SRM INSTITUTE OF SCIENCE & TECHNOLOGY

DEPARTMENT OF AUTOMOBILE ENGINEERING

LAB MANUAL

CAD ANALYSIS FOR AUTOMOTIVE ENGINEERS

15AE308J
REGULATION 2015

Faculty of Engineering and Technology

SRM Nagar, Kattankulathur
Kancheepuram, Tamil Nadu-603203

FOR PRIVATE CIRCULATION ONLY

ALL RIGHTS RESERVED
 SYLLABUS

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 INSTRUCTIONS
General:

1. Students must follow proper dress code (uniform) inside the laboratory with shoes
covering the whole foot as a measure of safety. Long hair should be tied back.
2. Mai nt ai n si l en c e, o rd e r and di s ci pl i ne i nsi de t h e l ab a n d a voi d usi n g
c el l p hon es i n s i d e t h e laboratory.
3. Make sure you possess the lab manual prior to entering the lab.
4. Read carefull y and understand the description of the experiment as provided in the l
ab manual .
5. Refer the manual provided and other appropriate books, to be completely familiar
with the concepts and hardware and be prepared to answer the pre-lab questions.
6. Do not hesitate to report to the faculty or the lab instructor in case of any
doubts/grievances.
7. Bring necessary material s needed (writing materials, graphs, calculators, etc. ) to
perform the required preliminary analysis.
8. Ensure that you get your experiments evaluated by the facult y in - charge prior to
coming for the next lab session.

Specific:

1. Do not browse unnecessary website.

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 15AE308J – CAD ANALYSIS FOR AUTOMOTIVE ENGINEERS

CONTENTS

S.NO Name of the Experiment Page No

1. INTRODUCTION ABOUT CAD 5

2. EXERCISES ON 2D SKETCH 8

3. EXERCISES ON 3D MODELLING 11

4. EXERCISES ON CONNECTING ROD 13

5. EXERCISES ON ASSEMBLY OF SCREWJACK 15

6. EXERCISES ON ASSEMBLY OF UNIVERSAL JOINT 17

7. SURFACE MODELLING OF CAR DOOR PANEL 19

8. FINITE ELEMENT ANALYSIS TRUSS AND BEAM 27

9. HEAT CONDUCTION PROBLEM 38

FEA ANALYSIS OF CONNECTING ROD USING

10. ANSYS-WORKBENCH 41

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 DATE:

1. INTRODUCTION ABOUT CAD

CAD/CAE (computer-aided design and computer-aided engineering) refers to computer

software that is used to both design and analysis the mechanical components. CAD is the use of
computer technology for design and design documentation.

Why CAD/CAE?
Computer Aided Design and Computer Aided Manufacture is the way things are made these
days. Without this technology we wouldn’t have the range and quality of products available or, at
least, they wouldn’t be available at a price most of us can afford. Hand-building and manual
techniques still very much have their place and Design Education needs to treasure and foster these
skills so that future generations will have the hands-on skills to understand the man-made world
and provide the next generation of engineers, designers and technicians. All of these professionals
will be using CAD/CAE techniques or CAD/CAE products in their work, alongside practical
hands-on skill. Design and Technology education has to reflect modern practice so it is crucial that
students have the opportunity to use real CAD/CAE tools in their designing and making.

Design Process and Role of CAD:

1. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation

Solid Modelling:
A solid modelling system is usually an interactive computer graphics system that is
intended to create true three-dimensional components and assemblies. Recent advances in CAD
software, computers, and graphical displays have made it possible to use solid representations of

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components being considered in the design process. These solid models can be employed in
numerous ways.

Advantages of Solid Modelling:

A realistic visual display: By producing a shaded visible surface image of the solid, solid
modelling allows a designer to see exactly what has been created. Easy to deal with different views:
Once a part has been created, we have the ability to rotate, shade, section, or produce almost any
view required by a designer. Single associated model database: The solid modeler provides the
only database suitable for all CAD operations. Almost all information needed for part generation
is contained in the solid model. The algorithm should be able to ensure that it represents physically
possible shape that is complete and unambiguous applications. E.g. automatic generation of a mesh
for a finite element analysis.

