Workshop Barra Axial

Workshop Structural Analysis
Stepped shaft in axial tension
ISABELLA BRISOT
CAE Applications Intern. Academic Area: Latin America and Spain
ibrisot@esss.co / www.esss.co
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Table of contents
Introduction Physics Setup
Problem Specification Numerical Solution
Pre-Analysis Numerical Results
Geometry Verification
Mesh Exercises
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Introduction
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1. INTRODUCTION
https://en.wikipedia.org/wiki/Rolls-Royce_RB.50_Trent
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1. INTRODUCTION
Árbol de levas VW Tiguan https://www.pumpsandsystems.com/why-are-there-holes-my-new-impeller-part-1
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1. INTRODUCTION
https://blog.maxprocorp.com/the-difference-between-tension-shear-and-bending-joints
https://hayn.com/cables/systems/architectural_adjuster_fork_system.html
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Problem Specification
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2. PROBLEM SPECIFICATION
r
Value Unit
𝐷 = 100 mm
D d
𝑑 = 75 mm
𝑟 = 10 mm
𝐿 = 400 mm
L
𝐹 = 3,0E5 N
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2. PROBLEM SPECIFICATION
AISI 4320 Normalized
Property Value Unit

Density 7,9𝑒3 kg/m3
Young’s Modulus 212 GPa
Poisson’s ratio 0,295 -
Yield Strength 515 MPa
Tensile Strength 875 MPa
Compressive Strength 515 MPa
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Pre-Analysis
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3. PRE-ANALYSIS
Stepped shaft in
axial tension
Empirical Solution Numerical solution
Compute 𝐾 for the

Approximate shaft
stress
as a collection of
concentration
small elements
geometry
Compare Compare
𝜎𝑚𝑎𝑥 = 𝐾𝜎𝑛𝑜𝑚 Approximate 2D Approximate 3D
solution solution
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3. PRE-ANALYSIS
D
𝜎𝑚𝑎𝑥 = 𝐾𝜎𝑛𝑜𝑚 ℎ ℎ
𝐶1 = 1,225 + 0,831 − 0,01
𝑟 𝑟
𝐹 4𝐹
𝜎𝑛𝑜𝑚 = =
𝐴𝑚𝑖𝑛 𝜋𝑑 2 ℎ ℎ
𝐶2 = −1,831 − 0,318 − 0,049
𝑟 𝑟
2 3
2ℎ 2ℎ 2ℎ
𝐾 = 𝐶1 + 𝐶2 + 𝐶3 + 𝐶4
𝐷 𝐷 𝐷 ℎ ℎ
𝐶3 = 2,236 − 0,522 + 0,176
𝑟 𝑟
𝐷−𝑑
ℎ=
2
ℎ ℎ
Roark’s Formulas for Stress and Strain, Warren C. Young and
𝐶4 = −0,63 + 0,009 − 0,117
𝑟 𝑟
Richard G. Budynas, 2002
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3. PRE-ANALYSIS
r (mm) K 𝝈𝒎𝒂𝒙 (MPa) Maximum axial stress vs fillet radius

1 3,276 222,446 250.000
2 2,613 177,436
200.000
3 2,310 156,887
Sigma_max (MPa)
4 2,127 144,459 150.000
5 2,001 135,902 100.000

6 1,908 129,546
50.000
7 1,835 124,582
8 1,775 120,567 0.000
0 2 4 6 8 10 12
9 1,726 117,230 Fillet radius (mm)
10 1,685 114,401
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Geometry
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4. GEOMETRY
3D - Symmetric
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4. GEOMETRY
2D - Symmetric
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Mesh
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5. MESH
3D-Mesh – nonlinear elements Body Sizing
(mm)
• Hex-20
10
• Wed-15
8
6
4
2,5
2
1,5
1
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5. MESH
2D-Mesh – nonlinear elements Face Sizing
(mm)
• Tri-6
7,5
• Quad-8
5
3,33
2,22
1,48
0,99
0,66
0,44
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Physics Setup
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6. PHYSICS SETUP
Symmetry 1 – 3D problem
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6. PHYSICS SETUP
Symmetry 2 – 3D problem
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6. PHYSICS SETUP
Fixed support – 3D problem
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6. PHYSICS SETUP
Frictionless support – 3D problem
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6. PHYSICS SETUP
Pressure = 67,91 MPa (3D problem)
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6. PHYSICS SETUP
Material Assignment
Symmetry Region – 2D problem
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6. PHYSICS SETUP
Fixed Support – 2D problem
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6. PHYSICS SETUP
Frictionless Support – 2D problem
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6. PHYSICS SETUP
Pressure = 67,91 MPa (2D Problem)
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Numerical Solution
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7. NUMERICAL SOLUTION
Displacement Normal Stress
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7. NUMERICAL SOLUTION
Safety Factor
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Numerical Results
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8. NUMERICAL RESULTS
Displacement 3D – Coarse Mesh
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Normal Stress 3D – Coarse Mesh
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Displacement 2D – Coarse Mesh
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Normal Stress 2D – Coarse Mesh
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Verification
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9. VERIFICATION
Results for r = 10 mm (Coarser mesh)

Empirical 2D problem 3D problem
114,401 MPa 109,67 MPa 113,54 MPa
- 4,14 % 0,75 %
Results for r = 10 mm (Finer mesh)

Empirical 2D problem 3D problem
114,401 MPa 109,67 MPa 110,66 MPa
- 4,14 % 3,27 %
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9. VERIFICATION
Mesh convergence - 2D problem
145
140
135
Sigma_max (MPa)
130
125
120
115
8 7 6 5 4 3 2 1 0
Face Sizing (mm)
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9. VERIFICATION
Mesh convergence - 2D problem

145
140
135
Sigma_max (MPa)
130
125
120
115
0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Number of Elements
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Exercises
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EXERCICES
1. Based on the safety factor, find the minimum fillet
radius.
2. Do a parametric analysis and plot the maximum
normal stress versus the fillet radius.
3. Do a mesh convergence analysis using parametric
analysis.
4. What happens if we change the material?
5. How can we reduce the maximum stress without
changing either diameters and fillet radius?
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Workshop Structural Analysis

Stepped shaft in axial tension

Problem Specification Numerical Solution

Pre-Analysis Numerical Results

Árbol de levas VW Tiguan https://www.pumpsandsystems.com/why-are-there-holes-my-new-impeller-part-1

Property Value Unit

Empirical Solution Numerical solution

Compute 𝐾 for the

r (mm) K 𝝈𝒎𝒂𝒙 (MPa) Maximum axial stress vs fillet radius

5 2,001 135,902 100.000

Fixed support – 3D problem

Frictionless support – 3D problem

Pressure = 67,91 MPa (3D problem)

Fixed Support – 2D problem

Frictionless Support – 2D problem

Pressure = 67,91 MPa (2D Problem)

Displacement Normal Stress

Displacement 3D – Coarse Mesh

Normal Stress 3D – Coarse Mesh

Displacement 2D – Coarse Mesh

Normal Stress 2D – Coarse Mesh

Results for r = 10 mm (Coarser mesh)

Results for r = 10 mm (Finer mesh)

Mesh convergence - 2D problem

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