
OK
Specification dialog.
OK
Selection dialog.

"Selection: Select: Vertices"
"Select" pull-out menu. Select the "Vertices" command.
Mouse Click on the vertex at point 1.
Select the "Add" pull-out menu and select the "Nodal
"Add: Nodal Force"
Force" command.
-10000 Type "-10000" in the "Magnitude" field.
"Y" Select the "Y" radio button in the "Direction" section.
Mouse With point 1 still selected, right-click again in the display area.
"Add: Nodal Boundary Select the "Add" pull-out menu and select the "Nodal
Condition" Boundary Condition" command.
Activate the "Tz" checkbox in the "Constrained DOFs"
Mouse
section.
Mouse Click on the vertex at point 2.
Holding down the <Ctrl> key, click on the vertices at points
<Ctrl>Mouse
3 and 4.
Press the "Fixed" button in the "Predefined" section of the
"Fixed"
dialog.

Viewing the Results
Access the RESULTS pull-down menu and select the

"Displacement" pull-out menu. Select the "X" command.
"Results: Displacement: X"
The maximum displacement in the X direction is about
0.00414 inches.
"Displacement" pull-out menu. Select the "Y" command.
"Results: Displacement: Y"
The maximum displacement in the Y direction is about
-0.01586 inches.
"Results: Stress: Beam and
"Stress" pull-out menu. Select the "Beam and Truss"
Truss: Axial Stress (Local 1
pull-out menu and select the "Axial Stress (Local 1
Direction)"
Direction)" command.
Access the INQUIRE pull-down menu and select the
"Inquire: Results"
"Results" command.
Click on the fixed end of the horizontal truss. The axial
Mouse
stress should be about -1,036 psi (compression).
Click on the fixed end of the vertical truss. The axial stress
Mouse
should be about 3,964 psi (tension).
Click on the fixed end of the diagonal truss. The axial
Mouse
stress should be about 1,464 psi (tension).
To review a completed archive of this exercise, refer to the file Exercise A.ach in the "Exercise A\
Results Archive" directory.
Exercise B
Truss Frame Model
Truss Elements
Objective: Construct and analyze a frame of truss elements loaded with forces.
Geometry: Model is built in the XY plane (Top View).

Cross-sectional area = 1 in2
Loads: A nodal force of 2,000 pounds downward will be applied to point C.

A nodal force of 1,000 pounds downward will be applied to point E.
Constraints: Fully fixed at point A.

Translation in the Y and Z directions will be constrained at point G.
The rest of the model will be constrained against translation in the Z direction.
Elements: Truss
Material: Aluminum 6061-T6
Exercise B Truss Frame Model
Solution
Building the Model
Type "Exercise B" in the "File name:" field in the "Save
Exercise B
View"
command.
"Geometry: Add: Line" "Add" pull-out menu. Select the "Line" command to
bring up the "Define Geometry" dialog.
Press <Enter> to accept (0, 0, 0) as the coordinate for the
<Enter>
initial vertex at joint A.
Type "432" in the "X" field and press <Enter> to accept
432<Enter>
(432, 0, 0) as the coordinate for joint G.
Press <Esc> to terminate the current line segment and start
<Esc>
a new one.
Type "72" in the "X" field, press <Tab>, type "96" in the
72<Tab>96<Enter> "Y" field and then press <Enter> to accept (72, 96, 0) as
the coordinate for the initial vertex at joint B.
Type "360" in the "X" field, press <Tab>, type "96" in the
360<Tab>96<Enter> "Y" field and then press <Enter> to accept (360, 96, 0) as
the coordinate for the vertex at joint F.
<Esc> Press <Esc> to terminate the current line segment.
<Esc> Press <Esc> to exit the line command.
"View: Enclose" "Enclose" command. Your screen should now look like
Figure B1.
NOTE: For images of this model, the "Draw thicker lines" option has been enabled for better visibility
of the trusses. This setting is found under "Tools: Options: Graphics: Miscellaneous."
Figure B1: Adding Line Segments

"Selection: Select: Lines"
"Select" pull-out menu. Select the "Lines" command.
Mouse Click on the upper horizontal line.
"Geometry: Tools: Divide"
"Tools" pull-out menu. Select the "Divide" command.
OK Click the OK button to divide the line into two segments.
Mouse Click on the lower horizontal line.
3 Type "3" in the "Number of Lines:" field.
Click the OK button to divide the line into three
OK
segments.
Access the VIEW pull-down and select the "Options" pull-
"View: Options: Endpoint
out menu. Select the "Endpoint Vertices" command.
Vertices"
Blue Xs will appear on the vertices.
Move the mouse cursor to the left end of the bottom line
segment (joint A) as shown in Figure B2. When the cursor
Mouse is in the vicinity of the vertex (i.e. endpoint), a "lock" icon
will appear. When the "lock" icon is visible, click to start a
new line segment at the endpoint.
Figure B2: Vertex at Joint A
Move the mouse cursor to the left end of the upper line
segment (joint B) as shown in Figure B3. When the "lock"
Mouse
icon is visible, click to create the next vertex at the existing
endpoint.
Figure B3: Vertex at Joint B
Continue this process, working in a "zigzag" fashion to add

Mouse the remaining lines to joints C, D, E, F, and G to complete
the mesh for the truss assembly.
Your screen should now look like Figure B4.
Figure B4: Completed Truss Mesh

Mouse
the tree view.
"Truss" Select the "Truss" command.
Mouse
in the tree view.
"Modify Element Definition..." Select the "Modify Element Definition" command.
1 Type "1" in the "Cross-Sectional Area" field.
OK Click the OK button to accept the change.
Mouse
view.
Highlight the material "Aluminum 6061-T6; 6061-T651"
"Aluminum 6061-T6; 6061- within the "Aluminum" folder of the "Element Material
T651" Selection" dialog. The associated material properties for
this material are shown in the right half of the dialog.
OK Click the OK button to accept the selected material.
After assigning the material properties, all red Xs and red text should now be removed from the tree view,
indicating that the elements are completely defined.

"Selection: Select: Vertices" "Select" pull-out menu. Select the "Vertices" command.
This will allow you select vertices.
Click on the vertex at point A. When selected, the vertex
Mouse will turn to a magenta color to signify that it is part of the
current selection set.
Press the "Fixed" button. Note that checkmarks appear in
"Fixed"
all six boxes in the "Constrained DOFs" section.
Click the OK button to apply these constraints to the
OK selected vertex. A red triangle will now appear at the
location of the vertex, indicating that it is fully constrained.
Mouse Click on the vertex at point G.
Condition" Boundary Condition" option.
Activate the "Ty" checkbox in the "Constrained DOFs"
Mouse
section to constrain the translation in the Y direction.
Mouse
section to constrain the translation in the Z direction.
Click the OK button to apply these constraints. A red
OK circle will now appear at the location of the vertex,
indicating that it is partially constrained.
Access the SELECTION pull-down menu and select the
"Shape" pull-out menu. Select the "Rectangle"
"Selection: Shape: Rectangle"
command. This will allow you to select multiple vertices
with a rectangle selection box.
Draw a box around the entire model except for the vertices
Mouse
at points A and G (see Figure B5).
Figure B5: Rectangle Select of Vertices

Mouse
to activate the constraint in the Z direction.
OK
selected vertices.
"Selection: Shape: Point" "Shape" pull-out menu. Select the "Point" command.
This will allow you select an object by clicking on it.
Mouse Click on the vertex at joint C.
"Add: Nodal Force"
Force" command.
Type "-2000" in the "Magnitude" field to specify a force
-2000
of 2000 pounds acting in a negative direction.
In the "Direction" section, select the "Y" radio button to
"Y"
specify that the force will be applied in the Y direction.
Click the OK button to apply the force to the selected
OK
vertex.
Mouse Click on the vertex at joint E.
"Add: Nodal Force"
Force" command.
-1000
In the "Direction" section, select the "Y" radio button to
"Y"
Click the OK button to apply the force to the selected
OK
vertex.
Analysis

"Analysis: "Perform Analysis" command to run the analysis. At
Perform Analysis" the completion of the analysis, the program will
Viewing the Results

"Displacement" pull-out menu. Select the "Magnitude"
Magnitude"
command.
Access the RESULTS OPTIONS pull-down menu and
"Results Options: Displaced
select the "Displaced Model Options" command to
Model Options"
bring up the "Displaced Model Options" dialog.
Select the "Mesh" radio button in the "Show Undisplaced

"Mesh"
Model As" section of the dialog.
Press the button in the upper right corner of the
"Displaced Model Options" dialog to close it. Your
Mouse
screen should now look similar to the one shown in
Figure B6.
Figure B6: Displacement Results

"Results: Element Forces and
"Element Forces and Moments" pull-out menu. Select
Moments: 1) Axial Force"
the "1) Axial Force" command.
Access the DISPLAY OPTIONS pull-down menu and
"Display Options: Show
select the "Show Element Numbers" command. Note that
Element Numbers"
the truss element connecting joints C and D is number 8.
"Inquire: Results" "Results" command to bring up the "Inquire: Results"
dialog.
Click on the node at joint D. The "Inquire: Results"
Mouse dialog indicates that the axial force for element number 8 is
416.667 lbf ,as shown in Figure B7.
Press the "Close" button to close the "Inquire: Results"
"Close"
dialog.
Figure B7: Inquire Results Dialog
Validation of Results
The force in truss CD can be verified using the method of sections.
First, the vertical reaction force at joint A is determined by summing the moments about joint G.
Mz = 0
1000(144) + 2000(288) - RA(432) = 0
RA = 1666.667 lbs.
Then, the truss assembly is sectioned though trusses BD, CD, and CE and the vertical forces are balanced.
Fy = 0
1666.667 2000 + FCD(8/10) = 0
FCD = 416.667 lbs.
Comparison of Results
Algor
Theoretical % Difference
Simulation
416.667 416.667 0.00%
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise B.ach
in the "Exercise B\Results Archive" directory.
Exercise C
Support Beam under Gravity
Beam Elements
Objective: Determine the maximum deflection of the beam due to its own weight.
Geometry: The beam is parallel to the X axis.

Cross-section: W10 x 100.
Loads: Gravity is applied in the -Y direction.
Constraints: Far end is constrained against all degrees of freedom except for rotation about the Z axis.
Near end is constrained against all degrees of freedom except for translation in the
X-direction and rotation about the Z axis.
Elements: Beam
Material: Steel (AISI 4130)
Exercise C Support Beam Under Gravity
Solution
Building the Model
Type "Exercise C" in the "File name:" field in the "Save
Exercise C
View"
command.
Mouse Deselect the Use as Construction checkbox.
Press <Enter> to accept (0, 0, 0) as the coordinate for the
<Enter>
initial vertex.
Type "480" in the "X:" field and press <Enter> to accept
480<Enter>
(480, 0, 0) as the coordinate for the next vertex.
Access the VIEW pull-down and select the "Enclose"
"View: Enclose"
command.
Mouse Click on the line that was just created to select it.
"Geometry: Tools: Divide" "Tools" pull-out menu. Select the "Divide" command to
bring up the "Divide Lines" dialog.
Type "10" in the "Number of Lines:" field in the "Divide
10
Lines" dialog.
Click the OK button to divide the single line segment
OK
into 10 line segments.

Mouse
the tree view.
"Beam" Select the "Beam" option.
Mouse
in the tree view.
In the "Element Definition" dialog, click anywhere in the
Mouse
"Layer 1" row to select it.
"Cross-Section Libraries" Press the "Cross-Section Libraries" button.
In the "Cross-Section Libraries" dialog, select the
"aisc2005" "aisc2005" option in the "Section database:" drop-down
box.
"W" Select the "W" option in the "Section type:" drop-down box.
Type "w10" in the "Section name:" field to automatically
w10
scroll down to the start of the W10 cross-sections.
"W10X100" Select the "W10X100" item in the "Section name:" area.
Click the OK button to accept the properties and close
OK
the "Cross-Section Libraries" dialog.
Click the OK button to accept the changes and close the
OK
"Element Definition" dialog.
Mouse
view.
Highlight the "Steel (AISI 4130)" item within the Steel
folder of the Autodesk Algor Material Library. The
"Steel (AISI 4130)"
properties of the selected material will appear in the right
side of the Element Material Selection dialog.
After assigning the material properties, all red Xs and red text should now be removed from the tree view,
indicating that the elements are completely defined.

