Static Stress with Nonlinear Material Models Tutorial

3-D Motor Mount Assembly Model

Part Number 6700.515

Revision 1.14
December 2003
December 17, 2003

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Files List for this Tutorial
In addition to this document file, the following file is referenced in the tutorial:

 CoarseMeshMotorMount.ach - An ALGOR model archive file, which contains a meshed model that is used in the
tutorial.

This file is available in the Tutorials\models directory.

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Tutorial Conventions
To make this tutorial easy to use, the following conventions will be employed. For the command conventions, the item (or an
example of one) that you need to perform is noted in bold on the left. To the right of the item is a short description of the
action and/or results of the action.

User Input Notation Conventions

algframe Type "algframe" using the keyboard. Text that you need to type is noted in bold type using a Courier
font.

<Esc> Press the <Esc> key. Some of the other keys expressed in this manner are <Enter>, <Tab> and the
function keys, for example <F9>.

<Ctrl>-c Press <Ctrl> and the letter "c" simultaneously. Keys to be pressed at the same time are shown with a
hyphen between them.

"Enclose" Select the "Enclose" command. The names of pop-up menus, options and buttons are bold-faced,
enclosed in quotation marks and shown as they are on the screen.

"Selection: Access the SELECTION pull-down menu and select the "Shape" pull-out menu. Select the "Point"
Shape: Point" command. Commands in sequences are separated by colons.

Mouse Use the mouse to click on the specified location. FEMPRO is designed for a two-button mouse. Where
"click" or "left-click" is used, you should press the left mouse button. "Right-click" means you should
press the right mouse button. If you have a three-button mouse, you will not use your middle button
for ALGOR software.

In the tables throughout this tutorial, input instructions for using toolbars and pull-down menus are in the two left columns.
Descriptions or more detailed instructions are given in the right column. For example:

"Selection: Shape: Point" Access the SELECTION pull-down menu and select the "Shape"
pull-out menu. Select the "Point" command to enter point
selection mode.

Other Notation Conventions

sd3.dmit, an .esx file Filenames and file extensions are lowercase with the filename in italic.

filename.doc Filenames that are user-supplied are in bold, lowercase italics.

\model directory Directory names will appear in Courier type and be followed by the term "directory". (The directory
where the ALGOR software is stored is usually referred to as the installation directory).

FILE pull-down menu Pull-down menu names are shown in uppercase characters.

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3-D Motor Mount Assembly Model
In this tutorial, we will introduce you to ALGOR software's capabilities for Static Stress with Nonlinear Material Models
analysis. The example demonstrated in this tutorial shows how to set up and analyze a three-dimensional (3-D) model of a
motor mount assembly.

You will perform the following steps:

I. Setting up the Model – Retrieve the supplied model archive file, which contains a meshed model; specify data
needed for Static Stress with Nonlinear Material Models analysis including the analysis type, element type, element
definition, applied loads, boundary conditions and analysis parameters; check the model geometry and validate
using Superview.

II. Analyzing the Model – Analyze the model using the Static Stress with Nonlinear Material Models processor.

III. Reviewing the Results – Examine the stress results graphically with the Superview IV Results environment.

I. Setting up the Model

In this phase, you will retrieve a supplied model archive file, named CoarseMeshMotorMount.ach, which contains a meshed
model. You will specify all data needed for a Static Stress with Nonlinear Material Models analysis including the analysis
type, element type, element definition, applied loads, boundary conditions and analysis parameters. Then, you will check the
model geometry and finite element data using the Superview IV, Results environment to verify that the model is ready for
analysis.

1. Problem Description

A motor mount assembly is designed to hold a 15-pound motor. The assembly consists of a left bracket, a right bracket and a
knuckle shaft. The brackets are made of aluminum (6061-T6) and the shaft is made of steel (ASTM-A36). The motor is
mounted to the brackets with bolts. The assembly has a tensile force due to the output of the motor.

For the nonlinear static stress analysis, traction loads will be applied where the motor is bolted to the mount through holes on
the brackets, which take the X- and Y-direction forces due to the tension from the output of the motor. Nodal forces will be
applied where the motor is bolted to the mount through slots on the brackets. The ends of the shaft will be constrained
against all motion.