Requirements for Modelling Assembling:

1. Part modelling and analysis
The part analysis includes the material type, mass and inertial properties, functional properties
of the faces, etc.

2. Hierarchical relationships
An assemble tree and assemble sequence must be given.

3. Mating conditions.
There are two methods for specifying mating conditions: Specify the location and orientation
of each part in the assembly, together with the representation of the part itself, by providing a 4 x
4 homogeneous transformation matrix. (i.e., transformation from MCS to WCS).Specify the
spatial relationships between its individual parts as mating conditions.

CAD/CAE/CAM Data Exchange:

Computer databases are now replacing paper blueprints in defining product geometry and
non-geometry for all phases of product design, analysis, and manufacturing. It becomes
increasingly important to find effective procedures for transferring data among CAD/CAE/CAM

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systems. The need to exchange modelling data is directly motivated by the need to integrate and
automate the design and manufacturing process to obtain the maximum benefits from
CAD/CAE/CAM systems.

Four Types of Modelling Data to be transferred:

(1)Shape
(2)Non-shape
(3)Design
(4)Manufacturing
(1) Shape data consists of both geometrical and topological information as well as part
features. Entity attributes such as font, color, and layer as well as annotation is considered
part of the entity geometrical information. Topological information applies only to
products described via solid modelling. Features allow high-level concept communication
about parts.Examples is hole, flange, web, pocket, chamfer, etc.
(2) Non-shape data includes graphics data such as shaded images, and model global data as
measuring units of the database and the resolution of storing the database numerical values.
(3) Design data has to do with the information that designers generate from geometric
models for analysis purposes. e.g., mass property and finite element mesh data.
(4) Manufacturing data consists of information such as tooling, NC tool paths, tolerance,
process planning, tool design, and bill of materials.
Commonly Used CAD Data Exchange Format:
IGES (Initial Graphics Exchange Specification)
PDES (Product Data Exchange Using STEP)
IGES is focused on CAD-to-CAD exchange where primarily shape and non shape data were to be
transferred from one system to another.
PDES is previous called Product Data Exchange Standard. It is for the exchange of complete
product descriptions which covers the four types of modelling data (i.e., shape, non-shape, design
and manufacturing).
Other data exchange interfaces include: STL, Neutral, SET, ECAD, VDA, STEP, PDGS,
CATIA, Render, CGM, VRML, PATRAN, TIFF,etc.

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 DATE:
2. EXERCISES ON 2D SKETCH

Aim: To create a 2D view of the given diagram using SOLIDWORKS 2016.

Hardware Used:
Monitor
CPU
Keyboard
Mouse

Software Used:
SOLIDWORKS 2016

2D sketch:

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Procedure:
1. Type limits in command menu & set value to 297, 290.

2. Change the units to millimeters from inches and also precision to 0 by clicking format
→units →ok.

3. To set the paper size type zoom → enter and type a → enter in Command bar.

4. Draw the 3 concentric circles with diameters 94, 74 & 54.

5. Draw the two axis lines from centre of circles.

6. Draw the vertical line from the centre of circle.

7. From the modify tool bar, use the array command to draw the 6holes with 12dia from
Centre of circles.

8. Now draw the 300 line by use the vertical line.

9. Then mirror the 300 line, with vertical line.

10. Again draw the concentric of radius 100 from centre of circle.

11. From the modify toolbar, use the offset command to draw the 12 & 23 distance circle.

12. Draw 2 circles. With radius 23 & 12 on the 100R circle where the 300 line co-inside.

13. From modify toolbar, mirror these circle to represent another side.

14. And offset vertical line from centre of circle with a distance both side of vertical line.

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 15. From modify toolbar, use the fillet command to represent fillet of radius 10 & 9 to the
offset line.
16. Trim the unwanted lines to get required 2D drawing.

