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Finite Element Analysis in Practice PDF
Finite Element Analysis in Practice PDF
in Practice
Instructor Manual
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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
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
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.
• 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.
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
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
VIII FEA in Practice – Instructor Manual – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Course Introduction
* 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 user’s guide, contains
the following information:
• 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
• 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.
• 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
• 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 User’s
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:
X FEA in Practice – Instructor Manual – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Course Introduction
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 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.
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.
• 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
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.
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.
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 polled—on-demand, daily, weekly, or monthly. When a program update notification
is received, the user will be given the option of downloading and installing it.
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
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.
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.
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.
XIV FEA in Practice – Instructor Manual – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Course Introduction
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.
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Course Introduction
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.
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.
• SteeringWheels
• Pan
• Zoom
• Orbit
• Center
• Previous View
• Next View
Each of these icons, except for the Previous and Next commands, function as a
toggle—clicking 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
modes—Zoom, 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 menu—Orbit, 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.
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.
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.
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.
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Thermal
Analyses
Slide 158:
Thermal Analyses
The following two types of thermal analysis
are available:
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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
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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.
© 2010 Autodesk, Inc. All rights reserved.
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Slide 165:
Thermal Results
• Temperature
• Heat flux (energy / time / length2)
• Heat rate of face (energy / time)
Slide 166:
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Electrostatic
Analyses
Slide 168:
Electrostatic Analyses
The following two types of electrostatic
analysis are available:
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Electrostatic Elements
• Electrostatic 2-D and brick elements are
geometrically identical to the analogous
structural elements.
Slide 170:
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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)
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Fluid Flow
Analyses
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Mechanical
Event
Simulation
(MES)
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• 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
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© 2010 Autodesk, Inc. All rights reserved.
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 wheel’s 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 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 the effects of 0.001” part clearances
and prevents chatter, resulting in a quicker and more stable solution).
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© 2010 Autodesk, Inc. All rights reserved.
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Slide 199:
Exercise M (continued)
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 4’s lumped mass,
specify a 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”.
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.
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© 2010 Autodesk, Inc. All rights reserved.
Slide 200:
Exercise M (continued)
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 wheel’s 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”.
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© 2010 Autodesk, Inc. All rights reserved.
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Slide 201:
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.
© 2010 Autodesk, Inc. All rights reserved.
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Multiphysics Example:
Analysis of Stresses due to
Electrostatic Forces
Refer to the software’s “Help: Tutorials” menu
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:
Material
Models
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Isotropic
• This is the standard material model. The
material properties are independent of
direction.
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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.
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Drucker-Prager
• This material model is used to model rock
and concrete.
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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.
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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:
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Finite Element Analysis
in Practice
Steps for Exercises
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
SE.4 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Foreword
Starting Autodesk® Algor® Simulation
• 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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.5
Forward
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.
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.
SE.6 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.7
Introductory Example
SE.8 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Introductory Example
Solution
"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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.9
Introductory Example
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.
Holding down the <Ctrl> key, click on the "Material"
<Ctrl>Mouse
heading for Part 3 in the tree view.
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.
SE.10 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Introductory Example
Click the “OK” button to accept this material for all three
“OK”
parts.
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).
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.11
Introductory Example
SE.12 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Introductory Example
The von Mises stress contour on the displaced shape will appear as shown in Figure 0.5.
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.13
Introductory Example
We will now capture a screen image of the displacement results for inclusion within the analysis report.
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).
SE.14 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Introductory Example
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.15
Introductory Example
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 formats—Word 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.
SE.16 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise A
FEA Example by Hand
Truss Elements
Objective: Construct and analyze a system of three trusses supporting a vertical load.
Elements: Truss
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.17
Exercise A – FEA Example by Hand
SE.18 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise A – FEA Example by Hand
Solution
"New" Select the "New" 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."
"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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.19
Exercise A – FEA Example by Hand
SE.20 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise A – FEA Example by Hand
To review a completed archive of this exercise, refer to the file Exercise A.ach in the "Exercise A\
Results Archive" directory.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.21
Exercise A – FEA Example by Hand
SE.22 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise B
Truss Frame Model
Truss Elements
Objective: Construct and analyze a frame of truss elements loaded with forces.
Elements: Truss
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.23
Exercise B – Truss Frame Model
SE.24 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise B – Truss Frame Model
Solution
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise B" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise B
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 VIEW pull-down menu and select the
"View: Orientation: Top
"Orientation" pull-out menu. Select the "Top View"
View"
command.
