6_FILBAR

(Plane Stress Problem – Filleted Bar)

Units are in mm.

Static Structural **

A3: Geometry*
Properties of Schematic A3: Geometry >Basic Geometry Options > 13-Surface Bodies 
Properties of Schematic A3: Geometry >Advanced Geometry Options > 21-Analysis Type=2D

Geometry ** (Starts up Design Modeler)

 Millimeter [OK] XYPlane > Look At Face/Plane/Sketch

Sketching > Draw > Rectangle (or Line)

Draw the above geometry. Give necessary dimensions. Fillets are 15mm.

Modeling*
Concept > Surfaces from Sketches > Select [Sketch1] > Apply
Details of “SurfaceSk1” > Thickness = 10 mm
Generate

File > Close DesignModeler (DM)

File > Save As… > 6_FILBAR_geo (6_FILBAR_geo.stp created)

A4: Model**

Outline Tree > Geometry *

Details of “Geometry” > 2D Behavior = Plane Stress

Units > Metric (mm, kg, N, s, mV, mA)

Static Structural (Right click) > Insert > Frictionless Support

Select left vertical line > Apply

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Static Structural (Right click) > Insert > Force
Select right vertical line > Apply
Define by = Components
X Component = 50000 N

Solution (Right click) > Insert > Deformation > Total

Solution (Right click) > Insert > Deformation > Directional
Solution (Right click) > Insert > Stress > Normal
Solution (Right click) > Insert > Stress > Normal

Rename “Directional Deformation” as “X Axis - Directional Deformation”

Rename “Normal Stress” as “X Axis - Normal Stress”

Rename “Normal Stress 2” as “X Axis - Normal Stress (Unaveraged)”

Details of “X Axis - Normal Stress (Unaveraged)”
Integration Point Results > Display Option = Unaveraged

Mesh*
Details of “Mesh” > Sizing > Use Advanced Size Function = Off
> Element Size = 10 mm
> Advanced > Element Midside Nodes = Dropped

Mesh (Right click) > Insert > Method > Select Object > Apply
Details of “Automatic Method” > Method = Triangles

Mesh > Generate Mesh

Note: This is a coarse mesh with linear (midside nodes dropped) triangular elements.

Solution (Right click) > Solve

View >  Wireframe (Toggle Wireframe Mode On or Off)

Total Deformation* Max=0,078169 mm Min=8,7777e-5 mm

X Axis Dir Deformation* Max=0,078075 mm Min=0 mm
X Axis Normal Stress* Max=141,35 MPa Min=2,6755 MPa
X Axis Normal Stress (Una)* Max=145,58 MPa Min=2,6755 MPa

Solution*
Pull-Down Menu > Stress  > Error (Structural Error object is inserted.)

Solution (Right click) > Evaluate All Results

Structural Error* Max=0,67442 mJ Min=7,4512e-7 mJ

File > Close Mechanical

File > Save As… > 6_FILBAR_final

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A4: Model**

Mesh > All Triangles Method*

Details of “All Triangles Method” > Method = Quadrilateral Dominant (instead of Triangles)
Free Face Mesh Type = All Quad
Mesh > Generate Mesh
Solution (Right click) > Solve

Total Deformation* Max=0,078517 mm Min=1,8701e-5 mm

X Axis Dir Deformation* Max=0,078427 mm Min=0 mm
X Axis Normal Stress* Max=144,25 MPa Min=-2,074 MPa
X Axis Normal Stress (Una)* Max=148,05 MPa Min=-3,3583 MPa
Structural Error* Max=0,3428 mJ Min=7,1763e-8 mJ

(Note that Structural Error has significantly decreased.)

Outline Tree > Model *

Top menu > “Construction Geometry” > Path
(“Construction Geometry” and “Path” are inserted in the Outline Tree

Select the first vertex (V1)

Details of “Path”> Start > Location > Apply

Select the second vertex (V1) > Apply

Details of “Path”> End > Location > Apply

Solution (Right click) > Insert > Stress > Normal

Details of Normal Stress > Scoping Method = Path
Path = Path

Solution (Right click) > Evaluate All Results

View > Windows > Reset Layout (Path must be seen)

“Graphics” window*

Normal Stress*

Stress values are listed as a function of path length. A curve is also drawn.

Close Mechanical
Exit WB > Save > No

Reference:
Huei-Huang Lee; Finite Element Simulations with ANSYS Workbench 14, SDC Publications,
2012. (p.148)

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 TECHNICAL INFORMATION
Structural Error
For an element, strain energies calculated using averaged stresses and unaveraged stresses
respectively are different. The difference between these two energy values is called “Structural Error”
of the element. The finer the mesh, the smaller the structural error.
The structural error can be used for two purposes: (a) As an indicator of global mesh adequacy. In
general, we want the values as small as possible. Refining the mesh globally is a way of reducing
structural error. (b) As an indicator of local mesh adequacy. In general, we want the structural error
distribution as uniform as possible to maximize the efficiency of computing resource usage. This
implies that in the region of large values of structural error we need to reduce the element size while
in the region of small values we may enlarge the element size.

Rule-of-thumb principle:
1. Never bet the farm on the third significant figure.
2. Never expect to match results from a test you haven't witnessed or a calculation you haven't
reviewed.

Finite Element Convergence

• Note that the two curves share the same asymptote, which is the analytical solution.
• In general, we know that quadrilateral element converges faster than the triangular element.
In some cases, the difference can be significant.
• Another important point is that, all the convergence curves approach the same asymptote
from below; the finite element solutions never exceed the analytical solution. That means
the finite element solutions always underestimate the deformation; i.e., the stiffness matrix
is always overestimated.

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