Result:
Thus the required 2D diagram was created using Auto CAD 2014.

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 DATE:
3. EXERCISES ON 3D MODELLING

Aim: To create a 3D view of the given diagram using SOLIDWORKS.

Hardware Used:
Monitor
CPU
Keyboard
Mouse
Software Used:
SOLIDWORKS 2016
3D Diagram:

Procedure:
1. Select a sketch plane. (Front, top or side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Extrude the sketch.
6. Select the face in which you are going to draw the cut profile.

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 7. Make the plane to normal to you.
8. Sketch the cut profile & Dimension it.
9. Using Extrude cut and Rib feature complete the model.

Result:
Thus the required 3D diagram was created using SOLIDWORKS 2016.

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 DATE:
4. EXERCISES ON CONNECTING ROD

Aim: To create a connecting rod 3D model of the given diagram using SOLIDWORKS.

Hardware Used:
Monitor
CPU
Keyboard
Mouse

Software Used:
SOLIDWORKS 2016
Dimensions of Connecting rod:

Procedure:
1. Select a sketch plane. (Front, top or side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Extrude the sketch.

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 6. Select the face in which you are going to draw the cut profile.
7. Make the plane to normal to you.
8. Sketch the cut profile & Dimension it.
9. Using Extrude cut and loft feature complete the model.

Result:
Thus the required Connecting rod diagram was modelled using SOLIDWORKS 2016.

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 DATE:

5. EXERCISES ON ASSEMBLY OF SCREWJACK

Aim:

To create a model and assemble the screw jack as per the dimensions given and also
convert the 3D model with Bill of Materials.

Hardware Used:
Monitor
CPU
Keyboard
Mouse
Software Used:
SOLIDWORKS 2016

Detail drawing of screw jack:

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Procedure:
1. Model different parts of a screw jack using Extrude, Revolve etc., features.
2. Select the assembly in solid works main menu.
3. Using insert component icon of property manager, insert base component & next
components to be assemble.
4. Assemble using Mate feature. Continue the inserting the component & mating until
the entire component are assembled.
5. Save the assembly.
6. From the main menu of solid works select the drawing option.
7. Select the drawing sheet format size as-A4 Landscape.
8. Using the model view manager browse the document to be open.
9. Using the placed view as parent view project the other or needed views.
10. Move cursor to any one view and right click the mouse button.
11. Select the table-BOM. Place the BOM in the proper place in the drawing sheet.
12. Save the drawing sheet.

Result:
Thus the given screw jack was modelled and assembled using SOLIDWORKS 2016.

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 DATE:

6. EXERCISES ON ASSEMBLY OF UNIVERSAL JOINT

Aim:
To create a model and assemble the universal joint as per the dimensions given and also
convert the 3D model with Bill of Materials.

Hardware Used:
Monitor
CPU
Keyboard
Mouse

Software Used:
SOLIDWORKS 2016

Detail Drawing of Universal Joint:

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Procedure:
1. Model different parts of a universal joint using Extrude, Revolve etc., features.
2. Select the assembly in solid works main menu.
3. Using insert component icon of property manager, insert base component & next
components to be assemble.
4. Assemble using Mate feature. Continue the inserting the component & mating until
the entire component are assembled.
5. Save the assembly.
6. From the main menu of solid works select the drawing option.
7. Select the drawing sheet format size as-A4 Landscape.
8. Using the model view manager browse the document to be open.
9. Using the placed view as parent view project the other or needed views.
10. Move cursor to any one view and right click the mouse button.
11. Select the table-BOM. Place the BOM in the proper place in the drawing sheet.
12. Save the drawing sheet.

Result:
Thus the given universal joint was modelled and assembled using SOLIDWORKS 2016.

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 7. SURFACE MODELLING OF A CAR DOOR PANEL

Aim:
To create a surface model of the car door panel as per the dimensions given and perform
rendering.

Hardware used:
Monitor
CPU
Keyboard
Mouse

Software used:
SOLIDWORKS 2017

Procedure:
1. Sketch the 2-D profile of the Car door panel in FRONT PLANE.

