Chapter 5 3D Simulations 1

Chapter 5 3D Simulations
Chapter 5
3D Simulations
5.1 Step-by-Step: Beam Bracket
5.2 Step-by-Step: Cover of Pressure Cylinder
5.3 More Details
5.4 More Exercise: LCD Display Support
5.5 Review
Section 5.1 Beam Bracket
Section 5.1
Beam Bracket
Problem Description
[1] The bracket is

made of
structural steel.
[2] The
bracket is designed to
withstand a load of 27 kN
uniformly distributed over
the seat plate.
[3] Fixed
support at
the back
face.
Techniques/Concepts
Engineering Data
Material Assignment
Stress Tool>Safety Factor
Structural Error
Mesh Control>MultiZone
3D Solid Elements
Section 5.2 Cover of Pressure Cylinder
Section 5.2
Cover of Pressure Cylinder
Problem Description
[2] The cover is
designed to hold
up an internal
pressure of 0.5
MPa.
[1] The cover is

made of an
engineering
plastic.
[3] Circularity of
this internal
surface is what
concerns us most.
Techniques/Concepts
Add a new material in

<Engineering Data>
Isotropic Elasticity
Material Assignment
Loads>Pressure
Create a new coordinate
system
Cylindrical Coordinate
Systems
Section 5.3
More Details
Global Mesh Controls
Relevance Center
Relevance
Number of nodes/elements
Mesh Quality Metric
Section 5.3 More Details
Mesh with MultiZone Method
Generally, hexahedral elements are more

desirable than tetrahedral.
A simple idea of creating hexahedra is to

mesh faces (source) of a body with
quadrilaterals and then "sweep" along a path
up to other end faces (target) of the body.
Not all bodies are sweepable.

The idea of <MultiZone> method is to
decompose a non-sweepable body into
several sweepable bodies, and then apply
<Sweep> method on each of bodies.
Coordinate Systems
When defining an environment
[1] Type of
the coordinate
system.
condition or a solution object by

<Components>, you need to refer
[2] Origin.
to a coordinate system. By default,

<Global Coordinate System> is
used, which is a Cartesian
coordinate system.
To define a new coordinate

system, you need to define the
type of the coordinate system, the
origin, and the axes.
[3] Axes.
Legend Controls
[3] Double-click
to edit value.
[1] Increase/
decrease contour
bands.
[5] Turn on/off

the date/time.
[2] The divider

can be dragged.
[4] Number of
significant digits.
[6] Display
independent
bands.
[7] Reset
the legend.
Adaptive Meshing
Workbench provides a tool to

automate the mesh refinement
until a user-specified level of
accuracy is reached.
This idea is termed adaptive

meshing.
Internally, Workbench exploits

the structural errors to help
adjust the mesh, that is, it refines
the mesh size in the area of
large structural errors.
10
Section 5.4 LCD Display Support
Section 5.4
LCD Display Support
Problem Description
[1] The LCD

display support is
made of an ABS
plastic.
[2] The design load

(40 N) applies on
the trough.
11
Techniques/Concepts
Loads>Bearing Load
Section 5.4 LCD Display Support
12
Chapter 6 Surface Models
Chapter 6
Surface Models
6.1 Step-by-Step: Bellows Joints
6.2 Step-by-Step: Beam Bracket
6.3 More Exercise: Gearbox
6.4 Review
Section 6.1
Bellows Joints
Problem Description
With the internal pressure, the

engineers are concerned about the
radial deformation (due to an
engineering tolerance
consideration) and hoop stress
(due to a safety consideration).
Section 6.1 Bellows Joints
28
Unit: mm.
28
R315
20
R315
Techniques/Concepts
Create surface bodies

using <Revolve>.
Top/Bottom of a surface
body
Shell Elements
Section 6.2
Beam Bracket
Techniques/Concepts
Create surface bodies

using <Mid-Surface>
Section 6.3 Gearbox
Section 6.3
Gearbox
Problem Description
[1] The flanged

bearing is made
of gray cast iron.
[2] The base is

also made of cast
iron.
[3] The housing

is made of
stainless sheet
steel of 3 mm
thickness.
Section 6.3 Gearbox
170
200
(R170)
100
70
30
Unit: mm.
355
(R70)
R20
R40
15
170
R30
R50
520
180
540
240
Techniques/Concepts
Create surface bodies by

