Workshop 10 Rocky AnsysMechanical Coupling PDF

Workshop 10 – ROCKY – ANSYS
Mechanical Coupling
Click to edit Master title style
www.rocky-dem.com
WORKSHOP 1: Simulating a Simple Transfer Chute Page 1 www.rocky-dem.com
Workshop objectives
• During this workshop, you will learn to:

– use ANSYS Workbench for coupling ROCKY and ANSYS Mechanical;
– create a geometry with input parameters in ANSYS SpaceClaim;
– set up a simulation in ROCKY and ANSYS Mechanical defining both input

and output parameters;
– set up multiple simulations using the parameters previously defined.

Step 1::Rocky Installation
• During Rocky installation, ensure

that the default options remain
selected:
– Ansys Fluent Coupling Support;
– Ansys Workbench Addin.

• Additionally, ensure this default option is
enabled while installing Rocky:
– ANSYS Workbench Addin Integration
(for desired ANSYS version).

Step 2::Starting ANSYS Workbench and SpaceClaim
1. Start a new ANSYS Workbench

session;
2. Save the new project;
3. Drag and drop a Geometry block
onto the Project Schematic from
the Component Systems
Click to edit MasterToolbox;
title style

Step 2::Starting ANSYS Workbench and SpaceClaim
4. Right-click on the
geometry block and
choose New
SpaceClaim
Geometry.

Step 3: Defining the geometry in ANSYS SpaceClaim
1. Once ANSYS SpaceClaim launches, open the input-file

Chute.scdoc. The following geometry will open, composed of
multiple parts;

2. The visibility of all parts should be hidden, except for

TransferChute;
Security, Structure, InspectionDoor and
Supports are not necessary for the
simulation.
FeedConveyor and ReceivingConveyor will

be recreated using ROCKY.
The hypothetical scneario that we will

Click to edit Master consider
title style
is that the transfer chute in
question is not adequately structually
supported, and one consideration may be
to modify the design slightly. Adding an
angle in the highlited area would relieve
the amount a particles that build up.

3. A first parameter will be created,

the length of a horizontal portion
of the chute, through the (a)
following steps:
a. Click on the Move tool;
b. Click on the highlighted face;
c. Click on the Anchoring tool; (c)
d. Choose the vertex pointed out

in the picture; (b)

(d)

3. Continuing these steps to create

the parameter:
e. When an axis appears on the
chosen vertex, click on the blue
arrow;
f. The Ruler option must then be
chosen;
(f)
(e)

3. Continuing these steps to

create the parameter:
(i)
g. With the Ruler option
chosen, click on the vertex
behind, so that a 400 mm
measure appears;
h. For establishing this (h)
measure as a parameter,
click on Groups;
(g)
i. Then, click on Create
Group. A parameter named
Group 1 will appear.

(a) (b)
4. A second parameter will be
created, the angle of the
horizontal wall, through similar
steps:
(d)
a. Use the Spin function to rotate
the geometry to get a view of
the face (c);
(e)
b. Click on the Move tool; (c)
c. Click on the highlighted face;
d. Click on the Anchoring tool;
e. Choose the vertex pointed out
in the picture;

4. Continuing these steps to

create the parameter:
f. When an axis appears
on the chosen vertex,
click on the red angular (g)
arrow, keep the left
mouse button held and
move the mouse so that
you see the surface
moving;
(f)
g. When you reach an
angle of 25o, go to
Groups andClick clicktoon
edit Master title style
Create Group. A
parameter named Group
2 will be created.

5. Let’s take a final look at the

Groups menu:
a.Rename Group 1 and 2 to Size
and Angle, respectively;
b. By clicking on Ruler
dimension, the values can be
changed and the geometry will
be changed automatically;
c. Try some changes to see how
the geometry varies, but keep
Size as 400 mm and Angle as
25o for proceeding with this
workshop. Click to edit Master title style
6. Save and Close SpaceClaim, go
back to Workbench and save the
project.