2. Using Extrude surface option under surfaces. Extrude the surfaces to 600mm.
3. Sketch the 2D-profile as shown below for trimming.

4. For the above 2D-model fillet the corners as shown in below.

5. Using TRIM SURFACE option, trim the extruded figure from the filleted 2D model.

6. For windows in door panel, draw the 2D sketch drawn below and use TRIM SURFACE option to
view the space for window in door panel.
7. Render the obtained surface model using EDIT APPEARANCE tool to improve its appearance.

CONCLUSION:
The CAR door panel was modelled and rendered using SOLIDWORKS 2017.
 INTRODUCTION TO ANSYS

ANSYS is a general purpose finite element modelling package for numerically solving a wide
variety of mechanical problems. These problems include: static/dynamic structural analysis (both
linear and non-linear), heat transfer and fluid problems, as well as acoustic and electro-magnetic
problems.
In general, a finite element solution may be broken into the following three stages. This is a
general guideline that can be used for setting up any finite element analysis.

1. Pre-processing: defining the problem: The major steps in pre-processing are given
below:
Define key points/lines/areas/volumes
Define element type and material/geometric
properties Mesh lines/areas/volumes as required

2. Solution: assigning loads, constraints and solving;

Here we specify the loads (point or pressure), constraints (translational and rotational) and
finally solve the resulting set of equations.

3. Post-processing: Further processing and viewing of the results;

In this stage one may wish to see:
Lists of nodal displacements
Element forces and moments
Deflection plots
Stress contour diagrams

The ANSYS Environment contains 2 windows: the Main Window and an Output Window.
Within the Main Window are 5 divisions:

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I. Main Window

1. Utility Menu
The Utility Menu contains functions that are available throughout the ANSYS session, such as
file controls, selections, graphic controls and parameters.
2. Input Window
The Input Line shows program prompt messages and allows you to type in commands directly.
3. Toolbar
The Toolbar contains push buttons that execute commonly used ANSYS commands. More
push buttons can be added if desired.
4. Main Menu
The Main Menu contains the primary ANSYS functions, organized by pre-processor, solution,
general post-processor, design optimizer. It is from this menu that the vast majority of modelling
commands are issued.
5. Graphics Window
The Graphic Window is where graphics are shown and graphical picking can be made. It is
here where you will graphically view the model in its various stages of construction and the
ensuring results from the analysis.

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II. Output Window

The Output Window shows text output from the program, such as listing of data etc. It is
usually positioned behind the main window and can put to the front if necessary. FEM
Convergence Testing:
A fundamental premise of using the finite element procedure is that the body is sub-divided
up into small discrete regions known as finite elements. These elements defined by nodes and
interpolation functions. Governing equations are written for each element and these elements are
assembled into a global matrix. Loads and constraints are applied and the solution is then
determined.
The Problem
The question that always arises is: How small do I need to make the elements before I can
trust the solution?
What to do about it...
In general there are no real firm answers on this. It will be necessary to conduct convergence
tests! By this we mean that you begin with a mesh discretization and then observe and record the
solution. Now repeat the problem with a finer mesh (i.e. more elements) and then compare the
results with the previous test. If the results are nearly similar, then the first mesh is probably good
enough for that particular geometry, loading and constraints. If the results differ by a large amount
however, it will be necessary to try a finer mesh yet.

