Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

Workshop 8 Bonded Contact

Swaybar-Shaft Assembly

8. Bonded Contact

Swaybar-Shaft Assembly
Description

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

A swaybar-shaft assembly is subjected to a vertical force of 500 kgf at the right end of the swaybar. The objective is to determine the overall stresses in the assembly. Use bonded contact to simulate the assembly, and replace the right twothirds of the swaybar with a "rigid region" (constraint equations). As a follow-up, join the two parts using a Boolean glue operation and redo the analysis.

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8. Bonded Contact

Swaybar-Shaft Assembly
Loads and Material Properties

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INTRODUCTION TO ANSYS 5.6 - Part 2

8. Bonded Contact

Swaybar-Shaft Assembly
1. 2.

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INTRODUCTION TO ANSYS 5.6 - Part 2

Enter ANSYS in the working directory specified by your instructor using bondedcontact as the jobname. Read input from the file bonded-contact.inp to 1) mesh the model, 2) create rigid links, and 3) apply constraints and loads:
Utility Menu > File > Read Input from Or issue: /INP,bonded-contact,inp

3.

Create the bonded contact elements between the shaft and the swaybar: a) Select the two areas that define the contact surface (areas 12 and 54):
Utility Menu > Select > Entities Utility Menu > Plot > Areas Or issue: ASEL,S,,,12,54,42 APLOT

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Swaybar-Shaft Assembly
3. (contd) b) Create the contact elements:
Main Menu > Preprocessor > -Modeling- Create > Contact Pair > Contact Wizard

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

Select Areas, then [Pick Target ]

Pick area 12, then [OK] Pick [Next >] Select Areas, then [Pick Contact ] Pick area 54, then [OK] Pick [Next >] Pick [Optional settings ] Select the Contact Options tab Select Exclude everything for Initial penetration Select Bonded (always) for Contact surface behavior [OK] [Create >] [Finish]

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8. Bonded Contact

Swaybar-Shaft Assembly
3. (contd) c) Plot the target surface contact elements:
Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

Select Target Surface and check normals shown under Options

[Display] Select all nodes attached to elements

Utility Menu > Select > Entities Utility Menu > Plot > Elements Or issue: ESEL,S,TYPE,,5 NSLE /PSYMB,ESYS,1 /PNUM,TYPE,1 EPLOT

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8. Bonded Contact

Swaybar-Shaft Assembly
3. (contd) d) Plot the contact surface contact elements:
Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

Select Contact Surface and check normals shown under Options

[Display] Select all nodes attached to elements

Utility Menu > Select > Entities Utility Menu > Plot > Elements Or issue: ESEL,S,TYPE,,6 NSLE /PSYMB,ESYS,1 /PNUM,TYPE,1 EPLOT

e) Close the View Contact Pair window

[Close]

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8. Bonded Contact

Swaybar-Shaft Assembly
4.

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INTRODUCTION TO ANSYS 5.6 - Part 2

Select volume component v_bar-sh and all entities associated with and below the volume component. Then select the contact and MASS21 nodes and elements, and then plot elelemts:
Utility Menu > Select > Comp/Assembly > Select Comp/Assembly Utility Menu > Select > Everything Below > Selected Volumes Utility Menu > Select > Entities Or issue: CMSEL,S,v_bar-sh ALLSEL,BELOW,VOLU NSEL,ALL

ESEL,ALL
EPLOT

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Swaybar-Shaft Assembly
5.
Main Menu > Solution > Unabridged Menu Main Menu > Solution > -Load Step Opts- Solution Ctrl Set to Off, then [OK] Pick the Soln Options tab Select Pre-Condition CG Pick the Nonlinear tab Enter 1 for the number of Equilibrium Iterations [OK] Read and then close yellow warning message window (or select: Utility Menu > File > Save as Jobname.db) Main Menu > Solution > -Analysis Type- Soln Control ...

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INTRODUCTION TO ANSYS 5.6 - Part 2

Enter the solution processor and turn off solution controls. Then choose the PCG solver, set the number of equilibrium iterations to one, and solve:

Pick the SAVE_DB button in the Toolbar Main Menu > Solution > -Solve- Current LS Or issue: /SOLU

SOLCONTROL,OFF
EQSLV,PCG NEQIT,1 SAVE SOLVE

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8. Bonded Contact

Swaybar-Shaft Assembly
6.
Utility Menu > Select > Entities ... Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ... Or issue: ESEL,U,,,8000 /POST1 PLNSOL,S,EQV

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INTRODUCTION TO ANSYS 5.6 - Part 2

Unselect element 8000 (MASS21 element), then enter POST1 and plot the nodal von Mises stresses:

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8. Bonded Contact

Swaybar-Shaft Assembly
7.
Utility Menu > Select > Comp/Assembly > Select Comp/Assembly Utility Menu > Select > Everything Below > Selected Volumes Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ... Or issue: CMSEL,S,v_bar ALLSEL,BELOW,VOLU PLNSOL,S,EQV

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INTRODUCTION TO ANSYS 5.6 - Part 2

Plot von Mises stresses for elements associated with volume component v_bar:

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8. Bonded Contact

Swaybar-Shaft Assembly
8.
Utility Menu > Select > Comp/Assembly > Select Comp/Assembly Utility Menu > Select > Everything Below > Selected Volumes Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ... Or issue: CMSEL,S,v_shaft ALLSEL,BELOW,VOLU PLNSOL,S,EQV

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

Plot von Mises stresses for elements associated with volume component v_shaft:

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8. Bonded Contact

Swaybar-Shaft Assembly
9.
Utility Menu > File > Read Input from Or issue: /INP,swaybar-shaft-glued,inp

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INTRODUCTION TO ANSYS 5.6 - Part 2

Now rerun the stress analysis, with the swaybar and shaft volumes glued together, by reading input from the file swaybar-shaft-glued.inp:

10. After the solution completes, the nodal solution for SEQV is displayed for the swaybar (i.e. v_bar volume component):

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8. Bonded Contact

Swaybar-Shaft Assembly
Utility Menu > Select > Comp/Assembly > Select Comp/Assembly Utility Menu > Select > Everything Below > Selected Volumes Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ... Or issue: CMSEL,S,v_shaft ALLSEL,BELOW,VOLU PLNSOL,S,EQV

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

11. Plot von Mises stresses for elements associated with volume component v_shaft:

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8. Bonded Contact

Swaybar-Shaft Assembly

Workshop Supplement

INTRODUCTION TO ANSYS 5.6 - Part 2

12. Recall in the bonded contact solution that we turned off solution control and forced only one equilibrium iteration. If we chose to leave solution control on and let the number of equilibrium iterations default between 15 and 26, then the bonded contact solution would have converged after 8 equilibrium iterations, taking approximately 2 hours of elapsed time. (The multiple iterations are used by the contact elements to update their geometry and converge.) The results of this analysis are as follows:

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8. Bonded Contact

Swaybar-Shaft Assembly
12. (contd) The results for the swaybar (i.e. v_bar volume component):

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INTRODUCTION TO ANSYS 5.6 - Part 2

13. Exit ANSYS.

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