COPYRIGHT DASSAULT SYSTEMES Generative Part Structural Analysis CATIA Training Exercises Version 5 Release 8 March 2002 EDU-CAT-E-GPS-FX-V5R8
COPYRIGHT DASSAULT SYSTEMES Table of Contents 1. Hanger Static Analysisp.3 Creation of the Analysis Document and Pre-Processingp.6 Computep.8 Results Visualization and Analysisp.10 Perform the same study using Virtual Partsp Static Analysis of a Steering Yokep Hanger Dynamic Modal Analysis p.17 Pre-Processing and Computingp.20 Results Visualizationp Conrod Stress Analysisp Torsional Stiffness Analysis of a Crankshaftp.27 6.Free-free Vibration Analysis of a Crankshaftp Steering Yoke (Adaptative Meshing)p Knowledge Advisor Analysis for Hangerp Bearing loadp.36 Law creationp.36 Static analysis computationp.38 Tips and hintsp.40
COPYRIGHT DASSAULT SYSTEMES Master Exercise 1. Hanger Static Analysis In this Exercise you will perform a Static Analysis of a Hanger, visualize the Results and Refine the Analysis: You will use: Pre-Processing Tools Image Tools Result Management Tools Analysis Refinement Tools Virtual Parts 60 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Hanger Static Analysis Create and Name the Analysis Define Pre-Processing Features (Loads and Restraints) Perform a First Rough Computation Analyze the Results Perform a Refined Analysis Introduce a Virtual Part Clamps Von Mises Stress Distributed Force
COPYRIGHT DASSAULT SYSTEMES Design Process: Hanger Static Analysis Create an Analysis of the Part and define Pre- Processing Elements 1 Compute 2 Analyze Results and Perform a Refined Analysis 3 Perform the same study using Virtual Parts 4
COPYRIGHT DASSAULT SYSTEMES min. Master Exercise Hanger Static Analysis: Creation of the Analysis Document and Pre-Processing In this step you will: apply a Material to the part start the Analysis Workbench define the static Pre-Processing Elements (Restraints and a Loads sets) save the Analysis Document
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Creation of the Analysis Document and Pre-Processing: Apply Aluminum to the part while in the Part Design Workbench Open the GPS Workbench and create a Static Analysis of the Hanger Apply Clamps to the smaller inner surfaces of both mounting holes Apply a load to the inner surface of the footpeg mounting hole, use a force of – 1000 N directed downwards. Save the part and the analysis documents in a new folder Support of Force Support of Clamps Load: CATGPS_Hanger.CATPart
COPYRIGHT DASSAULT SYSTEMES Master Exercise Hanger Static Analysis: Compute In this step you will: specify the external storage location compute the static analysis case 15 min.
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Compute: Specify an external storage location. Update all objects in the analysis features tree in computing a Static Case Solution. Save your Analysis Document. Load: CATGPS_Hanger_1.CATAnalysis
COPYRIGHT DASSAULT SYSTEMES Master Exercise Hanger Static Analysis: Results Visualization and Analysis In this step you will: analyze the results of the static analysis previously made refine the analysis in order to obtain more precise results 30 min.
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Results Visualization and Analysis: Search for the point(s) of minimum precision. What is the global estimated error rate? Search for the point(s) of maximum Von Mises Stress. Will this part plastically deform? Search for the reactions tensor on each restraint (with the Reaction Sensors). Check whether you obtain zero when you sum these reactions and the external loads. Make a report of the analysis and check the global precision. Recompute with parabolic elements, how much has global error decreased? Recompute with a mesh size of 10mm and a mesh sag of 1mm, how much has global error decreased ? Create two adaptivity boxes on areas where error is maximum and one box where Von Mises Stress is maximum. Set target error rates of 10% for the first two boxes and 4% for the last. Launch adaptative computation with three iterations. Check target error. Load: Your previous CATAnalysis Document
COPYRIGHT DASSAULT SYSTEMES min. Master Exercise Hanger Static Analysis: Perform the same study using Virtual Parts In this step you will: perform the same static analysis as before apply the force on a surface apply it on a smooth virtual part apply it on a rigid virtual
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Perform the same study using Virtual Parts: Perform the same analyze as before using a Global Sag of 0.1 mm Perform the same analyze using a Smooth Virtual Part for force transmission Perform the same analyze using a Rigid Virtual Part for force transmission Compare the results of theses studies Clamps Load: CATGPSHanger_1. CATAnalysis Force
COPYRIGHT DASSAULT SYSTEMES Fundamental Steps Creation of the Analysis Document and Pre-Processing Apply a material. Open a static analysis in the GPS workbench. Apply clamps and forces. Computation Specify external storage, launch analysis, save. Results and visualization Extrema from a precision or a VonMises analysis. Reactions tensor. Analysis report and global precision. Recomputation with parabolic elements, mesh size and sag modification. Adaptivity boxes, adaptative computation and target error optimisation. Analysis with virtual parts Apply smooth and rigid virtual parts for restraints and force transmission. Differences with the first analysis.
