D0006137 Duraplate Assembly - FEA Report for 10 kN

Load According to Class A, AS 3996: 2006

Contents
• Units

• Model (A4)
o Geometry
 Parts
o Materials
o Coordinate Systems
o Connections
 Contacts
 Contact Regions
o Mesh
o Static Structural (A5)
 Analysis Settings
 Fixed Support
 Standard Earth Gravity
 Force
 Solution (A6)
 Solution Information
 Equivalent Stress

• Material Data
o 3.3547 (EN-AW 5083)
o AISI 304
Units
TABLE 1
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (A4)
Geometry
TABLE 2
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source C:\Workspace\...\Model\D0006137 Duraplate Assembly.SLDASM
Type SOLIDWORKS
Length Unit Millimeters
Display Style Body Color
Bounding Box
Length X 1200, mm
Length Y 82,57 mm
Length Z 1200, mm
Properties
Volume 9,5627e+006 mm3
Mass 51,459 kg
Scale Factor Value 1,
Statistics
Bodies 24
Active Bodies 24
Nodes 206260
Elements 89446
Mesh Metric None

Coordinate Systems
TABLE 3
Model (A4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0,
 Origin
Origin X 0, mm
Origin Y 0, mm
Origin Z 0, mm
Directional Vectors
X Axis Data [ 1, 0, 0, ]
Y Axis Data [ 0, 1, 0, ]
Z Axis Data [ 0, 0, 1, ]

Connections
TABLE 4
Model (A4) > Connections
Object Name Connections
State Fully Defined
Auto Detection
Generate Automatic Connection On Refresh Yes
Transparency
Enabled Yes

TABLE 5
Model (A4) > Connections > Contacts
Object Name Contacts
State Fully Defined
Definition
Connection Type Contact
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Auto Detection
Tolerance Type Slider
Tolerance Slider 0,
Tolerance Value 4,2477 mm
Use Range No
Face/Face Yes
Face-Face Angle Tolerance 75, °
Face Overlap Tolerance Off
Cylindrical Faces Include
Face/Edge No
Edge/Edge No
Priority Include All
Group By Bodies
Search Across Bodies
Statistics
Connections 63
Active Connections 63
 TABLE 6
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 1699,1 mm
Average Surface Area 1195,7 mm2
Minimum Edge Length 6,6353e-003 mm
Quality
Check Mesh Quality Yes, Errors
Error Limits Standard Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0,272
Maximum Layers 5
Growth Rate 1,2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 206260
Elements 89446
 FIGURE 1
Model (A4) > Mesh > Figure

Static Structural (A5)

TABLE 7
Model (A4) > Analysis
Object Name Static Structural (A5)
State Solved
Options
Environment Temperature 22, °C
Generate Input Only No

TABLE 8
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1,
Current Step Number 1,
 Step End Time 1, s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Output Controls
Stress Yes
Surface Stress No
Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled

TABLE 9
Model (A4) > Static Structural (A5) > Loads
Object Name Fixed Support
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Fixed Support
Suppressed No

TABLE 10
Model (A4) > Static Structural (A5) > Accelerations
Object Name Standard Earth Gravity
State Fully Defined
Scope
Geometry All Bodies
Definition
Coordinate System Global Coordinate System
X Component 0, mm/s2 (ramped)
Y Component 0, mm/s2 (ramped)
Z Component -9806,6 mm/s2 (ramped)
Suppressed No
Direction -Z Direction
 FIGURE 2
Model (A4) > Static Structural (A5) > Standard Earth Gravity

TABLE 11
Model (A4) > Static Structural (A5) > Loads (Class A)
Object Name Force
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Force
Define By Components
Coordinate System Global Coordinate System
X Component 0, N (ramped)
Y Component -10000 N (ramped)
Z Component 0, N (ramped)
Suppressed No
 FIGURE 3
Model (A4) > Static Structural (A5) > Force (Class A)

TABLE 12
Model (A4) > Static Structural (A5) > Loads (Class B)
Object Name Force
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Force
Define By Components
Coordinate System Global Coordinate System
X Component 0, N (ramped)
Y Component -80000 N (ramped)
Z Component 0, N (ramped)
Suppressed No
 FIGURE 4
Model (A4) > Static Structural (A5) > Force (Class B)

Solution (A6)

It was checked the equivalent stress (von-Mises) and found that the maximal value occurs in the parts
named “Duraplate Main Frame Bracket”.
The magnitude of the equivalent stress (von-Mises) is:

• For Class A: 56.693 MPa (consistently below the Yield strength limit for any of the materials
used)
• For Class B: 455,28 MPa (much higher than the Yield strength limit for the parts involved, but
below the tensile ultimate strength. This means that the parts involved will be deformed but
will not crack.