Figure 1 shows a diagram of the motor mount assembly. The goal of the nonlinear static stress analysis is to determine
stresses in the motor mount assembly due to:
 the dead weight load of the motor resting on the mount;
 the force of the motor output acting on the mount; and
 plastic deformation and residual stress remaining after external loads are removed.

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 Figure 1: Diagram of the Motor Mount Assembly

2. Retrieving the Supplied Model Archive File

In this section, you will use FEMPRO to retrieve the supplied model archive file, CoarseMeshMotorMount.ach.

Starting FEMPRO

Start FEMPRO from the Windows taskbar.

"Start: Programs: ALGOR V14: In the Windows taskbar, press the "Start" button. Select the
FEMPRO" "Programs" pull-out menu and select the "ALGOR V14" pull-
out menu. Select the "FEMPRO" command.

FEMPRO will now appear with the "Open" screen active.

"Cancel" Press the "Cancel" button to close the "Open" screen.

In FEMPRO, you have a variety of tasks available to you. You can start a new model, choose an existing model and perform
any complete engineering analysis. Help information is available by accessing the HELP pull-down menu and selecting the
"Contents" command. This will access the ALGOR User’s Guide.

Retrieving the Supplied Model Archive File

Retrieve the supplied model archive file from the Tutorials\Models directory. This archive file contains a meshed
model of the motor mount. (To learn more about meshing, see the InCAD tutorials on the motor bracket model).

"File: Archive: Retrieve…" Access the FILE pull-down menu and select the "Archive" pull-
out menu. Select the "Retrieve…" command (see Figure 2). The
"Extract Archive" screen will appear.

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 Figure 2: Retrieving the Archive File

Mouse Use the "Look in:" drop-down box to navigate to the

Tutorials\Models directory, which is where the archive file
is stored.
CoarseMeshMotorMount Click on the CoarseMeshMotorMount.ach file.
"Open" Press the "Open" button.
Mouse Specify the archive restore location in the "Browse for Folder"
screen.
"OK" Press the "OK" button to accept the location. The meshed model
will be displayed in the FEA Editor environment (see Figure 3).

Figure 3: Meshed Model in the FEA Editor Environment

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3. Specifying Model Data in the FEA Editor Environment

In this section, you will specify all data needed for a Static Stress with Nonlinear Material Models analysis including the
analysis type, element type, element definition, applied loads, boundary conditions and analysis parameters.

Specifying the Units System

Mouse Right-click on "Units" heading in the tree view.

"Unit System…" Select the "Unit System…" command.
"OK" Press the "OK" button to accept the default units definition
choice.

Setting the Analysis Type

Specify the analysis type so that the appropriate loads and constraints can be applied for processing.

"Static Stress with Nonlinear Select the "Static Stress with Nonlinear Material Models" option
Material Models" in the "Analysis type" drop-down box in the lower left corner.
Note: Depending on the products that you own, you may need to
select the "MES with Nonlinear Material Models" option.

Figure 4: Specifying the Analysis Type

100 Type "100" in the "Duration" field.

0.1 Type "0.1" in the "Capture rate" field. The "Set Event
Duration and Capture Rate" screen should look like Figure 5.
"OK" Press the "OK" button.

Figure 5: Duration and Capture Rate for the Analysis

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Proceed to define the remaining parameters for the analysis, including the load curve, which describes how the load varies
with time.

Mouse Right-click on the "Analysis Parameters" heading in the tree

view.
"Modify Analysis Parameters…" Select the "Modify Analysis Parameters…" command.
"Non-Linear Static (NLS)" Select the "Non-Linear Static (NLS)" option in the "Analysis
type – automatic setup" drop-down box (see Figure 6).

Figure 6: Specifying the Analysis Type for Automatic Setup

"Add Row" Press the "Add Row" button in the "Load Curves" tab.
100 Type "100" in the second row of the "Time" column in the
"Load Curve" table.
"Add Row" Press the "Add Row" button.
50<Tab>8 Type "50" in the third row of the "Time" column. Press <Tab>
to move to the "Multiplier" column and type "8".
"Sort" Press the "Sort" button to the right of the table to sort the table
entries by time. The load table should look like that in Figure 7.