COPYRIGHT DASSAULT SYSTEMES Recap Exercise 2. Static Analysis of a Steering Yoke In this exercise you will perform a static analysis of the steering yoke using various virtual parts You will use: Rigid Virtual Parts Smooth Virtual Parts Contact Virtual Parts Loads, Restraints Modifying Loads 60 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Static Analysis of a Steering Yoke Clamp the centre (stem) hole Apply a rigid virtual part to one of the outer (fork stanchion) holes, and a smooth virtual part to the other Apply a moment of 106N.mm along the x axis, to both virtual parts Compute using TE10 (parabolic) elements On a Von Mises image, visualize the differences between both virtual parts Load: CATGPS_Yoke_1.CATPart
COPYRIGHT DASSAULT SYSTEMES min. Recap Exercise 3. Hanger Dynamic Modal Analysis In this Exercise you will perform a dynamic analysis of the hanger, and analyze the resulting modes
COPYRIGHT DASSAULT SYSTEMES Design Intent: Hanger Dynamic Modal Analysis Create and Name the Analysis Define Pre-Processing Features (Mass Equipment and Restraints) Compute Create Images Select Modes Analyze Results Distributed mass equipment Clamp Third modes displacements
COPYRIGHT DASSAULT SYSTEMES Design Process: Hanger Dynamic Modal Analysis Create Frequency Analysis of Hanger. Define Pre- Processing Elements 1a Compute 1b Create Images 2a Select Dynamic Mode 2b Analyze Results 2c
COPYRIGHT DASSAULT SYSTEMES min. Recap Exercise Hanger Dynamic Modal Analysis In this step you will define dynamic pre-processing elements on the hanger by: creating restraints set creating an additional mass equipment computing the dynamic modes
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Pre-Processing and Computing: Start a frequency analysis Apply a Clamp to the smaller inner surface of the top mounting hole Apply a distributed mass equipment set to the inside surface of the foot peg mounting hole. Use a total mass of 5Kg Compute the frequency analysis. Only compute the first five dynamic modes Save the Part and Analysis Documents in another folder Support of Clamp Load: CATGPS _Hanger_Frequency.CATPart Support of Distributed mass equipment
COPYRIGHT DASSAULT SYSTEMES min. Recap Exercise Hanger Dynamic Modal Analysis In this step you will: analyze the results of the modal analysis previously performed animate the resulting dynamic modes
COPYRIGHT DASSAULT SYSTEMES Do It Yourself Results Visualization: Create a deformations and a displacements image Change the displacements visualization mode from symbols to average-iso Select the third mode and animate it Make a report of the analysis Load: Your previous CATIA Part and Analysis documents
COPYRIGHT DASSAULT SYSTEMES Fundamental Steps Creation of the Analysis Document and Pre-Processing Open a frequency analysis. Apply a clamp and a distributed mass. Computation Compute a frequency analysis, choose a number of dynamic modes. Results and visualization Create results images : deformations and displacements. Change displacements visualization mode. Animation. Report of the analysis.
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 4. Step (1): Conrod Stress Analysis In this exercise you will learn how to perform a Stress Analysis on a conrod. This analysis is used during the conceptual analysis of the conrod in order to determine its life- duration 20 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Conrod Stress Analysis The compressive load must be applied on the rod eye. Apply a 8000N force in the xy plane, along the part, transmitted by a rigid virtual part. Use a user-define axis system, selecting a rod edge. The restraint must be applied onto the crank end. Apply a clamp. Compute the stresses coming from the compressive load of the piston on the conrod Display Von Mises Stress. Where is the maximum stress located ? Will the part fail? Re-compute using TE10 elements (parabolic), after changing the global mesh size to 10mm and the global mesh sag to 1mm. How much global precision has improved? Will the part fail? Rod eye Crank end Load: CATGPS_Connecting_Rod.CATPart
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 5. Step (2): Torsional Stiffness Analysis of a Crankshaft In this exercise you will learn how to perform a stiffness analysis of a crankshaft. This conceptual analysis allows to compute the crankshaft torsional stiffness and then to modify if necessary the main journals. 20 min.