Step 4: Starting ROCKY in ANSYS Workbench
Here, all other Systems

Menus are collapsed to
facilitate ROCKY 1. Drag and drop a ROCKY
component view.
block onto the project;
2. If this block is dropped on the
Click to edit MasterGeometry
title stylecomponent (tab
A2), the connection is
automatically created;

Step 4: Starting ROCKY in ANSYS Workbench
3. Right-click on the Setup

component and choose Edit.

Step 5: Defining physics parameters
1. In the Data window, click on Physics;

2. In the Data Editors window, choose the Rolling Resistance Model
and then enter the Gravity Components that will be used in the
simulation.

For this workshop, the default settings will
be kept for the physics values.

Step 6: Visualizing the geometry
1. Geometry is automatically imported from ANSYS SpaceClaim;

2. Drag and drop the Geometries component to the workspace in order
to visualize the geometry.
In this case, the TransferChute was the

only imported, since the others were
omitted.

3. Since a coupled simulation with ANSYS Mechanical will be carried out

for this geometry part, it is important to refine the mesh on the chute:
a. Right click anywhere on the workspace and go to Grids > Edges > Visible.
One can see that the

mesh is very coarse. It
needs to be refined.

3. Since a coupled simulation with ANSYS Mechanical will be carried out

for this geometry part, it is important to refine the mesh on the chute:
b. In the Data menu, click on TransferChute. In the Custom Boundary tab of
the Data Editors panel, change the Triangle Size to 0.1 m.
The new mesh

is well suited
for the analysis
that will be
done.

Step 7: Creating geometries in ROCKY
1. In the Data window, right-click Geometries, go to Create, and then

click on Feed Conveyor. A new geometry part named Feed Conveyor
<01> will be included in the tree:
2. Change the parameters in each

tab in order to finish building the
feed conveyor.Click
Parameters
to edit are
Master title style
shown in the next slides.

Geometry:
-Transition Length: 1 m
- Loading length: 4 m
- Belt width: 0.6 m
- Triangle size: 0.1 m
- Belt Thickness: 0.025 m
Orientation:
- Alignment angle: -90º
- Belt incline angle: 10º

Click to edit- Vertical
Master title style
Offset: 3.1 m
- Horizontal Offset: 0.6 m
- Out-of-plane offset: 0.7 m
- Return Belt Angle: 0º

Step 7: Creating geometries inside ROCKY
Skirt Board:
- Material: yet to be defined
- Width: 0.5 m
- Length: 2.5 m
- Skirtboard height: 0.3 m
- Length offset: 1.5 m
-Height offset: 0 m
Feeder Box:
- Front plate offset: 0 m
Click to edit- Drop

Master
box length:title
1.5 m style
- Drop box width: 0.5 m
- Drop box height: 0.5 m
- Wall thickness: 0.025 m

Head Pulley:
- Face width: 0.6 m
- Diameter: 0.2 m
- Offset to Idlers: -0.1 m
Belt profile:
Click to edit- Belt

Master title
profile: Three rolls style
- Use 0.371 ratio for center roll length: checked
- Troughing angle: 35º
- Lower Corner Radius: 0.15 m

Belt motion:
- Belt speed: 3 m/s
- Beginning start time: 0 s
- Beginning stop time: 1000 s
- Aceleration period: 0 s
- Decelarion period: 0 s
In this case, after setting up all the Feed Conveyor

parameters, this is the resulting feed
conveyor.

3. To create the receiving conveyor, a similar procedure is applied. In the

Data window, right-click Geometries, go to Create, and then click on
Receiving Conveyor. A new geometry part named Receiving
Conveyor <01> will be included in the tree:
4. Change the parameters in each

tab in order to Click
finish building
to edit the
Master title style
receiving conveyor. Parameters
are shown in the next slides.

