Finite Element Methods

CEP

Design and FEA Analysis of three - link actuator for the pick and place
mechanism

Submitted by

Ehtisham Ul Hassan
MEEN201101097
BS-MEEN-8A

Submitted to
Engr. Syed Saad Farooq

Institute of Mechanical and Manufacturing Engineering

Khwaja Fareed University of Engineering & IT
Rahim Yar Khan
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Table of Contents
Abstract......................................................................................................................................4
Nomenclature.............................................................................................................................4
Part A: Identification of Links and Joints..................................................................................4
Purpose.................................................................................................................................................4
Identification of Links and Joints........................................................................................................4
Moment of Inertia (I)...........................................................................................................................4
Assumptions.........................................................................................................................................4
Description of the Mechanism.............................................................................................................5
Part B: Sketch and SolidWorks Modeling.................................................................................5
Freehand Sketch...................................................................................................................................5
SolidWorks Modeling..........................................................................................................................5
Base Link.........................................................................................................................................5
Intermediate Link.............................................................................................................................6
End Effector Link............................................................................................................................7
Final Assembly................................................................................................................................7
Part C: Beam Elements and Conditions.....................................................................................8
Material Selection................................................................................................................................8
Necessary and Sufficient Conditions...................................................................................................8
Part D: Global Stiffness Matrix and Force-Displacement Relation...........................................8
Nodes and Elements.............................................................................................................................8
Formulation of Global Stiffness Matrix...............................................................................................8
Stiffness Matrix for Each Link........................................................................................................8
Global Stiffness Matrix..................................................................................................................10
Force-Displacement Relation........................................................................................................10
Axial and Bending Stress/Strain Calculations...............................................................................10
Part E: ANSYS Analysis..........................................................................................................11
Model Import.....................................................................................................................................11
Static Structural Analysis...................................................................................................................11
1) FEM setup..................................................................................................................................11
1) Connections...........................................................................................................................11
2) Axial Loading Condition...........................................................................................................12
Axial Loading Solution Results.....................................................................................................13
3) Bending Loading Condition.......................................................................................................15
Bending Loading Solution Results................................................................................................15
Part F: Mesh and Element Size................................................................................................17
Mesh Type.........................................................................................................................................17

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Mesh Size...........................................................................................................................................17
Part G: Corrections for Equilibrium.........................................................................................18
Load Balancing........................................................................................................................18
Steps for Load Balancing...................................................................................................................18
Calculation.........................................................................................................................................19
Conclusion................................................................................................................................19
References................................................................................................................................20

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Table of Figures
Figure 1: Freehand Sketch 5

Figure 2: Base Link........................................................................................................................................

Figure 3: Intermediate Link...........................................................................................................................
Figure 4: End Effector Link...........................................................................................................................
Figure 5: Three Link Actuator Assembly......................................................................................................
Figure 6: Nodes and Element.........................................................................................................................
Figure 7: Revolute-Ground to Solid Joint....................................................................................................
Figure 8: Body-Body Joint...........................................................................................................................
Figure 9: Body-Body Joint...........................................................................................................................
Figure 10: Loading Condition......................................................................................................................
Figure 11: Directional Deformation.............................................................................................................
Figure 12: Equivalent Stress........................................................................................................................
Figure 13: Equivalent Strain.......................................................................................................................
Figure 14: Loading Condition......................................................................................................................
Figure 15: Directional Deformation.............................................................................................................
Figure 16: Equivalent Stress........................................................................................................................
Figure 17: Equivalent Strain........................................................................................................................
Figure 18: Tetrahedral Mesh method...........................................................................................................
Figure 19: Mesh...........................................................................................................................................

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Abstract
This report presents the comprehensive design and Finite Element Analysis (FEA) of a three-
link actuator intended for a pick-and-place mechanism in a CNC shop. The primary objective
is to handle raw materials between workstations. The analysis encompasses stress-strain
evaluation, deformation analysis, and validation using ANSYS software. Recommendations
for necessary corrections to ensure equilibrium and safe design are also provided.

Nomenclature
E - Young's Modulus
I - Moment of Inertia
F - Force
δ - Deformation
σ - Stress
ϵ - Strain
DOF - Degrees of Freedom
ANSYS - Analysis System

Part A: Identification of Links and Joints

Purpose
The requirement for uplifting parts involves moving raw materials efficiently from one
workstation to another within the CNC shop. The design must ensure precise positioning,
stability, and capability to handle specified loads.