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 6. Step (3): Free-free Vibration Analysis of a Crankshaft In this exercise you will learn how to perform a free-free vibration analysis on a crankshaft. This conceptual analysis is performed before the neighbouring parts (flywheel and the damper geometry) are designed. 20 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Free-free Vibration Analysis of a Crankshaft Compute the first 11 natural frequencies and the associated mode shapes of a crankshaft. The mass of the flywheel and the damper geometry must be take into account. Use a 2kg mass equipment on both ends, transmitted using a smooth virtual part. The flywheel and damper gravity centres have been represented and are to be used as part handler points. No restraints are applied on the crankshaft: free-free vibration analysis. Animate an image of the 11th mode displacements map, using an average- iso visualization. Damper Load: CATGPS_Crankshaft.CATPart Flywheel
COPYRIGHT DASSAULT SYSTEMES Design Intent: Torsional Stiffness Analysis of Crankshaft The crankshaft is restrained at the flywheel face (drilled planar surface ). Use a clamp that will be transmitted using a rigid virtual part. The torque is applied onto the last main bearing. Apply to both cylindrical surfaces a moment of magnitude N.mm with respect to the y axis, transmitted using a rigid virtual part Compute the angular displacement of a crankshaft. Flywheel face Last main bearing Load: CATGPS_Crankshaft.CATPart
COPYRIGHT DASSAULT SYSTEMES Fundamental Steps Pre-Processing Use of a rigid virtual part to apply a clamp to a surface. Use of a rigid virtual part to apply a moment to a surface. Computation and results Compute a free-free vibration analysis (with no restraints). Apply distributed masses to simulate the flywheel and the damper, with part handler points. Choose of a mode displacement. Animation of this mode. Use of an average-iso visualization.
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 7. Step (4): Steering Yoke (Adaptative Meshing) In this exercise, you will discover the adaptive mesh method, for fast mesh refinement. This exercise is based on a simplified steering yoke from a motorcycle. 20 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Steering Yoke (Adaptative Meshing) Clamp the inner hole and apply surface sliders to both split faces. Apply a 10000N force along y axis and a 10000N.mm torque with respect to x axis. Both are applied to the outer hole through rigid transmission. Perform a first computation using TE10 elements, a 16mm mesh size and a 4mm mesh sag. Using adaptative meshing, recompute with an objective error of 5% around the point where Von Mises stress is maximum. Will the part fail? Outer hole Inner hole Split faces Load: CATGPS_Yoke_2.CATPart
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 8. Step (5): Knowledge Advisor Analysis for Hanger In this exercise you will learn how to use the Sensors and the Knowledge Advisor product. This conceptual analysis allows to create rules and checks to verify the behavior of your CATIA product pertaining to the analysis solution. 20 min.
COPYRIGHT DASSAULT SYSTEMES Design Intent: Knowledge Advisor Analysis for Hanger Creating a Rule on Maximum Displacement Creating a Check on Maximum Von Mises Apply Clamps to the smaller inner surfaces of both mounting holes. Apply a load to the inner surface of the footpeg mounting hole. Use a force of –1500 N directed downwards. Save the part and the analysis documents in CATGPS_Hanger_Knw.CATAnalysis. Perform a first computation, create Maximum Von Mises and Displacement sensors and notice the values. Create a warning check which informs the user when Maximum Von Mises > Yield Strength Material. Create a rule which asks the user to increase the EdgeFillet.27 from 6 mm if Maximum Displacement is greater than 0.7 mm and which tells the user DispMax < 0.7mm when Maximum Displacement gets less than 0.7 mm. Verify with the sensors that the check and rule are consistent. Change EdgeFillet.27 dimension as the rule asks for, perform a second computation and after the update, verify with the sensors whether the check and the rule are consistent. Change EdgeFillet.27 dimension following the rule request, perform a third computation and after the update, verify with the sensors whether the check and rule are consistent. Load: CATGPS_Hanger_Knw.CATPart
COPYRIGHT DASSAULT SYSTEMES Additional Exercise 9. Static Analysis with a Bearing Load : Law creation In this exercise, you will create a Bearing Load using a user-defined law profile type. 10 min.
COPYRIGHT DASSAULT SYSTEMES Open the GPS Workbench and create a new Static Analysis Apply clamp under the ball bearing support. Apply a Bearing Load on the intern revolution surface of the part. Select the cylindrical surface as support. Choose a 500 N force along the Y axis. Choose an angle of 180 deg and a radial orientation (usual). Select a law type for the profile of the loading. Access the law editor. Create two formal parameters (angle and force). Enter : `FormalForce.1` = cos(`FormalAngle.1`) Click OK, and select Law.1 in the tree in Bearing Load window. Load: BearingPart.CATPart You must enter the law in the PartDesign workbench Design Intent: Static analysis with a Bearing load
COPYRIGHT DASSAULT SYSTEMES min. Additional Exercise Static Analysis with a Bearing Load : Analysis computation In this exercise, you will analyze stresses generated by the Bearing Load.
COPYRIGHT DASSAULT SYSTEMES The Bearing Load command allows to be closer to reality, with a no uniform loading only applied on a part of the surface. Use parabolic elements, 5 mm for size and 0.5 mm for sag. Design Intent: Static analysis with a Bearing load Launch a static analysis. Visualize the Von Mises stresses and displacements.
COPYRIGHT DASSAULT SYSTEMES Hints and Tips Use historic to select restraint so as to put a connection.