Mouse Click on the vertex at the left end of the beam.
Press the "Fixed" button in the "Predefined" section of the
"Fixed"
dialog.
Deactivate the "Rz" checkbox in the "Constrained DOFs"
Mouse
section of the dialog.
Click the OK button to apply the constraints to the

OK selected vertex. A red circle will now appear, indicating that
the vertex is partially constrained.
Mouse Click on the vertex at the right end of the beam.
"Fixed" Press the "Fixed" button.
Mouse Deactivate the "Tx" and "Rz" checkboxes.
Click the OK button to apply the constraints to the
OK
selected vertex.
Expand the "Analysis Type" branch in the tree view by
clicking on the plus sign to the left of the icon (if it is not
Mouse
already expanded). Double-click on the "Gravity/
Acceleration" heading.
Press the "Set for standard gravity" button to automatically
"Set for standard gravity"
apply the standard acceleration due to gravity constant.
Type "-1" in the "Y multiplier" field to indicate that
-1
gravity will act in the negative Y direction.
Type "0" in the "Z multiplier" field to disable gravity
0
from acting in the Z direction.
OK Click the OK button to accept the changes.
"Yes" Press the "Yes" button to set the gravity multiplier.
Analysis

Viewing the Results

View"
command.
Use the ViewCube to reposition the model for a Y-up
isometric view of the beam. Specifically, click just inside the
Mouse
upper-right corner of the "Top" face of the cube. A light blue
square at the corner will mark the proper clicking zone.
"View: Display: Shaded with "Display" pull-out menu. Choose the "Shaded with
Mesh" Mesh" command to enhance the 3-D visualization of the
beam shape.
"Results: Displacement: "Displacement" pull-out menu. Select the "Magnitude"
Magnitude" command. The maximum displacement is indicated as 0.305
in, as shown in Figure C1.
Figure C1: Displacement Results

"Shape" pull-out menu. Select the "Rectangle" command.
"Selection: Select: Elements"
"Select" pull-out menu. Select the "Elements" command.
Mouse Draw a box enclosing the entire model.
Access the INQUIRE pull-down menu and select the "Add
"Inquire: Add Shear Diagrams
Shear Diagrams (Axis 2)" command to display the shear
(Axis 2)"
diagram.
"Element Forces and Moments" pull-out menu. Choose
Moments: Local 2 Force"
the "Local 2 Force" command.
The element force results in the local 2 direction and the shear diagram for the same direction should now
appear as shown in Figure C2.
Figure C2: Shear Diagram
With the beam elements still selected, access the INQUIRE

"Inquire: Clear Beam
pull-down menu and select the "Clear Beam Diagrams"
Diagrams"
command to remove the display of the shear diagram.
Access the INQUIRE pull-down menu and select the "Add
"Inquire: Add Moment
Moment Diagrams (Axis 3)" to display the moment
Diagrams (Axis 3)"
diagram as shown in Figure C3.
"Element Forces and Moments" pull-out menu. Choose
Moments: Local 3 Moment"
the "Local 3 Moment" command.
The element moment results about axis 3 and the corresponding moment diagram should now appear as
shown in Figure C3.
Figure C3: Moment Diagram
Reference
Marks Standard Handbook for Mechanical Engineers, Tenth Edition, McGraw-Hill, 1996, page 5-23,
Table 5.2.2.
Theoretical Solution
f is the maximum displacement for a simply supported beam with a uniform load.
5Wl 3
f =
384 EI
The actual total load from gravity can be calculated as follows:
W = (cross-sectional area)(mass density)(gravitational constant)(beam
length)
W = (29.4)(0.000732)(386.4)(480)
W = 3991.5 lb *
* Note that this differs slightly from the nominal specific weight of
the beam times its length (100 lb/ft. * 40 ft. = 4,000 lb.)
Variable Value Units Comments

W 3991.5 lb Calculated total load
l 480 in Length of beam
E 30E6 lb/in2 Modulus of elasticity
I 623 in4 Moment of inertia
Algor
Simulation
0.30753 0.30507 0.8%
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise C.ach in
the "Exercise C\Results Archive" directory.
Exercise D
Axisymmetric Thick-Walled Cylinder
2-D Elements
Objective: Determine the hoop stress at the inner radius of the cylinder from the applied pressure
load.
Geometry: Model is built in the YZ plane (Right View).

The axis of the cylinder is parallel to the Z axis.
Cross-sectional area = 24 in2.
Loads: Uniform internal pressure of 10,000 psi.
Constraints: The bottom surface will be constrained against translation in the Z direction.
Elements: 2-D Axisymmetric
Exercise D Axisymmetric Thick-walled Cylinder
Solution
Building the Model
Start Autodesk Algor Simulation from the Windows Start menu. The mesh for the 2-D elements will
be generated from a sketch in the FEA Editor environment.
Type "Exercise D" in the "File name:" field in the "Save
Exercise D
Right-click on the "Plane 2 < YZ(+X) >" heading in the
Mouse
tree view.
"Sketch" Select the "Sketch" command.
"Geometry: Add: Access the GEOMETRY pull-down menu and select the
Rectangle" "Add" pull-out menu. Select the "Rectangle" command.
Type "7" in the "Y:" field and press <Enter> to define the
7 <Enter>
point (0, 7, 0) as the first corner of the rectangle.
Type "10" in the "Y:" field, press <Tab>, type "8, and
10 <Tab> 8 <Enter> press <Enter> to define the point (0, 10, 8) as the opposite
corner.
"Apply" Press the "Apply" button.
<Esc> Press <Esc> to exit the rectangle command.
"View: Enclose"
"Enclose" command.
Mouse
tree view.
"Sketch" Deselect the "Sketch" command.
Right-click on the "1 < YZ(+X) >" heading in the tree view
Mouse
under Part 1.
"Create 2D Mesh" Select the "Create 2D Mesh" command.

Mouse
the tree view.
"2-D' Select the "2-D"' command.
Mouse
in the tree view.
"Modify Element Definition..." Select the "Modify Element Definition..." command.
In the "Element Definition" dialog, select the
"Axisymmetric" "Axisymmetric" option in the "Geometry Type" drop-
down box.
OK Click the OK button to accept the change.
Mouse
view.
Highlight the material, "Steel (AISI 4130)", from the list of
"Steel (AISI 4130)" available materials within the Steel folder. The properties
of this material can be seen in the right side of the dialog.
After assigning the material properties, all red Xs and red text should now be removed from the tree view.

Select the bottom surface of the model. The chain of lines
Mouse
along the bottom edge of the mesh should turn magenta.
Mouse
section to add the constraint in the Z direction.
OK selected vertices. A red circle will appear on each vertex
along the bottom to indicate that it is partially constrained.
Mouse Click on the left vertical edge of the rectangle.
"Add: Surface Select the "Add" pull-out menu and select the "Surface
Pressure/Traction" Pressure/Traction" command.
10000 Type "10000" in the "Magnitude" field.
OK Click the OK button to apply the pressure.

Click the "Toggle Load and Constraint Display" toolbar
Mouse button to turn off the display of these items, if they are not
already hidden.
Results Evaluation and Presentation
The hoop stress is in the tangential (X) direction, which is normal to the plane formed by the radial (Y) and
axial (Z) directions.

"Results: Stress: Stress "Stress" pull-out menu. Select the "Stress Tensor" pull-
Tensor: 1) XX" out menu and select the "1) XX" command. Your screen
should now look like Figure D1.
Figure D1: Hoop Stress Results
To compare the results with the theoretical value, the hoop stress should be obtained from a node at a
distance removed from free ends or constraints. This will avoid local effects, which the theoretical solution
does not take into account. When comparing FEA results with closed form solutions, it is important to be
aware of any assumptions or limitations of the theoretical solution. We will inquire on the nodal stresses at
the mid-height of the ring (that is, at Z = 4).

dialog.
Click on the node at the middle of the inner radius. The
"Inquire: Results" dialog indicates that node number 71,
Mouse
at coordinates (0, 7, 4), has a stress value of approximately
29,188 psi.
Click on the node at the middle of the outer radius. The
"Inquire: Results" dialog indicates that node number 30,
Mouse
at coordinates (0, 10, 4), has a stress value of approximately
19,208 psi.
"Close"
dialog.
Reference
Roark, R. J. and Young, W. C., Roark's Formulas for Stress and Strain, Fifth Edition, New York, McGraw-
Hill, 1975, page 504, Table 32, Case 1A.
2 is the normal stress in the hoop or tangential direction at radius r.
qb 2 a 2 + r 2
2 = 2 2 2
r a b

a 10 in. Outer radius
b 7 in. Inner radius
q 10,000 psi Internal pressure
r - in. Radial location at which
results are calculated.
For r = 7": 2 = 29,216 psi. For r = 10: 2 = 19,216 psi.
Algor
r Theoretical % Difference
Simulation
7 29,216 29,188 -0.10%
10 19,216 19,208 -0.04%
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise D.ach in
the "Exercise D\Results Archive" directory.
Exercise E
Plate under Uniform Pressure
Plate Elements
Objective: Determine the maximum stress in the plate from the applied pressure load. Use the
4 Point structured meshing tool to make the plate.
Geometry: Model is built in the XY plane (Top View) with the long side parallel to the X axis.
Plate is 10" x 5" x 0.25".
Loads: Uniform pressure of 50 psi
Constraints: The two long edges will be constrained against translation in the Y and Z directions and
rotation in the Z direction.
One of the short edges will be constrained against translation in the X and Z directions.
Elements: Plate
Exercise E Plate Under Uniform Pressure
Solution
Building the Model
Type "Exercise E" in the "File name:" field in the "Save
Exercise E
Access the MESH pull-down menu and select the
"Mesh: Structured Mesh: 4
"Structured Mesh" pull-out menu. Select the "4 Point
Point Rectangular"
Rectangular" command.
20 Type "20" in the "AB:" field.
10 Type "10" in the "BC:" field.
<Enter> Press <Enter> to define the origin as the first point.
Type "10" in the "X:" field and press <Enter> to define
10 <Enter>
the point (10 ,0, 0) as the second point.
Type "10" in the "X:" field, press <Tab>, type "5, and
10 <Tab> 5 <Enter>
press <Enter> to define the point (10, 5, 0) as the third point.
5 <Enter>
point (0, 5, 0) as the fourth point.
"Apply" Press the "Apply" button to create the mesh.
<Esc> Press <Esc> to exit the mesh command.
View"
command. The mesh will appear as shown in Figure E1.
Figure E1: Plate Element Mesh

Mouse
the tree view.
"Plate" Select the "Plate" command.
Mouse
in the tree view.
"Modify Element
Select the "Modify Element Definition..." command.
Definition"
In the "Element Definition" dialog, type "0.25" in the
0.25
"Thickness" field.
Type "100" in the "Normal Point (Z)" field. This will be
100
used to control the direction of the uniform pressure load.
Click the OK button to accept the change and close the
OK
dialog.
Mouse
view.
"Steel (AISI 4130)"
available materials within the Steel folder.
After assigning the material properties, all red Xs should now be removed from the tree view.

Mouse Click on the vertex at the bottom left corner of the plate.
Holding down the <Ctrl> key, click on the vertex at the
<Ctrl> Mouse
upper left corner of the plate to add it to the selection set.
Press the "Pinned" button to activate the translation
"Pinned"
constraints in the X, Y, and Z directions.
OK selected vertices. A red circle will appear on each vertex to
indicate that it is partially constrained.
Draw a box enclosing all of the vertices along the top edge
Mouse
except for the one at the upper left corner (see Figure E2).
Figure E2: Rectangle Select of Upper Vertices
Holding down the <Ctrl> key, draw a box enclosing all of

<Ctrl>Mouse the vertices along the bottom edge except for the one at the
lower left corner.
Activate the "Ty" checkbox in the "Constrained DOFs"
Mouse
section to constrain the translation in the Y direction.

Mouse
Activate the "Rz" checkbox in the "Constrained DOFs"
Mouse
section to constrain the rotation in the Z direction.
OK
selected vertices.
Draw a box enclosing the left edge except for the lower left
Mouse
and upper left corners.
Activate the "Tx" checkbox in the "Constrained DOFs"
Mouse
section to constrain the translation in the X direction.
Mouse
OK
selected vertices.
Click on the + next to the "Surfaces" heading for Part 1 in
Mouse
the tree view to expand this branch.
Right-click on the "Surface 1" heading for Part 1 in the
Mouse
tree view.
OK Click the OK button to apply the pressure.
Analysis

Viewing the Results
The maximum stress is in a direction parallel to the free edge, which for this example is the Y direction.

"View: Orientation: Isometric
"Orientation" pull-out menu. Select the "Isometric
View"
View" command.
Tensor: 2) YY" out menu and select the "2) YY" command. The maximum
stress is indicated as 15,772 psi.
To verify the location of boundary conditions and the
orientation of the pressure, press the "Toggle Load and
Mouse Constraint Display" toolbar button near the bottom of the
screen. Your screen should now look similar to the one
shown in Figure E3.
Figure E3: Stress Tensor Results
Reference
Roark, R. J. and Young, W. C., Roark's Formulas for Stress and Strain, Fifth Edition, New York, McGraw-
Hill, 1975, page 389, Table 26, Case 2A.
max is parallel to the free edge.
Bqb 2
max = = 15,800 psi
t2

a 10 in. Length of long side
b 5 in. Length of short side
q 50 psi Uniform pressure
t 0.25 in. Thickness
B 0.79 - Parameter from
reference based on
a/b ratio of 2.
Algor
Simulation
15,800 15,772 0.18%
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise E.ach
in the "Exercise E\Results Archive" directory.
Exercise F
Cantilever Beam Model
Brick Elements
Objective: Determine the maximum bending stress in the beam from the applied load.
Geometry:
Loads: 10,000 pounds will be applied downward at the free end of the beam. This should be
distributed between the nodes in the center horizontal row. The two end nodes will have
half the force that is applied to the other nodes.
Constraints: The center row of nodes (running in the Y-direction) at the fixed end will be fully
constrained. The remaining nodes at the fixed end will be constrained only against
translation in the X-direction.
Elements: Brick
Exercise F Cantilever Beam Model
Solution
Building the Model
Type "Exercise F" in the "File name:" field in the "Save
Exercise F
We will create a mesh with four elements across the width of the cantilever cross-section and six elements
across the height of the cross-section. Since the bending stresses vary, and in fact reverse, across the cross-
section height, the higher element count in this direction will help to ensure that these bending stresses are
accurately captured. We will then extrude the cross-sectional mesh into a solid mesh, using twenty-four
elements along the length of the cantilever.

