Static Stress with Linear Material Models/Multiphysics Tutorial

3-D Motor Mount Assembly Model

Part Number 6000.510

Revision 15.000
June 2004
June 29, 2004

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Files List for this Tutorial
In addition to this document file the following file is referenced in the tutorial:

RefinedMeshMotorMount.ach

This file is available in the Tutorials\Models subdirectory of the installation directory.

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Tutorial Conventions
To make this tutorial easy to use, the following conventions will be employed. For the command conventions, the item (or an
example of one) that you need to perform is noted in bold on the left. To the right of the item is a short description of the
action and/or results of the action.

User Input Notation Conventions

algframe Type "algframe" using the keyboard. Text that you need to type is noted in bold type using a Courier
font.

<Esc> Press the <Esc> key. Some of the other keys expressed in this manner are <Enter>, <Tab> and the
function keys, for example <F9>.

<Ctrl>-c Press <Ctrl> and the letter "c" simultaneously. Keys to be pressed at the same time are shown with a
hyphen between them.

"Enclose" Select the "Enclose" command. The names of pop-up menus, options and buttons are bold-faced,
enclosed in quotation marks and shown as they are on the screen.

"Selection: Access the SELECTION pull-down menu and select the "Shape" pull-out menu. Select the "Point"
Shape: Point" command. Commands in sequences are separated by colons.

Mouse Use the mouse to click on the specified location. FEMPRO is designed for a two-button mouse. Where
"click" or "left-click" is used, you should press the left mouse button. "Right-click" means you should
press the right mouse button. If you have a three-button mouse, you will not use your middle button
for ALGOR software.

In the tables throughout this tutorial, input instructions for using toolbars and pull-down menus are in the two left columns.
Descriptions or more detailed instructions are given in the right column. For example:

"Selection: Shape: Point" Access the SELECTION pull-down menu and select the "Shape"
pull-out menu. Select the "Point" command to enter point
selection mode.

Other Notation Conventions

sd3.dmit, an .esx file Filenames and file extensions are lowercase with the filename in italic.

filename.doc Filenames that are user-supplied are in bold, lowercase italics.

\model directory Directory names will appear in Courier type and be followed by the term "directory". (The directory
where the ALGOR software is stored is usually referred to as the installation directory).

FILE pull-down menu Pull-down menu names are shown in uppercase characters.

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3-D Motor Mount Assembly Model
In this tutorial, we will introduce you to ALGOR software's capabilities for Static Stress with Linear Material
Models/Multiphysics analysis. The example demonstrated in this tutorial shows how to set up and analyze a three-
dimensional (3-D) model of a motor mount assembly that incorporates temperatures from a Steady-State Heat Transfer
analysis.

You will perform the following steps:

I. Setting up the Model – Retrieve the supplied model archive file, which contains a meshed model with temperature
data from a previous Steady-State Heat Transfer analysis; specify data needed for a Static Stress with Linear
Material Models analysis including the analysis type, element type, element definition, applied loads, boundary
conditions and analysis parameters; check the model geometry and validation using the Results environment.

II. Processing – Analyze the model using the Static Stress with Linear Material Models processor.

III. Postprocessing – Examine the stress results graphically with the Results environment.

I. Setting up the Model

In this phase, you will retrieve a supplied model archive file, named RefinedMeshMotorMount.ach, which contains a meshed
model with temperature results from a previous Steady-State Heat Transfer analysis. You will specify all data needed for a
Static Stress with Linear Material Models analysis including the analysis type, element type, element definition, applied
loads, boundary conditions and analysis parameters. Then, you will check the model geometry and finite element data using
the Results environment to verify that the model is ready for analysis.

1. Problem Description

A motor mount assembly is designed to hold a 15-pound motor. The assembly consists of a left bracket, a right bracket and a
knuckle shaft. The brackets are made of aluminum (6061-T6) and the shaft is made of steel (ASTM-A36). The motor is
mounted to the brackets with bolts. The assembly has a tension force due to the output of the motor.

