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Combining Beam Elements with CAD Solid Models Tutorial, Revision 15.000—printed locally from files supplied electronically. 2
Files List for this Tutorial
In addition to this document file, the following file is referenced in the tutorial:
CrankAssembly.ach
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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.
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.
sd3.dmit, an .esx file Filenames and file extensions are lowercase with the filename in italic.
\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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Crank Shaft Assembly Model
In this tutorial, we will introduce you to ALGOR software's capabilities for Linear Static Stress analysis. The example
demonstrated in this tutorial shows how to set up and analyze a three-dimensional (3-D) model of a crank assembly.
II. Analyzing the Model – Analyze the model using the Static Stress with Linear Material Models processor.
III. Reviewing the Results – Examine the stress results graphically with the Results environment.
1. Problem Description
A crank assembly is designed to support a 500 lbf-in moment and a 50lbf force on the knob. The assembly consists of a
shaft, arm, and a knob. The arm and knob are made of aluminum (6061-T6) and the shaft is made of steel (ASTM-A36).
The assembly is fixed at the end of the shaft.
Figure 1 shows a diagram of the crank shaft assembly. The goal of the Static Stress with Linear Material Models analysis is
to determine stresses in the assembly due to the simultaneous loading:
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2. Retrieving the Supplied Model Archive File
In this section, you will use FEMPRO to retrieve the supplied model archive file, CrankAssembly.ach.
Starting FEMPRO
"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.
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.
Retrieve the supplied model archive file from the Tutorials\Models directory. This archive file contains a meshed
model of the crank shaft assembly. (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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Mouse Use the "Look in:" drop-down box navigate to the
Tutorials\Models directory, which is where the archive file
is stored.
"CrankAssembly" Click on the CrankAssembly.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. The meshed model
will be displayed in the FEA Editor environment (see Figure 3.)
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3. Specifying Model Data in the FEA Object Editor
In this section, you will specify all data needed for Static Stress with Linear Material Models analysis including the analysis
type, element type, element definition, applied loads, boundary conditions and analysis parameters. You will note that in the
lower left corner of the screen, the analysis type has already been set to Static Stress with Linear Material Models.
By default, the solid mesh engine has set the element type to brick elements with the default element definitions. We are
going to accept the defaults and change the material types.
Specify the material properties for Part 1, the crank shaft (the green part).
Mouse In the tree view, right-click on the "Material" heading for Part 1.
"Modify Material…" Select the "Modify Material…" command. The "Element
Material Selection" dialog will appear.
"Steel (ASTM-A36)" Highlight the "Steel (ASTM-A36)" option in the "Select
Material" section. (See Figure 4.)
"OK" Press the "OK" button to accept the material property choice.
The selected material will be shown in the tree view.
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Figure 5: Material Properties for Parts 2 and 3
Add beams to transfer a moment. These beams will be used to simulate the rotation of the knob.
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Hide the rest of the surfaces in Part 3.
Mouse Click the + next to the "Surfaces" heading for Part 3 in the tree
view.
Mouse Click on the "Surface 1" heading for Part 3.
<Shift>-Mouse Holding down the <Shift> key, click on the "Surface 9" heading
for Part 3.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on the "Surface 5" heading
for Part 3 to remove it from the selection set.
Mouse Right-click on the heading for one of the selected surfaces in the
tree view.
"Hide" Select the "Hide" command. See Figure 7.
"View: Orientation: XZ Back" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "XZ Back" command. See Figure 8.
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Figure 8: XZ Back Viewpoint
"Geometry: Elements: Line…" Access the GEOMETRY pull-down menu and select the
"Elements" pull-out menu. Select the "Line…" command.
"Single Line" Activate the "Single Line" checkbox in the "Define Geometry"
dialog. This will let us create individual line segments. See
Figure 9.
Repeat the previous two steps, adding lines from the center point to the right, top, and bottom edges.