Access the GEOMETRY pull-down menu and select the
"Geometry: Add: Line…" "Add" pull-out menu. Select the "Line…" command to
bring up the "Define Geometry" dialog.
Mouse Deactivate the "Use as Construction" checkbox.
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.
Access the VIEW pull-down menu and select the
"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."
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.25
Exercise B – Truss Frame Model
SE.26 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise B – Truss Frame Model
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.27
Exercise B – Truss Frame Model
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.
SE.28 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise B – Truss Frame Model
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.29
Exercise B – Truss Frame Model
Analysis
SE.30 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise B – Truss Frame Model
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.31
Exercise B – Truss Frame Model
Validation of Results
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.
SE.32 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise C
Support Beam under Gravity
Beam Elements
Objective: Determine the maximum deflection of the beam due to its own weight.
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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.33
Exercise C – Support Beam Under Gravity
SE.34 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise C – Support Beam Under Gravity
Solution
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise C" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise C
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 VIEW pull-down menu and select the
"View: Orientation: Top
"Orientation" pull-out menu. Select the "Top View"
View"
command.
Access the GEOMETRY pull-down menu and select the
"Geometry: Add: Line…" "Add" pull-out menu. Select the "Line…" command to
bring up the "Define Geometry" dialog.
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.
<Esc> Press <Esc> to terminate the current line segment.
<Esc> Press <Esc> to exit the line command.
Access the VIEW pull-down and select the "Enclose"
"View: Enclose"
command.
Access the SELECTION pull-down menu and choose the
"Selection: Select: Lines"
"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 the
"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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.35
Exercise C – Support Beam Under Gravity
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.
SE.36 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise C – Support Beam Under Gravity
Analysis
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.37
Exercise C – Support Beam Under Gravity
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.
SE.38 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise C – Support Beam Under Gravity
The element moment results about axis 3 and the corresponding moment diagram should now appear as
shown in Figure C3.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.39
Exercise C – Support Beam Under Gravity
SE.40 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise C – Support Beam Under Gravity
Validation of Results
Reference
Mark’s 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.)
Comparison of Results
Algor
Theoretical % Difference
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.41
Exercise C – Support Beam Under Gravity
SE.42 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
Constraints: The bottom surface will be constrained against translation in the Z direction.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.43
Exercise D – Axisymmetric Thick-walled Cylinder
SE.44 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise D – Axisymmetric Thick-walled Cylinder
Solution
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.
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise D" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise D
analysis files will be created. This location can be changed
by navigating to an alternate working folder if desired.
"Save" Press the "Save" button.
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.
Access the VIEW pull-down menu and select the
"View: Enclose"
"Enclose" command.
Right-click on the "Plane 2 < YZ(+X) >" heading in the
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.
"Apply" Press the "Apply" button.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.45
Exercise D – Axisymmetric Thick-walled Cylinder
After assigning the material properties, all red Xs and red text should now be removed from the tree view.
SE.46 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise D – Axisymmetric Thick-walled Cylinder
The hoop stress is in the tangential (X) direction, which is normal to the plane formed by the radial (Y) and
axial (Z) directions.
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”).
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.47
Exercise D – Axisymmetric Thick-walled Cylinder
Validation of Results
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.
Theoretical Solution
qb 2 a 2 + r 2
σ 2 = 2 2 2
r a − b
Comparison of Results
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.
SE.48 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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".
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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.49
Exercise E – Plate Under Uniform Pressure
SE.50 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise E – Plate Under Uniform Pressure
Solution
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise E" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise E
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 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.
Type "5" in the "Y:" field and press <Enter> to define the
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.
Access the VIEW pull-down menu and select the
"View: Orientation: Top
"Orientation" pull-out menu. Select the "Top View"
View"
command. The mesh will appear as shown in Figure E1.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.51
Exercise E – Plate Under Uniform Pressure
After assigning the material properties, all red Xs should now be removed from the tree view.
SE.52 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise E – Plate Under Uniform Pressure
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.53
Exercise E – Plate Under Uniform Pressure
Analysis
The maximum stress is in a direction parallel to the free edge, which for this example is the Y direction.
SE.54 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise E – Plate Under Uniform Pressure
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.55
Exercise E – Plate Under Uniform Pressure
Validation of 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.
Theoretical Solution
Bqb 2
σ max = = 15,800 psi
t2
Comparison of Results
Algor
Theoretical % Difference
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.