Figure 7: Load Curve Definition Table

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 "View Plot…" Press the "View Plot" button to see a graphical representation of
the load curve. The intended load curve is shown in Figure 8. If
your curve does not match this, you will need to edit the data
entered into the table.
"OK" Press the "OK" button to close the plot view.
"OK" Press the "OK" button to close the "Analysis Parameters"
window.

Figure 8: Plot of Load Curve 1; Startup Loading

Notice that the red "X" on the "Nonlinear Structural" tree view heading has disappeared, and has been replaced by a green
dot, indicating that all analysis parameters have been set up. (Note: Depending on the products that you own, the
"Nonlinear Structural" heading may be replaced by the "MES" heading). Next, the remaining red "X"‘s will be addressed
by assigning material properties to the elements of the 3 parts.

Specifying Element and Material Information

By default, the solid meshing engine set the element type to brick elements. The element definitions and material types must
be changed.

Specify element definitions for the Part 1.

Mouse Right click on the "Element Definition" heading for Part 1.

<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the "Element
Definition" heading for Part 2.
<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the "Element
Definition" heading for Part 3.
"Modify Element Definition…" Select the "Modify Element Definition…" command (see Figure
9).

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 Figure 9: Element Definition for Part 1

"von Mises with Isotropic Hardening" Select the "von Mises with Isotropic Hardening" option in the
"Material Model" drop-down box (see Figure 10).

Figure 10: Specifying Element Definition for Part 1

"OK" Press the "OK" button to accept the element definition for the
part.

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Specify the material properties for Part 1, the knuckle shaft (green).

Mouse In the tree view, right-click on the "Material <Unknown>" field

for Part 1.
"Modify Material…" Select the "Modify Material…" command.
"Steel (ASTM-A36)" Highlight the "Steel (ASTM-A36)" option in the "Select
Material" section of the "Element Material Selection" screen
(see Figure 11).
"OK" Press the "OK" button to accept the material property choice.
The selected material will be shown in the model tree.

Figure 11: Specifying Material Properties for Part 1

Specify material properties for Part 2, the left bracket (red) and Part 3, the right bracket (yellow). The material properties can
be specified for both parts at once because they share the same material, the same element type and the same values for the
element definition.

Mouse Click on the "Material <Unknown>" heading for Part 2.

<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the "Material
<Unknown>" field for Part 3 (see Figure 12).

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 Figure 12: Material Properties for Parts 2 and 3

"Modify Material…" Select the "Modify Material…" command.

"Aluminum (6061-T6)" Highlight the "Aluminum (6061-T6 )"option in the "Select
Material" section of the "Element Material Selection" screen.
"OK" Press the "OK" button to accept the material property choice for
Parts 2 and 3.

Applying Traction Loads

Apply traction loads to the bolt holes on the brackets. These loads are used to simulate the tensile forces and dead weight of
the motor acting on the mount.

"Selection:Select:Surfaces"
"View:Orientation:XZ Back"
Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Surfaces" command. The model will
be redisplayed with coloring according to surface number and
surface selection mode will be activated.
Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "XZ Back" command.

Zoom in on the holes of the brackets, where the traction loads will be applied.

"View:Zoom Area" Access the VIEW pull-down menu and select the "Zoom Area"
command.
Mouse Draw a rectangle around the holes (see Figure 13) by clicking
above and to the left of the holes, then below and to the right of the
holes.

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 Figure 13: Drawing a Zoom Area around the Holes of the Brackets

<Esc> Press the <Esc> key to exit zoom area mode. The cursor will
change back to surface selection mode.

Rotate the zoomed in display of the model to see the inner surfaces of the holes.

"View:Rotate" Access the VIEW pull-down menu and select the "Rotate"
command. The cursor will change to rotation mode.
Mouse Click and drag the cursor in the working area to rotate the model.
Position the model so that you can see the inner surfaces of the
holes as shown in Figure 14.
<Esc> Press the <Esc> key to exit rotation mode. The cursor will change
back to the surface selection mode.

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Select the inner surfaces of the holes.

Mouse Click on one of the inner surfaces of a hole (see Figure 14). The
selected surface will be highlighted.

Figure 14: Selecting One of the Inner Surfaces of a Hole

<Ctrl>-Mouse Holding down the <Ctrl> key, click on the other inner surfaces of
the holes. Make sure that all inner surfaces of the holes are
selected. You might need to rotate the model on your own to see
all of the inner surfaces (as shown in Figure 15). For all surfaces
to be selected, you will need to select two surfaces in each hole (a
total of 8 surfaces).