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The Consequences
Finer meshes come with a cost however: more calculation time and large memory requirements
(both disk and RAM)! It is desired to find the minimum number of elements that give you a
converged solution.
Beam Models
For beam models, we actually only need to define a single element per line unless we are
applying a distributed load on a given frame member. When point loads are used, specifying
more than one element per line will not change the solution, it will only slow the calculations
down. For simple models it is of no concern, but for a larger model, it is desired to minimize the
number of elements, and thus calculation time and still obtain the desired accuracy. General
Models
In general however, it is necessary to conduct convergence tests on your finite element model
to confirm that a fine enough element discretization has been used. In a solid mechanics
problem, this would be done by creating several models with different mesh sizes and comparing
the resulting deflections and stresses, for example. In general, the stresses will converge more
slowly than the displacement, so it is not sufficient to examine the displacement convergence.
Saving Your Job
It is good practice to save your model at various points during its creation. Very often you will
get to a point in the modelling where things have gone well and you like to save it at the point. In
that way, if you make some mistakes later on, you will at least be able to come back to this point.
To save your model, select Utility Menu Bar → File → Save as Job name.db. Your model will
be saved in a file called job name.db, where job name is the name that you specified in the Launcher
when you first started ANSYS. It is a good idea to save your job at different times throughout the
building and analysis of the model to back up your work in case of a system crash or other
unforeseen problems.
Recalling or Resuming a Previously Saved Job
Frequently you want to start up ANSYS and recall and continue a previous job.

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There are two methods to do this:
1. Using the Launcher...
In the ANSYS Launcher, select Interactive... and specify the previously defined jobname. Then
when you get ANSYS started, select Utility Menu → File → Resume Jobname.db.
This will restore as much of your database (geometry, loads, solution, etc) that you previously
saved.
2. Start ANSYS and select Utility Menu → File → Resume from... and select your job from the
list that appears.

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 DATE:
8. a. SIMPLE 2D TRUSS PROBLEM

Aim:
To determine the maximum deflections and reaction forces for the given truss system.

Hardware Used:
Monitor
CPU
Keyboard
Mouse

Software Used:
ANSYS 19
Procedure:
Modelling Phase
1. Give the Simplified Version a Title.

1. In the Utility menu bar select File → Change Title:

2. Enter the title (Bridge Truss) and click 'OK'.

3. Select Utility Menu, Plot →Re-plot

2. Enter Key Points

1. Select Pre-processor → Modelling → Create → Key points→ In Active CS

Key point x y
1 0 0
2 1800 3118
3 3600 0
4 5400 3118
5 7200 0
6 9000 3118
7 10800 0

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 2. To define the first key point which has the coordinates x = 0 and y = 0:
3. Click Apply
4. Enter the remaining key points using the same method
5. Click on OK

3. Form Lines

1. Select Pre-processor → Modelling → Create → Lines → Lines → In Active Co-ord.

2. Pick Point 1 and Point 2
3. Connect the remaining key points using the same method.
4. Finally, click on OK.

2D TRUSS PROBLEM:

Take E = 200GPa, A = 3250mm2

Manual Calculations
Find Rx1 and Ry1 at Point &Find Ry7 at Point 7
4. Define the Type of Element

1. Select Element Type → Add/Edit/Delete.

2. Click on the 'Add...' button.
3. Select Link – 2D spar 1 element from the dialog box.
4. Click on 'Close' in the 'Element Types' dialog box.

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5. Define Geometric Properties

1. Select Real Constants → Add/Edit/Delete.

2. Click Add... and select 'Type 1 LINK1.
3. Click on 'OK'.
4. Enter the cross-sectional area -3250mm2.
5. Click on OK. Set 1 now appears in the dialog box.
6. Click on Close in the 'Real Constants' window.

6. Element Material Properties

1. Select Material Props → Material Models.

2. Double click on Structural → linear → Elastic → Isotropic.
3. Enter the following field: EX 200000
4. Click on 'OK'.

7. Mesh Size

1. Select Meshing → Size Cntrls → Manual Size → Lines → All Lines

2. In the size 'NDIV' field, enter the desired number of divisions per line.
3. Enter '1'
4. Click OK.

8. Mesh

1. Select Meshing → Mesh → Lines

2. Click Pick All
3. Utility Menu (top of screen) select Plot Ctrls → Numbering.

Solution Phase: Assigning Loads and Solving

9. Define Analysis Type

1. Solution → Analysis Type → New Analysis.

2. Select Static
3. Click OK.

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10. Apply Constraints
In mechanical structures, the constraints will typically be fixed, pinned and roller-type
connections. In this problem, the left end of the truss bridge is pinned while the right end has a
roller connection.
1. Solution→ Define Loads → Apply → Structural → Displacement → On Key points
2. Select →Key point 1
3. Click on OK
4. select 'All DOF'
5. Enter '0' in the Value field
6. Click OK.
7. Select → Key point 7
8. Click on OK
9. select UY
10. Click OK.