SE.56 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.57
Exercise F – Cantilever Beam Model
SE.58 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise F – Cantilever Beam Model
Solution
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise F" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise F
analysis files will be created. This location can be changed
by navigating to an alternate working folder if desired.
"Save" Press the "Save" button.
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.59
Exercise F – Cantilever Beam Model
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.
Access the VIEW pull-down menu and select the
"View: Orientation: Isometric
"Orientation" pull-out menu. Select the "Isometric View"
View"
command. The model should appear as shown in Figure F2.
SE.60 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise F – Cantilever Beam Model
Note that the solid mesh could also have been constructed using the 8 Point 3-D structured meshing tool.
After assigning the material properties, all red Xs and red text should now be gone from the tree view.
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.
Mouse Right-click in the display area.
"Add: Nodal Boundary Select the "Add" pull-out menu and select the "Nodal
Conditions…" Boundary Conditions…" command.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.61
Exercise F – Cantilever Beam Model
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).
SE.62 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise F – Cantilever Beam Model
Analysis
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.63
Exercise F – Cantilever Beam Model
SE.64 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise F – Cantilever Beam Model
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.
Press the "Close" button to close the "Inquire: Results"
"Close"
dialog.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.65
Exercise F – Cantilever Beam Model
Validation of Results
Reference
Mischke, C. R. and Shigley, J. E., Mechanical Engineering Design, Fifth Edition, McGraw-Hill, 1989,
page 44.
Theoretical Solution
M = F·L = 10,000 * 24” = 240,000 in.lb.
Mc
σ bending = = 22,500 psi
I
Comparison of Results
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.
SE.66 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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:
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).
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.67
Exercise G – Comparing Element Types
SE.68 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise G – Comparing Element Types
Solution
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise G" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise G
analysis files will be created. This location can be changed
by navigating to an alternate working folder if desired.
"Save" Press the "Save" button.
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.
“OK” Click the “OK” button.
Access the MESH pull-down menu and select the
"Mesh: Structured Mesh:
"Structured Mesh" pull-out menu. Select the "4 Point
4 Point Rectangular…"
Rectangular…" command.
34 Type "34" in the "AB:" field.
4 Type "4" in the "BC:" field.
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.
"Apply" Press the "Apply" button to create the mesh.
<Esc> Press <Esc> to exit the mesh command.
Access the VIEW pull-down menu and select the
"View: Orientation: Right
"Orientation" pull-out menu. Select the "Right View"
View"
command.
Access the SELECTION pull-down menu and select the
"Selection: Shape: Rectangle" "Shape" pull-out menu. Select the "Rectangle"
command.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.69
Exercise G – Comparing Element Types
SE.70 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise G – Comparing Element Types
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.
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.
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.71
Exercise G – Comparing Element Types
Next, we will build the geometry for the beam part, the 0.5” thick plate part, and the brick element part.
SE.72 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise G – Comparing Element Types
Type "3" in the "Z:" field and press <Enter> to define the
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.
"Apply" Press the "Apply" button to create the mesh.
4 Type "4" in the "Part:" field.
4 Type "4" in the "BC:" field.
Type "4" in the "Z:" field and press <Enter> to define the
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.
"Apply" Press the "Apply" button to create the mesh.
<Esc> Press <Esc> to exit the mesh command.
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.
Access the VIEW pull-down menu and select the
"View: Orientation: Right
"Orientation" pull-out menu. Select the "Right View"
View"
command.
Access the SELECTION pull-down menu and select the
"Selection: Shape: Rectangle"
"Shape" pull-out menu. Select the "Rectangle" command.
Mouse Draw a box enclosing the top edge of Part 4 (light-blue).
Access the GEOMETRY 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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.73
Exercise G – Comparing Element Types
SE.74 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise G – Comparing Element Types
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).
Mouse Right-click in the display area.
Select the "Add" pull-out menu and select the "Nodal
"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.
"Z" Select the "Z" radio button.
“OK” Click the “OK” button.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.75
Exercise G – Comparing Element Types
SE.76 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise G – Comparing Element Types
Results
Displacement X-Reaction Shear σy* σy* σ 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
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 ( σ 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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.77
Exercise G – Comparing Element Types
To review a completed archive of this exercise, refer to the file Exercise G.ach in the "Exercise G\Results
Archive" directory.
SE.78 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.79
Exercise H – Mesh Convergence
Solution
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.
"New" Select the "New" 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."
"New" Press the "New" button.