Point Rectangular"
<Enter> Press <Enter> to define the origin as the first point.
4 <Enter>
point (0, 4, 0) as the second point.
Type "4" in the "Y:" field, press <Tab>, type "4, and
4 <Tab> 4 <Enter>
press <Enter> to define the point (0, 4, 4) as the third point.
Type "4" in the "Z:" field and press <Enter> to define the
4 <Enter>
point (0, 0, 4) as the fourth point.
"View: Orientation: Right
"Orientation" pull-out menu. Select the "Right View"
View"
command. The mesh will appear as shown in Figure F1.
Figure F1: Four-Point Rectangular Mesh
Mouse Right-click on the "4-Point Mesh 1" heading in the tree view.
"Move or Copy" Select the "Move or Copy" command.
Mouse Activate the "Copy" checkbox.
24 Type "24" in the "Copy" field.
Mouse Activate the "Join" checkbox.
24 Type "24" in the "Total distance" field.
OK Click the OK button to perform the operation.
"Orientation" pull-out menu. Select the "Isometric View"
View"
command. The model should appear as shown in Figure F2.
Figure F2: Brick Mesh
Note that the solid mesh could also have been constructed using the 8 Point 3-D structured meshing tool.

Mouse
the tree view.
"Brick" Select the "Brick" command.
Mouse
view.
"Steel (AISI 4130)"
available materials within the "Steel" folder.
After assigning the material properties, all red Xs and red text should now be gone from the tree view.
To get a profile of the ends of the beam, access the VIEW

"View: Orientation: Front
pull-down menu and select the "Orientation" pull-out
View"
menu. Select the "Front View" command.
"Selection: Shape: Rectangle" "Shape" pull-out menu. Select the "Rectangle"
command.
Draw a box around the top three rows of vertices at the left
Mouse
end of the model to select them (see Figure F3).
Figure F3: Rectangle Select of Vertices
Holding down the <Ctrl> key, draw a box around the bottom
<Ctrl>Mouse three rows of vertices at the left end of the model to also
select these. Only the middle row should remain unselected.
Activate the "Tx" checkbox in the "Constrained DOFs"

Mouse
section.
Click the OK button to apply this constraint to the
OK
selected vertices.
Draw a box around the center row of vertices at the left end
Mouse
of the model.
"Fixed" Press the "Fixed" button to activate all constraints.
OK selected vertices. A red triangle will appear on each vertex
to indicate that it is fully constrained.
View"
View" command.
Access the "Selection" pull-down menu and select the
"Selection: Shape: Point"
"Shape" pull-out menu. Select the "Point" command.
Click on the vertex at the left side of the center row of
Mouse vertices at the free end (the face opposite of the end with the
boundary conditions).
Holding down the <Ctrl> key, click on the vertex at the
<Ctrl> Mouse
right side of the center row of vertices at the free end.
"Add: Nodal Forces"
Forces" command.
-1250
In the "Direction" section, select the "Z" radio button to
"Z"
specify that the force will be applied in the Z direction.
Click the OK button to apply the forces to the selected
OK
vertices.
Click on one of the 3 vertices between the two vertices with
Mouse
the nodal forces.
Holding down the <Ctrl> key, click on the other two
<Ctrl> Mouse
vertices in between the two vertices with the nodal forces.
"Add: Nodal Forces"
Forces" command.
-2500
In the "Direction" section, select the "Z" radio button to
"Z"
specify that the force will be applied in the Z direction.
Click the OK button to apply the forces to the selected
OK vertices. The model should now appear as shown in
Figure F4.
Note that the total force is 10,000 lbf and that the edge node forces are half the magnitude of the interior
node forces (-1,250 = -2,500/2) and (2 * -1,250 + 3 * -2,500 = -10,000).
Figure F4: Completed Brick Element Model
Analysis

Viewing the Results
We will look at the stress tensor in the X-direction, since this is the direction of the bending stress for
this cantilever. The stress inquiry will be performed at a node far removed from the beam corners to
avoid local effects.

Tensor: 1) XX" out menu and select the "1) XX" command. The maximum
stress is indicated as 22,321 psi as shown in Figure F5.
Figure F5: Stress Tensor Results

dialog.
Click on the node at the top middle of the constrained end
which is highlighted in Figure F6. The "Inquire: Results"
Mouse
dialog indicates that the stress for node number 15 at (0, 2, 4)
is 22,099 psi.
Figure F6: Inquire Results Dialog
Click on the nodes at (1, 2, 4), (2, 2, 4), (3, 2, 4), (4, 2, 4),
(5, 2, 4) and (6, 2, 4) down the middle of the beam to obtain
Mouse
the stress values at each node. These values will be used in
the validation of the results in the next section.
"Close"
dialog.
Reference
Mischke, C. R. and Shigley, J. E., Mechanical Engineering Design, Fifth Edition, McGraw-Hill, 1989,
page 44.
M = FL = 10,000 * 24 = 240,000 in.lb.
Mc
bending = = 22,500 psi
I

M 240,000 in.lb. Bending moment
Distance to neutral
c 2 in.
axis
Moment of inertia
I 21.333 in.4
(I = bh3/12)
Algor
Theoretical %
Simulation
(psi) Difference
(psi)
22,500 22,424 -0.34%
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise F.ach
in the Exercise F\Results Archive directory.
Exercise G
Comparing Element Types
Beam, 2-D, Plate and Brick Elements
Objective: Analyze a beam model using different element types and compare the results.
Geometry:
Loads: 100 psi downward along the top.
Constraints: Fixed at left end and simply supported at right end.
Elements: 2-D: The pressure is applied as a 100 psi surface load along the top edge.
Beam: Convert the 100 psi load over the 0.25 in width to a 25 lb/in distributed load.
Plate: Model the 10" x 0.5" dimensions and enter a thickness of 0.25". The pressure
must be converted to forces on the top edge as follows:
(Length/# elements along edge) * Width * Pressure = Force
Force/2 located at the end (i.e., corner) nodes
Plate: Model the 10" x 0.25" dimensions and enter a thickness of 0.5". The pressure is
applied as a -100 psi traction load in the Z direction.
Brick: The pressure is applied as a 100 psi surface load.
Note: This exercise must be performed using two design scenarios or two different analysis models. The
2-D element model must be analyzed separately from the rest of the models because 2-D elements cannot
be included in any model that has nodes outside of the YZ plane (X=0).
Exercise G Comparing Element Types
Solution
Building the 2-D Model
Type "Exercise G" in the "File name:" field in the "Save
Exercise G
Mouse Right-click on the "Design Scenario 1" heading in the tree
"Rename" view and select the "Rename" command.
2-D Model Type "2-D Model" in the "Description" field.
"Mesh: Structured Mesh:
4 Point Rectangular"
Type "1" in the "Z:" field and press enter to define the
1<Enter>
point (0, 0, 1) as the first corner of the rectangle.
Press <Tab>, type "10", press <Tab>, type "1", and press
<Tab>10<Tab>1<Enter> enter to define the point (0, 10, 1) as the second corner of
the rectangle.
Press <Tab>, type "10", press <Tab>, type "1.5", and
<Tab>10<Tab>1.5<Enter> press enter to define the point (0, 10, 1.5) as the third corner
of the rectangle.
Press <Tab> twice, type "1.5", and press enter to define the
<Tab><Tab>1.5<Enter>
point (0, 0, 1.5) as the fourth corner of the rectangle.
View"
command.
command.

Mouse Draw a box around the top edge of the model.
Access the GEOEMTRY pull-down menu and select the
"Geometry: Tools: Modify
"Tools" pull-out menu. Select the "Modify Attributes"
Attributes"
command.
2 Type "2" in the "Surface:" field.
Applying Loads and Constraints

Mouse Draw a box around the left end of the model.
Draw a box around the center node of the right end of the
Mouse
model.
Mouse Activate the "Tx" checkbox.
Mouse Activate the "Tz" checkbox.
Mouse Activate the "Ry" checkbox.
Mouse Activate the "Rz" checkbox.

Mouse
the tree view.
"2-D" Select the "2-D" command.
Mouse
in the tree view.
"Modify Element
Definition"
0.25 Type "0.25" in the "Thickness" field.

Mouse
view.
"Steel (AISI 4130)"
available materials within the Steel folder.
Mouse Click on the + next to the "Surfaces" heading for Part 1.
Mouse Right-click on the "Surface 2" heading.

"Analysis: Perform
"Perform Analysis" command. The model will be
Analysis"
analyzed and then displayed in the Results environment.
Viewing the Results
Inquire on the result types listed in the Results table at the end of the exercise solution (page SE.77) See
how the listed 2-D part values compare with your results.
Building the 3-D Model
We will create a second design scenario in which to build the 3-D model, since we cannot mix 2-D and 3-D
elements within a single analysis. However, the remaining three variants may all be constructed within the
second design scenario.
Access the TOOLS pull-down menu and select the "FEA

"Tools: FEA Editor"
Editor" command.
Mouse Right-click on the "1 <2-D Model>" heading in the tree view.
Select the "Copy" command. A new design scenario
"Copy" heading will appear in the tree view and it will become the
current design scenario.
Mouse Right-click on the "2 <2-D Model>" heading in the tree
"Rename" view and select the "Rename" command.
3-D Model Type "3-D Model" in the "Description" field.
The mesh copied from the 2-D analysis can be used to model the 0.25 thick plate elements. We will have
to delete the pressure load from the top of this part. We will apply equivalent nodal forces later.
Mouse Right-click on the Element Type heading for Part 1 in

Plate the tree view and choose Plate.
Mouse Double-click on the Element Definition heading for Part 1.
0.25 Type 0.25 in the Thickness field.
Click on the + sign to the left of the FEA Object
Mouse
Groups heading in the tree view to expand this branch.
Mouse Right-click on the 3 < Surface Pressure/Tractions >
Delete heading and choose Delete.
Next, we will build the geometry for the beam part, the 0.5 thick plate part, and the brick element part.

2 Type "2" in the "Part:" field.
<Enter> Press <Enter> to define the origin as the first end point.
Press <Tab>, type "10" in the Y: field, and press
<Tab>10<Enter>
<Enter> to define the second end point as (0, 10, 0).
<Esc> Press <Esc> to end the current line.
Mouse Click on the line you just drew.
34 Type "34" in the "Number of Lines:" field.
OK Click the OK button to create the divisions.
Click just inside the top edge of the Right face of the
ViewCube, near the middle of the edge. A light-blue
Mouse rectangle will indicate when you are within the proper
clicking zone. This will provide an oblique view that will
allow us to see the mesh for the next part.
Point Rectangular"
3 <Enter>
point (0, 0, 3) as the first point.
Press <Tab>, type "10" in the Y: field, press <Tab>,
<Tab> 10 <Tab> 3 <Enter> type "3" in the Z: field, and press <Enter> to define the
point (0, 10, 3) as the second corner of the rectangle.
Type "0.25" in the X: field, press <Tab>, type "10" in
0.25 <Tab> 10 <Tab> 3 the Y: field, press <Tab>, type "3" in the Z: field, and
<Enter> press <Enter> to define the point (0.25, 10, 3) as the third
corner of the rectangle.
Type "0.25" in the X: field, press <Tab> twice, type "3"
0.25 <Tab> <Tab> 3
in the Z: field, and press <Enter> to define the point
<Enter>
(0.25, 0, 3) as the fourth corner of the rectangle.
4 <Enter>
point (0, 0, 4) as the first point.
Press <Tab>, type "10" in the Y: field, press <Tab>,
<Tab> 10 <Tab> 4 <Enter> type "4" in the Z: field, and press <Enter> to define the
point (0, 10, 4) as the second corner of the rectangle.
Press <Tab>, type "10", in the Y: field, press <Tab>,
<Tab> 10 <Tab> 4.5
type "4.5" in the Z: field, and press <Enter> to define
<Enter>
the point (0, 10, 4.5) as the third corner of the rectangle.
Press <Tab> twice, type "4.5" in the Z: field, and press
<Tab> <Tab> 4.5 <Enter> <Enter> to define the point (0, 0, 4.5) as the fourth corner of
the rectangle.
Mouse Right-click on the "4-Point Mesh 3" heading in the tree view.
"Move or Copy" Select the "Move or Copy" command.
Mouse Activate the "Copy" checkbox.
2 Type "2" in the "Copy" field.
Mouse Activate the "Join" checkbox.
0.25 Type "0.25" in the "Total distance" field.
"DX" Select the "DX" radio button.
OK Click the OK button to perform the operation.
View"
command.
Mouse Draw a box enclosing the top edge of Part 4 (light-blue).
"Geometry: Tools: Modify
"Tools" pull-out menu. Select the "Modify Attributes"
Attributes"
command.

