Disk Drive

Stress Analysis of the Power Supply Switch

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q Prepare, analyze, and evaluate the power

supply switch.
q Redesign the switch.
q Re-analyze and evaluate the new design.
Step1: Preparing
the Part

30 min approx.

Step 4: Redesign
Step2: Set Boundary Step3: Compute and Part & Reanalyze
Conditions & Loads Analyses Results

1-5
 Step 1: Preparing the Part

Start Document Result Document

Objectives and Givens:

1 - Open Power_Switch.Part in PATH.
2 - Apply Material on Part and Apply shading with texture and Edge visualization.
3 - Change the Yield strength of the Part to 40e6 N/m2.
4 - Open Stress Analysis Document and select Power Switch to analyses.
5 - Deactivate Fillets.
6 - Save the Part in your working folder and Close the Part.

Click to display detailed steps 2-5

 Step 2: Set Boundary Conditions & Loads

Start Document Result Document

Objectives and Givens:

1 - Clamp inside of the hole of the Part.
2 - Apply negative Z Load of 10 Newtons to the end of the Power Switch (opposite side of the hole).

Click to display detailed steps 3-5

 Step 3: Compute and Analyses Results

Start Document Result Document

Objectives and Givens:

1 - Mesh Part & Compute, with global size of 10mm global sag of 0.5, local size of 5 and local sag
of 0.25 applied on the inside of the hole.
2 - Analyses the Results (Von Mises, Deformation).
3 - Analyses the Precision of the Computations and the Meshing.
4 - Visualization of the meshing.
5 - Modify the Global size of the meshing to 7.5mm, Compute and Analyses the Results.

Click to display detailed steps 4-5

 Step 4: Redesign Part & Reanalyze

Start Document Result Document

Objectives and Givens:

1 - Modify the Profile of the Part: modify the thickness of 1.5mm(the one near the hole) to 3 mm.
2 - Resize the diameter of the Hole to 8 mm.
3 - Analyses the modified Part

Click to display detailed steps 5-5

 Detailed Steps

Step 1: Preparing the Part(1 of 4)

1 - Open the Power_Switch_Start.CATPart document using
Open in the File drop down menu

8 The Power_Switch_Start.CATProduct is in the folder: /

CATIAdoc.

1-5
 Detailed Steps

2 - Apply a material to the Part.

1 2
4

5 6

8 (1)Select the Apply Material Icon (on the lower toolbar),

the Material Library Window appears.
8 (2)Select the Other tab, (3)Drag and (4)Drop the Plastic
Material on to the Part.

8 (5)Change the visualization of the Part to Shading with

Texture and Edges, (6)the Part is shown with the Plastic
texture.

2-5
 Detailed Steps

3 - Change Properties of the Part:

4
1
5

8 (1)MB3 on PartBody, select Properties.

8 (3)Select Material tab, (4)Select Analysis tab.

8 (4)Change Yield Strength to 40e6 N/m2, (5)Select OK.

3-5
 Detailed Steps

4 - Open Stress Analysis Document with Start Menu.

1

8 (1)Select the Start Menu, (2)select the Stress Analysis

option.

8 (3)The Power_Switch appears in the Analysis Window

ready to start the Analysis process.

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 Detailed Steps

5 - Deactivate Fillets
1

2 3

8 (1) Click MB3 on the Edge Fillet.1 in the tree, (2)select the
EdgeFillet.object > (3) Deactivate

8 (4)Look on the tree, the symbol that represents that the

Filet is deactivated.
6 - Save the Part in your working folder and close the Part

5-5
 Detailed Steps

Step 2: Set boundary conditions and loads (2 of 4)

1 - Clamp inside of the hole of the part

8 (1)Select the inside of the hole.

8 (2)Selct the Clamp Icon, (3)and press OK on the Clamp

dialog box.
8 (4)Two axis, representing the clamping appears in the
hole.

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 Detailed Steps

2 - Apply Load on the Power_Switch:.

2
4

8 (1)Select the Face at the end of the Power_Switch.

8 (2)Select the Traction Icon, (3)put 10 N in the Force field,

(4)Put a Negative Value to the Traction3 field if the Arrow
is going in the Z positive direction (5)and select OK.

8 (6)The Arrow represents the Force Applied, should be in

the Z negative direction.

2-2
 Detailed Steps

Step 3: Compute & Analyses results(3 of 4)

1 - Mesh Part & Compute

4
1

2 5

8 (1)Select the Compute Icon, (2)in the Manage area

activate the External storage and deactivate the Mesh
only checkbox and in the Accuracy make sure that the
High precision Checkbox is activated.

1-7
 Detailed Steps

8 (3)Select the More button so the Compute dialog box

expands and you can (4)insert the Wanted Value in the
Global Size(10 mm) and Sag(0.5 mm) and the Local
Size(5 mm) and Sag(0.25 mm).

8 Select the inside of the hole to apply a Local Meshing

(with local size and sag values mentioned above).

8 (6)Select the OK button and (7)the results appear.

2-7
 Detailed Steps

2 - Analyses the Results.

$ After the computation CATIA should switch to the Von

Mises Icon to see the results of the computation.

$ Here you must compare the Yield Strength to the

maximum load, if the maximum Load is greater than the
Yield Strength, you must change the design.
$ 73.5 MPa is greater then 40MPa, you must change the
design of the Power_Switch.

3-7
 Detailed Steps

Other Analysis

$ We can also Verify the Principal Stress and the

Displacement

4-7
 Detailed Steps

3 - Analyses the precision of Computation and Meshing.

8 (1)Select the Precision Icon .

$ Here you will verify the quality of your meshing, a general

rule of thumb is to get an Estimated global precision
around 10%.

$ Using the Palette we can also verify that the highest strain
energy difference is not in a critical area.

8 (2)Select OK when finished.

5-7
 Detailed Steps

4 - Visualization of the meshing

8 Select the Mesh Icon

$ The Mesh Icon allows you to look at the Meshing CATIA

created.

$ You can use the Shrink factor to create a gap between the
mesh elements, this is only a visualization tool.

6-7
 Detailed Steps

5 - Modify the Meshing, Compute and Analyses the Results

1
2

6
4

8 (1)We can add global meshing by reselecting the

compute icon and double clicking on the tetrahedron
representing the global meshing (you can also use the
leaf on the tree or change the value in the compute dialog
box).

8 (2)Insert the value of 7.5 mm in the Define size dialog

box, and (3)select OK when finished.

8 (4)Select the Compute Icon, and (5)Verify the Precision is

lower then the previous error (23%).

7-7
 Detailed Steps

Step 4: Redesign Part & Reanalyze (4 of 4)

1 - Modify the profile of the Part

8 (1)Double Click on the PartBody leaf on the tree to

activate the Part workbench.

8 (2)Select the sketcher icon and (3)select the Sketch of the

Pad (Sketch.1), in the Sketch (4)change the 1.5mm
thickness value that is near the hole to 3mm.

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 Detailed Steps

2 - Resize the Hole.

1 2

8 (1)Double click on the Hole.1 Leaf on the tree.

8 (2)Change the hole Diameter from 5.5 mm to 8 mm, and

(3)Slect OK when finished.

8 (4)Save Part as Power_Switch_modified in your working

directory.

2-3
 Detailed Steps

3 - Analyses the modified Part

3

1
2

8 (1)Double Click on the Preprocessing leaf of the tree.

8 (2)Mesh Part, just select OK in the Compute dialog box to

recompute the meshing.

8 (3)The results appear, (4)compare the Maximum Stress

with the Yield strength of the Part.

8 (5)Select the Precision Icon to verify the validity of the

computation.

3-3