<Thin/Surface>
Loads>Bearing Loads
Set up <Bonded>
connections.
Section 6.3 Gearbox
Chapter 7 Line Models
Chapter 7
Line Models
7.1 Step-by-Step: Flexible Gripper
7.2 Step-by-Step: 3D Truss
7.3 More Exercise: Two-Story Building
7.4 Review
Section 7.1 Flexible Gripper
Section 7.1
Flexible Gripper
[4] Gripping
direction
(output).
Problem Description
P4(35,160)
P3(69,120)
P5(34,100)
P6(24, 60)
P7(0, 50)
P2(90, 40)
P1(70, 0)
[1] The gripper is

made of POM.
[2] The ends are

connected to a rigid
ground (preventing
translations and
rotations).
[3] Actuation
direction (input).
Techniques/Concepts
Line bodies
Cross Sections
Cross Section Alignments
Cross Section Solids
Beam Elements
Symmetry Conditions
Geometric Advantage
Horizontal Displacement (mm)
60
50
40
30
20
10
0
5 10 15 20 25 30 35 40 45 50
Input Displacement (mm)
Convergence Study of Beam Elements

[2] The displacement
converges to 52.381 mm.
Output Displacement (mm)
52.32
52.30
[1] In this exercise, we
meshed with 34
elements, resulting 52.335
mm of displacement.
52.28
52.26
52.24
125
250
375
Number of Elements
500
625
Section 7.2 3D Truss
Section 7.2
3D Truss
75"
Design Loads for the Transmission Tower
Joint
FX (lb)
FY (lb)
FZ (lb)
P1
1,000
-10,000
-10,000
P2
-10,000
-10,000
P3
500
P6
600
P5
25
13
P4
17
X
P8
10
12
22
24
19
P9
200 "
P6
20
16
21
11
100 "
7 6
P10
75"
P3
14
15
100 "
Problem Description
P1
P2
23
18
P7
Y
200 "
Techniques/Concepts
Create points
Concepts>Lines From Points
Convergence of straight beam
elements
Section 7.2 3D Truss
Section 7.3 Two-Story Building
Section 7.3
Two-Story Building
Problem Description
20 '
[3] Each
floor-to-floor
height is 10'.
20 '
20 '
20 '
[1] All beams and

columns are made
of structural steel,
with a cross
section of W16x50.
[2] The floor slabs

are made of reinforced
concrete, with a
thickness of 5".
Techniques/Concepts
Adjust Cross Section

Alignments
Concepts>Surface From
Edges
Use of Selection Panes

Flip Surface Normal
Form New Part
Import Engineering Data
Inertial>Standard Earth
Gravity
Inertial>Acceleration
Section 7.3 Two-Story Building
Chapter 8 Optimization
Chapter 8
Optimization
8.1
Step-by-Step: Flexible Gripper
8.2
More Exercise: Triangular Plate
8.3
Review
Section 8.1
Flexible Gripper
P4( 35,160)
Problem Description
P3( 69,120)
The idea is to x the X-coordinates of these points and

adjust their Y-coordinates to achieve a better GA value.
Allowable adjustment ranges are 10 mm for P2, 20 mm

for P3, and 5 mm for P6.
P5( 34,100)
Positions of the P2, P3, and P6 are free to be changed.
The maximum stress should not exceed 15 MPa.
P6( 24, 60)

P7(0, 50)
P2( 90, 40)

Y
P1( 70, 0)
Techniques/Concepts
Input Parameters
Output Parameters
Design Points
Goal Driven Optimization
Design of Experiments
DOE Tables
Response Surfaces
Optimization
Objectives and Constraints
Optimization algorithms
Current Design
Section 8.2 Triangular Plate
Section 8.2
Triangular Plate
[1] we want to
change the values
of W and R to
reduce the amount
of material.
[2] The initial value

of the width of the
bridge is 30 mm and
its allowable range is
20-30 mm.
[3] The initial value of the

radius of the llet is 10 mm
and its allowable range is
5-15 mm.
Problem Description
Techniques/Concepts
No additional techniques/concepts are introduced.
Section 8.2 Triangular Plate
Chapter 9 Meshing
Chapter 9
Meshing
9.1 Step-by-Step: Pneumatic Fingers
9.2 More Exercise: Cover of Pressure Cylinder
9.3 More Exercise: Convergence Study of 3D Solid Elements
9.4 Review
Chapter 9 Meshing
Section 9.1 Pneumatic Fingers
Section 9.1
Pneumatic Fingers
Problem Description
Plane of
symmetry.
Unit: mm.
(19.2)
1
80
3 3.2
4
5.1
Chapter 9 Meshing
Techniques/Concepts
Mesh Metric: Skewness

Hex Dominant Method
Sweep Method
MultiZone Method
Section View
Nonlinear Simulations
Line Search
Displacement Convergence
Section 9.1 Pneumatic Fingers
Chapter 9 Meshing
Section 9.2
Cover of Pressure Cylinder
Techniques/Concepts
Patch Conforming Method