Figure 15: Model with All Inner Surfaces of the Holes Selected

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Add surface loads to the selected surfaces.

Mouse Right-click in the display area.

"Add: Surface Loads…" Select the "Add" pull-out menu and then the "Surface Loads…"
command (see Figure 16).

Figure 16: Adding Surface Loads

"Vector (Traction)" Select the "Vector (Traction)" option in the "Direction of

Load" drop-down box in the "Parameters and Controls" section
of the "General " tab.
Mouse Click on the "Uniform" tab.
-154 Type "-154" in the "X Direction Traction" field.
130 Type "130" in the "Y Direction Traction" field. Make sure that
your screen looks like Figure 17.

Figure 17: Specifying the Traction Load

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 "OK" Press the "OK" button to accept the specified values and close the
"Surface Properties" screen. Graphical symbols ("L" shaped
icons) will be displayed on the holes of the brackets indicating the
applied traction loads (see Figure 18).

Figure 18: Model with Traction Loads Applied

Applying Nodal Forces

Apply nodal forces to slots on the brackets where the motor is bolted to the mount.

"Selection: Select: Vertices" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Vertices" command to change to
vertices selection mode.
"View: Orientation: XZ Back" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "XZ Back" command.
"View: Zoom Area" Access the VIEW pull-down menu and select the "Zoom Area"
command.
Mouse Draw a zoom rectangle around the slots of the brackets (as shown
in Figure 19).

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 Figure 19: Drawing a Zoom Area around the Slots of the Brackets

<Esc> Press the <Esc> key to exit zoom area mode. The cursor will
change back to vertices selection mode.

Select the vertices that will have forces added to them.

Mouse Click on a vertex along one of the slots. The selected vertex will
be highlighted with a magenta dot.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on three more vertices along
the slots (as shown in Figure 20) to add them to the current
selection set.

Figure 20: Inquiring on the Coordinates of the Selected Vertex

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Add nodal forces to the selected vertices.

Mouse Right-click in the display area.

"Add: Nodal Forces…" Select the "Add" pull-out menu and select the "Nodal Forces..."
command.
9.4 Type "9.4" in the "Magnitude" field.
Direction "Y" Select the "Y" radio button in the "Direction" section. Make
sure that your screen looks like Figure 21.

Figure 21: Specifying the Magnitude and Direction of Forces

"OK" Press the "OK" button to accept the specified values and close the
"Creating 4 Nodal Force Objects" screen. Symbols
representing the nodal forces will appear on the model.

Applying Boundary Conditions

Fully constrain the ends of the shaft by applying surface boundary conditions to the inside of the bolt holes.

"View: Enclose" Access the VIEW pull-down menu and select the "Enclose"
command. The model will be resized and centered in the working
area.
"Selection: Select: Surfaces" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Surfaces" command.
"View: Rotate" Access the VIEW pull-down menu and select the "Rotate"
command.
Mouse Click in the working area and drag the cursor to rotate the model.
Position the model so that you can see the inner surfaces of the
holes at the ends of the shaft (see Figure 22).

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 Figure 22: Rotating the Model so that the Inner Surfaces of the Shaft Holes Are Visible

<Esc> Press <Esc> to exit rotation mode. The cursor will change back to
surface selection mode.

Select the inner surfaces of the shaft holes.

Mouse Click on one of the inner surfaces of a hole. The surface will be
highlighted.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on the other three inner
surfaces of the shaft holes. Make sure that all four surfaces are
selected as shown in Figure 23.

Figure 23: Model with All Four Inner Surfaces of the Shaft Holes Selected

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Add surface boundary conditions to the selected surfaces.

Mouse Right-click in the display area. A pop-up menu of options will

appear for the selected objects.
"Add: Surface Boundary Select the "Add" pull-out menu and select the "Surface
Conditions…" Boundary Conditions…" command (see Figure 24).