Identification of Links and Joints

 Base Link: Length = 200 mm, Width = 50 mm, Thickness = 10 mm
 Intermediate Link: Length = 300 mm, Width = 50 mm, Thickness = 10 mm
 End Effector Link: Length = 150 mm, Width = 50 mm, Thickness = 10 mm

Moment of Inertia (I)

I =50 mm ׿ ¿

Assumptions
 Force (F): 100 N applied at the end of the End Effector Link.
 Base Link: Fixed to the ground and rotates about its center, providing stability.
 Intermediate Link: Connects to the base link via a revolute joint allowing rotational
movement.
 End Effector Link: Attached to the intermediate link through another revolute joint
and ends with a gripper for holding materials.

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Description of the Mechanism

 Base Link: Serves as the foundation and is rotates about its axis.
 Intermediate Link: Provides the primary range of motion.
 End Effector Link: Executes the pick-and-place operation.

Part B: Sketch and SolidWorks Modeling

Freehand Sketch
A preliminary hand-drawn sketch is essential to visualize the basic structure and connections
between the links and joints.

End Effector Link

Intermediate Link

Base Link

Figure 1: Freehand Sketch

SolidWorks Modeling
Base Link
 Sketch a rectangle (50 mm ×10 mm ) to represent the base.
 Extrude the sketch to the 200 mm thickness.
 Add mounting pin of 10 mm for joint.

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Figure 2: Base Link

Intermediate Link
 Sketch a rectangular bar (50 mm ×10 mm ).
 Extrude to the 300 mm.
 Add holes at one end and pin on other of 10 mm for revolute joints.

Figure 3: Intermediate Link

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End Effector Link

 Sketch a rectangular shape (50 mm ×10 mm ).
 Extrude the sketch to 150 mm.
 Skipping the gripper mechanism for simplicity.

Figure 4: End Effector Link

Final Assembly
Final Assembly is as follows:

Figure 5: Three Link Actuator Assembly

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Part C: Beam Elements and Conditions

Material Selection
 Material: Aluminum
 Young’s Modulus (E): 70 GPa

Necessary and Sufficient Conditions

 Revolute Joints: Provide the required rotational degrees of freedom.
 Boundary Conditions: Base link is fixed with revolute joint, intermediate and end
effector links connected via revolute joints.

Part D: Global Stiffness Matrix and Force-Displacement Relation

Nodes and Elements

N4 N3
Element 3

Element 2

N2

Element 1

N1

Figure 6: Nodes and Element

Formulation of Global Stiffness Matrix

Stiffness Matrix for Each Link
9
E=70× 10 Pa
4 −9
I =4166.67 mm =4.16667 × 10

Element 1

L=200 mm=0.2 m

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u1 v 1 u2 v 2

[ ]
12 6 L −12 6 L u1
EI 2 2 v1
k 1= 3 6 L 4 L −6 L 2 L
L −12 −6 L 12 −6 L u2
6 L 2 L2 −6 L 4 L2 v2

u1 v 1 u2 v 2

[ ]
12 6( 0.2) −12 6(0.2) u1
9 −9
(70 ×10 )(4.16667 × 10 ) 6 (0.2) 4(0.2) −6( 0.2) 2( 0.2)2
2 v1
k 1= 3 u2
(0.2) −12 −6 (0.2) 12 −6(0.2)
2
6 (0.2) 2(0.2) −6( 0.2) 4 (0.2)
2 v2

u1 v 1 u2 v 2

[ ]
12 1.2 −12 1.2 u1
1.2 0.16 −1.2 0.08 v1
k 1=36458.4
−12 −1.2 12 −1.2 u2
1.2 0.08 −1.2 0.16 v2

u1 v 1 u2 v 2

[ ]
437500.8 43750.08 −437500.8 43750.08 u1
43750.08 5833.4 −43750.08 2916.7 v1
k 1=
−437500.8 −43750.08 437500.8 −43750.08 u2
43750.08 2916.7 −43750.08 5833.4 v2
Similarly for Element 2 and Element 3 are as follows 10802.48