Type "Exercise H" in the "File name:" field in the "Save
As" dialog. Note the default folder location where the
Exercise H
analysis files will be created. This location can be changed
by navigating to an alternate working folder if desired.
"Save" Press the "Save" button.
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.
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.
"Apply" Press the "Apply" button.
<Esc> Press <Esc> to exit the rectangle command.
Access the GEOMETRY pull-down menu and select the
"Geometry: Add: Circle:
"Add" pull-out menu. Select the "Circle" pull-out menu
Center and Radius…"
and select the "Center and Radius…" command.
Type "2" in the "Y:" field and press <Enter> to define the
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.
"Apply" Press the "Apply" button.
<Esc> Press <Esc> to exit the circle command.
Access the VIEW pull-down and select the "Enclose"
"View: Enclose"
command.
Access the SELECTION pull-down menu and choose the
"Selection: Select:
"Select" pull-out menu. Select the "Construction
Construction Objects"
Objects" command.
Access the GEOMETRY pull-down menu and select the
"Geometry: Tools: Trim"
"Tools" pull-out menu. Select the "Trim" command.
SE.80 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise H – Mesh Convergence
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.81
Exercise H – Mesh Convergence
SE.82 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise H – Mesh Convergence
Record the stress value in the following table so that the results for each trial mesh density setting may be
easily compared:
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.83
Exercise H – Mesh Convergence
SE.84 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
Loads: 40 pounds will be applied downward at the hole (that is, in the –Y direction).
Elements: Brick
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.85
Exercise I – Bracket Model
SE.86 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise I – Bracket Model
Solution
"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 "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.
"Open" Press the "Open" button.
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.
“OK” Click the “OK” button.
Access the MESH pull-down menu and select the
"Mesh: Generate Mesh"
"Generate Mesh" command.
"No" Press the "No" button when asked to view the mesh results.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.87
Exercise I – Bracket Model
SE.88 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise I – Bracket Model
Analysis
To review a completed archive of this exercise, refer to the file Exercise I.ach in the "Exercise I\Results
Archive" directory.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.89
Exercise I – Bracket Model
SE.90 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
Elements: Brick
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.91
Exercise J – Hanger Assembly Model
SE.92 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise J – Hanger Assembly Model
Solution
"Open" Select the "Open" icon at the left side of the dialog
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.
"Open" Press the "Open" button.
Select the location where you want the model to be
“OK”
extracted and Click the “OK” button.
Access the MESH pull-down menu and select the "Model
"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.
Holding down the <Ctrl> key, click on the "Material"
<Ctrl>Mouse
heading for Part 2 in the tree view.
Mouse Right-click on one of the selected headings.
"Modify Material…" Select the "Modify Material…" command.
Highlight the material, "Iron, Fe", from the list of
"Iron, Fe"
available materials within the “Iron” folder.
“OK” Click the “OK” button to accept the selected material.
Right-click on the "Material" heading for Part 3 in the tree
Mouse
view.
"Modify Material…" Select the "Modify Material…" command.
Highlight the material, "Steel (AISI 4130)", from the list
"Steel (AISI 4130)"
of available materials within the "Steel” folder.
“OK” Click the “OK” button to accept the selected material.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.93
Exercise J – Hanger Assembly Model
SE.94 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise J – Hanger Assembly Model
Analysis
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.95
Exercise J – Hanger Assembly Model
To review a completed archive of this exercise, refer to the file Exercise J.ach in the
"Exercise J\Results Archive" directory.
SE.96 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
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
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.97
Exercise K – Linear Contact Model
SE.98 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise K – Linear Contact Model
Solution
"Open" Select the "Open" icon at the left side of the dialog
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 input file is located.
Select the Exercise K.stp file in the "Exercise K \Input File"
Exercise K.stp
directory.
"Open" Press the "Open" button.
Choose the option to "Use STEP file units" if it is not
"Use STEP file units"
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.
“OK” Click the “OK” button.
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).
Mouse Right-click on one of the selected headings.
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).
Mouse Right-click on one of the selected headings.
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.
"Mesh: Model Mesh Access the MESH pull-down menu and select the "Model
Settings…" Mesh Settings…" command.
"Options" Click on the "Options" button.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.99
Exercise K – Linear Contact Model
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.
Access the SELECTION pull-down menu and select the
"Selection: Shape: Circle" "Shape" pull-out menu. Select the "Circle" command. This
will allow you select objects within a circular selection zone.
