ENGD2106D – Product Design

Lab 2 - Stress convergence

Name
Student Number:
Date:

Instructions
1. Read this lab sheet, including any appendix information.
2. Using Creo and ANSYS software packages investigate the impact of mesh density on a simple flat
plate with a hole. Run simulations and import the requested data into the figures and graphs
presented in this document. Please also answer the questions with a concise response.
3. This work accounts for 15% of coursework 1.
4. Complete the tasks and present for assessment during the lab-session time period.
5. Submit your completed log sheet via blackboard to the deadline specified on the module shell.

Learning Outcomes
1) Understand the importance of stress convergence when conducting FEA.
2) Understand the difference between h and p method for convergence.

Step 1 - Generate the components displayed in Figure 1 using Creo Parametric.

Figure 1: Dimensions of the flat plate with hole.

Step 2 - Using Creo Simulate investigate the stress generated in the component using an auto
gem mesh. Apply the material properties described in table 1 to your model and then apply
the boundary conditions as described below in Figure 2.

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Figure 2: Model setup information.

Table 1: Sample material properties for mild steel.

Material Properties Value
Poisson’s ratio 0.29
Youngs modulus 212 GPa
Density 7.85E-9 tonne/mm^3

Step 3 - Paste an image of your model with boundary conditions into the box below (Figure
3). Once the boundary conditions and material have been set, run the simulation. Once
finalised paste a screenshot of your initial results and input the max stress (Figur e 4) into the
boxes below.

Figure 3: Initial model setup in Creo Simulate. [5/100]

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Figure 4: Initial stress result generated using Creo Simulates auto gem mesh. [4/100]

Max Stress (MPa) 21.3321 MPa [1/100]

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 Step 4 - Change the mesh density in Creo simulate to 20 mm and rerun the test. Record the
results using the axis presented in Figure 5. Once plotted repeat for the following mesh
sizes:
● 40 mm
● 20 mm
● 10 mm
● 5 mm
● 2.5 mm

Recording the data in Figure 5.

Figure 5: Stress convergence plot. [25/100]

Please comment on the data trend observed using Creo Simulate [50 Words Max].

From the above graph, it is observed that the Graph increases first and then decreases downwards. This
shows that the increase in mesh size can provide more accurate results, an increase in mesh size can raise
the max stress till 10mm and then declines.

[10/100]

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 Step 5 - Using the same component geometry, import your model into ANSYS. Remember
to convert the file to the stp. format. Once imported, apply the material properties shown
in Table 1 and the same boundary conditions as described in Figure 2. Allow ANSYS to auto
mesh your component. Paste an image into the box below showing the default mesh and
the applied boundary conditions to your model (Figure 5).

Figure 6: Initial model setup in ANSYS.

Step 6 – Once initial setup is complete, run the simulation and evaluate the results for the
equivalent stress and total deformation. Paste a screenshot of your initial results for stress
and max stress value into the boxes below.

Figure 7: Initial Stress result generated using an auto mesh in ANSYS. [9/100]

Max Stress (MPa) 19.95 MPa [1/100]

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 Step 7 - Conduct stress analysis with the following mesh sizes:
● 20 mm
● 10 mm
● 5 mm
● 2.5 mm
● 1.25 mm

Plot the results on the axis in Figure 5.

Comment on the data trend observed from the ANSYS data. [50 words Max]

Blue - Ansys

Orange – Creo stimulate

From the above graph, it is observed that with increase in mesh size there is a decrease in max stress

[10/100]

Step 8 - Using analytical methods determine the theoretical stress level. (Show all
calculations in the box below) Once completed plot a straight line representing the
theoretical value on to the axis in Figure 5.

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 𝑃 𝑃
𝜎= =
𝐴 (𝑏 − 𝑑 )ℎ
𝜎𝑚𝑎𝑥 = 𝐾𝑐 𝜎
𝐾𝑐 can be obtained from MATLAB script on the module shell.

[5/100]

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 Step 9 - Comment on the differences/similarities between the results presented in Figure 5,
consider the following areas of discussion:
● How close are the simulation results to the analytical value?
● How to the data sets compare?
● What is causing the difference between Creo Simulate and ANSYS? [200 words max]

From both the graphs, it is clearly visible that in Creo stimulation and Ansys there is a huge difference in
the Graph pattern. For Creo Stimulation with Increase in mesh size, the max stress increases steeply in the
initial phase and then decreases downwards rapidly whereas For Ansys the increase in max stress is
negligible than that compared to the decrease in the max stress with increase in mesh size.

The cause of this dissimilarity is due to the sectors in which both the software are used. Creo Stimulation is
used for the Aviation and Aerospace industry to validate the performance of the manufactured parts while
Ansys is used in Automotive to energy to healthcare industry to numerically solve wide variety of
mechanical problems. Both the software have different technical functions and different way of portraying
it and thus show a different but correct result individually.

[30 /100]