Geometry:
- Length: 5 m
- Belt Width: 1.4 m
- Triangle size: 0.1 m
- Belt Thickness: 0.025 m
Here, a parameter
will be created.
Instead of a number,
just write the name
Orientation: of the parameter for
it to be created.
- Alignment angle: 0º
- Belt incline angle: 10º Next slide shows

Click to edit Master title style what happens.
- Vertical Offset: -2 m
- Horizontal Offset: 0 m
- Out-of-plane offset: BeltPosition

-Initial Value: 0.9
- Return Belt Angle: 0º

To see this window, go to

Tools > Expressions and
Variables.
A dialog appears for determining the value of the

Click to edit Master
parameter. After creating this parameter, it is listed
title style
in the Expressions/Variables window.
You might try some changes in this value to see how

it influences the geometry, but keep 0.9 m for
proceeding with the workshop.

Skirt Board:
- Width: 0.7 m
- Length: 3 m
- Skirtboard height: 0 m
- Length offset: 0 m
- Height offset: 0 m
Belt profile:
- Belt profile: Three rolls

- Use 0.371 ratio for center roll length: checked
- Troughing angle: 35º
- Lower Corner Radius: 0.15 m

Belt motion:
- Belt speed: 1.5 m/s
- Beginning start time: 0 s
- Beginning stop time: 1000 s
- Aceleration period: 0 s
- Decelarion period: 0 s
In this case, after setting up all the

parameters, this is the resulting
receiving conveyor.
Geometry is now ready!

Step 8: Defining materials
1. In this case, default materials will be used to define geometry and

particles;
2. Thus, no changes are needed.

Step 9: Defining interaction between materials
1. In this case, as there are three materials, it is necessary to define three

interactions:
a. Particle x Particle;
b. Particle x Belt Material;
c. Particle x Boundary material.
2. It is necessary to define Static Friction, Dynamic Friction,

Coefficient of restitution, Adhesive Distance and Force fraction.
Default values will be used.
Click to edit Master title

Material 1 style
Material 2

Step 9: Defining interaction between materials
Static Friction: 0.6

Dynamic Friction: 0.6
Coefficient of Restitution: 0.3 Default
Adhesive Distance: 0.0001 Belt
Force Fraction: 0

Dynamic Friction: 0.3
Default Coefficient of Restitution: 0.3
Default
Particles Adhesive Distance: 0.0001 Boundary
Force Fraction: 0

Dynamic Friction: 0.7 Default
Coefficient of Restitution: 0.3
Particles
Adhesive Distance: 0.0001
Force Fraction: 0

Step 10: Defining a particle group
1. In the Data window, right-click on Particles and go to Create Particle;

2. In the Data Editors window, define the parameters for each tab in order
to define size distribution, shape and breakage parameters for particles;
3. In the Size Distribution tab, define all relative parameters that will be
used:
Click on the plus button to add

lines in the size distribution.
For this workshop the following distribution

will be used:
Click
Size to edit Master title style
0.15 | 100%
distribution 0.1 | 30%

Step 10: Defining a particle group
4. In the Geometry tab, define the shape and geometrical parameters of

the particle:
For this case, the following values will be

used:
Enable Rotations: Checked

Shape Type: Faceted
Rolling Resistance: 0
Vertical Aspect Ratio: 1.5
Horizontal Aspect Ratio: 1.0
Number of corners: 15
Super quadric Degree: 2.00

Step 11: Defining boundary materials
1. After all materials are defined, it is possible to finish the boundary
condition definition;
2. In this case, all materials are kept with the default options. An example is
shown for Feed Conveyor:
Default Boundary
Default Belt

Step 12: Defining particle input
1. In the Data window, right-click on Input and go to Create Particle
Input;
2. In the Data Editors window, define the entry point and the mass flow for
this case.
For this case, the following settings will be
used:
Entry point: Feed Conveyor <01>

Particle: Particle <1>
Tonnage: 300 t/h
Material inlet
Click on the plus button to add

lines in the particle input.

