Combined Multi-Body-System and Finite Element Analysis of a Complex

Mechanism
Nader GHAREEB
Dieter WEICHERT
Institute of General Mechanics
RWTH Aachen University, Germany

Abstract: This paper deals with the modelling and simulation of a lift-up system used in the furniture field as an
application of combined FEM and MBS Analysis using SAMCEF. Some parts of the mechanism are modelled as
super elements, yet the critical parts are modelled as finite elements. Consequently, the joints are considered as
flexible elements and all the external forces and boundary conditions are taken into account. Finally, the
simulation results are compared to the experimental results in order to check the validity of this technique.

Introduction
One of the main purposes of simulation is to predict the lifetime of mechanical components
prior to mass production. In addition, loads, deformations and other mechanical properties
could be found at different positions of the inspected mechanism as well.
The well known finite-element-method (FEM) has proved to be the dominating technique
used in calculating the stresses at different parts of the system, and at different time steps and
operating conditions. Yet, while dealing with complex structures, the number of degrees of
freedom (DOF) generated by using the FEM will be very large, so that the simulation would
be very expensive.
To overcome the drawbacks of the FEM, the multi-body-simulation (MBS) method was
developed. The main concept of this technique is to build all components of the whole
mechanism as rigid bodies and after that, kinematic constraints are used to link them together.
Although the number of DOF will drop dramatically since every rigid body has only 6 DOF,
however not all physical effects can be included in the simulation (clearance, flexibility, etc).
Thus, the best way to model complex mechanisms is a combination of both methods. This
combination will be explained though the modelling and simulation of a lift-up mechanism
(fig.1).

Fig. 1: The lift-up mechanism used in the illustration of the combined FEM-MBS technique

This mechanism, which was designed to be used in the furniture field, did not fulfil the lifetime expectations of the manufacturer. The task was to model this mechanism and then to
carry out the simulation in order to detect the causes for premature failure.
The first step was to build a CAD model of the mechanism. After that, the corresponding
loads and boundary conditions acting on the model were applied and the simulation was
carried out. The resulting loads were compared to the critical loads that could be withstood
and a conclusion was reached, showing possible reasons for the failure.

The modelling methodology

The different components of the mechanism were all constructed using CATIA. After that,
they were assembled using SAMCEF (fig. 2).

Fig. 2: The CAD model of the mechanism

The parts that are not considered to be critical were modelled as super elements, while the
critical parts were modelled as finite elements. Super elements were used in order to reduce
the number of degrees of freedom in the model, and thus the computing time. The
components that were considered to be critical were the linkage between the lever and the
lever arm, as well as the pivoting element (fig. 3). Hence, the parts were joined together by
using kinematic constraints (hinges). These constraints are used to model the elements like
screws, bolts, etc. The super elements were generated separately and then imported in the
main model. On each of these solid elements, some nodes were designated as retained nodes,
so that the boundary conditions can still be applied to these nodes once all parts are assembled
to form the mechanism.

(a)
Fig. 3: The critical parts of the mechanism: (a) Linkage
(b) Pivoting element

(b)

Simulation
After the geometry was created and the material properties assigned, the boundary conditions
were applied. The pre-stress of the springs was taken into consideration as well. A correlation
was found between the movement of the lever and the pressure on the springs, so that the
displacement of the lever was used as the applied load.
The finite elements were produced for the critical parts through the mesh creation, and after
that the simulation was performed.

Results
In the post processing stage, the deformation and stress concentration on the critical elements
that were modelled as finite elements were shown (fig. 4). Yet, regarding the super elements,
the resulting stresses of the simulation were imposed on them and the simulation was carried
out separately for these components to see their mechanical behaviour. This was done
automatically by SAMCEF once the super elements have been chosen.

Fig. 4: The deformed model after the simulation

The numerical results matched with those from experiment. In case of the linkage (fig. 5), the
maximum Von Mises stress was found to be exactly in the region where fracture occurred.

(a)
Fig. 5: (a) Von Mises stress on the linkage
(b) Photograph of the fractured part

(b)

After displaying the stress distribution along the linkage, it was found that the maximum
stress was bigger than the yield stress of the material, which was interpreted as cause for
fracture.
Concerning the pivoting element, the calculated maximum stress was below the yield stress of
its material. Thus, this was an indication that this element should not fail during service, and
this was really the case (fig. 6).

(a)

(b)

Fig. 6: (a) Von Mises stress on the pivoting element

(b) Photograph of the part

Conclusion
This example emphasizes the importance of simulation in the design stage of complex
mechanical structures subjected to critical operating conditions. Possible errors in the design
can be avoided before prototyping and testing. This way reduces naturally production costs as
well as the time needed to reach the final design.
SAMCEF has proven to be an excellent software package for this purpose.

Literature
1) J.E. Shigley, C.R. Mischke, Shigleys mechanical engineering design, McGraw Hill,
8th edition, 2008
2) Weichert, Mechanics I for engineers, statics, Institute of General Mechanics, RWTH
Aachen University, 10th edition, 2007
3) Ghareeb, Krapoth, Stamp, Simulation of drive trains as the basis for operational
monitoring, Windenergy Symposium in Husum, Germany, 2007
4) www.samcef.com