Access the SELECTION pull-down menu and choose the
"Selection: Select: Surfaces" "Select" pull-out menu. Select the "Surfaces" command.
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.
SE.100 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise K – Linear Contact Model
Analysis
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.101
Exercise K – Linear Contact Model
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.
SE.102 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise K – Linear Contact Model
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.103
Exercise K – Linear Contact Model
SE.104 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.105
Exercise L – Thermal Model
SE.106 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise L – Thermal Model
Solution
"Open" Select the "Open" icon at the left side of the dialog
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.
"Open" Press the "Open" button.
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.
"No" Press the "No" button when asked to view the mesh results.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.107
Exercise L – Thermal Model
"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.
SE.108 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise L – Thermal Model
We will now check the temperature of the top surface of the block.
To review a completed archive of this exercise, refer to the file "Exercise L.ach" in the "Exercise L\Results
Archive" directory.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.109
Exercise L – Thermal Model
SE.110 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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, 90º 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.
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”
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.111
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
Elements: Drive and Driven Wheels – Brick, Analysis Type = "Large Displacement"
Joints – Pipe, O.D. = 0.1", Wall Thickness = 0.03"
SE.112 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
Solution
"Open" Select the "Open" icon at the left side of the dialog.
Select the "STEP (*.stp, *.ste, *.step)" option in the CAD
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.
"Open" Press the "Open" button.
Choose the option to "Use STEP file units" if it is not
"Use STEP file units"
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."
“OK” Click the “OK” button.
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"
"Contact: 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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.113
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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.
SE.114 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
Figure M1: Selection Polyline (Yellow) and Lines Selected for Modification of Attributes (Magenta)
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.115
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
Figure M2: Selection Polylines (Yellow) and Lines Selected for Modification of Attributes (Magenta)
SE.116 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
Figure M3: Selection Box (Yellow) and Lines Selected for Modification of Attributes (Magenta)
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.117
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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,
"101" select surface "101."
Mouse Using the pull-down menu in the "Second Part" field,
"2" select part "2."
Mouse Using the pull-down menu in the "Second Surface" field,
"101" select surface "101."
"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,
"102" select surface "102."
Mouse Using the pull-down menu in the "Second Part" field,
"2" select part "2."
Mouse Using the pull-down menu in the "Second Surface" field,
"102" select surface "102."
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.
SE.118 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
We will next create the four joints used to rotationally mount the two Geneva wheels.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.119
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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.
SE.120 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
We will set the element type, element definition, and material properties for all four joints simultaneously.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.121
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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.
SE.122 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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.
Mouse Right-click in the display area, access the "Add" pull-out
"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.
“OK” Click the “OK” button.
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.
“OK” Click the “OK” button.
Access the VIEW pull-down menu and choose the
"View: Orientation: Isometric
"Orientation" pull-out menu. Select the "Isometric
View"
View" command.
Before proceeding further, save the work performed thus far
"File: Save" by accessing the FILE pull-down menu and selecting the
"Save" command.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.123
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
This completes the application of constraints, loads, element properties, and materials to the assembly. We
will now define the analysis parameters.
"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”.
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.
SE.124 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.125
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
SE.126 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
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
frames—otherwise, 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 lower—changing 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.
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.127
Exercise M – Mechanical Event Simulation (MES), Geneva Mechanism
To review a completed archive of this exercise, refer to the file "Exercise M\Results Archive\Exercise M.ach”.
SE.128 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
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.
Elements: Beam (use the “Large Displacement” analysis type option in the “Element
Definition” dialog)
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.129
Exercise N – Nonlinear Material Model
SE.130 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise N – Nonlinear Material Model
Solution
"New" Select the "New" icon at the left side of the dialog.
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.
"New" Press the "New" button.
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.
"Save" Press the "Save" button.
Access the VIEW pull-down menu and select the
"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.
Mouse Deactivate the "Use as Construction" checkbox.
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.
<Esc> Press <Esc> to terminate the current line segment.
<Esc> Press <Esc> to exit the line command.
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.
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Exercise N – Nonlinear Material Model
SE.132 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise N – Nonlinear Material Model
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.133
Exercise N – Nonlinear Material Model
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.
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.
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.
Since the material model has been changed, we will revisit the material selection dialog to refresh the
properties for the selected material.
SE.134 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010
Exercise N – Nonlinear Material Model
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.
FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010 SE.135
Exercise N – Nonlinear Material Model
SE.136 FEA in Practice – Steps for Exercises – Autodesk® Algor® Simulation Professional 2011 4/30/2010