The areas marked with blue labels in Figure 11 must be reinforced in the case of complying with Class B
conditions from AS 3996: 2006 standard.
It was checked the total deformation and found that the maximal value occurs in the parts named
“Duraplate Main Frame Bracket”.
The magnitude of the total deformation is:

• For Class A: 0,19858 mm

• For Class B: 1,587 mm

The product checked is complying with Class A and B deflection conditions from AS 3996: 2006
standard (Table 4.2). See Figures 9 and 10 for the map of the displacement magnitudes over the
structure of the product.

TABLE 13
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Object Name Equivalent Stress Total Deformation
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Equivalent (von-Mises) Stress
By Time
Display Time Last
Calculate Time History Yes
Integration Point Results
Display Option Averaged
Average Across Bodies No
Results
Class A
Minimum 9,781e-003 MPa 0, mm
Maximum 56,693 MPa 0,19858 mm
Minimum Occurs On D0005918 Duraplate Main Frame Bracket|Duraplate Main Frame Bracket
Maximum Occurs On D0005918 Duraplate Main Frame Bracket|Duraplate Main Frame Bracket[2]

Class B
Minimum 8,3127e-002 MPa 0, mm
Maximum 455,28 MPa 1,587 mm
Minimum Occurs On D0005918 Duraplate Main Frame Bracket|Duraplate Main Frame Bracket
Maximum Occurs On D0005918 Duraplate Main Frame Bracket|Duraplate Main Frame Bracket[2]
Information
Time 1, s
Load Step 1
Substep 1
Iteration Number 1
 FIGURE 5
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress (Class A)
 FIGURE 6
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress (Class A)
 FIGURE 7
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress (Class B)
 FIGURE 8
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress (Class B)
 FIGURE 9
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation (Class A)
 FIGURE 10
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation (Class B)
 FIGURE 11
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress > Safety Factor (Class B)

The areas shown in the images below are under the loads which exceeds the safety factor for the equivalent
stress in case of Class B.
Material Data
3.3547 (EN-AW 5083)
TABLE 15
3.3547 (EN-AW 5083) > Constants
Density 2,66e-006 kg mm^-3
Coefficient of Thermal Expansion 2,4e-005 C^-1

TABLE 16
3.3547 (EN-AW 5083) > Color
Red Green Blue
235, 222, 222,

TABLE 17
3.3547 (EN-AW 5083) > Isotropic Elasticity
Young's Modulus MPa Poisson's Ratio Bulk Modulus MPa Shear Modulus MPa Temperature C
70000 0,3897 1,0577e+005 25185

TABLE 18
3.3547 (EN-AW 5083) > Tensile Yield Strength
Tensile Yield Strength MPa
270,

TABLE 19
3.3547 (EN-AW 5083) > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
3,45e-004

AISI 304
TABLE 20
AISI 304 > Constants
Density 8,e-006 kg mm^-3
Coefficient of Thermal Expansion 1,8e-005 C^-1
Thermal Conductivity 1,6e-002 W mm^-1 C^-1
Specific Heat 5,e+005 mJ kg^-1 C^-1

TABLE 21
AISI 304 > Color
Red Green Blue
130, 177, 176,
 TABLE 22
AISI 304 > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22,

TABLE 23
AISI 304 > Tensile Yield Strength
Tensile Yield Strength MPa
206,81

TABLE 24
AISI 304 > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
517,02

TABLE 25
AISI 304 > Isotropic Elasticity
Young's Modulus MPa Poisson's Ratio Bulk Modulus MPa Shear Modulus MPa Temperature C
1,9e+005 0,29 1,5079e+005 73643