Step 13: Solver Settings
1. Select Solver from the Data window and define the solver settings in Data
Editors;
2. After this definition, press Start Simulation button.
For this case, the following settings will be
used:
Time Duration: 10s

Output frequency: 0.1s
Statistics/Wear/Breakage Start: 10s
Configuration of time and Statistics/Attrition/Breakage Delay After
output frequency. Release: 2s
Wear Geometry Update Frequency:
0.005 s
Loading N-steps: 15
Collect Forces to FEM Analysis: Checked
Release Particles without Overlap:
Checked
Configuration of parallelization It is important to check this because a

and CPU. coupled analysis will be done!
Step 14: Simulation
1. From the start of the simulation, the real time progress of the solver
can be seen. How quickly the simulation is executed depends on
various factors, among which are included:
a. Triangular mesh refinement used in geometry. A more refined mesh
requires more computational resources.
b. Amount of particles in simulation. More particles means more
computations.
c. Particle type in simulation (granulometry). Round particles are more
simple to calculate and, as the complexity of the particle geometry
increases, so does the computation time.
d. Frequency of results saved (Output Frequency). How often the
simulation computation is paused to save results: the more frequent,
Click
the slower the to editexecution.
simulation MasterNotably,
title style
this is also dependent
on hardware: with faster write/seek times on a hard drive, this can be
reduced.

Step 15: Post Processing
1. Particle visualization:
a. In the Data window, select Particles for visualization;
b. In the Time bar, select the final time (10 seconds);
c. Color the particles by Absolute Translational Velocity.
(b) (c)
(a)

2. Analysis of force values on receiving conveyor over time:
a. In the Window menu, select New Time Plot;
b. Select Receiving Conveyor in the Data window;
c. In the Data Editors window, select Grid Functions;
(b)
(a)
(c)

d. Drag and drop Instantaneous Nodal Forces Z to the plot workspace and
select the sum of these values to be plotted:
(d)

e. Drag and drop Instantaneous Nodal Forces Z to the Output tab of
Expressions/Variables window.
f. Double click on the variable created to do a new operation:
(e)
(f)
For this case, the following settings will 3. Close ROCKY and
be used: go back to
Click to edit Master title style Workbench.
Name: AverageTotalForce
Grid Function to Curve: sum
Operation on Curve: average
Domain Range: Time Range
Initial: 3.5 s
Final: 10 s
Step 16: Starting a Static Structural analysis
1. Drag and drop a Static 3. Right-click on

Click
Structural block onto the toTo create a connection left click on
edit Master title style
the desired component, hold the Model and go to
project; mouse button and release it on the Edit to initialize a
target component. Static Structural
2. Create the connections
analysis.
between ROCKY and Static
Structural blocks as shown
above.
Step 17: Defining the structural simulation setup
1. To import a load from ROCKY, follow these steps:
a. Right-click on Imported Load and insert Pressure;
b. Click on Geometry “No Selection”;
c. Use the Box tool to select 44 faces;
(c)
d. Click on Apply.
(a)
(b)
(d)

1. To import a load from ROCKY, follow these steps:
e. Do the following changes in the Details and Data View menus:
Apply to: Corner nodes

Define by: Components
Click to
X Component edit
(Pa): Master title
TransferChute01:Px style
Y Component (Pa): TransferChute01:Py
Z Component (Pa): TransferChute01:Pz

2. To define a Fixed Support, follow these steps:
a. Right-click on Static Structural and insert Fixed Support;
b. Click on Geometry “No Selection”;
c. Use the Single Select tool to select the 21 faces shown. Note: There are
faces above and below the highlighted green faces shown.
d. Click on Apply.
(c)
(a)
(b) (d)

2. Right-click on Solution, go to Insert and look for Total Deformation
and Equivalent Stress to setup the post-processing.

Step 18: Running and post-processing the simulation
1. Run the simulation by hitting the Solve button;
2. When the simulation concludes, results can be investigated by
selecting Total Deformation or Equivalent Stress. The effect caused
by the particles on the surfaces can be easily seen:

Step 18: Running and post-processing the simulation
3. Select Equivalent Stress and click
on the box next to the Maximum
value to create a parameter. Do the
same for Total Deformation.
4. Close the Static Structural analysis
and go back to Workbench.

