Workshop 5d Applications - Bracket

14. 5 Release

Introduction to ANSYS
DesignModeler
2012 ANSYS, Inc.

November 20, 2012

Release 14.5

Introduction
Background

This workshop will demonstrate the

import, modification,
parameterization and mid-surface
extraction of a simple bracket.

Objectives

Creating a Workbench project

Cad Import
Parameterization of the Model

Creating Parameters from Neutral

CAD
Using the Parameter Manager
Generating Mid-Surfaces
Creating Design Points

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Project Startup
Create the Project

Start Workbench.
Start All Programs ANSYS
14.5 Workbench 14.5
Expand Component Systems and
drag and drop a Geometry
component system into the Project
Schematic.
Double click on the Geometry cell
(A2) to start DesignModeler.

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Starting the DesignModeler Session

Set Units

In the Units specification box select

Millimetre.

Click OK.

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Preparation
Planning

The objective of this workshop is to

Parameterized
Mid-Surface
Model

demonstrate how a CAD model can

be imported, modified and selected
features parameterized.

Solid CAD
Model

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Preparation
Planning

The first step will be to create a sketch based on the center holes of the imported
CAD model, the sketch will then be modified and used to recreate the features.
CAD Model

Regenerated Features

Outline Plane & Modified

Sketch

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CAD Import
Import the Bracket Model

From the File Menu, select Import External

Geometry File.

Browse to the file in the Input Files folder

bracket.x_t and open it.

Click Generate.

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Plane
Create an Outline Plane

Select the face selection filter and select the

face as shown (right).

When you select the face click near to the
forward hole as shown the selection
position dictates where the plane origin
snaps to.
Select the New Plane button.
Check the Details (right).
Generate.

Click the Plane

button to display
the new plane.
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Sketch Creation
Create a Sketch

In the Tree Outline, select the new Plane.

Click the Look At button in the toolbar.

Select the Sketching Mode Tab.
This will display the Sketching Toolboxes

Select the Modify Toolbox.

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Sketch Creation
Create a Sketch (Continued)

Select the Duplicate Tool.

Select the two circular edges

bounding the inner two large circles

as shown (CTRL click for multiple
select).
Right click in the Graphics Window
and select Duplicate Selection from
the Context Menu which appears.
Click the Display Model button to
temporarily hide the model.

The duplicated sketch entities are

initially constrained to the Plane
Outline as indicated by the blue color
(well defined).
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Constraints
Create a Sketch (Continued)

In the Details View set Show

Constraints? To Yes.
Each of the circles is constrained to
be coincident to the outline plane.
Remove the two constraints by right
clicking and selecting delete from the
context menu as shown (do this for
both Coincident Constraints).

The sketch entities are now

unconstrained as indicated by the
teal color.

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Sketch Dimensions
Adding Dimensions

Select the Dimensions Toolbox

Make sure the General tool is selected.
1. Click once on the lower circle edge.
2. Move the cursor away and click once
again to set the position of the
dimension. In the Details View set D1
to 2mm.
2

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Constraints
Add an Equal Radius Constraint

In the Constraints Toolbox select the

Equal Radius tool.

Select the small dimensioned circle
edge followed by the upper circle
edge as shown in the sequence
(right).
The larger circle will snap to the
radius of the dimensioned circle.

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Face Delete
Remove the Original Holes

Switch to Modeling Mode.

Click the Iso Ball to snap to the
isometric view

Select the two faces as shown.

From the Create Menu, select Face

Delete.
Apply the selection in the Details
View and click Generate.

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Extrude
Create the New Holes

Select Sketch1 from the Tree Outline.

Select Extrude from the Toolbar or
Create Menu.

Apply the Geometry selection in the

Details View.
Set Operation to Cut Material,
Direction to Reversed and Extent
Type to Through All.

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Preparation
Planning

The next step will be to modify the front brace slot and brace height by extruding
geometric features. Well need to create a parametric function such that the
brace height changes by the same amount as the slot height.

Extruding a
Geometric Feature

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Modified Front
Brace Geometry

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Extrude
Modify the Front Brace

Select the two faces forming the top of

the bracket as shown (right).

Select Extrude from the Toolbar or Create
Menu.

Apply the Geometry selection in the

Details View.
Activate the Direction Vector Selection
Box.
Select the edge as shown and click the
direction toggle (lower left corner of
Graphics Window) to ensure the
direction vector points upwards.
Apply the selection.