11. Apply Loads

As shown in the diagram, there are four downward loads of 280kN, 210kN, 280kN and
360kN at key points 1, 3, 5, and 7 respectively.

1. Select Define Loads → Apply → Structural → Force/Moment → on Key points.

2. Select Key point 1 and click OK.
3. Select FY in the 'Direction of force/mom.
4. Enter a value of -280000 in the 'Force/moment value' box
5. Click OK.
6. Apply the remaining loads in the same manner.

12. Solving the System

Solution' menu → Solve → Current LS.

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Post-processing: Viewing the Results
13. Reaction Forces

1. Select General Post proc → List Results → Reaction Soln.

2. Note the reaction value Rx1, Ry1 at point 1 and Ry7 at point 7.
3. Compare the results with your Hand calculations.

14. Deformation

1. Select Plot Results → Deformed Shape.

2. Select 'Def + undef. edge' and click OK

Observe the value of the maximum deflection in the upper left hand corner (DMX)

1. Plot results → Contour Plot → Nodal Solution

2. Select 'DOF solution' and displacement vector sum → OK

Results:

1. Horizontal Reaction Force at left support =

2. Vertical Reaction Force at left support =
3. Vertical Reaction Force at right support =
4. Maximum deflection =

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 DATE:

8. b. STRESS ANALYSIS ON CANTILEVER BEAM

Aim:
To determine the maximum deflection and bending stress of the cantilever beam
subjected by a point load.
Hardware Used:
Monitor
CPU
Keyboard
Mouse
Software Used:
ANSYS 19
Procedure:
Modelling Phase
1. Give the Simplified Version a Title.

In the Utility menu bar select File → Change Title

Enter the title (Cantilever beam) and click 'OK'.

Select Utility Menu → Plot →Re-plot

2. Enter Key points


Select Pre-processor → Modelling → Create → Key points → In Active CS

Key point x y

1 0 0

2 500 0


To define the first key point which has the coordinates x = 0 and y = 0:

Click Apply

Enter the remaining key points using the same method

Click on OK

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3. Form Lines

Select Pre-processor → Modelling → Create → Lines → Lines →STRAIGHT LINE

Pick Point 1 and Point 2

Finally, click on OK.

Cantilever Beam Subjected to Load at free end:

Take E = 70GPa, μ = 0.33, Load = 100 N, Outside diameter =25mm and Wall thickness = 2 mm.

Model Calculations:
4. Define the Type of Element
➢
Select Element Type → Add/Edit/Delete.
➢
Click on the 'Add...' button.
➢
Select Elast straight 16 element from the dialog box.
➢
Click on 'OK' in the 'Element Types' dialog box.
➢
Click on the 'Options...' button
➢
Select Member force + Member output K6
➢
Select Include output

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5. Define Geometric Properties
➢
Select Real Constants → Add/Edit/Delete.
➢
Click Add... and select 'Type 1 PIPE16.
➢
Click on 'OK'.
➢
Enter the OD =25 and TKWALL=2
➢
Click on OK. Set 1 now appears in the dialog box.
➢
Click on Close in the 'Real Constants' window.
6. Element Material Properties
➢
Select Material Props → Material Models.
➢
Double click on Structural → linear → Elastic → Isotropic.
➢
Enter the following field: EX 70000 and PRXY 0.33
➢
Click on 'OK'.
7. Mesh Size
➢
Select Meshing → Size Cntrls →Manual Size → Lines→ All Lines
➢
In the size 'NDIV' field, enter the desired number of divisions per line.
➢
Enter '25'
➢
Click OK.
8. Mesh
➢
Select Meshing → Mesh → Lines
➢
Click Pick All

Utility Menu (top of screen) select Plot Ctrls → Numbering.