View"
View" command to verify that the model appears correctly.
Applying Loads and Constraints

View"
command.
Draw a box enclosing the left endpoint of the bottom
(beam) part (Part 2).
Holding down the <Ctrl> key, draw a box around the left
Mouse
end of the two top parts (Parts 3 and 4).
Draw a box around the right end of the bottom (beam) part
Mouse
(Part 2).
Holding down the <Ctrl> key, draw a box around the right
<Ctrl> Mouse
end of Part 3.
Holding down the <Ctrl> key, draw a box around only the
<Ctrl> Mouse
center node of the right end of Part 4.
Mouse Activate the "Tx" checkbox.
Mouse Activate the "Tz" checkbox.
Mouse Activate the "Ry" checkbox.
Mouse Activate the "Rz" checkbox.
Draw a box around the top edge of Part 1 (second part from
Mouse
the bottom), excluding the two corner nodes.
"Add: Nodal Forces"
Forces" command.
Type "-250/34=" in the "Magnitude" field. The resultant
-250/34=
force per node of -7.35294 lbf will be shown.
"Z" Select the "Z" radio button.
The leftmost and rightmost nodes will see a force half the magnitude of the remaining nodes along the top
edge. However, since the node at the top left corner is fully constrained, a force there will have no effect. We
will therefore omit this particular nodal force and apply the reduced force only to the top right corner node.
Draw a box around the node at the top right corner of Part 1
Mouse
(second part from the bottom).
"Add: Nodal Force"
Force" command.
Type "-250/68=" in the "Magnitude" field. The resultant
-250/68=
force per node of -3.67647 lbf will be shown.
Defining the Remaining Element and Material Data

Mouse
the tree view.
"Beam" Select the "Beam" command.
Mouse
in the tree view.
"Modify Element
Definition"
Click in one of the fields for Layer 1 in the "Sectional
Mouse
Properties" table.
Select the "Rectangular" option in the User-Defined
"Rectangular"
drop-down box in the upper right corner.
0.25 Type "0.25" in the "b" field.
0.5 Type "0.5" in the "h" field.
Click the OK button to exit the Cross-Section Libraries
OK
dialog.
OK Click the OK button to exit the Element Definition dialog.
Mouse
view.
"Steel (AISI 4130)"
Mouse Draw a rectangle around all of the beam elements.
"Add: Beam Distributed Select the "Add" pull-out menu and select the "Beam
Loads" Distributed Loads" command.

Mouse
the tree view.
"Plate" Select the "Plate" command.
Mouse
in the tree view.
"Modify Element
Definition"
0.5 Type "0.5" in the "Thickness" field.
Mouse
view.
"Steel (AISI 4130)"
"Traction" Select the "Traction" radio button.
-100 Type "-100" in the "Z Magnitude" field.
Mouse
the tree view.
"Brick" Select the "Brick" command.
Mouse
view.
"Steel (AISI 4130)"

"Analysis: Perform
Analysis"
analyzed and then displayed in the Results environment.
Viewing the Results
Mouse Click on the heading for Part 2 in the tree view.

Holding down the <Shift> key, right-click on the heading
<Shift>Mouse
for Part 4 in the tree view.
Select the "Hide" command. The legend will be updated to
"Hide" only show the range for the stress in Part 1. You can use this
command to view the results for each part individually.
Results: Displacement:
"Displacement" pull-out menu. Choose the "Magnitude"
Magnitude
command.
Right-click on the various parts in the tree view and
alternately Show and/or Hide them until you have
reviewed the individual stress results for each part. Also,
Mouse
review the various applicable results for each part (bending
Show and/or Hide
and shear stresses and reactions. Compare your results for
the various parts to each other and to those listed in the
table below.
Results
Displacement X-Reaction Shear y* y* yz
Element Type Magnitude Moment * Force * Max. at mid-span Max.
(inch) (in-lb) (lb) (psi) (psi) (psi)
2-D 0.01751 ** ** 28,349 14, 976 1,625
First Plate Model
0.01751 ** ** 28,349 14,976 1,625
(0.25" Thick)
Beam 0.01761 311.9 156.2 29,933 15,024 **
Second Plate Model
0.01722 313.5 *** ** 30,413 14,929 **** **
(0.5" Thick)
Brick 0.01741 ** ** 29,331 14,912 **** 1,814
Values above are magnitudes. Actual results may be positive or negative.
Notes: * For the beam element part, the Local 3 Moment corresponds to the X-Reaction Moment; the
"Local 2 Force" corresponds to the Shear Force; and the "Bending Stress in Local 3 Direction"
corresponds to the bending stress ( y).
** This result type is not calculated for this element type.
*** The X-Reaction moment for the 0.5 thick plate is the sum the reactions for all fixed nodes.
**** This stress was determined at the node in the middle of the 0.25 thickness.
To review a completed archive of this exercise, refer to the file Exercise G.ach in the "Exercise G\Results
Archive" directory.
Exercise H
Mesh Convergence
2-D Elements
Objective: To perform a static stress analysis with linear material models on a classical problem,
utilizing different meshes densities to determine where convergence occurs. Use mesh
density settings of 200, 400, 800, 1600, 3200, and 6400. Increase the 2-D mesh
generation "Angle" from the default value of 15 to 30 degrees. This will ensure that the
mesh density controls the element size for all cases, otherwise the angle would control
the element size for coarser meshes.
Geometry: The part shown below is 1" thick.
Loads: 1,000 psi on the right edge.
Constraints: Fully fixed at the left end.
Elements: 2-D Plane Stress
Material: Stainless Steel (AISI 302) Cold-rolled
Exercise H Mesh Convergence
Solution
Building the Model
The mesh for the 2-D elements will be generated from a sketch in the FEA Editor environment. Start
Autodesk Algor Simulation from the Windows Start menu.
Type "Exercise H" in the "File name:" field in the "Save
Exercise H
Mouse
tree view.
"Geometry: Add: Access the GEOMETRY pull-down menu and select the
Rectangle" "Add" pull-out menu. Select the "Rectangle" command.
Press <Enter> to define the origin as the first corner of the
<Enter>
rectangle.
Type "4" in the "Y:" field, press <Tab>, type "1.5, and
4 <Tab> 1.5 <Enter> press <Enter> to define the point (0, 4, 1.5) as the opposite
corner.
<Esc> Press <Esc> to exit the rectangle command.
"Geometry: Add: Circle:
"Add" pull-out menu. Select the "Circle" pull-out menu
Center and Radius"
and select the "Center and Radius" command.
2 <Enter>
point (0, 2, 0) as the center of the circle.
Type "2.45 in the "Y:" field and press <Enter> to define
2.45 <Enter>
the point (0, 2.45, 0) as a point on the circle.
<Esc> Press <Esc> to exit the circle command.
Access the VIEW pull-down and select the "Enclose"
"View: Enclose"
command.
"Selection: Select:
"Select" pull-out menu. Select the "Construction
Construction Objects"
Objects" command.
"Geometry: Tools: Trim"
"Tools" pull-out menu. Select the "Trim" command.

Mouse Click on the circle.
Click on the lower half of the circle. It will be removed
Mouse
from the sketch.
Mouse Click on the semicircle.
Click on the part of the horizontal line inside the circle. It
Mouse
will be removed from the sketch.
<Esc> Press <Esc> to exit the trim command.
"Geometry: Add: Line"
"Add" pull-out menu. Select the "Line" command.
Type "0.75" in the "Z:" field and press <Enter> to define
0.75 <Enter>
the point (0, 0, 0.75) as the beginning of the line.
Type "4" in the "Y:" field, press <Tab>, type "0.75" and
4 <Tab> 0.75 <Enter> press <Enter> to define the point (0, 4, 0.75) as the end of
the center line.
<Esc> <Esc> Press <Esc> twice to exit the line command.
Mouse Click on the semicircle.
"Geometry: Tools: Mirror"
"Tools" pull-out menu. Select the "Mirror" command.
"Pick" Press the "Pick" button.
Mouse Click on the middle horizontal line.
"Geometry: Tools: Trim"
"Tools" pull-out menu. Select the "Trim" command.
Mouse Click on the upper semicircle.
Mouse Click on the upper horizontal line.
Click on the part of the horizontal line inside the circle. It
Mouse
will be removed from the sketch.
<Esc> Press <Esc> to exit the trim command.
Mouse Click on the middle horizontal line.
Access the EDIT pull-down menu and select the "Delete"
"Edit: Delete"
command.
Mouse
tree view.
Right-click on the "1 < YZ(+X) >" heading for Part 1 in
Mouse
the tree view.
"Create 2D Mesh" Select the "Create 2D Mesh" command.
200 Type "200" in the "Mesh Density" field.
"Apply" Press the "Apply" button to generate the mesh.
Defining the Element Parameters

Mouse
the tree view.
"2-D" Select the "2-D" command.
Mouse
in the tree view.
"Modify Element
Definition"
1 Type "1" in the "Thickness" field.
Right-click on the "Material" heading in the tree view
Mouse
under Part 1.
"Modify Material" Select the "Modify Material" command in the menu.
"Stainless Steel (AISI 302) Select the material, "Stainless Steel (AISI 302) Cold-rolled",
Cold-rolled" from the list of available materials in the Steel folder.
Adding the Loads and Constraints

Mouse Click on the surface at the right end.
"Add: Surface In the menu, select the "Add" pull-out menu and select the
Pressure/Traction" "Surface Pressure/Traction" command.
Mouse Click on the surface at the left end.
"Add: Surface Boundary In the menu, select the "Add" pull-out menu and select the
Condition" "Surface Boundary Condition" command.

"Analysis: Perform
Analysis"
analyzed and will be loaded in the Results environment.
Viewing the Results

"Stress" pull-out menu. Select the "Stress Tensor" pull-
"Results: Stress: Stress
out menu. Select the "2) YY" command. The accepted
Tensor: 2) YY"
value for the stress in this direction is 3,560 psi based upon
known stress concentration behavior.
Record the stress value in the following table so that the results for each trial mesh density setting may be
easily compared:
Mesh Density Maximum YY Stress (psi)

200
400
800
1,600
3,200
6,400
Analyzing the Model with Different Mesh Sizes

"Tools: FEA Editor"
Editor" command.
Mouse Right-click on the "2-D Mesh 1" heading in the tree view.
"Modify" Select the "Modify" command.
value Type the next mesh density value in the "Mesh Density"
"Apply" field and press the "Apply" button.
Repeat the steps from "Running the Analysis" through the
end of the exercise until the stress results for all specified
mesh densities have been obtained and recorded.
To review a completed archive of this exercise, refer to the file Exercise H.ach in the "Exercise H\Results
Archive" directory. All six trials have been combined into a single model and design scenario for easy
comparison.
Exercise I
Bracket Model
Brick Elements
Objective: Determine the maximum stress in the bracket from a load applied at the hole. Use default
mesh settings.
Geometry: Use the Exercise I.igs file located in the "Exercise I\Input File" directory. Use the default
mesh settings.
Fully constrain
the back surface.
Apply 40 pound load

downward (-Y) at hole.
Loads: 40 pounds will be applied downward at the hole (that is, in the Y direction).
Constraints: The back surface (-X end of bracket) is fully constrained.
Elements: Brick
Exercise I Bracket Model
Solution
Meshing the Model
"Open" Select the "Open" icon at the left side of the dialog
Select the "IGES (*.igs, *.iges)" option in the CAD Files
"IGES (*.igs, *.iges)" section of the "Files of type" drop-down box. Navigate to
the directory where the model is located.
Select the Exercise I.igs file in the "Exercise I \Input File"
Exercise I.igs
directory.
If the desired analysis type is not already selected, click on
Mouse
the arrow button to the right of the analysis type field.
"Linear: Static Stress with
Select the Linear pull-out menu and choose the Static
Linear Material Models"
Stress with Linear Material Models" option.
"Mesh: Generate Mesh"
"Generate Mesh" command.
"No" Press the "No" button when asked to view the mesh results.