For the Steady-State Heat Transfer analysis that was done previously, there was a convection load applied to the mount due
to the air around the mount. Applied temperatures of 150 degrees Fahrenheit were applied to the mount where the motor
would be in contact with the mount due to the bolts.

For the Static Stress with Linear Material Models analysis, traction loads will be applied where the motor is bolted to the
mount through holes on the brackets, which take the X- and Y-direction forces due to the tension from the output of the
motor. Nodal forces will be applied where the motor is bolted to the mount through slots on the brackets. The ends of the
shaft will be fully fixed.

Figure 1 shows a diagram of the motor mount assembly. The goal of the Static Stress with Linear Material Models analysis
is to determine stresses in the motor mount assembly due to:
 the dead weight load of the motor resting on the mount;
 the force of the motor output acting on the mount; and
 the thermal-stress on the mount from the hot motor. The assembly experiences no thermal stress at 80 F.

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 Figure 1: Diagram of the Motor Mount Assembly

2. Retrieving the Supplied Model Archive File

In this section, you will use FEMPRO to retrieve the supplied model archive file, RefinedMeshMotorMount.ach.

Starting FEMPRO

Start FEMPRO from the Windows taskbar.

"Start:Programs: ALGOR V15: In the Windows taskbar, press the "Start" button. Select the
FEMPRO" "Programs" pull-out menu and select the "ALGOR V15" pull-
out menu. Select the "FEMPRO" command.

FEMPRO will now appear with the "Open" dialog active.

"Cancel" Press the "Cancel" button to close the "Open" dialog.

In FEMPRO, you have a variety of tasks available to you. You can start a new model, choose an existing model and perform
any complete engineering analysis. Help information is available by accessing the HELP pull-down menu and selecting the
"Contents" command. This will access the ALGOR User’s Guide.

Retrieving the Supplied Model Archive File

Retrieve the supplied model archive file from the Tutorials\Models directory. This archive file contains a meshed
model of the motor mount. (To learn more about meshing, see the InCAD tutorials on the motor bracket model).

"File: Archive: Retrieve…" Access the FILE pull-down menu and select the "Archive" pull-
out menu. Select the "Retrieve…" command (see Figure 2). The
"Extract Archive" dialog will appear.

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 Figure 2: Retrieving the Archive File

Mouse Use the "Look in:" drop-down box to navigate to the

Tutorials\Models directory, which is where the archive file
is stored.
RefinedMeshMotorMount Click on the RefinedMeshMotorMount.ach file.
"Open" Press the "Open" button.
Mouse Specify the archive restore location in the "Browse for Folder"
dialog.
"OK" Press the "OK" button to accept the location.
"OK" Press the "OK" button to accept the default units definition. The
meshed model will be displayed in the FEA Editor environment
(see Figure 3).

Figure 3: Meshed Model in the FEA Editor Environment

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3. Specifying Model Data in the FEA Editor Environment

In this section, you will specify all data needed for a Static Stress with Linear Material Models analysis including the analysis
type, element type, element definition, applied loads, boundary conditions and analysis parameters.

Specifying Element and Material Information

By default, the meshing engine set the element type to brick elements.

Specify the element parameters for the three parts.

Mouse In the tree view, click on the "Element Definition" heading for
Part 1.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on the "Element Definition"
heading for Part 2. (Using the <Ctrl> key enables selection of
multiple items).
<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the "Element
Definition" heading for Part 3.
"Modify Element Definition…" Select the "Modify Element Definition…" command. (See
Figure 4).

Figure 4: Selecting Element Definitions for Parts 1, 2, and 3 from the Model Tree

80 Type "80" in the "Stress Free Reference Temperature" field.

This is the temperature at which the part will experience no
thermal stress. (See Figure 5).
"OK" Press the "OK" button to accept the element definition.

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 Figure 5: Setting the Element Definitions for Parts 1, 2 and 3

Specify the material properties for Part 1, the knuckle shaft (green).

