ME6194 LAB 5: Miscellaneous BCs J.

Shah
Part A. Centrifugal Stresses
Determine the centrifugal stresses in a rimmed flywheel with 4 elliptic spokes. Dimensions are in inches.

Elliptic cross-
sec of spokes

The flywheel rotates at a max speed of 3500 Rpm. The hub thickness and rim thickness are 4 in. Assume the
material is steel. Find the nominal axial stress (away from stress concentration) in the spokes and the average
tangential stress in the rim at mid-radius due to centrifugal load only. Compare to analytical equations in design
books ( an Excel spreadsheet incorporating empirical formulas is available on request)

Part B: Hydrostatic BCs

Find the axial and hoop stresses in conical water tank made of steel, 0.1 in thick.
The bottom is flat with medial dia = 25 in, the top is 75 in dia and the height is 120
in. The fillet radius between the bottom and side is 3 in. It is supported on the flat
bottom. Consider both the hydrostatic load and the weight of the structure.
Determine (a) max hoop and axial stress (b) The max bending stress as a
percentage of the max membrane stress in circumferential direction. (c) the
contribution to stresses from the hydrostatic load vs the gravity load. (d) You could
use axisymmetric, shell or solid elements. Justify the particular choice you made.
Refer to the back page for guidelines on applying hydrostatic load. Also, justify the
portion of the geometry that was modeled.

Part C: Simulating shrink fit stresses with a common trick!

Many structures are pre-stressed in various ways to reduce operating stresses. How can one simulate pre-loads
and pre-stress? A common trick is to apply thermal expansion even though the structure is at room temperature.

PROBLEM: an interference fit between two compound cylinders shown is to be modeled. We want to see the
benefit on reducing stresses due to internal pressure.

Material:
Inner cylinder Generic
ID=4 in, OD=6 Steel
in
E=30e6;
Outer cylinder =0.3;
ID=6in, OD=8 in
= 6.5e-5
P
Create the geometry in WB (use frozen and merge to keep cylinders separate);

Case (a): Stresses due to internal pressure: Analyze the stresses under an internal
pressure of p=25,000 psi, NO shrink fit. Take advantage of symmetry.
Get X-Y graphs of hoop and radial stresses through the thickness

Case (b): Stresses due to shrink fit: Simulate the interference from the shrink fit of 0.006 inches. Use a fictitious
temperature increase on the inner cylinder to simulate thermal expansion to cause the estimated interference. You
will need to figure out what T value will simulate 0.006 in interference. If you want to do this in WB you will
need to do a “token” HT analysis to get different temperature on the two cylinders ( T and T+T). In Classic you
can do the structural analysis directly. Get X-Y graphs of hoop and radial stresses through the thickness.
Case (c): Shrink fit cylinders under internal pressure
Analyze the stresses when pressure is applied with shrink fit. Combine the stresses from the two previous cases.
Get X-Y graphs of hoop and radial stresses through the thickness

REPORT
1. Show calculation of temp BC to simulate an interference of 0.006
2. Show theoretical formulas used for both cases and create a plot of hoop & radial stresses in Excel (from
theoretical equations); also tell us where your Excel spreadsheet is located
3. Show a screen shot of the mesh and all BCs for each load case; what type of element was used and why?
4. Plots of hoop stresses for all three cases; 5. Fill in the Table below for stresses at key sections
Hoop stress  (ksi)
Load Inner cyl, R=4 Inner cyl, R=6 Outer cyl, R=6 Outer cyl, R=8
FEA Theory FEA Theory FEA Theory FEA Theory
Pressure only
Shrink fit only
TOTAL 
6.. Compare the shape of FEA plot to the theoretical plot for all load cases. What is the max error?
7. Compare the stress plots for (b) and (c) answer this question: What is the functional benefit of the pre-load
created by a shrink fit?

Formulas from Timoshenko, “Strength of Materials”, Part II

Thick cylinders (OD=2b, ID=2a) Thick cylinders under external Equivalent pressure from shrink fit, pe (inner
under internal pressure, pi pressure, po cyl ID=2a, OD=2b; outer cyl ID=2b,
a 2 pib2 b 2 po a2 OD=2c), =interference
 r  2 2 (1  2 ) (1a)  r   2 2 (1  2 ) ( 2a )
b a r b a r
E (b 2  a 2 )(c 2  b 2 )
2
a pi b2
2
b p a2 pe  (3)
 t  2 2 (1  2 ) (1b)  t   2 o 2 (1  2 ) (2b) b 2b 2 (c 2  a 2 )
b a r b a r
To find stresses due to shrink fit only, first find pe from (3). Use this pe in place of pi in (1) for the outer cylinder and in place
of po in (2) for the inner cylinder
Part D: Sub-modeling
Perform a coarse full analysis of the truss below, followed by a finer analysis of the critical joints (Sub-model).

Two types of analysis will be done: Beam to solid submodel and solid to solid submodel. A Catia file (Truss3) is
on Carmen; it contains a single solid of the full truss. You should be able to extract everything you need from this
CAD part: full solid, beam geometries and sliced solid for joint analysis.
The top beam carries a transverse load of 10,000 lbf; the bottom beam is “supported”; no disps in z direction.
When you are done, your Project page will look like this:

Beams can be extracted in SCDM after importing the solid. But if you go back to DM, cross-secs will be lost. On
the other hand, since this truss consists of round 1 in dia rods, re-creating Xsec is not hard.
You may need to use a combination of Auto-contact detection and manual to connect all extracted beams.
To create the sliced solid, you can use DM. Define 2
planes offset from YZ on each side; decide how far based
on capturing good load transfer. The same solid can be
used in both sub-models. However, load transfer for solid-
solid is done via Remote Force, while for beam-solid is
done by remote constraints.
To verify you you cut too little or too much, check how
vM or Sx compare at the cuts, betwen the full model and submodel. Create a comparison Table in your report.