Mouse
view.
"Modify: Material" Select the "Modify Material" command.
Highlight the material, "Steel (ASTM - A514)" near the
bottom of the list of available materials in the "Steel folder.
Access the VIEW pull-down menu, select the

"Orientation" pull-out menu, and choose the Right
View"
View command.
"Selection: Select: Surfaces" "Select" pull-out menu. Select the "Surfaces" command.
This will allow you to select the surfaces.
Click on the large square surface, which is the base of the

Mouse
bracket.
OK Click the OK button to apply these constraints.
Click just inside the right edge of the ViewCube face, about
midway between the top and bottom corners. A light-blue
rectangle will indicate the correct clicking zone. This will
Mouse
reposition the model to an oblique view in which the two
half-cylindrical surfaces of the hole through the bracket will
both be visible.
Mouse Click on one of the two surfaces on the inside of the hole.
<Ctrl>Mouse Holding down the <Ctrl> key, click on the second surface.
"Add: Surface Forces"
Forces" command.
Type "-20" in the "Magnitude" field to specify a force of
20 pounds in the negative Y direction on each of the surfaces.
-20
This force will be evenly distributed across each of the
surfaces so that the total magnitude will be 40 pounds.
Select the "Y" radio button, in the "Direction" section, to
Mouse
OK Click the OK button to apply these surface forces.
View"
command. Your model should now look like Figure I1.
Figure I1: Bracket with Constraints and Loads Applied
Analysis

Viewing the Results

"View: Orientation:
"Orientation" pull-out menu. Select the "Axonometric
Axonometric View"
View" command. The model should look like Figure I2.
Figure I2: Displaced Model Showing von Mises Stresses
To review a completed archive of this exercise, refer to the file Exercise I.ach in the "Exercise I\Results
Archive" directory.
Exercise J
Hanger Assembly Model
Brick Elements
Objective: Determine the maximum stress in the hanger assembly from a load applied at the center
of the shaft.
Geometry: Use the Exercise J.ach file located in the "Exercise J\Input File" directory. Mesh the
model at 90% of the default mesh size.
Loads: 100 pounds will be applied in the downward (-Y) direction. Apply the load to a full ring
of nodes at the center of the shaft span.
Constraints: The bottom surfaces of the brackets will be fully constrained.
Elements: Brick
Material: Brackets: Iron, Fe

Shaft: Steel (AISI 4130)
Exercise J Hanger Assembly Model
Solution
Meshing the Model
Select the "Algor Simulation Archive (*.ach)" option in
"Algor Simulation Archive the Algor Simulation Files section of the "Files of type"
(*.ach)" drop-down box. Navigate to the directory where the model
is located.
Select the Exercise J.ach file in the "Exercise J \Input File"
Exercise J.ach
directory.
Select the location where you want the model to be
OK
extracted and Click the OK button.
"Mesh: Model Mesh
Mesh Settings" command to mesh the model using
Settings"
default settings.
Mouse Move the "Mesh size" slider towards the right until the
"90%" indicator shows "90%."
"Mesh model" Press the "Mesh model" button.
Press the "No" button when asked to view the mesh results.
"No"
A mesh will be displayed at this time.
Mouse Click on the "Material" heading for Part 1 in the tree view.
<Ctrl>Mouse
Highlight the material, "Iron, Fe", from the list of
"Iron, Fe"
available materials within the Iron folder.
Mouse
view.
Highlight the material, "Steel (AISI 4130)", from the list
"Steel (AISI 4130)"
of available materials within the "Steel folder.

This will allow you to select the surfaces.
Mouse Click on the bottom of one of the brackets.
Holding down the <Ctrl> key, click on the bottom of the
<Ctrl>Mouse
other bracket.
View"
command.
"Selection: Select: Vertices" "Select" pull-out menu. Select the "Vertices" command.
This will allow you to select the vertices.
Click and drag the mouse to enclose the ring of vertices
nearest to the middle of the shafts span. Distributing the
Mouse total load over these nodes will prevent a local stress
exaggeration at the point of load attachment. Hint: The
Z-coordinate at the mid-span of the shaft is 7.465".
Mouse Right-click in the display.
"Add: Nodal Forces"
Forces" command.
Note the number of nodes listed in the "Creating Nodal
Force Object" dialog box (16). Type "-100/16=" in the
-100/16=
"Magnitude" field. This will calculate and enter the
resultant force of -6.25 lbs. per node.
Select the "Y" radio button in the "Direction" section to
"Y"
Click the OK button to apply this force. The model
OK
should now look like Figure J1.
Figure J1: Bracket with Constraints and Loads Applied
Analysis
"Analysis: Access the ANALYSIS pull-down menu and select the

Perform Analysis" "Perform Analysis" command to run the analysis.
Click the OK button to dismiss the pop-up message at the
OK completion of the analysis. The model will be displayed
within the Results environment.
Viewing the Results

View"
View" command. The model should look like Figure J2.
Figure J2: von Mises Stress, Displaced Model
To review a completed archive of this exercise, refer to the file Exercise J.ach in the
"Exercise J\Results Archive" directory.
Exercise K
Linear Contact Model
Brick Elements
Objective: Determine the stress in the assembly for a maximum upward load of 1000 pounds applied
at the bottom of the exposed end of the latch.
Geometry: Use the Exercise K.stp file located in the "Exercise K\Input File" directory.
Loads: 1,000 pounds upward force will be applied at the extended underside of the sliding latch.
Constraints: The four bolt holes will be fully constrained.

"Rigid" boundary elements with a stiffness of 100 lbf/in will be applied in the X, Y, and
Z directions to the back end surface of the sliding latch.
Elements: Brick An absolute mesh size of 0.15 in. will be used.
Material: Sliding Latch: Iron, Fe

Handle: Brass, Red
Housing & Base Plate: Steel (ASTM - A36)
Contact: The default contact is bonded. Two surface contact pairs should be created:
1. Between the sliding latch and the housing
2. Between the sliding latch and the base plate
Exercise K Linear Contact Model
Solution
Meshing the Model
"STEP (*.stp, *.ste, *.step)" Files section of the "Files of type" drop-down box. Navigate
to the directory where the model input file is located.
Select the Exercise K.stp file in the "Exercise K \Input File"
Exercise K.stp
directory.
Choose the option to "Use STEP file units" if it is not
already selected and click the OK button. The original
OK
STEP file length unit is inches.
If the desired analysis type is not already selected, click on
Mouse
the arrow button to the right of the analysis type field.
"Linear: Static Stress with
Select the Linear pull-out menu and choose the Static
Linear Material Models"
Stress with Linear Material Models" option.
For the latch assembly, the contact areas include the interface between the sliding latch and the housing and
between the sliding latch and the base plate. For the purpose of this example, the remaining part interfaces
will be bonded. The default contact option of "Bonded" will be kept and two contact pairs will be defined
as "Surface Contact," overriding the default. This type of contact will prevent the surfaces from
penetrating each other, but will allow them to pull away from each other or slide relative to each other with
no resistance.
Mouse Click on the heading for Part 2 in the tree view (the housing).
Holding down the <Ctrl> key, click on the heading for Part
<Ctrl> Mouse
4 in the tree view (the sliding latch).
Select the "Contact" pull-out menu and select the "Surface
"Contact: Surface Contact"
Contact" command. Press the <Enter> key to accept the
<Enter>
default contact pair name and to complete the command.
Mouse Click on the heading for Part 3 in the tree view (the base plate).
Holding down the <Ctrl> key, click on the heading for
<Ctrl> Mouse
Part 4 in the tree view (the sliding latch).
Select the "Contact" pull-out menu and select the "Surface
Contact" command. Press the <Enter> key to accept the
<Enter>
default contact pair name and to complete the command.
"Mesh: Model Mesh Access the MESH pull-down menu and select the "Model
Settings" Mesh Settings" command.
"Options" Click on the "Options" button.
Select "Absolute mesh size" from the "Type" pull-down

"Absolute mesh size"
menu.
0.15 Enter "0.15" in the "Size" field.
OK Click on the OK button to exit the options dialog.
"Mesh model" Press the "Mesh model" button to create the mesh.
Defining Element and Material Data
Double-click on the "Material" heading for Part 1 in the

Mouse
tree view. This will open the material selection screen.
Highlight the material, "Brass, Red", within the Brass
"Brass, Red"
folder of the Autodesk Algor Material Library..
OK Click the OK button to accept this material for the handle.
Mouse Select the "Material" heading for Part 2 in the tree view.
<Ctrl>Mouse
Select the "Modify" pull-out menu and select the
"Modify: Material"
"Material." command.
Highlight the material, "Steel (ASTM-A36)", near the bottom
"Steel (ASTM-A36)"
of the list of available materials within the Steel folder.
Click the OK button to accept this material for the
OK
housing and base plate.
Mouse
tree view.
Highlight the material, "Iron, Fe", from the list of
"Iron, Fe"
available materials within the Iron folder.
Click the OK button to accept this material for the sliding
OK
latch.
After assigning the material properties, all red Xs should now be removed from the tree view.
"View: Orientation: Top Access the VIEW pull-down menu, select the "Orientation"
View" pull-out menu, and choose the "Top View" command.
"Selection: Shape: Circle" "Shape" pull-out menu. Select the "Circle" command. This
will allow you select objects within a circular selection zone.
This will set a filter to allow you to select surfaces.
Click near the center of one of the bolt holes and drag the
Mouse mouse to make a circular selection area large enough to
encompass the ID surfaces of one bolt hole.
While holding down the <Ctrl> key, repeat this selection

procedure for the remaining three holes. Since you are
<Ctrl>Mouse looking at the edge of the surface, the magenta coloring
indicating that the surface has been selected may not be
readily apparent unless you rotate the view.
Click just inside the top edge of the ViewCube face, about
midway between the top corners. A light blue rectangle
Mouse will indicate the correct clicking zone. This will provide an
oblique view of the assembly with the back of the sliding
latch visible.
"Selection: Shape: Point" "Shape" pull-out menu. Select the "Point" command. This
will allow you select objects by clicking on them.
Mouse Click on the surface at the back end of the sliding latch.
"Add: Surface Rigid Select the "Add" pull-out menu and select the "Surface
Boundaries" Rigid Boundaries" command.
Mouse Activate the checkboxes to apply the boundary elements in
"X," "Y," and "Z" the "X," "Y," and "Z" directions.
Enter "100" in the "Stiffness" field. This soft boundary
provides stability during the contact solution by preventing
100
rigid-body motion but is small enough to produce an
insignificant reaction at the surface for the converged solution.
"View: Orientation: Bottom Access the VIEW pull-down menu, select the "Orientation"
View" pull-out menu, and choose the "Bottom View" command.
Click on the surface at the extended underside of the sliding
Mouse
latch.
"Add: Surface Force"
Force" command.
1000 Enter "1000" in the "Magnitude" field.
Mouse Activate the "Z" direction radio button.
OK Click the OK button to apply this force.
"View: Orientation: Isometric Access the VIEW pull-down menu, select the "Orientation"
View" pull-out menu, and choose the "Isometric View" command.
Analysis
"Analysis: Access the ANALYSIS pull-down menu and select the

Perform Analysis" "Perform Analysis" command to run the analysis.
Click OK to dismiss the pop-up message when the

OK analysis has finished. The model will be displayed in the
Results environment.
Viewing the Results
There are many options available in the Results environment to customize the presentation of results. For
this exercise, the stress range and the legend box precision and font will be modified.
"Display Options: Access the DISPLAY OPTIONS pull-down menu and

Plot Settings" select the "Plot Settings" command.
Mouse Select the "Legend Properties" tab.
Using the down-arrow next to the "Precision" field,
Mouse
decrease the precision from 7 to "5".
"Font" Press the "Font " button.
Select the "16" option in the "Size:" field. Note that you
"16"
can also change the font to any of the TrueType fonts listed.
Click the OK button to accept the changes to the legend
OK
box font.
Mouse Select the "Range Settings" tab.
Deactivate the "Automatically calculate value range"
Mouse
checkbox.
0 Type "0" in the "Low" field.
Type "20000" in the "High" field. Any areas with stresses
larger than this value will now be rendered using the highest
color in the legend box (typically red). One common use of
20000 this feature is to set the value to the yield stress of the
material in order to quickly see what areas of the model may
have yielded. Another is to bring out the full range of colors
when focusing on more lowly stressed regions of the model.
Click the OK button and your presentation should now
OK
look similar to the one shown in Figure K1.
Figure K1: Stress Results
This completes the exercise. To review a completed archive of this exercise, refer to the file Exercise
K.ach in the "Exercise K\Results Archive" directory.
Exercise L
Thermal Model
Brick Elements
Objective: To analyze the thermal effects of a block that has hot and cold water passages running
through it.
Geometry: Use the Exercise L.ach file located in the "Exercise L\Input File" directory. Use 80% of
the default mesh size.
Loads: Largest Hole:

Water temperature (ambient): T = 65 F
in lbs
Convection coefficient: H = 1.4
in 2 sec F
Second Largest Hole:

Water temperature (ambient): T = 180 F
in lbs
Convection coefficient: H = 28
in 2 sec F
Elements: Brick
Exercise L Thermal Model
Solution
Meshing the Model
Select the "Algor Simulation Archive (*.ach)" option in
"Algor Simulation Archive the Algor Simulation Files section of the "Files of type"
(*.ach)" drop-down box. Navigate to the directory where the model
is located.
Select the Exercise L.ach file in the "Exercise L\Input File"
Exercise L.ach
directory.
Select the location where you want the model to be
extracted and click the OK button. Note that the analysis
OK
type has already been set to Steady-State Heat Transfer for
the input archive.
"Mesh: Model Mesh Access the MESH pull-down menu and select the "Model
Settings" Mesh Settings" command.
Mouse Move the "Mesh size" slider towards the right until the
"80%" indicator shows "80%."
"Mesh model" Press the "Mesh model" button.
Defining the Element Data

Mouse
view.
Highlight the material, "Steel (ASTM - A514)", from the
list of available materials within the Steel folder.
Mouse Click on one of the surfaces of the largest hole.
Holding down the <Ctrl> key, click on the second surface
<Ctrl>Mouse of the largest hole. Rotate the model slightly, if desired, to
clearly see both surfaces of the hole.
"Add: Surface Convection Select the "Add" pull-out menu and select the "Surface
Loads" Convection Loads" command.
Type "1.4" in the "Temperature Independent
1.4
Convection Coefficient" field.
65 Type "65" in the "Temperature" field.

Mouse Click on one of the surfaces of the second largest hole.
Holding down the <Ctrl> key, click on the other surface of
<Ctrl>Mouse the second largest hole. Rotate the model slightly, if
desired, to clearly see both surfaces of the hole.
"Add: Surface Convection Select the "Add" pull-out menu and select the "Surface
Loads" Convection Loads" command.
Type "28" in the "Temperature Independent Convection
28
Coefficient" field.
180 Type "180" in the "Temperature" field.