Step 19: Running multiple simulations
1. In ANSYS Workbench, double click the Parameter Set block;
2. In Outline Of All Parameters, all the parameters created during the analysis
are listed, no matter in which application they were created or if they are input or
output parameters;

3. In Table of Design Points, the user can create new analyses by changing the
parameters. DP0 is the current Design Point. In this image, DP1 was just
created and the output parameters will be calculated.
4. The new analyses can be run by hitting the Update All Design Points button.

5. Everything is automatically updated, without the user needing to make any
changes;
6. At the end of the simulation, the user can take a look at the output parameters
for the new design points or open any of the applications to further investigate
the results.

Workshop Objectives
During this workshop, it was possible to:

 use ANSYS Workbench for coupling ROCKY and ANSYS
Mechanical;
 create a geometry with input parameters in ANSYS

SpaceClaim;
 set up a simulation in ROCKY and ANSYS Mechanical

defining both input and output parameters;
 set up multiple simulations using the parameters previously
defined.

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Workshop 10 – ROCKY – ANSYS

Click to edit Master title style

• During this workshop, you will learn to:

– create a geometry with input parameters in ANSYS SpaceClaim;

– set up a simulation in ROCKY and ANSYS Mechanical defining both input

– set up multiple simulations using the parameters previously defined.

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 2 www.rocky-dem.com

• During Rocky installation, ensure

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 3 www.rocky-dem.com

1. Start a new ANSYS Workbench

WORKSHOP 1: Simulating a Simple Transfer Chute Page 4 www.rocky-dem.com

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 5 www.rocky-dem.com

1. Once ANSYS SpaceClaim launches, open the input-file

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 6 www.rocky-dem.com

2. The visibility of all parts should be hidden, except for

FeedConveyor and ReceivingConveyor will

The hypothetical scneario that we will

WORKSHOP 1: Simulating a Simple Transfer Chute Page 7 www.rocky-dem.com

3. A first parameter will be created,

d. Choose the vertex pointed out

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 8 www.rocky-dem.com

3. Continuing these steps to create

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 9 www.rocky-dem.com

3. Continuing these steps to

WORKSHOP 1: Simulating a Simple Transfer Chute Page 10 www.rocky-dem.com

WORKSHOP 1: Simulating a Simple Transfer Chute Page 11 www.rocky-dem.com

4. Continuing these steps to

WORKSHOP 1: Simulating a Simple Transfer Chute Page 12 www.rocky-dem.com

5. Let’s take a final look at the

WORKSHOP 1: Simulating a Simple Transfer Chute Page 13 www.rocky-dem.com

Here, all other Systems

WORKSHOP 1: Simulating a Simple Transfer Chute Page 14 www.rocky-dem.com

3. Right-click on the Setup

WORKSHOP 1: Simulating a Simple Transfer Chute Page 15 www.rocky-dem.com

1. In the Data window, click on Physics;

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 16 www.rocky-dem.com

1. Geometry is automatically imported from ANSYS SpaceClaim;

Click to edit Master title style

In this case, the TransferChute was the

WORKSHOP 1: Simulating a Simple Transfer Chute Page 17 www.rocky-dem.com

3. Since a coupled simulation with ANSYS Mechanical will be carried out

One can see that the

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 18 www.rocky-dem.com

3. Since a coupled simulation with ANSYS Mechanical will be carried out

The new mesh

Click to edit Master title style

WORKSHOP 1: Simulating a Simple Transfer Chute Page 19 www.rocky-dem.com

1. In the Data window, right-click Geometries, go to Create, and then

2. Change the parameters in each

WORKSHOP 1: Simulating a Simple Transfer Chute Page 20 www.rocky-dem.com

- Belt width: 0.6 m

- Triangle size: 0.1 m

- Belt Thickness: 0.025 m

- Belt incline angle: 10º

- Horizontal Offset: 0.6 m