Element 2

u2 v 2 u3 v 3

[ ]
129629.76 19444.46 −129629.76 19444.46 u2
19444.46 3888.89 −19444.46 1944.446 v2
k 2=
−129629.76 −19444.46 129629.76 −19444.46 u3
19444.46 1944.446 −19444.46 3888.89 v3
Element 3

u3 v 3 u 4 v 4

[ ]
1037037.8 77777.8 −1037037.8 77777.8 u3
77777.8 7777.78 −77777.8 3888.9 v3
k 3=
−1037037.8 −77777.8 1037037.8 −77777.8 u4
77777.8 3888.9 −77777.8 7777.78 v4

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[ ]
Global Stiffness Matrix
43700.8 43750.08 −43700.8 43750.08 0 0 0 0
43750.08 5833.4 −43750.1 2916.7 0 0 0 0
−43700.8 −43750.1 173330.6 −24305.6 −129630 19444.46 0 0
43750.08 2916.7 −24305.6 9722.29 −19444.5 1944.446 0 0
k=
0 0 −129630 −19444.5 1166668 58333.34 −1037038 77777.8
0 0 19444.46 1944.446 58333.34 11666.67 −77777.8 3888.9
0 0 0 0 −1037038 −77777.8 1037038 −77777.8
0 0 0 0 77777.8 3888.9 −77777.8 7777.78

Force-Displacement Relation
ku=F

[ ][ ] [ ]
12 6 L −12 6 L 0 0 0 0 u1 F x1
2
6 L 4 L −6 L 2 L
2
0 0 0 0 v1 F y1
−12 −6 L 24 0 −12 6 L 0 0 u2 F x2
2 2 2
EI 6 L 2 L 0 8 L −6 L 2 L 0 0 v2 F
= y2
L 3
0 0 −12 −6 L 24 0 −12 6 L u3 F x3
2 2 2
0 0 6L 2L 0 8 L −6 L 2 L v3 F y3
0 0 0 0 −12 −6 L 12 −6 L u4 Fx 4
2 2
0 0 0 0 6L 2 L −6 L 4 L v4 F y4

[ ][ ] [
43700.8 43750.08 −43700.8 43750.08 0 0 0 0 u1 Fx
43750.08 5833.4 −43750.1 2916.7 0 0 0 0 v1 Fy
−43700.8 −43750.1 173330.6 −24305.6 −129630 19444.46 0 0 u2 Fx
43750.08 2916.7 −24305.6 9722.29 −19444.5 1944.446 0 0 v2 F
= y
0 0 −129630 −19444.5 1166668 58333.34 −1037038 77777.8 u3 Fx
0 0 19444.46 1944.446 58333.34 11666.67 −77777.8 3888.9 v 3 Fy
0 0 0 0 −1037038 −77777.8 1037038 −77777.8 u Fx
4
0 0 0 0 77777.8 3888.9 −77777.8 7777.78 v Fy
4

Axial and Bending Stress/Strain Calculations

Axial Stress (σ)

F 100 N
σ Axial= = =0.2 MPa
A 50 mm ×10 mm

Strain (ϵ )

σ Axial 0.2 MPa −6

ϵ= = =2.857 ×10 mm /mm
E 70000 MPa

Bending Stress (σ)

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2
Mc 15000 N . mm ×5 mm
σ Bending= = 4
=17.999 ≈ 18 MPa
I 4166.67 mm

Here,
2
M =Fd=100 N ×150 mm=15000 N . mm

Strain (ϵ )
σ Bending 18 MPa −4
ϵ= = =2.57 ×10 mm/mm
E 70000 MPa

Part E: ANSYS Analysis

Model Import
 Import the SolidWorks model into ANSYS.
 Define material properties (Aluminum).

Static Structural Analysis

1) FEM setup
FEM setup is as follows:
1) Connections
Add Body-Ground revolute joint on base link pin as shown below.

Figure 7: Revolute-Ground to Solid Joint

Add Body-Body revolute Joint between “Base link” and “Intermediate link”.

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Figure 8: Body-Body Joint

Add Body-Body Revolute Joint between “Intermediate link” and “End Effector”.

Figure 9: Body-Body Joint

2) Axial Loading Condition

Add force of 100N at end of effector link as shown below.