"Analysis: Perform
Analysis"
displayed in the Results environment and solved.
Viewing the Results
"View: Orientation: Isometric Access the VIEW pull-down menu, select the "Orientation"
View" pull-out menu, and choose the "Isometric View" command.
The small circles on the surfaces of the two largest holes
indicate the applied surface convection loads. Click the
Mouse "Toggle Load and Constraint Display" toolbar button to
turn off the display of the load and constraint symbols. Your
screen should now look similar to Figure L1.
Figure L1: Temperature Results
We will now check the temperature of the top surface of the block.

"Inquire: Results"
"Results" command.
Click on a node on the top face (hot end) of the model. The
"Inquire: Results" dialog will report that the temperature
Mouse
is somewhere between 174.3 and 176.6 degrees, depending
upon which node was selected.
To review a completed archive of this exercise, refer to the file "Exercise L.ach" in the "Exercise L\Results
Archive" directory.
Exercise M
Mechanical Event Simulation (MES), Geneva Mechanism
Brick and Pipe Elements
Objective: Create universal joints for the rotation, loading, and constraining of two CAD-
based parts. Define surface to surface contact to produce the proper component
interaction. The drive wheel will be rotated one-half of a revolution to produce
a single, 90 indexing movement of the driven wheel. Produce a von Mises
stress animation as well as a graph showing the displacement magnitude versus
time at the drive wheel's indexing pin and at the OD of the driven wheel.
Geometry: Use the Exercise M.stp file located in the "Exercise M\Input File" directory. See
next page for meshing, geometry modification, and contact setup instructions.
Joint 1 center vertex location; (0, 0, -0.125)

Joint 2 center vertex location; (1.414214, 0, -0.125)
Joint 3 center vertex location; (0, 0, 0.875)
Joint 4 center vertex location; (1.414214, 0, 0.875)
Loads: Initial velocity of 30 rpm about axis through Joints 1 and 3 (parallel to Z-axis)
applied to the Drive Wheel (Part 1)
Prescribed displacement of a half-revolution in one second (30 rpm) at Joint 3.
Constant 2 lbf.in. nodal Z-moment at Joint 4 (Assign to Load Curve 2 and set a
"Death Time" of 1 second for Active Range 1 to ensure that the displacement
remains active for the entire simulation event.)
Nodal lumped mass at Joint 4 Uniform mass of 0.00088 lbf s2/in and a mass
moment of inertia in the Z-direction of 0.00135 lbf s2 in. These values simulate
a steel disk 1/8 thick with a diameter of 3.5
Exercise M Mechanical Event Simulation (MES), Geneva Mechanism
Constraints: Center vertices of Joints 1 and 2 Fixed except for Rz

Center vertices of Joints 3 and 4 Tx, Ty, Rx and Ry
Elements: Drive and Driven Wheels Brick, Analysis Type = "Large Displacement"
Joints Pipe, O.D. = 0.1", Wall Thickness = 0.03"
Materials: Drive Wheel (Part 1) Brass, Red

Driven Wheel (Part 2) Plastic- Nylon Type 6/6
All Joints Custom Density=0.0, Modulus of Elasticity =100E6,
Poisson's = 0.0, Shear Modulus of Elasticity = 0.0
Analysis Parameters: Duration = 1 second

Capture rate = 90 (This will produce a resultant time step for every 2 of drive
wheel rotation.)
Displacement Tolerance = 0.02 (found under the "Equilibrium" tab of the
advanced analysis parameters dialog. Disable "Automatic" tolerance control.)
Load Curve Information:

Load Curve 1 (Prescribed Rotation) Time Multiplier
(s)
0 0
1 1
Load Curve 2 (Nodal Moment) Time Multiplier

(s)
0 1
1 1
Meshing, Geometry Modification, and Surface Contact Setup Instructions:

1. Set the default contact = Free/No Contact and define a surface contact
pair between Part 1 and Part 2, which will prevent mesh matching between
the parts (this is desirable for MES contact surfaces).
2. Mesh the model at an absolute mesh size of 0.0625.
3. Modify line attributes to consolidate the contact surfaces. Use surface 100
for the 1st contact pair, 101 for the 2nd, and 102 for the 3rd. For the drive
wheel, surfaces 100 and 101 will each encompass approximately one-third
of the perimeter of the wheels C-shaped cylindrical contact surface.
4. From the General Surface-to-Surface Contact settings, redefine the first
pair to be Part 1/Surface 100 to Part 2/Surface 100. Create two more pair;
Part 1/Surface 101 to Part 2/Surface 101 and Part 1/Surface 102 to
Part 2/Surface 102. Set the contact element Updating to Automatic.
Set the contact parameters for all three pair as follows
Contact problem type = High Speed Contact (Impact)
Contact type = Surface to Surface
User specified contact stiffness = 1000 lbf/in
User specified contact tolerance = 0.0011 (eliminates clearance and
chatter).
Solution
Meshing the Model
"Open" Select the "Open" icon at the left side of the dialog.
Files section of the "Files of type" drop-down box.
"STEP (*.stp, *.ste, *.step)"
Navigate to the directory where the model input file is
located.
Select the Exercise M.stp file in the "Exercise M\Input File"
Exercise N.stp
directory.
Choose the option to "Use STEP file units" if it is not
already selected and click the OK button. The original
OK
STEP file length unit is inches.
"Nonlinear: MES with From the analysis type pull-out menu, choose "Nonlinear:
Nonlinear Material Models" MES with Nonlinear Material Models."
Right-click on the "Contact (Default: Bonded)" heading
Mouse
at the bottom of the tree view and select "Free/No
"Free/No Contact"
Contact" as the default contact type.
Mouse Click on the Part 1 heading in the tree view.
Hold the <Ctrl> key and click on the Part 2 heading in the
<Ctrl>Mouse
tree view.
Right-click on one of the selected two headings, access the
Mouse
"Contact" pull-out menu, and select the "Surface Contact"
command. Hit <Enter> to complete the command without
<Enter>
entering a description for the contact pair.
Nonlinear contact occurs between a node and an element face rather than between pairs of nodes, as is the
case for linear contact. For this reason, it is best if the meshes between adjacent contact parts are not
matched. By default, meshes are not matched for MES contact pairs. That's why it's important to define
surface contact between parts 1 and 2 prior to meshing. Later, we will modify the geometry and the contact
definitions, localizing the contact calculations to include only those surface pairs where contact will
actually occur. This will be done to minimize the number of contact calculations the solver must perform
and to speed up the analysis.
We will also specify an absolute mesh size of 0.0625". The program's default geometry-based mesh sizing
function will automatically provide finer elements around the circumference of the small pin, resulting in an
acceptable mesh without further refinement.

"Mesh: Model Mesh Settings"
Mesh Settings" command.
"Options" Click on the "Options" button.
Under the "Mesh size" heading, click on the pull-down

Mouse
menu button at the right end of the "Type" field. Select
"Absolute mesh size"
"Absolute mesh size."
0.0625 Enter "0.0625" in the "Size" field.
"Mesh model" Click the "Mesh model" button.
No Click No when prompted to view the meshing results.
Modifying the Model
We will now select lines on the surface of the wheels and modify their surface number attribute so that they
are conveniently grouped into the desired contact surfaces.

Click and drag the middle mouse button to temporarily
Mouse enter the rotate view mode. Rotate the model so that the
underside of the wheels can be seen.
Click on the bottom surface of the drive wheel (the disk and
Mouse
not the shaft Part 1, Surface 29). Then right-click and choose
"Hide"
the "Hide" command.
Access the VIEW pull-down menu and choose the
View"
command.
"Selection: Shape: Polyline"
"Shape" pull-out menu. Select the "Polyline" command.
Refer to Figure M1. Clicking multiple times with the
mouse, draw a selection polyline enclosing all of the lines
of the first contact pair surfaces (including both the drive
Mouse and the driven wheel). Hit <Enter> to draw the final
<Enter> segment and to close the polyline loop. Be sure to include
the chamfers on both wheels. The lines should be
highlighted in magenta as shown in Figure M1. The yellow
outline represents the selection polyline.
Figure M1: Selection Polyline (Yellow) and Lines Selected for Modification of Attributes (Magenta)

"Modify Attributes" Select the "Modify Attributes" command.
Press <Tab> once to jump to the "Surface" field and type
<Tab> 100
"100" in this field.
"Yes" Click the "Yes" button when asked if you want to proceed.
Refer to Figure M2. Clicking multiple times with the
mouse, draw a selection polyline enclosing all of the lines
Mouse
of the second contact pair surface that belong to the drive
<Enter>
wheel). Hit <Enter> to draw the final segment and to close
the polyline loop. Be sure to include the chamfer.
Clicking multiple times with the mouse, draw another
selection polyline enclosing all of the lines of the second
contact pair surface that belong to the driven wheel). While
Mouse holding the <Ctrl> key, hit <Enter> to draw the final
<Ctrl> <Enter> segment and to close the polyline loop. Be sure to include
the two chamfers. The lines should be highlighted in
magenta as shown in Figure M2. The yellow outlines
represent the selection polylines.
Note: If you close the polyline by clicking again on the starting point, rather than by hitting the <Enter> key
before reaching it; you must hold the <Ctrl> key when clicking so that the second group of lines is added to
the selection set. Otherwise, the prior selection will be discarded.
Figure M2: Selection Polylines (Yellow) and Lines Selected for Modification of Attributes (Magenta)

<Tab> 101
View"
command.
Click on the upper left half of the indexing pin's cylindrical
Mouse
surface.
Holding down the <Ctrl> key, click on the upper right half
<Ctrl> Mouse
of the indexing pin's cylindrical surface.
Mouse Right-click in the display area and choose the "Select
"Select Subentities: Lines" Subentities" pull-out menu. Select the "Lines" command.
<Tab> 102
Mouse In the tree view, right-click of the heading for Part 1 and
"Hide" select the "Hide" command.
View"
command.
Click once anywhere within the model display area, making

Mouse this the active window, rather than the previously accessed
tree view area.
Holding <Z> While holding the <Z> key, press the <Cursor Left> key
<Cursor Left> <Cursor Left> three times. This action will rotate the view about the Z-
<Cursor Left> axis, 45 degrees clockwise (15 degrees per keystroke).
command.
Click and drag the mouse to create a selection box
enclosing the driven wheel's lines that belong to the third
contact surface. This will be the slot at the left side of the
Mouse display. Include the chamfers at the outside end of the slot
but not at the inside end. The lines should be highlighted in
magenta as shown in Figure M3. The yellow outline
represents the selection box.
Figure M3: Selection Box (Yellow) and Lines Selected for Modification of Attributes (Magenta)

<Tab> 102
Right-click on the Part 1 heading and select the "Show"
Mouse
command, restoring the visibility of this previously hidden
"Show"
part.
Right-click on the "Surfaces" heading under Part 1 in the
Mouse
tree view. Select the "Show All Surfaces" command. The
"Show All Surfaces"
bottom surface of the drive wheel will reappear.

View"
View" command.
"Selection: None" "None" command to deselect all items, whether in the
display area or tree view.
Before proceeding further, save the work performed thus far
"File: Save" by accessing the FILE pull-down menu and selecting the
"Save" command.
Defining Surface Contact Pairs and Parameters
Now that the proper surface line assignments have been applied to the model, we will go into the "MES:
Surface-to-Surface Contact" dialog and set up the three contact pairs and their specified parameters.
Mouse
Right-click in the display area and select the "General
"General Surface-to-Surface
Surface-to-Surface Contact" command.
Contact"
Mouse Using the pull-down menu in the "First Surface" field at
"100" the top of the dialog, select surface "100."
Mouse Using the pull-down menu in the "Second Surface" field,
"100" select surface "100."
"Add Row" Click on the "Add Row" button.
Mouse Using the pull-down menu in the "First Part" field, select
"1" part "1."
Mouse Using the pull-down menu in the "First Surface" field,
Mouse Using the pull-down menu in the "Second Part" field,
"2" select part "2."
"Add Row" Click on the "Add Row" button.
Mouse Using the pull-down menu in the "First Part" field, select
"1" part "1."
Mouse Using the pull-down menu in the "First Surface" field,
Mouse Using the pull-down menu in the "Second Part" field,
"2" select part "2."
Access the pull-down menu at the "Updating" field and
Mouse
choose "Automatic." The active contact elements will be
"Automatic"
reevaluated as the wheels move to different positions.
In the first row (Pair 1) of the Contact Pairs table, click on
Mouse
the "Parameters" column (currently showing "Default").
Mouse
Change the "Contact problem type" to "High Speed
"High Speed Contact
Contact (Impact)" using the provided pull-down menu.
(Impact)"
Mouse Change the "Contact type" to "Surface to Surface" using
"Surface to Surface" the provided pull-down menu.
"Advanced" Click on the "Advanced" button.
Mouse Activate the checkboxes for both "User-specified contact

Mouse stiffness" and "User-specified contact tolerance."
1000 Enter "1000" into the "Contact stiffness" field.
0.0011 Enter "0.0011" into the "Contact tolerance" field.
Click the OK button to exit the "Advanced Controls and
OK
Parameters for Contact Pair" screen.
Click the OK button to exit the "Controls and Parameters
OK
for Contact Pair" screen.
To conveniently duplicate these contact settings for the
Mouse
remaining two pairs, access the pull-down menu at the "To
"All"
Pair" field and select "All."
"Copy" Click on the "Copy" button.
Click the "Yes" button to verify that you want the
parameters copied from the source pair (#1) to all other pairs.
"Yes"
Note that the Parameters column in the Contact Pairs table
will now show "Custom" for all pairs.
Click the OK button to exit the "MES: Surface to Surface
OK
Contact" screen.
Creating the Joints
We will next create the four joints used to rotationally mount the two Geneva wheels.

