Week - 5 - Modelling Spotwelds

OBJECTIVE We are to utilize the concept of mass scaling to alter the run time of the provided file by editing the DT and TSSFAC parameters through trial and error using the explicit solver. A histogram is then plotted to compare the run times of said trials. The mass scaling is not supposed to go beyond 8%. The same model…

OBJECTIVE To create a simulation of a pedestrian head impact and calculate the Head Impact Criterion (HIC) for each of the following cases. Simple head model impacting against rigid wall Child headform dummy model impacting against rigid wall Child headform dummy model impacting against hood INTRODUCTION The head injury…

OBJECTIVE To carry out a tensile test on a created 10mmx10mmx10mm block and generate uniaxial tensile behaviour results from simulation using either the explicit or implicit solver. Additionally, the results are compared between ELFORM 1, 2, -1 & -2 of the created block using a plot of Engineering Stress vs Stretch…

OBJECTIVE To model spotwelds for the given assembly of parts and run a test to compare results between spotwelds modelled using beam and solid elements. Conditions: 1. The spotwelds should be modelled using beam elements and solid elements separately. 2. The axial and shear force should be compared among beam and solid…

OBJECTIVE To simulate a crash test of a meshed crash box on a rigid wall. The crash box will be of two differing thicknesses (1.2mm and 1.5mm) and in addition to generating their animations, their results need to be compared based on the following outputs: - Cross-sectional force generated in the middle of the crash box…

OBJECTIVE To simulate a mobile drop test event on LS-Dyna using the given .k file - which contains basic representations of a mobile and floor containing nodes and elements. MODEL IMAGE PROCEDURE 1. Firstly, on LS PrePost, the .k file of the model is imported via File > Import > LS-DYNA keyword file. 2. After importing,…

INTRODUCTION The finite element method (FEM) is a numerical problem-solving methodology commonly used across multiple engineering disciplines for numerous applications such as structural analysis, fluid flow, heat transfer, mass transport, and anything existing as a real-world force. This practice systematically yields…

AIM To convert the following measurements to the specified system of units, in addition to specifying the conversion factors: MASS: 1 kgLENGTH: 1 mTIME: 1 sFORCE: 1 NSTRESS: 1 PaENERGY: 1 NmDENSITY: 1 kg/m3YOUNG'S MODULUS: 210 GPaVELOCITY: 56.33 kphGRAVITY: 9.8 m/s2 The above values are to be converted to the following…

OBJECTIVE To set up a simulation and carry out an explicit dynamic analysis of a car body crashing into a wall. A parametric study is to be carried out between the outputs of three different thicknesses of the car body. The outputs to be compared are total deformation and equivalent stresses acting on the model. MODEL…

OBJECTIVE To set up a simulation and carry out an explicit dynamic analysis of a bullet penetrating a bucket. Three different cases involving different non-linear materials for the bucket is to be carried out and compared. The outputs to be generated are as mentioned in the video - equivalent stress and total deformation.…

OBJECTIVE To carry out an explicit dynamics analysis through a tension and torsion test on a given test piece specimen. For the tension test, one end of the specimen is to undergo a displacement of 18mm whereas, for the torsion test, the end is to undergo a displacement of 1200 degrees. The outputs to be requested for…

OBJECTIVE To carry out an explicit dynamics analysis on a given model that involves a planer carrying out machining on a workpiece. Two cases differentiated by planer speed are to be carried out and outputs compared. The outputs to be requested are equivalent stress, total deformation and the temperatures generated in…

OBJECTIVE To carry out a transient structural analysis on the given worm gear model and generate equivalent stress, equivalent strain and total deformation outputs of the model for the worm rotating the gear up till halfway through the gear (which is to be cut in half). MODEL IMAGE PROCEDURE 1. After opening ANSYS Workbench,…

OBJECTIVE To carry out a transient structural analysis on a given double universal joint model. The analysis is to be carried out in 3 cases with each case involving a different material for the spring joint in the model. The materials to be used are structural steel, stainless steel and titanium alloy. The outputs to…

OBJECTIVE To carry out a transient structural analysis on the provided piston and cam mechanism. Three cases of differing contact properties are to be compared via their equivalent stress, directional deformation and equivalent strain outputs. MODEL IMAGE PROCEDURE 1. After opening ANSYS Workbench, we are met with the…

