1 ME-430 INTRODUCTION TO COMPUTER AIDED DESIGN STRESS ANALYSIS Using Pro/MECHANICA Pro/ENGINEER Wildfire 2.0 Dr. Herli Surjanhata The bicycle wrench shown in the figure below is made of stainless steel. The wrench is 5 mm thick. A total load of 264 Newtons is uniformly distributed over the top surface located on the horizontal plane in the right of the wrench. The inside surfaces of the left hexagon are fixed to simulate the bolt tightening. Determine the von Mises stresses, and maximum deflection under the given distributed load and boundary conditions. Check the convergence of your analysis. Step 1: Using Pro/ENGINEER, create a bicycle wrench as shown in the Figure below. Make sure the units is in mmNs. Add the two hexagon cut-outs on the left and right ends of the wrench 2 Step 2: Transfer the model to Integrated Mode of Pro/MECHANICA. Three algorithms that can be chosen: 1. Quick Check (No convergence): Pro/MECHANICA performs a single pass analysis with uniform p = 3. This method is used to verify if your analysis has been set up correctly. 2. Single-Pass Adaptive: Pro/MECHANICA runs a first pass at p = 3 and determines a local estimate of stress error. Using this error estimate, Pro/MECHANICA determines a new p-order distribution and performs a final pass. 3. Multi-Pass Adaptive: When you run a design study, the Structure engine performs calculations and increases the polynomial order (p-order) for each element edge until the convergence criteria is satisfied. An analysis converges when the difference in the results of the results of the current and previous passes are within the percentage you specify under Convergence. From Applications pull-down menu, select Mechanica. The Unit Info window appears. 3 Click Continue button if the system of units is correct and consistent. From Model Type dialog box, select Structure Click OK. In MEC STRUCT menu, you will use, • Model menu to assign material properties of bike wrench, and also to define loads and constraints. • Analyses/Studies menu to define the type of analysis – in this case static analysis, and Convergence Method. Then run a design study. • Results menu to review design study results. Step 3: Define the material of bike wrench. From Properties pull down menu, select Materials Or click on Define Materials icon on the right toolbar. 4 From the Materials in Library list, select SS Click the Assign button, then Part - Pick the bike wrench. OK. Click the Close button. Note that use Stainless Steel (millimeter_Newton_sec) as the material of bike wrench. Step 4: Apply the boundary conditions or constraints on the left hexagon hole of bike wrench – see Figure below. 5 From Insert pull-down menu, select Displacement Constraint, or click on located on the right toolbar, and the Constraint window appears Enter the name of the constraint as “fixed” Click the arrow button under the Surfaces . Pick all surfaces of hexagon on the left – see Figure below. Make sure to press and hold Ctrl key while selecting the next surfaces. OK, then click OK button in the Constraint window. Done/Return. 6 Note that FIXED constraint should be applied on these surfaces. Step 5: Apply the load on the flat-top surface of the right part of the wrench – see Figure below. From Insert pull-down menu, select Force/Moment Load, or click on located on the right toolbar, and the Force/Moment window appears 7 Enter the name of the load as “Tightening_load”. Enter –264 Newtons force in the Y component. Click the arrow button under the Surfaces . Pick the top horizontal surface located on the right part of the wrench – see Figure below. OK, then click OK button in the Constraint window. Done/Return. 8 Step 6: Define the STATIC analysis by: From Analysis pull-down menu, select Mechanica Analyses/Studies, or click on icon on the top toolbar. Analyses and Design Studies dialog box opens. From File pull down menu, select New Static 9 Enter the name of analysis as “bike_wrench” Select Multi-Pass Adaptive method. Maximum Polynomial Order = 9 Percent Convergence = 5. Convergence on Local Displacement, Local Strain Energy and Global RMS Stress. Click the OK button. Step 7: 10 Run the design study by selecting . Click the Yes button. Click the Display study status button to review the progress of the analysis. Make sure you have “Run Completed” message. Click Close in the Run Status dialog box. Step 8: Review design study results. Click on to review the results of design study. The Result Window Definition dialog box opens. [...]...Enter Window Name as “von_Mises” for Von Mises stress Enter the Title of Von Mises Stress Distribution Plot By default bike_wrench Design Study and Analysis have been selected 11 Select the Display Options tab Make sure you fill in the following form (window) as shown on the left Click the OK and... the max _stress_ vm does NOT converge This is due to the sharp corners in the wrench – see the Von Mises Stress fringe plot Save the results windows as bike_wrench Click Enter the file name bike_wrench.rwd Click OK 19 Close the Analyses and design Studies To eliminate this problem, transfer the model back to Pro/ENGINEER, create the fillets or rounds at the location of sharp corner, and run the analysis. .. run are shown in Figures below 14 We are also interested in the Max Von Mises Stress, Max Displacement Magnitude and Strain Energy convergence Click the Copy button - in the Result Window, and name it as convm Set the following: Set the Display type to Graph Set the Quantity to Measure icon to Click select the Max Von Mises Stress 15 Click OK button Click OK Repeat the same procedure to create another... and design Studies To eliminate this problem, transfer the model back to Pro/ENGINEER, create the fillets or rounds at the location of sharp corner, and run the analysis again until the max von Mises stress converges The following results show the convergence 20 Save the results windows as bike_wrench_new 21 . 1 ME-430 INTRODUCTION TO COMPUTER AIDED DESIGN STRESS ANALYSIS Using Pro/MECHANICA Pro/ENGINEER Wildfire 2.0 Dr. Herli Surjanhata . Mises stresses, and maximum deflection under the given distributed load and boundary conditions. Check the convergence of your analysis. Step 1: Using