JANUARY 30, 2020 CASE STUDY FINITE ELEMENT ANALYSIS ON STEEL PEDAL mmm‘CASE STUDY teens seas ABSTRACT This paper shows the geometrical shapes of some complex elements established by shape functions. Obviously, the variation rule of strain within the element depends on the order of shape function. Therefore, shape functions are very important in the finite element method. ‘The chapter then demonstrates how to use coordinate transformation to establish elements with complex shapes and the corresponding calculation methods. It explains how to degrade an isoparametric element into a triangular or sphenoid element. In the isoparametric element, coordinate transformation and displacement function always adopt the same nodes, Finite element analysis program for isotropic and orthotropic axisymmetric micropolar elastic solids are developed in this thesis. Isoparametric elements of 8- and 20- node are used to solve general three-dimensional problems, and both 4- and 8-node elements are used for two- dimensional cases, Three-dimensional finite element formulation for eylindrical coordinate system is derived. Corresponding Fortran programs are then developed. Patch tests are performed for two-dimensional cases to verify the applicability of the finite element method to non-rectangular geometries, Several two-dimensional and three-dimensional problems for micropolar elastic solids are solved to verify the formulations and computer program. Good agreements were oblained in all cases, confirming the validity of the finite element method, In an isoparametric element, the stiffness matrix is obtained by numerical integration with large calculation amount and much computer work time. Elements can be sparse in the area with a small stress gradient and should be dense in the area with a large stress gradient. 1CASE STUDY Finite Element Analysis on Stel Peal 1 INTRODUCTION The isoparametric method may appear somewhat tedious (and confusing initially), butit will lead to a simple computer program formulation, and it is generally applicable for two and three-dimensional stress analysis and for nonstructural problems. Micropolar elastic solid is an elastic solid whose deformation can be described by a “macro” displacement, together with a "micro" rotation. Micropolar elastic materials are the elastic materials with extra independent degree of freedom for the local rotations, Micropolar elasticity materials include certain classes of materials with fibrous and elongated grains. The isoparametric formulation allows elements to he created that are nonrectangular and have curved sides. Numerous commercial computer programs have adapted this formulation for their various libraries of elements, Limitations to the finite element method occur when ‘numerous elements are required to achieve a desired degree of accuracy thus resulting cost. inlarge the isoparametric method may appear somewhat tedious (and confusing initially), but it will lead toa simple computer program formulation, and itis generally applicable for two- and three-dimensional stress analysis and for nonstructural problems. The isoparametric formulation allows elements to he created that are nonrectangular and have curved sides. Numerous | computer programs have adapted this formulation for their various roles in engineering. 2 METHODOLOGY 2.1 GEOMETRY OF THE STEEL PEDAL, Geometry of the steel pedal is shown below. 22‘CASE STUDY Finite Bement Analysis on Steel Pedal 2.2 SOLID MODELING OF THE STEEL PEDAL Solid model of the pedal was prepared in ANSYS R192 ee The model was composed or built using simple shapes such as rectangles and then extruded to the specified thickness. 2.21 Meshing: Meshing is a method used to subdivide the model into a several smaller elements, it affects the accuracy, speed and convergence of the solution. In this ease, the methad used in meshing is Hex Dominant (Meshing method for 3D bodies) Quadratic Element shown below. 2-3CASE STUDY Finite Eleenent Analysis on 5 This quadratic element is composed of 20 nodes with the inclusion of a total of 12 midside nodes. The free face mesh type used in the model is Quad/Tri or combination of quadratic and triangular face mesh since the geometry of the steel pedal is irregular. The mesh details and element statistics is shown below: ‘Mesh Details and Statistics Method: Hex Dominant Element Order Quadratic Free Face Mesh Type. Quad Nodes: 6128 Elements 102 Element Size: 4.¢mm 222 Loading ‘The the total superimposed load applied in the steel pedal is 0.1OOKN. Since the load was applied as pressure load, the total concenetrated load was converted into pressure load by 2CASE STUDY Finite Element Analysis on Steel Pedal dividing it to the area of application, in this case, 0.02mX0.10m. Thus the pressure load isequal to 50kpa or 0.05Mpa. 2.23 Restrain It was assumed that the steel pedal is fully restrained at the one end, thus it acts as cantilever beam.CASE STUDY Finite Element Analysison Stee! Pedal 3 RESULTS AND SUMMARY OF FEM IMPLEMENTATIONS 3.1 STRESS DISTRIBUTION IN THE PEDAL: The stress distributions obtained using ANSYS are shown in Fig 3.1-34 Fig.31 Eqivalent Von-Mses) Sess In Fig3.1 shows the Equivalent (Von-Mises) Stress of the pedal. Equivalent (Von-Mises) stress isa value used to determine if a given material will yield or fracture. As shown the stress is ‘maximum at the connection of the two bodies with a value of 18122 MPa.CASE STUDY Finite Element Analysis on Steel Pedal In Fig 3.2 shows the Maximum Principal Stress of the pedal. Maximum principal stress is the maximum tensile stress that acts on the body. As shown the tensile stress is maximum at the connection of the two bodies with a value of 146.94 MPa. Fig.32 Maximum Principal Stress In Fig 3.3 shows the Normal Stress of the pedal. A normal stress isa stress that occurs when a ‘member is loaded by an axial force. As shown the normal stress is maximum at the connection of the two bodies with a value of 61.146 MPa. = A s ae Fig 34 Maxtrum Shar Sress In Fig 34 shows the Maximum Shear Stress of the pedal. The maximum shear stress is the ‘maximum concentrated shear force in a small area. As shown the maximum shear stress is ‘maximum at the connection of the two bodies with a value of 102.92 MPa.‘CASE STUDY Finite Element Analysis on Stee! oe 0 Fig. 35 Tota Deformation In Fig 3.5 shows the Total Deformation of the pedal. The total deformation is the vector sum all directional displacements of the systems. As shown the total deformation is maximum at the edge of the pedal with a value of 0.867 mm. 32 SUMMARY OF STRESSES Maximum Stresses ‘ANGYS Resulis Equialnt (Ven Nesea) Sees Tao Maximum Principal Stess TS NPa oral Stes SLE NPa Wainum Shear Sess TO2SI Pa3.3 SUMMARY OF DEFORMATION Maximum Stresses, "ANSYS Results Tala Deformation DEBT wan 4 CONCLUSION Based on the results, conclusions were established in analyzing the stress acting on the steel pedal. The total deformation results to 0.867 mm. Checking for adequacy, the Maximum von mises stress induced in the steel pedal is 181.22 MPa which is below the tensile strength and the yield strength of the A36 steel material, which is 400 MPa and 248 MPa respectively, thus the steel pedal is adequate. ‘CASE STUDY is ii ze Finite Element Anah REFERENCES [1] Logan, D. L. (2012). Three-Dimensional Stress Analysis. In R, Adams et al. (Eds), A First Course in the Finite Element Method Fifth Edition. United States of America: Global Engineering. [2] Help and Documentation manual — ANSYS R19.2