Figure 24: Applying Boundary Conditions

"Fixed" In the "Predefined" section, press the "Fixed" button. All

checkboxes in the "Constrained DOFs" section will be activated,
which shows that all translational and rotational degrees of
freedom will be constrained.
"OK" Press the "OK" button to accept the specified data and close the
"Creating 4 Surface Boundary Condition Objects" screen.
Red triangles will appear on the model symbolizing the boundary
conditions.
<Esc> Press <Esc> to clear the current selection set. The model should
look like Figure 25.

Figure 25: Model with Applied Boundary Conditions

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4. Checking the Model

Now that all element types, element definitions, material items and analysis parameters have been specified, the model can be
checked to determine whether the geometry and finite element information is valid and ready for analysis.

"Analysis:Check Model" Access the ANALYSIS pull-down menu and select the "Check
Model" command. A "Model Validation" pop-up window will
appear indicating that the software is verifying the geometry and
finite element data. Once the check has been completed, the
model will be loaded in the Superview IV Results environment.
On your own, you can use the features of the Superview IV
Results environment to further check the model by examining the
nodes, elements, loadings and boundary conditions. (For more
information about using the Superview IV Results environment to
examine models, see the "In-depth Results Evaluation or
Presentation of Results" tutorial).
"Tools: FEA Editor" After you are finished checking the model, access the TOOLS
pull-down menu and select the "FEA Editor" command to return
to the FEA Editor environment.

The model is now ready to be analyzed with the Static Stress with Nonlinear Material Models processor.

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II. Analyzing the Model
In this phase, you will analyze the motor mount assembly model with the Static Stress with Nonlinear Material Models
processor.

1. Analyzing the Model with the Static Stress with Nonlinear Material Models Processor

Analyze the model using the Nonlinear Static Stress analysis processor.

"Analysis: Perform Analysis…" Access the ANALYSIS pull-down menu and choose "Perform
Analysis…." The "MES with Nonlinear Material Models"
screen will appear. The software will verify the geometry and
finite element data and then the analysis will begin to run
automatically.
"OK" Press the "OK" button to dismiss the message informing you that
the current sessions of the Superview IV Results environment will
be closed.

After the analysis is completed, the Superview IV Results environment will start up automatically.

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III. Reviewing the Results
In this phase, you will use the Superview IV Results environment to view the Static Stress with Nonlinear Material Models
analysis results.

1. Using Superview to View Analysis Results

Previously, you used the Superview IV Results environment to check the motor mount assembly model. Now you will use
the Superview IV Results environment to look at the results obtained from the Static Stress with Nonlinear Material Models
analysis. You will view stress results and rotate the model. Then, on your own, you can experiment with other Superview IV
Results environment capabilities.

Examining Results in the Superview IV Results environment

The model is displayed in the Superview IV Results environment. Examine the analysis results.

"Results Options: Load Case: Middle" Access the RESULTS OPTIONS pull-down menu and select the
"Load Case" pull-out menu. Select the "Middle" command.
The middle load case will appear.
"Results Options: Displaced Model Access the RESULTS OPTIONS pull-down menu and select the
Options" "Displaced Model Options" command.
"Show Displaced Model" Activate the "Show Displaced Model" checkbox.
"Show Undisplaced Model as Mesh" Activate the "Show Undisplaced Model as Mesh" checkbox.
"As An Absolute Value" Select the "As An Absolute Value" radio button in the "Scale
Factor" section.
1 Type "1" in the "Scale Factor" box for a smaller displacement
scale.
Mouse Press the "X" to close the window. The model will be displayed in
its displaced form, with the calculated displacement exaggerated
for display. The original shape of the model is displayed as a line
drawing for comparison.
"View: Rotate" Access the VIEW pull-down menu and select the "Rotate"
command.
Mouse Click and drag the cursor to rotate the model. Position the model
so that the stresses at the ends of the shaft can be seen.
"View:Enclose" Access the VIEW pull-down menu and select the "Enclose"
command (see Figure 26).

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 Figure 26: Examining von Mises Stress Results in Superview at Max Loading

Examining the stress results in the Superview IV Results environment shows that the highest stress occurred at the ends of
the shaft.

Note: Results may vary depending upon which nodes of the bracket slots you selected when applying the forces.

On your own, you are welcome to continue to use the Superview IV Results environment capabilities to further examine the
analysis results.

Congratulations! You have completed this Static Stress with Nonlinear Material Models Tutorial.

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