Mouse enter the rotate view mode. Rotate the model so that the
underside of the wheels can be seen.
Click on the bottom, end surface of the drive wheel's center
Mouse
shaft (Part 1, Surface 21).
Right-click in the display area, select the "CAD Mesh
"CAD Mesh Options: Create
Options" pull-out menu, and choose the "Create Joint"
Joint"
command.
"Universal Joint (lines to axis Access the pull-down menu at the "Joint" field and choose
midpoint)" "Universal Joint (lines to axis midpoint)."
Activate the "Manual axis/center-point specification" radio
Mouse
button.
Press <Tab> three times and type in "-0.125" for the Z-
<Tab> <Tab> <Tab> -0.125
coordinate of the center-point.
OK Click the OK button to create the first joint.
Click on the bottom, end surface of the driven wheel's
Mouse
center shaft (Part 2, Surface 4).
Joint"
command.

Mouse
button.
<Tab> once and type in "1.414214" for the X-coordinate of
<Tab> 1.414214
the center-point.
<Tab> twice and type in "-0.125" for the Z-coordinate of
<Tab> <Tab> -0.125
the center-point.
OK Click the OK button to create the second joint.
View"
View" command.
Click on the top, end surface of the drive wheel's center
Mouse
Joint"
command.
Mouse
button.
<Tab> three times and type in "0.875" for the Z-coordinate
<Tab> <Tab> <Tab> 0.875
of the center-point.
OK Click the OK button to create the third joint.
Click on the top, end surface of the driven wheel's center
Mouse
Joint"
command.
Mouse
Access the pull-down menu at the "Joint" field and choose
"Universal Joint (lines to axis
"Universal Joint (lines to axis midpoint)."
midpoint)"
Mouse
button.
<Tab> once and type in "1.414214" for the X-coordinate of
<Tab> 1.414214
the center-point.
<Tab> twice and type in "0.875" for the Z-coordinate of
<Tab> <Tab> 0.875
the center-point.
OK Click the OK button to create the fourth and final joint.
Next, we'll define the element type for the joints and the element definitions and materials for each part of
the assembly. The element type for the Geneva wheels will have already been set to brick.
Click on the "Element Definition" heading under Part 1 in

Mouse
the tree view.
Holding the <Ctrl> key, click on the "Element Definition"
<Ctrl> Mouse
heading under Part 2 in the tree view.
Mouse Right-click on one of the selected headings and choose the
"Modify Element Definition" "Modify Element Definition" command.
Mouse Use the pull-down menu in the "Analysis Type" field and
"Large Displacement" select "Large Displacement."
Click the OK button to clear the resulting pop-up

OK message (if the setting had been changed from small to
large displacement).
Click the OK button to exit the Element Definition
OK
screen.
Double-click on the "Material" heading under Part 1 in the
Mouse
tree view.
Click on the plus sign to the left of the "Brass" folder to
Mouse
expand this branch.
Select the material, "Brass, Red", within the Brass
"Brass, Red"
folder of the Autodesk Algor Material Library.
Click on the OK button to close the Element Material
OK
Selection screen.
Double-click on the "Material" heading under Part 2 in the
Mouse
tree view.
Select the material, "Plastic- Nylon Type 6/6", from the
"Plastic- Nylon Type 6/6"
list of available materials within the Plastic folder.
OK
Selection screen.
We will set the element type, element definition, and material properties for all four joints simultaneously.
Mouse Click on the "Part 3" heading in the tree view.

Holding down the <Ctrl> and the <Shift> keys, press the
<Ctrl> <Shift> "M"
"M" key to collapse the tree view's parts list.
Holding the <Shift> key, click on the "Part 6" heading in
<Shift> Mouse
the tree view. Parts 3 through 6 should now be highlighted.
Access the "Modify" pull-out menu, choose the "Element
"Modify: Element Type: Pipe"
Type" pull-out menu, and select "Pipe" from the list.
Once again, right-click on a selected heading, access the
Mouse
"Modify" pull-out menu, and select the "Element Data"
"Modify: Element Data"
command.
Mouse Double-click in the "Outside diameter" field and type the
0.1 value "0.1".
<Tab> once and enter the value "0.03" into the "Wall
<Tab> 0.03
thickness" field.
OK Click on the OK button.
One more time, right-click on a selected heading, access the
Mouse
"Modify" pull-out menu, and select the "Material"
"Modify: Material"
command.
"Edit Properties" Press the "Edit Properties" button.
Mouse Double-click in the "Modulus of Elasticity" field and enter
100e6 the value "100e6". All other values remain at zero.
Click the OK button to exit the Element Material
OK
Definition screen.
Click the OK button to exit the Element Material
OK
Selection screen.
"Save" command.
Next, we will define the specified loads and constraints. These consist of the nodal loads and constraints at
the joint center-points and the part-based load (initial velocity) to be applied to the drive wheel.

"View: Orientation: Front
"Orientation" pull-out menu. Select the "Front View"
View"
command.
command.
Click and drag the mouse to draw a selection window
Mouse enclosing the two center-nodes of the bottom two joints (#1
and #2).
Mouse Right-click in the display area, access the "Add" pull-out
"Add: Nodal Boundary menu and select the "Nodal Boundary Conditions"
Conditions" command.
"Fixed" Click on the "Fixed" button.
"Rz" {deselect} Deselect the "Rz" checkbox to release this DOF.
Click and drag the mouse to draw a selection window
Mouse enclosing the two center-nodes of the top two joints (#3 and
#4).
"Add: Nodal Boundary menu and select the "Nodal Boundary Conditions"
Conditions" command.
"Tx", "Ty", "Rx", "Ry" Activate the "Tx", "Ty", "Rx" and "Ry" checkboxes.
Click on the center-point of Joint #3 (upper-left). Be sure
Mouse to select the vertex and not the previously applied boundary
condition.
"Add: Nodal Prescribed menu, and select the "Nodal Prescribed Displacement"
Displacement" command.
"Rotation" Activate the "Rotation" radio button.
<Tab> 0.5 <Tab> once and enter "0.5" in the "Magnitude" field.
"Scalar Z" Activate the "Scalar Z" radio button.
"Curve" Press the "Curve" button.
Click the OK button to accept the default load curve
OK
(ramp from 0 to 1 in 1 second).
"Data" Press the "Data" button.
Type "1" in the "Death Time" column for Index 1 (the only
Mouse
displayed row). This value ensures that the prescribed
1
displacement remains active throughout the simulation event.
OK Click the OK button to accept the active range.
Click the OK button to close the Nodal Prescribed
OK
Displacement dialog.
Click on the center-point of Joint #4 (upper-right). Be sure
Mouse to select the vertex and not the previously applied boundary
condition.
"Add: Nodal Moment" menu, and select the "Nodal Moment" command.
2 Enter "2" in the "Magnitude" field.
"Z" Activate the "Z" direction radio button.
Mouse Using the up-arrow to the right of the "Load Case / Load
"2" Curve" field, increment the load curve number to "2."
"Curve" Press the "Curve" button.
"Add Row" Press the "Add Row" button.
Click in the "Multiplier" column for Time = 0.0 (first
Mouse
row).
1 Type "1" in the Row 1 Multiplier column.
<Tab> <Tab> 1 <Tab> twice and type "1" in the Row 2 Time column.
<Enter> Press the <Enter> key to update the load curve graph.
OK Click the OK button to accept Load Curve 2.
Click the OK button to close the Nodal Moment
OK
Object dialog.
Mouse While the joint 4 center-point is still selected, right-click
"Add: Nodal Lumped again, access the "Add" pull-out menu, and select the
Mass" "Nodal Lumped Mass" command.
<Tab> once and type "0.00088" in the "X Direction" field
<Tab> 0.00088
under the "Mass/Weight" heading.
<Tab> <Tab> <Tab> <Tab> three times and type "0.00135" in the "Z Direction"
0.00135 field under the "Mass Moment of Inertia" heading.
<Tab>
<Tab> once and type "3.5 inch diameter, 1/8 inch thick
3.5 inch diameter, 1/8
steel disk." in the "Description" field.
inch thick steel disk.
Right-click on the heading for Part 1 in the tree view.
Mouse
Access the "Add" pull-out menu and select the "Initial
"Add: Initial Velocity"
Velocity" command.
Mouse Double-click in the "Z" field under the "Rotational
30 Magnitude" heading and type "30" in this field.
View"
View" command.
"Save" command.
This completes the application of constraints, loads, element properties, and materials to the assembly. We
will now define the analysis parameters.
Defining the Analysis Parameters

"Analysis: Parameters"
"Parameters" command.
Mouse
Double-click in the "Capture Rate" field and enter "90".
90
"Advanced" Click on the "Advanced" button.
Deselect the "Automatic" checkbox to the right of the
Mouse
"Displacement Tolerance" field.
Mouse Double-click in the "Displacement Tolerance" field and
0.02 enter "0.02".
Click the OK button to close the Advanced analysis
OK
parameters screen.
Click the OK button to close the Analysis Parameters
OK
screen.
"Analysis: Perform Access the ANALYSIS pull-down menu and select the
Analysis" "Perform Analysis" command.
NOTE: Depending upon the computer hardware, this analysis may take an hour or several hours to run. If time is
limited, you may wish to allow several steps to converge, stop the analysis, and then load the already
completed model from the provided archive file, Exercise M\Results Archive\Exercise M.ach.
Viewing the Results
We will review the stress results for time step 44 (when the peak stress occurs), create and export a graph
showing the displacement magnitude as a function of time, and create an animation showing the stress
results for the whole simulation.
We will also turn off the display of contact diagnostic probes so that they will not appear within the
animation. These probes mark areas of node/surface penetration and/or chatter and are useful for
troubleshooting a model that is having difficulty converging. They do not necessarily indicate a problem,
since slight, localized penetration is not uncommon and may be insignificant. Contact behavior is
influenced by the mesh density, mesh smoothness, and contact stiffness. Chatter is generally the result of
excessive contact stiffness and makes convergence more difficult.
Click the "Toggle Load and Constraint Display" toolbar

Mouse button to turn off the display of the load and constraint
symbols. Your screen should now look similar to Figure L1.
Disable the displaying of Contact Diagnostic Probes by
Mouse
clicking the associated toolbar icon.
Access the RESULTS OPTIONS pull-down menu, select

"Results Options: Load Case:
the "Load Case" pull-out menu, and choose the "Set"
Set"
command.
44
Type "44" and Click the OK button.
OK
Click on the Maximum Result Probe toolbar icon. This
Mouse
will place a flag at the peak von Mises stress location.
Mouse Click on the heading for Part 2 in the tree view.
While holding the <Shift> key, click on the Part 6 heading
<Shift> Mouse
in the tree view.
Right-click on a selected heading and choose the "Hide"
Mouse
command. This will improve the visibility of the peak stress,
"Hide"
which is on the drive wheel's indexing pin.
enter the rotate view mode. Rotate the model for a better
Mouse
view of the peak stress area. If desired, roll the wheel to
zoom in somewhat.
The annotation and legend will indicate the maximum stress value. This stress should be approximately
5,000 to 5,200 psi and will be in the contact area of the indexing pin. Contact stresses are rather sensitive
to surface mesh and contact settings changes, so expect different peak values for modeling variants. The
screen image should resemble Figure M4.
Figure M4: Peak von Mises Stress Plot Time Step 44
Mouse Right-click on the Part 2 heading in the tree view and

"Show" choose the "Show" command.
Click the Maximum Result Probe toolbar icon to
Mouse
toggle off this flag.