Patch Independent Method
Chapter 9 Meshing
Section 9.3 Convergence Study of 3D Solid Elements
Section 9.3
Convergence Study of 3D Solid Elements
Problem Description
[2] The width of the beam
is 10 mm. A uniform load
of 1 MPa applies on the
upper face of the beam.
[1] The beam is

made of steel.
[3] We will
record the
vertical tip
deflection.
10 mm
100 mm
Chapter 9 Meshing
Element Shapes
[1] hexahedron.
[3] Parallel prism.
[2] Tetrahedron.
[4] Perpendicular
prism.
Chapter 9 Meshing
Lower-Order Elements
Tip Deflection (mm)
0.76
0.72
[4] Lower-order
hexahedron.
0.68
[2] Lower-order
perpendicular
prism.
0.64
[3] Lower-order
parallel prism.
[1] Lower-order
tetrahedron.
0.60
3000
6000
9000
Number of Nodes
12000
15000
Chapter 9 Meshing
Higher-Order Elements
[3] Higher-order
parallel prism.
0.752
Tip Deflection (mm)
0.751
[4] Higher-order
hexahedron.
0.750
0.749
[2] Higher-order
perpendicular prism.
0.748
[1] Higher-order
tetrahedron.
0.747
0.746
2000
4000
6000
Number of Nodes
8000
10000
Chapter 9 Meshing
Hexahedra
0.752
Tip Deflection (mm)
0.751
0.750
[2] Higher-order
hexahedron.
0.749
0.748
[1] Lower-order
hexahedron.
0.747
0.746
2000
4000
6000
Number of Nodes
8000
10000
Chapter 9 Meshing
Tetrahedra
Tip Deflection (mm)
0.760
[2] Higher-order
tetrahedron.
0.720
0.680
[1] Lower-order
tetrahedron.
0.640
0.600
2000
4000
6000
Number of Nodes
8000
10000
10
Chapter 9 Meshing
Parallel Prisms
Tip Deflection (mm)
0.76
0.74
[2] Higher-order
parallel prism.
0.72
0.70
[1] Lower-order
parallel prism.
0.68
0.66
2000
4000
6000
Number of Nodes
8000
10000
11
Chapter 9 Meshing
Perpendicular Prisms
Tip Deflection (mm)
0.76
0.74
0.72
[2] Higher-order
0.70
[1] Lower-order
0.68
0.66
2000
4000
6000
Number of Nodes
8000
10000
12
Chapter 9 Meshing
Guidelines
Never use lower-order tetrahedra/triangles.

Higher-order tetrahedra/triangles can be as good as other elements as long as the
mesh is fine enough. In cases of coarse mesh, however, they perform poorly and
are not recommended.
Lower-order prisms are not recommended.

Lower-order hexahedra/quadrilaterals can be used, but they are not as efficient as
their higher-order counterparts.
Higher-order hexahedra, prisms, and quadrilaterals are among the most efficient
elements so far we have discussed. Mesh your models with these elements
whenever possible. If that is not possible, then at least try to achieve a higherorder hexahedra-dominant or quadrilateral-dominant mesh.
13

Chapter 5 3D Simulations 1

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Chapter 5 3D Simulations

Section 5.1 Beam Bracket

[1] The bracket is

Section 5.1 Beam Bracket

Section 5.2 Cover of Pressure Cylinder

[1] The cover is

Add a new material in

Section 5.2 Cover of Pressure Cylinder

Section 5.3 More Details

Mesh with MultiZone Method

Generally, hexahedral elements are more

A simple idea of creating hexahedra is to

Not all bodies are sweepable.

Section 5.3 More Details

Section 5.3 More Details

When defining an environment

condition or a solution object by

to a coordinate system. By default,

To define a new coordinate

Section 5.3 More Details

[5] Turn on/off

[2] The divider

Workbench provides a tool to

This idea is termed adaptive

Internally, Workbench exploits

Section 5.3 More Details

Section 5.4 LCD Display Support

[1] The LCD

[2] The design load

Section 5.4 LCD Display Support

Chapter 6 Surface Models

Chapter 6 Surface Models

With the internal pressure, the

Section 6.1 Bellows Joints

Chapter 6 Surface Models

Section 6.1 Bellows Joints

Chapter 6 Surface Models

Create surface bodies

Section 6.1 Bellows Joints

Chapter 6 Surface Models

Create surface bodies

Section 6.2 Beam Bracket

Chapter 6 Surface Models

Section 6.3 Gearbox

[1] The flanged

[2] The base is

[3] The housing

Chapter 6 Surface Models

Section 6.3 Gearbox

Chapter 6 Surface Models

Create surface bodies by

Section 6.3 Gearbox

Chapter 7 Line Models

Chapter 7 Line Models

Section 7.1 Flexible Gripper

[1] The gripper is

[2] The ends are

Chapter 7 Line Models

Section 7.1 Flexible Gripper

Horizontal Displacement (mm)

Chapter 7 Line Models

Section 7.1 Flexible Gripper

Convergence Study of Beam Elements