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Analyzing Parts with Part Stress Analysis

Introduction
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Part Preparation ORDGV

Applying Boundary
Conditions and Loads

Computing Results

Displaying and
Interpreting Results

Part Redesign
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 Introduction

What is Part Stress Analysis (PSA)?

2 PSA in part design

2 The finite element method

Input for Part Stress Analysis

2 Well-defined part model

2 Material properties

2 Loads, boundary conditions

Results from Part Stress Analysis

2 Part deformation

2 Mechanical stresses

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 Mechanical analysis in part design

CATIA stress analysis allows you to check the mechanical strength and stiffness of your part

In PSA, you can simulate your part

under load conditions and
determine its mechanical strength

PSA uses the finite element

method to simulate the mechanical
conditions

Using PSA allows you to test

your part EARLY in its design, A part and its Analysis model
when changes can be made
easily and cheaply.

4-12
 The finite element method

PSA uses the finite element method to calculate deformation and stress under mechanical
load and boundary conditions

CATIA transforms the part into a

mathematical model. The stiffness
of the model is calculated, then
solved for the given conditions.

CATIA uses the finite

element analysis (FEA) to
make the deformation
calculation.

The FEA model is created

TRANSPARENTLY for you. You
apply the conditions to the part An analysis model with applied conditions.
geometry, and CATIA does the
rest.

5-12
 Well-defined Part

The part model needs to be well-defined in preparation for analysis

All features or details in the part

which don’t affect the analysis
should be deactivated.

Deactivate fillets or holes

that have nothing to do
with the analysis
problem.

Simplifying the problem by

removing unnecessary
Refining the part for analysis
geometry will decrease
solution time.

6-12
 Apply Material Properties

A material from the material library needs to be assigned to the part.

Every material has unique

mechanical properties that are
needed in the analysis.

The material is assigned

in the part document
from an available library
of materials.

The analysis model is formed

from the geometry and the
specific material properties. Selection of a material
for the part.

7-12
 Apply Loads and Boundary Conditions

External loads and boundary conditions are applied

The loads and boundary

conditions (restraints) should
simulate real conditions for the
part.

Loads and boundary conditions

must be applied to complete the
analysis model. Loads and restraints on a part

8-12
 Part deformation results from CATIA Analysis

The primary result of a part analysis under load is the deformation

The basic result from a

structural analysis is the
deformation of the part under
the prescribed load.

The calculated deformation is

used to determine mechanical
stress and strain in the part. Visualizing the deformed shape.

9-12
 Mechanical Stress Results

Mechanical stress plots are results

from a Part Stress Analysis

Contour plots of stresses

throughout the part can be
visualized.

The stress plots can directly

relate to the strength of the part
under the prescribed load and
boundary conditions. A stress contour plot

10-12
 Best Practices Title

The finite element analysis process

l Most finite element analyses follow this simple process:

Part geometry Part is meshed Assign Apply boundary

is with nodes material, conditions, loads SOLVE
created and elements- physical
properties

In the analysis, the mesh creation process is transparent Redesign Visualize and
to the user. part and evaluate
repeat results
Boundary conditions and loads are applied to part analysis if
geometry. necessary

11-12
 REMEMBER!

u PSA can help determine the stiffness and strength of your part

u Input into PSA includes material properties, loads, and boundary conditions

A
u
PS
Output from PSA includes the part deformation and induced stresses
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12-12
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13-18
 Part Preparation

Simplifying Geometry

2 Inactivating fillets, holes, features

Assigning a Material to the Part

2 Choosing a material from the material

library

Creating an Analysis Document

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 Simplifying Geometry

The part geometry should be simplified in preparation for analysis

Features and details not affecting

the analysis should first be
deactivated.

Specifications Tree

Use the specification tree to select

a feature, detail, fillet, etc. to
Deactivate fillets
deactivate.

Having less detail while

maintaining the important Example of fillets to be deactivated
aspects of the geometry will
produce a faster solution.

15-18
 Assigning a Material to the Part

A material needs to be assigned to the part

to attach specific mechanical properties

Mechanical properties, such as

Tensile Modulus, Poisson’s
ratio, and density, need to be
assigned to the part.

By selecting the material

application icon, a material
library is opened and a specific
material is selected and applied
to the part.

GPS uses the material

properties and the part
geometry to calculate the Selection of the
stiffness of the part. Material Library
Select the “Apply
Material” Icon

16-18
 Creating an Analysis Document

An analysis document is created to contain the analysis model

and to save the analysis results.

The Analysis Document is

created from the New document
window, and a copy of the part
is transferred into it for analysis.

Select “NEW” under FILE

to open an analysis
window, then pick
“analysis” in the window.

Several analyses can be done

and saved in separate Analysis
Creating an Analysis Document
Documents, independent from
the Part Document.

17-18
u Simplify your geometry to prepare for PSA

l Deactivate fillets, unnecessary holes, unnecessary features, etc.

u Assign a material to the part

l Use the material library to pick a material

u Create an analysis document to begin the analysis with PSA

18-18
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19-23
 Applying Boundary Conditions and Loads

Applying Restraints

2 Choosing the appropriate type of

restraint
2 Assigning restraint values and
direction
2 Positioning the restraint

Applying Loads

2 Choosing appropriate loads

2 Assigning load values and direction

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 Applying Restraints

Restraints have to be applied to the part geometry

Restraints are applied on the part

boundary and simulate how the
part is actually fastened in-place.