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Extrude
Modify the Front Brace (Continued)

Set FD1, Depth to 5mm.

Generate.

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Extrude
Modify the Front Brace Slot

Rotate the model as shown.

Select the Face Selection Filter.
Select the upper face of the slot as shown
Select Extrude from the Toolbar or Create
Menu.

Apply the selection in the Details View.

Activate the Direction Vector Selection
Box.
Select the edge as shown ensuring the
direction vector is pointing upwards.
Apply the selection.
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Extrude
Modify the Front Brace Slot (Continued)

Set Operation to Cut Material.

Set FD1, Depth to 5mm.

Generate.
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Click the Iso Ball to

snap back to the
isometric view
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Parameterization
Parameterize the Front Brace & Slot

In the Details View, check the box

next to FD1, Depth.

This promotes the dimension to a
parameter.
Enter the name Added_Slot_Height in
the dialog box as shown and click OK.

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Parameterization
Setup Parameters

Enter the Parameter manager by

clicking the button in the toolbar.

The first box displays the

parameter we have just created
and its current value.
Enter the Parameter/Dimension
Assignments box by clicking the
tab as shown.
Extrude3.FD1 dimension is
currently set to the value of the
parameter Added_Slot_Height.
Type in a new function below as
shown;
Extrude2.FD1 = @Added_Slot_Height
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Parameterization
Setup Parameters

The function we have just entered

references a dimension (Extrude2.FD1)

used to define the amount by which the
bracket is extended upwards.
This dimension reference can be
identified by selecting the appropriate
feature in the Tree Outline and checking
in the Details View.
The Details for the Extrude Operation
that defined the extension of the bracket
are shown (right).
The reference is made of the feature
name Extrude2 appended with the
dimension name FD1 separated with a
. hence Extrude2.FD1.

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Preparation
Planning

Well now remove the existing fillets and replace them with new fillets (Blends).
The new fillets will again need to be parameterized such that the outer fillet
radius is defined as a function of the inner fillet radius.

Remove Existing
Fillets

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Insert and
Parameterize New
Fillets

Outer Radius
= Inner Radius + Solid Thickness
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Face Delete
Remove the Original Fillets

Select the Face Selection Filter.

Select the three fillet faces as shown

(right) (CTRL click to multiple select).

From the Create Menu, select Face
Delete.

Apply the selection in the Details

View.
Click the Iso Ball to
snap back to the
isometric view

Generate.
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Blend
Replace the Fillets (Blend)

Select the Edge Selection Filter.

Select the edge as shown (right)
From the Toolbar or Create Menu,
select Fixed Radius Blend.

Apply the selection in the Details

View and set FD1, Radius to 4mm.

Generate.
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Blend
Replace the Fillets (Blend)

Select the two edges as shown (right)

(CTRL click to multiple select).

From the Toolbar or Create Menu,
select Fixed Radius Blend.

Apply the selection in the Details

View and set FD1, Radius to 2mm.

Generate.
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Parameterization
Parameterize the Fillets

In the Details View, check the box

next to FD1, Radius.

Enter the name Inner_Radius in the
dialog box as shown and click OK.

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Parameterization
Setup Parameters

In the Parameter manager, enter

the Parameter/Dimension
Assignments box by clicking the
tab as shown.
Type in a new function as shown;
FBlend1.FD1 = @Inner_Radius+2

The parametric functions we have

created will ensure that the two

fillets are always in proportion
and the bracket height will always
extend with the slot height.
Our driving parameters
(independent variables) are listed
in the Design Parameters tab.

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Parameterization
Test Parameter Functions

In the Design Parameters box,

change the value of

Added_Slot_Height to 2 and Inner
Radius to 1.
Enter the Check box using the tab.
The function is evaluated.
Check the values correspond
correctly to the respective
dimension references.
This confirms our
parameterization is working.
Generate to update the geometry
with the new parameterized input
values.

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Preparation
Planning

The final stage of the model will be to generate Mid-Surfaces based on the
existing solid model. The Mid-Surfaces (Surface Bodies) will be created by
identifying Face Pairs. A Mid-Surface will be generated for each identified Face
Pair mid way between the faces.
Identifying Face
Pairs

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Mid-Surfaces

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Mid-Surface
Create Mid-Surfaces

Select the Edge Selection Filter.

Select each of the edges shown in
turn and make a note of the edge
lengths displayed in the status bar
below the Graphics Window.