OBJECTIVE To carry out a static structural analysis of a sphere pressing on a plate. The deformation is to be captured after the sphere descends up to 4mm into the given plate of material non-linear structural steel. MODEL IMAGE PROCEDURE 1. After opening ANSYS Workbench, we are met with the Project Schematic window. Here,…

OBJECTIVE To carry out a static-structural analysis on an iPhone bending simulation to determine the capacity of the material used to make the frame of the iPhone (Aluminium Alloy NL). The analysis will involve two cases differentiated by the location of thumbs that will be the source of load on the iPhone. The following…

OBJECTIVE To carry out a static structural analysis on a rolling operation that is being carried out on a workpiece made of copper. Before carrying out the analysis, the workpiece needs to be edited as per requirements and there needs to be a displacement of 90mm of the workpiece during the operation and analysis. MODEL…

OBJECTIVE To carry out a static structural analysis on a wire bending simulation in ANSYS. The analysis will compare wires of the following non-linear materials - Copper Alloy, Aluminium Alloy and Magnesium Alloy. The analysis will be compared through outputs of the equivalent stress and strain generated on the wire. MODEL…

OBJECTIVE To carry out static structural analysis on a sheet metal bending setup for different materials and to generate the required outputs from the aforementioned analysis. Throughout the challenge, materials such as Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL are to be used for the sheet. Required…

OBJECTIVE To carry out a static structural analysis on a weld joint model and compare certain outputs of welds of different materials - specifically stainless steel, aluminium alloy and bronze. The outputs to be requested are directional deformation and equivalent strain generated in the model. The following are the specifications:…

OBJECTIVE To perform a static structural analysis on a railwheel and track setup and to compare the outputs of two different bearing loads of 100 kN and 500 kN. The outputs to be requested are that of total deformation, equivalent stress and life under both loads. In addition to that, a user-defined result for the total…

OBJECTIVE To run an analysis on a bevel gear pair and solve for von mises equivalent stress, equivalent elastic strain and total deformation. In addition to that, to also perform a grid dependency test for mesh sizes 6mm, 5mm and 4mm. WHAT IS GRID DEPENDENCY? Finite element preprocessors have come a long way over the years—to…

OBJECTIVE To carry out a static structural analysis on the given spur gear pair using ANSYS Workbench. The analysis is to be carried out on 3 cases wherein each case, different materials would be applied to these gears. Through the analysis, the maximum deformation, stress intensity, and stresses formed in the model are…

OBJECTIVE To carry out a static structural analysis on two different steel plates using ANSYS Workbench. The plates are to be created using the software and analysis will be carried out on them. Through the analysis, the maximum deformation and stresses formed in the model are to be derived and compared. Through observation,…

OBJECTIVE To perform a crash analysis on the left side of a Dodge Neon BIW, also known as a side crash. The analysis is to be carried on the deformation and the forces created as a result of the crash at a speed of 35 mph. Along with the analysis, certain output requests were to be generated and they are as follows: Sectional…

OBJECTIVE To perform a crash analysis on the front half of a Dodge Neon BIW, also known as a frontal crash. The analysis is to be carried on the deformation and the forces created as a result of the crash at a speed of 35 mph. Along with the analysis, certain output requests were to be generated and they are as follows:…

OBJECTIVES 1. To mesh the given bumper assembly with a mesh size of 6mm 2. To carry out simulations on the given crush tube model, so as to compare results as per the following requirements for each case: Run the crash tube model as it is. Change the Inacti=6 and run. Create the type 11 contact and run. Remove both notches…

OBJECTIVE To carry out simulations of the given starter files and compare the results. There shall be 7 cases (according to given parameters) and they are to be compared primarily via animations and plots. The files to be worked on are the FAILURE_JOHNSON_0000.rad file and the LAW27_0000.rad file. The cases are as follows:…

OBJECTIVE The primary objective of this assignment is to compare two simulations with different shell element properties. The comparison would be between the one with default properties and one with the following properties: Parameters  Comment  Ishell =24 QEPH 4 nodes shells are best combination of cost…