Restraint icons

Using the analysis taskbar, pick the

appropriate restraint and apply to
an edge or surface of the part.

Restraints are necessary for the Selecting restraints

structural analysis problem. The
goal is to accurately simulate
the actual boundary conditions.

21-23
 Applying Loads

Loading conditions have to be applied to the part geometry

Loads can be forces, tractions,

or even displacements, applied
to edges, surfaces, or the entire
body (like a gravity load).

Choose the appropriate load

from the analysis taskbar
and apply to the part edge,
surface, or body.

Without the load, there is no

problem to analyze. The load
simulates any external forces or Applying a load to the part.
displacements acting on the
part.

22-23
 Summary

u Loads and boundary conditions must be applied before the analysis problem can be solved

u Loads include both applied forces, pressures, tractions, AND applied deformations

u Loads and Boundary conditions can be applied to part edges, surfaces, or the entire part

23-23
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24-28
 Computing Results

Setting Solution Parameters

2 Assigning values for meshing

2 Providing temporary disk space for

computation

Computing the Solution

2 Computation feedback

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 Setting Solution Parameters

Solution parameters are set before the results are calculated.

Some parameters must be set

before results can be calculated.

The compute window controls the

precision of the calculation and
sets up temporary external storage.

Solution parameters control the

efficiency and accuracy of the Setting up parameters for solution
solver as it calculates the result

26-28
 Computing the Solution

The results are now computed

The results have to be

computed based on the given
loads and boundary conditions
applied to the part.

Select the Compute Icon to

initiate the calculation. Solution
Feedback is given in the
compute window.

The computation could require

several minutes for completion.
Calculation of solution

27-28
 Summary

u Set solution parameters, such as calculation precision and external storage before starting the
solution

u Solution progress can be monitored in the Compute Window

28-28
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 Displaying and Interpreting Results

Default Results

2 Deformation

2 von Mises stress

Meshing Checking

2 Mesh display

2 Mesh precision

Available Output Results

2 Arrow plots

2 Stress component contours

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 Default Results

Stress contours on the deformed geometry are displayed.

The default result display provides

the von Mises stress contours on
the deformed part.

The undeformed part geometry is

shown as a line drawing. The
colored areas indicate stress
ranges superimposed on the
deformed shape.

The von Mises stress is a

simple indication of stress
magnitude and can be The von Mises stress superimposed on the
compared to the Yield Stress of deformed shape of the part.
the material for most ductile
materials.

31-35
 Mesh Integrity

Display results include methods to check the mesh integrity

Displays are available to help

verify the mesh integrity for
confidence in the results.

Select the mesh icon and the

mesh precision icon for feedback
as to the meshing error and
adequacy.

This is just simple text to

comment images and provide
more information Mesh checks for integrity

32-35
 Available Output Results

Alternative output displays are available

There are several other types of

output displays available from
the analysis taskbar.

Select the display needed

based on the type of
output: arrow plots for
reaction forces, stresses,
or contour plots for
stresses and deformation.

Alternative displays enable

clear communication of
complex analysis results.
Analysis Results display

33-35
 Best Practices Title

u There are several types of measures of mechanical stress:

l The von Mises stress is applicable to most ductile materials and can be directly compared to the yield stress

l Maximum and minimum stresses are usually representative of the largest tension and compression stresses in the part,
respectively.

l In general, It is good practice to consider von Mises, maximum and minimum stress, as well as maximum shear, in
determining the strength of the part.

34-35
 Summary

u The default result display in GPS is von Mises stress on the deformed part

u Mesh integrity can be checked by displaying the mesh and by checking mesh precision

u Other results displays include arrow plots for stresses, reaction forces and contour plots for other
measures of stress

35-35
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36-40
 Part Redesign

Changing the Part Material

2 Altering overall stiffness

2 Increasing Yield Stress

Adjusting geometry

2 Increasing Radii

2 Changing thickness, dimensions

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 Changing the Part Material

Redesigning the part can include changing the material

Changing the material of the part

can affect stiffness and ultimately
the deformation of the part.

Re-applying a new material can

assign a new Tensile modulus and
Yield stress to the part.

Changing Part Material

A very quick and easy part
redesign can sometimes be
accomplished by changing the
material.

38-40
 Adjusting geometry

Redesign can be accomplished by altering geometric parameters

Adjusting geometric properties

can reduce stress or
deformation under given
boundary conditions.

Changing thickness,
increasing radii of fillets, etc.
can strengthen a part in a
critical region.

GPS allows quick analysis and

redesign EARLY in the part
design cycle. Redesign by changing
geometric parameters

39-40
 Summary

u Based on the initial GPS analysis, the part can be redesigned to improve the part stiffness or stress
distribution

l The part material can be changed to alter the stiffness and yield stress

l The part dimensions can be modified to reduce stress globally or at critical locations on the part

u CATIA Part Stress Analysis enables design changes early in the part design cycle, thus saving time
and expense

40-40
 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

41-45
 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 42-45

 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 43-45

 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 44-45

 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 45-45