The minimum width is 1mm and

the maximum 2mm.
We will use this information during
the mid-surface creation in the next
step.

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Mid-Surface
Create Mid-Surfaces (Continued)

From the Tools Menu, select MidSurface.

In the Details View set;

Selection Method to Automatic.

Minimum Threshold to 1mm.
Maximum Threshold to 2mm.
Find Face Pairs Now to Yes.

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Mid-Surface
Create Mid-Surfaces (Continued)

We need to reverse one of the face

pairs (the direction determines

applied load directions).
In the Details View, activate the Face
Pairs Selection Box (click in the box to
the right of Face Pairs).
In the Graphics Window, right click
and select Reverse Face Pairs from
the Context Menu.
Select the back brace Face Pair as
shown.
The Face Pair is reversed as
indicated by the change in color.
Generate.

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Review
Review the Model

The two solid bodies are replaced

with four surface bodies divided into

two parts. The surface bodies cannot
be combined into a single surface
body because the "T" intersections
would cause it to be non-manifold.
The resulting surface bodies for the
back brace are automatically
extended/trimmed to meet the main
part of the bracket, as these were all
part of one solid body originally.
The front brace was a separate body,
so it is not automatically extended
(gaps highlighted right).

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Surface Extension
Extend Surface

From the Tools Menu, select Surface

Extension.

In the Details View;

Set Selection Method to Manual.

Activate the Edges Selection box,
select the two edges as shown and
apply the selection.
Set Extent to To Next.
Generate.
The Front Brace surface is
extended to the main bracket
surface.

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Multibody Part
Create a Multibody Part

Select the Body Selection Filter.

In the Graphics Window, right click

and select Select All from the Context

Menu.
Right click again and select Form New
Part from the Context Menu.
The four Surface Bodies in one part
will ensure a conformal mesh.

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Surface Body Details

Check Surface Body Details

Select the first of the four

Surface Bodies in the Tree
Outline.
Note that the original solid
thickness is specified within
the Details View.
This can be edited and will be
carried forward to the solver.

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Design Points
Create a Table of Design Points

Switch to the Workbench Project

Page.
In the Project Schematic, double
click the Parameter Set Box.
In the Table of Design Points right
click on row 2 and select
Duplicate Design Point from the
Context Menu.

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Design Points
Create a Table of Design Points

Edit the cell C3 entering a new

value for the added slot height of

3.
Create a further Design Point
with a value for the inner radius
and slot height of 2 & 4
respectively using the same
method.
Click Return to Project.

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Saving the Project

This completes the workshop.
From the Workbench Project Page use the file menu and save
the project as DMWS5d.wbpj to your working folder.

Review the optional tasks detailed on the following slides.

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Optional Tasks
Alternative Method for determining

Minimum and Maximum thresholds for

Mid-Surfacing.
In this example geometry, it was
relatively easy to identify and measure
the solid body thicknesses. In practice, it
may be preferable to select the face
pairs first, then allow the program to
calculate the Minimum and Maximum
thresholds.
In the Tree Outline, right click on MidSurf1
and select Edit Selections from the Context
Menu.
This will reset the operations selections.
Right click in the Graphics Window and
select Clear Existing Face Pair Selections
from the Context Menu.

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Optional Tasks
In the Details View, set Selection

Method to Manual.
Activate the Face Pairs Selection Box
(click in the box to the right of Face
Pairs).
Select the two faces on the main
bracket as shown (CTRL click to
multiple select).
The faces will change colour
indicating the face pair is defined.
Select the two faces on the back
brace as shown to define the second
face pair.
Apply the selection in the Details
View.

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First
Pair

Second
Pair

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Optional Tasks
The Face Pairs Selection Box lists the 2 pairs we selected manually.
Set Selection Method to Automatic.

The Minimum & Maximum Thresholds will now be populated automatically.

Set Find Face Pairs Now to Yes Add to Face Pairs.
The 10 required Face Pairs are selected.

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Optional Tasks
You can reverse the selected Face
Pairs using the method previously
described.
Activate the Face Pairs Selection
box, right click in the Graphics
Window and select Reverse Face
Pairs from the Context Menu.
Click on the pairs (main bracket
and back brace) to reverse the
normals.
Note that the normal direction
color code is described in the
Status Bar.
Apply the selection and
Generate.
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Saving the Project

This completes the workshop optional tasks.
From the main menu select File Close DesignModeler
Workbench will save any application data.

From the Workbench Project Page use the file menu and save
the project.

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