Solution Phase: Assigning Loads and Solving

9. Define Analysis Type
➢
Solution → Analysis Type → New Analysis.
➢
Select Static
➢
Click OK.

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10. Apply Constraints
➢
Solution → Define Loads → Apply → Structural → Displacement → On Key points
➢
Select → Key point 1
➢
Click on OK
➢
select 'All DOF'
➢
Enter '0' in the Value field
➢
Click OK.

11. Apply Loads

➢
Select Define Loads → Apply → Structural → Force/Moment → on Key points.
➢
Select Key point 2 and click OK.
➢
Select FY in the 'Direction of force/mom.
➢
Enter a value of -100 in the 'Force/moment value' box
➢
Click OK.
12. Solving the System
➢
Solution menu → Solve → Current LS.

13. Reaction Forces

➢
Select General Post-proc → List Results > Reaction Soln.
➢
Note the reaction value Rx1, Ry1 at point 1
➢
Compare the results with your Hand calculations.
14. Deformation
➢
Select Plot Results → Deformed Shape.
➢
Select 'Def + undef edge' and click OK
Observe the value of the maximum deflection in the upper left hand corner (DMX)
➢
Plot results → Contour Plot → Nodal Solution
➢
Select 'DOF solution' and displacement vector sum → OK
➢
Note the Maximum deflection value
➢
Compare the results with your Hand calculations.
➢
Utility Menu →Plot Ctrls → Style → Contours → Uniform Contours ...
➢
Enter NCONT Number of contours ‘0’
➢
VMIN Minimum contour value ‘0’

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 ➢
VMAX Maximum contour value ‘26’
➢
Click OK
➢
General Postprocessor →Plot results → Contour Plot → Nodal Solution.
➢
Select DOF solution → Displacement vector sum.
➢
Click OK.
15. Stresses
➢
General Postprocessor menu select Element Table → Define Table...
➢
Click on 'Add...'
➢
Select Stress → Von Misses SEQV
➢
Click OK and Click Close
➢
Element Table → Plot element Table...
➢
Ensure that 'SEQV' is selected and click 'OK
➢
Note the Maximum bending stress value
➢
Compare the results with your Hand calculation.
➢
Utility Menu →PlotCtrls → Style → Contours → Uniform Contours
➢
Element Table → List Elem Table
➢
Select SEQV

16. Bending Moment Diagrams

➢
General Post-proc → Element Table → Define Table→ Click 'Add'

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In the window,
A. Enter I Moment as the 'User label for item' - this will give a name to the data
B. Select 'By sequence num' in the Item box
C. Select 'SMISC' in the first Comp box
D. Enter SMISC, 6 in the second Comp box
E. Click 'OK'
➢
Again, click 'Add...' in the 'Element Table Data' window.
A. Enter J Moment as the 'User label for item' - again, this will give a name to the data
B. Same as above
C. Same as above
D. For step D, enter SMISC, 12 in the second Comp box
E. Click 'OK'
➢
Close the Element table
➢
Plot Results → Contour Plot →Line Elem Res...
➢
Select Lab1→I Moment
➢
Select Lab2→J Moment
➢
Scale factor → 1
➢
Item to plotted →Def shape only
➢
Check the bending moment diagram with your calculated value.

Results:
1. Reaction Force at left support =
2. Maximum deflection at free end =
3. Maximum bending stress =
4. Maximum bending moment =

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 DATE:

9. HEAT CONDUCTION PROBLEM

Aim:
To determine the temperature distribution on the solid block.
Hardware Used:
Monitor
CPU
Keyboard
Mouse
Software Used:
ANSYS 19
Procedure:
Modelling Phase
1. Give the Simplified Version a Title.
➢
In the Utility menu bar select File Change Title:
➢
Enter the title (Heat transfer) and click 'OK'.
➢
select Utility Menu → Plot →Re-plot
2. Create Geometry
➢
Pre-processor → Modelling → Create → Areas → Rectangle → By 2 Corners → X=0,
Y=0, Width=1, Height=1