Mouse In the tree view, right-click on the "Material <Unknown>"

heading for Part 1
"Modify Material…" Select the "Modify Material…" command.
"Steel (ASTM-A36)" Highlight the "Steel (ASTM-A36)" option in the "Select
Material" section. (See Figure 6).
"OK" Press the "OK" button to accept the material property choice.
The selected material will be shown in the tree view.

Figure 6: Selecting the Material for Part 1

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Specify material properties for Part 2, the left bracket (red) and Part 3, the right bracket (yellow). The material properties can
be specified for both parts at once because they share the same material, the same element type and the same values for the
element definition.

Mouse Click on the "Material <Unknown>" heading in the tree view for
Part 2.
<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the "Material
<Unknown>" heading for Part 3.
"Modify Material…" Select the "Modify Material…" command. (See Figure 7).

Figure 7: Selecting Material Properties for Parts 2 and 3 from the Tree View

"Aluminum (6061-T6)" Highlight the "Aluminum (6061-T6)" option in the "Select

Material" section.
"OK" Press the "OK" button to accept the material property choice for
Parts 2 and 3.

Applying Traction Loads

Apply traction loads to the bolt holes on the brackets. These loads are used to simulate the tension forces and dead weight of
the motor acting on the mount.

"Selection: Select: Surfaces"
"View: Orientation: XZ Back"
Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Surfaces" command. The model will
be redisplayed with coloring according to surface number and
surface selection mode will be activated.
Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "XZ Back" command. This will be the
best view for applying traction loads.

Zoom in on the holes of the brackets, where the traction loads will be applied.

"View: Zoom Area" Access the VIEW pull-down menu and select the "Zoom Area"
command. The cursor will change to zoom area mode.
Mouse Draw a rectangle around the holes (see Figure 8) by clicking above
and to the left of the holes and then again below and to the right.

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 Figure 8: Drawing a Zoom Area around the Holes of the Brackets

<Esc> Press the <Esc> key to exit zoom area mode. The cursor will
change back to surface selection mode.

Rotate the zoomed in display of the model to see the inner surfaces of the holes.

"View: Rotate" Access the VIEW pull-down menu and select the "Rotate"
command. The cursor will change to rotation mode.
Mouse Click and drag the cursor in the working area to rotate the model.
Position the model so that you can see the inner surfaces of the
holes as shown in Figure 9.

Figure 9: Rotating the Model to See the Inner Surfaces of the Holes

<Esc> Press the <Esc> key to exit rotation mode. The cursor will change
back to the surface selection mode.

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Select the inner surfaces of the holes.

Mouse Click on one of the inner surfaces of a hole (see Figure 10). The
selected surface will be highlighted.

Figure 10: Selecting One of the Inner Surfaces of a Hole

<Ctrl>-Mouse Holding down the <Ctrl> key, click on the other inner surfaces of
the holes. Make sure that all inner surfaces of the holes are
selected. You might need to rotate the model on your own to see
all of the inner surfaces (as shown in Figure 11). For all surfaces
to be selected, you will need to select two surfaces in each hole.

Figure 11: Model with All Inner Surfaces of the Holes Selected

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Add surface loads to the selected surfaces.

Mouse Right-click in the display area.

"Add: Surface Loads…" Select the "Add" pull-out menu and select the "Surface Loads
(Structural)…" command (see Figure 12).

Figure 12: Adding Surface Loads

"Traction" Select the "Traction" option in the "Type of surface load" drop-
down box.
-1540 Type "-1540" in the "X-direction component" field in the
"Traction Loads" section..
1300 Type "1300" in the "Y-direction component" field in the
"Traction Loads" section. (See Figure 13).

Figure 13: Specifying the Traction Load

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 OK Press the "OK" button to accept the specified values. Graphical
symbols will be displayed on the holes of the brackets indicating
the applied traction loads (see Figure 14).

Figure 14: Model with Traction Loads Applied

Applying Nodal Forces

Apply nodal forces to slots on the brackets where the motor is bolted to the mount.