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Figure 10: Loading Condition

Axial Loading Solution Results

Insert Directional deformation and set orientation to Y-axis. Also insert Equivalent (Von-Mises)
stress and strain. And hit solve.
a) Directional Deformation

Figure 11: Directional Deformation

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b) Equivalent Stress

Figure 12: Equivalent Stress

c) Equivalent Strain

Figure 13: Equivalent Strain

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3) Bending Loading Condition

Add force of 100N at end of effector link as shown below.

Figure 14: Loading Condition

Bending Loading Solution Results

Insert Directional deformation and set orientation to Y-axis. Also insert Equivalent (Von-Mises)
stress and strain. And hit solve.
d) Directional Deformation

Figure 15: Directional Deformation

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e) Equivalent Stress

Figure 16: Equivalent Stress

f) Equivalent Strain

Figure 17: Equivalent Strain

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Analytical Results Numerical Results (Ansys)

Axial Loading Bending Loading Axial Loading Bending Loading

Stress Strain Stress Strain Stress Strain Stress Strain

(MPa) (mm/mm) (MPa) (mm/mm) (MPa) (mm/mm) (MPa) (mm/mm)

0.2 2.857×10-6 18 2.143×10-4 0.267 3.89×10-6 15 2.57×10-4

Part F: Mesh and Element Size

Mesh Type
1) Insert mesh method and set method Tetrahedral mesh. Tetrahedral mesh is used for
complex geometries.

Figure 18: Tetrahedral Mesh method

Mesh Size
Setting mesh size to minimum edge length divided by 2 for refined meshing.

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Figure 19: Mesh

Part G: Corrections for Equilibrium

Load Balancing
Load balancing involves distributing the applied forces and moments across the links and
joints in such a way that no single component is excessively stressed. This is crucial for
preventing failure and ensuring smooth operation.

Steps for Load Balancing

i. Analyze the Free Body Diagram (FBD):
 Draw FBDs for each link, showing all applied forces, reaction forces, and moments.
 Ensure all forces and moments are accounted for at each joint and link connection.
ii. Calculate Reaction Forces:
 Use static equilibrium equations to calculate the reaction forces at the supports and
joints.
 For each link, the sum of forces in the x-direction ( Σ F x) and y-direction ( Σ F y )
should be zero, and the sum of moments about any point ( ∑ M base ) should also be
zero.
iii. Redistribute Loads if Necessary:
 If any link or joint is found to be over-stressed, consider redistributing the loads. This
can be done by adjusting the positions of the joints or the lengths of the links.
 Ensure that the loads are transferred more evenly across the structure.

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Calculation
A load of 100 N is applied vertically downwards at the end effector, and reaction forces at the
base and joints are to be calculated.

Sum of Forces in Y-Direction:

∑ F y =0
Resultant base−100=0

Resultant base =100

Sum of Moments about the Base:

∑ M base =0
M base=100 ×150

M base=15000 Nmm

These calculations help to determine if adjustments are needed to balance the forces and
moments.

Conclusion
In conclusion, this report has detailed the comprehensive design and finite element analysis
(FEA) of a three-link actuator for a pick-and-place mechanism in a CNC shop. By accurately
identifying links and joints, utilizing beam elements, and selecting aluminum as the material,
we ensured a robust design. Hand calculations and ANSYS simulations validated the stress
and strain distributions.

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References
[1] K. G. Gandhewar and S. B. Muley, "A Review on Design and Analysis of Pick and Place
Robotic Arm," International Journal of Engineering Research and Technology, vol. 3, no.
4, pp. 147-152, Apr. 2014.
[2] X. Yu and T. Ma, "Design and Analysis of a Three-Link Robotic Arm," Journal of
Robotics and Automation, vol. 8, no. 2, pp. 213-219, Jun. 2015.
[3] . L. Meriam and L. G. Kraige, Engineering Mechanics: Dynamics, 7th ed. New York, NY,
USA: Wiley, 2012.
[4] F. P. Beer, E. R. Johnston Jr., J. T. DeWolf, and D. F. Mazurek, Mechanics of Materials,
7th ed. New York, NY, USA: McGraw-Hill, 2015.
[5] K.-J. Bathe, Finite Element Procedures, 2nd ed. Englewood Cliffs, NJ, USA: Prentice
Hall, 1996.
[6] J. N. Reddy, An Introduction to the Finite Element Method, 3rd ed. New York, NY, USA:
McGraw-Hill, 2006.

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