3. Define the Type of Element

➢
Select Element Type → Add/Edit/Delete.
➢
Click on the 'Add...' button.
➢
Select Thermal Mass Solid, Quad 4Node 55- element from the dialog box.
➢
Click on 'OK' in the 'Element Types' dialog box.
4. Element Material Properties
➢
Select Material Props → Material Models.
➢
Double click on Thermal → conductivity → Isotropic.
➢
Enter the following field: KXX =10 (Thermal conductivity)
➢
Click on 'OK'.

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5. Mesh Size
➢
Select Meshing → Size Cntrls →Manual Size →Areas → All Areas
➢
Element Edge length = 0.05
➢
Click OK.

Thermal Problem:

Thermal conductivity (k) of the material is 10 W/m*C with infinite length

6. Mesh
➢
Select Meshing → Mesh → Areas → Free→ Pick all
➢ Click Pick All

7. Define Analysis Type

➢
Solution → Analysis Type → New Analysis.
➢
Select Steady state
➢
Click OK.
8. Apply Constraints
➢
Solution → Define Loads→ Apply → Thermal →Temperature → On Nodes
➢
Click Box option
➢
Select the all nodes on the top line
➢
Select Temperature
➢
Enter 500 in Temperature value
➢
Click OK.
➢
Using the same method, constrain the remaining 3 sides to a constant value of 100

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9. Solve the System
➢
Solution → Solve → Current LS
Post-processing: Viewing the Results

10. Plot Temperature

➢
General Post-proc → Plot Results
➢
Contour Plot → Nodal Soln ... → DOF solution,
➢
Temperature TEMP
11. Temperature in between the Walls
➢
General Post-proc → Plot Results
➢
Query Results →Sub-grid soln.
➢
DOF solution →Temperature TEMP
➢
Click anywhere in the figure.

Results:

Temperature at mid-section of the block =

40 | P a g e AUTOMOBILE ENGINEERING
 10. Finite element Analysis of Connecting rod using ANSYS workbench

Aim:
To conduct stress and deformation analysis of the connecting rod using ANSYS Workbench

Procedure:

1. Double click on the icon , to start ANSYS workbench

2. On the Toolbox, drag and drop the static structural on the project schematic area as shown below

3. Preprocessing – Double click on the engineering data to select the material, Select structural
steel for moving to engineering data and
4. Click on project on the top left corner to return to the project schematic window.
5. Then, Right click Geometry -> select import geometry -> Browse and point to the location of the
Connecting rod model.
6. Then, Right click Geometry -> select Design modeler, it will open the Design modeler window ->
select Generate, to view your model. Then close the Design modeler window.
7. Then, Right click Model -> Edit - > it will open the static structural – mechanical window.

8. In bottom left corner, under scope -> click body -> select the geometry - > select apply.
9. Then, Right click, Mesh - > select, Insert - > Sizing - > Replace element size as 0.002 -> click
update
10. Select static structural -> select the inner surface of the small end -> right click -> create Named
section as bearing load.
11. Same way, select the inner surface of the big end -> right click -> create Named section as fixed
load.
12. Applying Boundary Condition – Right click, static structural - > insert -> Fixed support -> select
the named section fixed load and give OK
13. Again, Right click, static structural - > insert -> Bearing load -> select the named section bearing
load and give the magnitude as 4319N and select the direction along Y axis and give ok.
14. Solution: Then right click, Solution -> Insert -> Deformation -> Total
15. Same way, right click, Solution -> Insert -> stress -> Equivalent (Von - Mises)
16. Then, right click, Solution -> Solve
17. Post Processing: View the results by selecting Equivalent stress and Total deformation under
Solution.
Von – Mises stress
 Total deformation

Result:

From the above analysis of connecting rod, it was found that

Max Von Mises stress = 7.135 * 107 N/m2

Total deformation = 6.53 * 10-5 m