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Figure 10: Beams Added in 4 Directions
"Use Relative" Activate the "Use Relative" checkbox in the "Define Geometry"
dialog.
Mouse Click on the center point of the beams.
1.5 <Enter> In the "DY" field, type "1.5" and press <Enter>.
Mouse Click on the X at the upper right corner of the "Define
Geometry" dialog.
"View: Orientation: Isometric" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "Isometric" command. The model
should like Figure 11.
Mouse Click on the heading for part 1 in the tree view.
<Ctrl>-Mouse Holding down the <Ctrl> key, click on the heading for part 2 in the
tree view.
<Ctrl>-Mouse Holding down the <Ctrl> key, right-click on the heading for part 3
in the tree view.
"Show" Right-click in the display area and select the "Show" command.
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Specify the element type for part 4, the beam structure.
Mouse In the tree view, right-click on the "Element Type" heading for
part 4.
"Beam" Select the "Beam" command.
Mouse In the tree view, right-click on the "Material" heading for part 4.
"Modify Material…" Select the "Modify Material…" command. The "Element
Material Selection" dialog will appear.
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"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.
"View: Orientation: YZ Right" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "YZ Right" command.
"Selection: Shape: Rectangle" Access the SELECTION pull-down menu and select the "Shape"
pull-out menu. Select the "Rectangle" command.
"Selection: Select: Vertices" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Vertices" command.
Mouse Draw a rectangle enclosing the left edge of the model. See Figure
14.
"Selection: Shape: Point" Access the SELECTION pull-down menu and select the "Shape"
pull-out menu. Select the "Point" command.
Mouse Click on the vertex on the very end of the beam extending from
the face of the knob. The selected vertex will be highlighted with
a magenta dot. See Figure 15
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Figure 15: Selecting a Point at the End of the Beam
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Apply a surface force to the top of the knob.
"Selection: Select: Surfaces" Access the SELECTION pull-down menu and select the "Select"
pull-out menu. Select the "Surfaces" command.
"View: Orientation: Axonometric" Access the VIEW pull-down menu and select the "Orientation"
pull-out menu. Select the "Axonometric" command.
Mouse Use the mouse to right click on the top surface of the knob. It
should turn magenta in color and a menu should appear. See
Figure 17.
"Add: Surface Force…" Select the "Add" pull-out menu and select the "Surface
Force…" command.
50 In the "Magnitude" field, type "50".
"OK" Press the "OK" button to apply the surface force.
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4. Checking the Model
Now that all element types, element definitions, material items and 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, loadings 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 crank-shaft 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 choose "Perform
Analysis…." The "ALGOR Structural – Static Stress with
Linear Material Models" dialog will appear. The software will
verify the geometry and finite element data and then the analysis
will begin to run automatically.
"OK" Press the "OK" button to dismiss the message informing you that
the current sessions of the Results environment will be closed.
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.
Previously, you used the Results environment during the analysis setup to check the crank shaft assembly model. Now you
will use the Results environment again, this time as a tool to look at the results obtained from the Static Stress with Linear
Material Models analysis. You will view stress results and rotate the model. Then, on your own, you can experiment with
other capabilities.
The model is displayed in the Results environment. Examine the analysis results.
"Results Options: Displaced Model Access the RESULTS OPTIONS pull-down menu and select the
Options…" "Displaced Model Options…" command.
"Show Displaced Model" Activate the "Show Displaced Model" checkbox.
20 Type "20" in the "Scale Factor" field for a smaller displacement
scale.
Mouse Click on the "X" at the upper right corner of the "Displaced
Model Options" dialog. The model will be displayed in its
displaced form, with the calculated displacement exaggerated for
display. The original shape of the model is displayed as a line
drawing for comparison. The model should now appear as Figure
20.
Figure 20: Examining von Mises Stress Results in the Results Environment
On your own, you are welcome to continue to use the Results environment to further examine the analysis results.
Congratulations! You have completed the Combining Beam Elements with CAD Solid Models Tutorial.
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