"Selection: Select: Vertices" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Vertices" command to change to
vertices selection mode.
"View: Orientation: XZ Back" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "XZ Back" command.
"View: Zoom Area" Access the VIEW pull-down menu and select the "Zoom Area"
command.
Mouse Draw a zoom rectangle around the slots of the brackets (as shown
in Figure 15).

Figure 15: Drawing a Zoom Area around the Slots of the Brackets

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 <Esc> Press the <Esc> key to exit zoom area mode. The cursor will
change back to vertices selection mode.

Select the vertices that will have forces added to them.

Mouse Click on a vertex along one of the slots. The selected vertex will
be highlighted with a magenta dot.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on three more vertices along
the slots (as shown in Figure 16) to add them to the current
selection set.

Figure 16: Model with Four Vertices Selected along the Bracket Slots

Add nodal forces to the selected vertices.

Mouse Right-click in the display area

"Add: Nodal Forces…" Select the "Add" pull-out menu and select the "Nodal Forces..."
command.
94 Type "94" in the "Magnitude" field.
"Y" Select the "Y" radio button in the "Direction" section to specify
that the force will be applied in the Y direction. Make sure that
your screen looks like Figure 17.

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 Figure 17: Specifying the Magnitude and Direction of Forces

"OK" Press the "OK" button to accept the specified values and close the
"Creating 4 Nodal Force Objects" dialog. Symbols representing
the nodal forces will appear on the model.
<Esc> Press the <Esc> key to clear the current selection set. The screen
should look like Figure 18.

Figure 18: Model with Forces Applied to the Bracket Slots

Applying Boundary Conditions

Fully constrain the ends of the shaft by applying surface boundary conditions to the inside of the bolt holes.

"View: Enclose" Access the VIEW pull-down menu and select the "Enclose"
command. The model will be resized and centered in the working
area.
"Selection: Select: Surfaces" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Surfaces" command.
"View: Rotate" Access the VIEW pull-down menu and select the "Rotate"
command. The cursor will change to rotation mode.

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 Mouse Click anywhere in the display area and drag the cursor to rotate the
model. Position the model so that you can see the inner surfaces
of the holes at the ends of the shaft (see Figure 19).

Figure 19: Rotating the Model so that the Inner Surfaces of the Shaft Holes Are Visible

<Esc> Press <Esc> to exit rotation mode. The cursor will change back to
surface selection mode.

Select the inner surfaces of the shaft holes.

Mouse Click on one of the inner surfaces of a hole. The surface will be
highlighted.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on the other three inner
surfaces of the shaft holes. Make sure that all four surfaces are
selected as shown in Figure 20.

Figure 20: Model with All Four Inner Surfaces of the Shaft Holes Selected

Add surface boundary conditions to the selected surfaces.

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 Mouse Right-click in the display area.
"Add: Surface Boundary Select the "Add" pull-out menu and select the "Surface
Conditions…" Boundary Conditions…" command.
"Fixed" In the "Predefined" section, press the "Fixed" button. All of the
checkboxes in the "Constrained DOFs" section will be activated,
which shows that all translational and rotational degrees of
freedom will be constrained.
"OK" Press the "OK" button to accept the specified data and close the
"Creating 4 Surface Boundary Condition Objects" dialog. Red
triangles will appear on the model symbolizing the fixed boundary
conditions.
<Esc> Press <Esc> to clear the current selection set. The model should
look like Figure 22.

Figure 22: Model with Applied Boundary Conditions

Specifying Analysis Parameters

Specify analysis parameters including the source of the nodal temperatures.

Mouse In the tree view, right-click on the "Analysis Parameters"

heading.
"Modify Analysis Parameters…" Select the "Modify Analysis Parameters…" command.
1 Type "1" in the first row of the "Thermal" column of the "Load
Case Multipliers" table in the "Multipliers" tab of the
"Analysis Parameters" dialog to include the thermal effects in
this analysis. We will specify the thermal results from a previous
analysis in the next step.
Mouse Click on the "Multiphysics" tab.
"Steady-state analysis" Select the "Steady-state analysis" option in the "Source of
nodal temperatures" drop-down box in the "Thermal" section.
"Browse…" Press the "Browse…" button..