"View: Enclose"
"Enclose" command.
Access the RESULTS pull-down menu, select the
"Displacement" pull-out menu, and choose the
Magnitude"
"Magnitude" command.
Click on a node on the top, end face of the drive
Mouse wheel's indexing pin. Choose the node that is furthest
from the centerline of the wheel.
Holding the <Ctrl> key, select a node at the OD of the
<Ctrl> Mouse driven wheel, for example, one at the outer edge of one
of the slot chamfers.
Mouse Right-click in the display area and select the "Graph
"Graph Values" Values" command.
Right-click in the graph display area, access the "Font
Mouse
Size" pull-out menu and select the "Large" option. The
"Font Size: Large"
resulting plot should look like Figure M5.
Figure M5: Displacement versus Time Graph
Mouse Right-click in the graph display area and select the

"Export Dialog" "Export Dialog" command.
Select the "PNG" radio button under the "Export"
"PNG"
heading.
Select the "File" radio button under the "Export
"File"
Destination" heading.
"Browse" Click on the "Browse" button, accept the default file
Exercise M Displacement location and type "Exercise M Displacement
Graph.png Graph.png" into the "File name" field.
Click on the "Save" button to return to the Exporting

"Save"
dialog.
Mouse Double-click on the "Width" field under the "Export
1024 Size" heading and enter "1024".
<Tab> 768 <Tab> once and enter "768" in the "Height" field.
Using the pull-down menu in the "DPI" field, choose
Mouse
"100," which is the closet value to the typical computer
"100"
screen's resolution.
"Export" Click on the "Export" button to create the PNG file.
Click on the first heading, "1 < Stress >," listed under
Mouse the Presentations heading in the tree view to return to
the color contour plot.
Access the SELECTION pull-down menu and choose
Selection: None
"None" to deselect the two nodes.
Access the RESULTS pull-down menu, select the
"Results: Stress: von Mises" "Stress" pull-out menu, and choose the "von Mises"
command.
Before making the stress animation, let's override the default legend range for the plot. This will be done
for the following two reasons:
1. To make the correlation between stress level and plot color consistent for all video
framesotherwise, the stress range in the legend will be recalculated for each frame
based on the minimum and maximum stress result at that time step only.
2. Because the high contact stresses are localized and the typical stresses in the two
wheels are much lowerchanging the display range to a lesser maximum value will
bring out a broader range of color throughout the assembly and reveal the more
typical and lower stress values.
Access the DISPLAY OPTIONS pull-down menu and

"Display Options: Plot Settings"
select the "Enclose" command.
"Range Settings" Click on the "Range Settings" tab.
Deactivate the "Automatically calculate value range"
Mouse
checkbox.
<Tab> once and enter "0" in the "Low" field under the
<Tab> 0
Current Range heading.
<Tab> 2000 <Tab> once and enter "2000" in the "High" field.
OK Click on the OK button.
enter the rotate view mode. Rotate the model to a good
Mouse
viewpoint for creating the animation (AVI file). Also,
roll the mouse wheel to zoom in or out as desired.
If necessary, reposition the view by holding the <Ctrl>
<Ctrl> Mouse key and clicking and dragging the middle mouse
button to temporarily enter the pan view mode.
Access the ANIMATION pull-down menu and select
"Animation: Save as AVI" the "Save as AVI" command. Or, click on the
Export Animation toolbar icon.
We will keep the default settings for frames per second, start and end steps, step increment, and video
compression. We will however change the resolution to a standard 4/3 format of 1024 x 768 (assuming it
is not already set to that resolution) and we'll change the filename.
Deactivate the "Lock" checkbox under the Target

Mouse
Resolution heading.
Mouse
Double-click in the "Width" field and type "1024".
1024
<Tab> 768 <Tab> once and type "768" in the "Height" field.
Click twice (slowly) in the "File name" field at the end
of the default name, the first click selects the name, the
Mouse
second one positions the cursor just before the point.
- von Mises Stress
Append the text, " von Mises Stress" to the end of
the "Exercise M" default filename.
"Save" Click on the "Save" button to generate the AVI file.
Click the "Yes" button when asked if you want to view
"Yes"
the animation now.
Use the Analysis Replay controls to play, pause, or
rewind the animation. Click on the button in the
Mouse
upper right corner of the Analysis Replay control
screen to close both it and the animation window.
To review a completed archive of this exercise, refer to the file "Exercise M\Results Archive\Exercise M.ach.
Exercise N
Nonlinear Material Model
Beam Elements
Objective: First, analyze a cantilever beam using an elastic material model. If the stress
exceeds the yield stress of 36,000 psi, run another analysis using a plastic
material model.
Geometry: The beam shown below is 10 feet long. The cross section is a 5" x 4, with the
beam oriented for maximum strength and stiffness for the applied load direction.
Loads: 56,000 pound force downward (-Y direction) at the free end.
Constraints: Fully constrained at one end.
Elements: Beam (use the Large Displacement analysis type option in the Element
Definition dialog)
Material: Steel (ASTM-A36)
Analysis Parameters: Duration = 10 seconds

Capture rate = 2
Load Curve Information:

Time Multiplier
(s)
0 0
10 1
Exercise N Nonlinear Material Model
Solution
Building the Model
Click on the arrow button to the right of the analysis
Mouse
type field.
"Nonlinear: MES with Nonlinear Select the "Nonlinear" pull-out menu and select the
Material Models " "MES with Nonlinear Material Models" option.
Type "Exercise N" in the "File name:" field in the
"Save As" dialog. Note the default folder location
Exercise N where the analysis files will be created. This
location can be changed by navigating to an alternate
working folder if desired.
"View: Orientation: Top View" "Orientation" pull-out menu. Select the "Top
View" command.
Access the GEOMETRY pull-down menu and select
"Geometry: Add: Line" the "Add" pull-out menu. Select the "Line"
command to access the "Define Geometry" dialog.
Press <Enter> to accept (0, 0, 0) as the coordinate
<Enter>
for the initial vertex.
Type "120" in the "X:" field and press <Enter> to
120<Enter>
accept (120, 0, 0) as the coordinate for the next vertex.
Access the VIEW pull-down and select the
"View: Enclose"
"Enclose" command.
Access the SELECTION pull-down menu and
"Selection: Select: Lines" choose the "Select" pull-out menu. Select the
"Lines" command.
Mouse Click on the line that was just created to select it.
Access the GEOMETRY pull-down menu and select
"Geometry: Tools: Divide" the "Tools" pull-out menu. Select the "Divide"
command to bring up the "Divide Lines" dialog.
Type "20" in the "Number of Lines:" field in the
20
"Divide Lines" dialog.
Click the OK button to divide the single line
OK
segment into 20 line segments.
Right-click on the "Element Type" heading for

Mouse
Part 1 in the tree view.
"Beam" Select the "Beam" command.
Right-click on the "Element Definition" heading
Mouse
for Part 1 in the tree view.
Select the Large Displacement option from the drop-
Large Displacement
down list in the Analysis Type field.
OK Click OK to dismiss the pop-up message.
Click any cell within the Layer 1 row of the Sectional
Mouse
Properties table to select this row.
Select the "Rectangular" option in the drop-down
"Rectangular"
box in the upper right corner.
4 Type "4" in the "b" field.
5 Type "5" in the "h" field.
Click the OK button to exit the Cross-Section
OK
Libraries dialog.
Click the OK button to exit the Element
OK
Definition dialog.
Access the SELECTION pull-down menu and select
"Selection: Shape: Rectangle" the "Shape" pull-out menu. Select the "Rectangle"
command.
Mouse Draw a box enclosing the entire model.
Select the "Beam Orientations" pull-out menu and
"Beam Orientations: New"
select the "New" command.
Type0 in the X: field, press <Tab>, type "10"
in the "Y:" field, and press <Enter>. This defines an
0 <Tab> 10 <Enter> auxiliary vertex (0, 10, 0) that orients the local 2 axis
of the beam elements, corresponding to the direction
for the 5 inch dimension.
Right-click on the "Material" heading for Part 1 in
Mouse
the tree view.
Highlight the material, "Steel (ASTM-A36)", near
"Steel (ASTM-A36)" the bottom of the list of available materials within
the Steel folder.
Click the OK button to accept the selected
OK
material.
Access the SELECTION pull-down menu and choose

"Selection: Select: Vertices" the "Select" pull-out menu. Select the "Vertices"
command.
Draw a box around the vertex at the left end of the
Mouse
beam.
"Add: Nodal Boundary Select the "Add" pull-out menu and select the
Condition" "Nodal Boundary Condition" command.
Press the "Fixed" button in the "Predefined"
"Fixed"
section.
OK Click the OK button to apply the constraint.
Draw a box around the vertex at the right end of the
Mouse
beam.
Select the "Add" pull-out menu and select the
"Add: Nodal Force"
"Nodal Force" command.
"Y" Select the "Y" radio button.
OK Click the OK button to apply the force.
Right-click on the "Analysis Parameters" heading
Mouse
in the tree view.
Select the "Modify Analysis Parameters"
"Modify Analysis Parameters"
command.
10 Type "10" in the "Duration" field.
100 Type "100" in the "Capture rate" field.
Type "10" in the second row of the Time column
10
within the Load Curve table.
OK Click the OK button to accept the changes.
Access the ANALYSIS pull-down menu and select

the "Perform Analysis" command. The model
"Analysis: Perform Analysis"
will be displayed in the Results environment while
the solution is progressing.
Viewing the Results
Access the RESULTS pull-down menu and select

"Results: Beam and Truss: Worst
the "Beam and Truss" pull-out menu. Choose the
Stress"
"Worst Stress" command.
The maximum stress is about 40,300 psi, which is well over the yield stress of 36,000 psi. Therefore, a
nonlinear material model is necessary. We will create a second design scenario within the model for the non-
linear run. Before doing so, we will check the displacement magnitude to compare with the later results,
which will consider plastic deformation.

"Displacement" pull-out menu. Choose the "Magnitude"
Magnitude"
command.
The maximum displacement magnitude should be about 2.67 inches. We expect this number to be less than
the actual displacement with plastic deformation considered.
Creating a New Design Scenario

"Tools: FEA Editor"
Editor" command.
Right-click on the "Design Scenario 1" heading in the tree
Mouse
view and select the "Copy" command.
Mouse
view and select the "Rename" command.
"Elastic Material" Type "Elastic Material" into the "Description" field.
Mouse
view and select the "Rename" command.
"Nonlinear Material" Type "Nonlinear Material" into the "Description" field.
You now have two design scenarios defined within the model, one for the elastic (isotropic) material model
and one for the non-linear (von Mises with isotropic hardening) material model. Double-clicking on an
inactive scenario heading will make it the active scenario. We will now modify the element data for the
second design scenario to specify the non-linear material model.
Modifying the Element Data

Mouse
in the tree view.
"von Mises with Isotropic Select the "von Mises with Isotropic Hardening" option
Hardening" in the "Material Model" drop-down box.
Since the material model has been changed, we will revisit the material selection dialog to refresh the
properties for the selected material.

Mouse
tree view.
Verify that a non-zero Strain Hardening Modulus is shown in
"OK"
the material properties list and click "OK."
Access the ANALYSIS pull-down menu and select

"Analysis: Perform Analysis"
the "Perform Analysis" command.
Viewing the Results

"Stress" pull-out menu. Select the "Beam and
"Results: Stress: Beam and Truss: Truss" pull-out menu and select the "Worst Stress"
Worst Stress" command. The maximum stress (~37,287 psi) is now
below the previous value. Therefore the effect of the
lower modulus that was used after yield is obvious.
"Displacement" pull-out menu. Choose the
"Magnitude" command. The displacement with
"Results: Displacement: Magnitude"
plasticity of the material taken into account (~4.65
inches) is approximately 2 inches greater than the
prior displacement.
To review a completed archive of this exercise, refer to the file "Exercise N.ach" in the "Exercise N\Results
Archive" directory. The results archive contains both the elastic and the nonlinear variants of the exercise.

Finite Element Analysis in Practice: Instructor Manual

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Finite Element Analysis

Based on: Autodesk Algor Simulation

Finite Element Analysis in Practice Instructor Manual

Analysis Options ......................................................................................... 30

Beam Elements .......................................................................................... 51

Plate/Shell Elements ................................................................................... 56

Brick Elements ............................................................................................ 59

Comparing Element Types ......................................................................... 61

Mesh Convergence ..................................................................................... 62

Meshing CAD Solid Models ........................................................................ 65

Exercise J - Hanger Assembly Model ............................................................69

Combining Element Types .......................................................................... 69

Solving Options ........................................................................................... 73

Electrostatic Analysis ............................................................................. 86

Combining Analysis Types (Multiphysics) ................................................. 103

STEPS FOR EXERCISES .......................................................... SE.1

This Course Introduction section contains necessary prerequisite information concerning

Software Installation, Services, and Support

Installing and Running Autodesk Algor Simulation

We recommend the following system specifications for a Microsoft Windows platform

Supported Operating Systems:

Microsoft Windows 7 (32-bit and 64-bit editions)

Other Requirements (All Platforms):

Mouse or pointing device

Notes Concerning System Requirements:

Autodesk Algor Simulation Help

How to Access the Help Files

Features of the Help Files

Figure 1: Autodesk Algor Simulation Users Guide

Search the Help Files using Keywords

Autodesk Algor Simulation product page

Training course information

Webcasts and Web Courses

How to Receive Technical Support

Five ways to contact Technical Support:

When contacting Technical Support:

Have your contract number ready before contacting Technical Support.

How to Determine the Software Version

How to Obtain an Update

Navigating the User Interface

Figure 2: Autodesk Algor Simulation User Interface

How to Display or Hide Specific Toolbars

How to Dock Toolbars

Figure 3: Steps to Dock a Toolbar

Using the Keyboard and Mouse

Introduction to the ViewCube

(a) Cursor not near the

Additional View Controls

Immediately below the ViewCube is a pallet of additional view controls. This

Figure 5: Additional View Controls Pallet

From top to bottom, the seven tools are as follows:

Figure 6: Full Navigation Wheel

Legacy View Controls in Autodesk Algor Simulation

Notes Concerning the Steps for Exercises Section

Beam Elements (continued)

NOTE: For details concerning beam element

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Other Analysis Types

2010 Autodesk, Inc. All rights reserved.

Steady-State Heat Transfer

2010 Autodesk, Inc. All rights reserved.

2010 Autodesk, Inc. All rights reserved.

Thermal Nodal Loads