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 MotorMount.to Click on the MotorMount.to file.
Note: MotorMount.to is a temperature output file, which was
created during a previous Steady-State Heat Transfer analysis.
The file was one of the model files that you retrieved from the
RefinedMeshMotorMount.ach file. You will use the temperature
output from MotorMount.to as input to the Static Stress with
Linear Material Models analysis to simulate thermal-stress on the
mount due to the motor heating up. The MotorMount.to file is
found in the directory where the RefinedMotorMount.ach was
restored.
"Open" Press the "Open" button to accept the selected file. In the
"Temperature data in file" field, the directory path for
MotorMount.to will be displayed. (See Figure 23).

Figure 23: Specifying the Source File for Temperature Data

"OK" Press the "OK" button to accept the specified information and
close the "Analysis Parameters" dialog.

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4. Checking the Model

Now that all element types, element definitions, material items and global analysis parameters have been specified, the model
can be checked to determine whether the geometry and finite element information is valid and ready for analysis.

"Analysis: Check Model" Access the ANALYSIS pull-down menu and select the "Check
Model" command. A "Model Validation" dialog will appear
indicating that the software is verifying the geometry and finite
element data. Once the check has been completed, the model will
be loaded in the Results environment. On your own, you can use
the features of the Results environment to further check the model
by examining the nodes, elements, loads and boundary conditions.
(For more information about using the Results environment to
examine models, see the "In-depth Results Evaluation" or
"Presentation of Results" tutorial).
"Tools: FEA Editor" After you are finished checking the model, access the TOOLS
pull-down menu and select the "FEA Editor" command to return
to the FEA Editor environment.

The model is now ready to be analyzed with the Static Stress with Linear Material Models processor.

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II. Analyzing the Model
In this phase, you will analyze the motor mount assembly model with the Static Stress with Linear Material Models
processor.

1. Analyzing the Model with the Static Stress with Linear Material Models Processor

Analyze the model using the Static Stress with Linear Material Models processor.

"Analysis: Perform Analysis…" Access the ANALYSIS pull-down menu and select the "Perform
Analysis…" command. The "Structural – Static Stress with
Linear Material Models" dialog will appear. The software will
solid mesh the model if necessary, verify the geometry and finite
element data and then the analysis will begin to run automatically.
If you want to view the progress of these processes, you can press
the "Details >>" button.
"OK" Press the "OK" button to dismiss the message informing you that
the current sessions of the Results environment will be closed.

If you want to stop the analysis, you can press the "Stop" button.

After the analysis is completed, the model will be loaded in the Results environment.

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III. Reviewing the Results
In this phase, you will use the Results environment to view the Static Stress with Linear Material Models analysis results.

1. Using the Results Environment to View Analysis Results

Previously, you used the Results environment to check the motor mount assembly model. Now you will use the Results
environment again, this time to look at the results obtained from the Static Stress with Linear Material Models analysis
processor. You will view stress results and rotate the model. Then, on your own, you can experiment with other capabilities
of the Results environment.

Examining Results in the Results Environment

The model is displayed in the Results environment. The von Mises stress contour will be displayed on the model. You can
rotate the model to find where the highest stresses occur.

"View: Rotate…" Access the VIEW pull-down menu and select the "Rotate…"
command.
Mouse Click and drag the cursor to rotate the model. Position the model
so that the stresses at the ends of the shaft can be seen. (See
Figure 24).

Figure 24: Examining von Mises Stress Results in the Results Environment

Examining the stress results in the Results environment shows that the highest stress occurred at the ends of the shaft.

Note: Results can vary depending upon which nodes of the bracket slots you selected when applying the forces.

On your own, you can you can experiment with other capabilities of the Results environment.

Congratulations! You have completed the Static Stress with Linear Material Models/Multiphysics Tutorial.

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