1. Calculation of the speed of sound in the steel rail. `E = 210000` MPa `rho = 0.0078`g/`mm^3` Speed of sound, `c = sqrt(E/rho)` `c = sqrt(210000/0.0078) = 0.5188`x `10^4`m/s = `5188.75`m/s   2. Time taken for the shockwave to travel a distance of 1000mm (one end of the rail to the other). Distance, `d = 1000` mm…

OBJECTIVE To mesh the given components as per the given criteria after geometry cleanup and midsurfacing. The three components are: Practice Component Clip Repair Mounting Bracket The 2D mesh is to have a target length of 5 mm with a minimum of 3.5 mm and a maximum of 7 mm. The thickness will also need to be assigned after…

OBJECTIVE To mesh the given rear suspension model in both 2D and 3D (according to the given quality criteria) after checking for and clearing geometrical errors. Also, to deploy appropriate connections as required between various parts of the assembly after which the model is symmetrically replicated using the reflect…

OBJECTIVE To extract the manual midsurface of the given instrument panel, mesh the component using the given quality parameters and assign thicknesses.   QUALITY CRITERIA S.No  Quality Criteria  Value  1 Target/Average length   4 2 Minimum Length  2 3 Maximum Length  6 4 Aspect …

OBJECTIVE To mesh the component as per the given quality criteria using three different methods. The first being the standard and manual process. The second being via the casting algorithm and the third using the batchmesh procedure.COMPONENT IMAGE QUALITY CRITERIA S.No  Quality Criteria  Value  1 Target/Average…

OBJECTIVE This challenge has multiple objectives and they are: 1. To practice morphing techniques discussed in the week 8 video, on the given sheet metal component called ‘Model-1’ 2. To morph ‘Model-2’ by increasing the height of the doghouses and ribs marked in the following screenshot: MODEL…

OBJECTIVE To mesh the given backdoor geometry of a car through manual midsurfacing process and the RADIOSS solver, as enunciated in the week 7 videos. To also ensure that mesh is of highest quality with low number of trias and good mesh flow. CAD MODEL IMAGE The model comprising of all its components:It is comprised mainly…

OBJECTIVE To morph the mesh of the given side body component of a car according to given specifications, in addition to writing a macro for the morphing process carried out: CAD MODEL IMAGE This is the component that was provided:PROCEDURE 1. The component received is a mesh completely. There are no surfaces. For the sake…

OBJECTIVE To attach the parts of given model using specific connectors after clean up and meshing said parts. REQUIREMENTS 1. Right_Rail_2 & Front_truss_1:- Seam-Quad(angled+capped+L) 2. Left_Rail_2 & Front_truss_1:- Quad elements 3. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot…

OBJECTIVETo perform suitable connections between various parts/components in the rear door FE model provided, after creating and applying different PIDs to the aforementioned components that are part of the model.CAD MODEL IMAGE PROCEDURE1. Firstly, in order to set up the more complex connections for the challenge, it…

OBJECTIVE To mesh the given rearview mirror component in both 2D and 3D, after checking the model for geometrical errors and fixing them. Also, to ensure the generated mesh follows the given quality criteria.   QUALITY CRITERIA Shell Elements S.No  Quality Criteria  Value  1 Target/Average length  …

OBJECTIVE To extract the manual midsurface of the given bottle cap, mesh the component using the given quality parameters and assign thickness. QUALITY CRITERIA S.No  Quality Criteria  Value  1 Target/Average length   1 2 Minimum Length  0.5 3 Maximum Length  3 4 Aspect  3 5 Warpage…

OBJECTIVE To mesh the given hood component after proper geometry cleanup and midsurface generation using the ANSA preprocessing software. Also, to ensure the generated mesh follows the given quality criteria and the corresponding thickness of each surface is assigned to the mesh. QUALITY CRITERIA S.No  Quality Criteria …

OBJECTIVE To generate the midsurface, clean up and mesh the given plastic component of a car door's plastic panel keeping in mind the given quality criteria.MESH QUALITY CRITERIA Target Element Length = 4mm S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper     …

OBJECTIVE To mesh the given floor panel geometry through after generating its midsurface. To also ensure that mesh is of the highest quality (following given quality criteria) with a low number of trias and good mesh flow. CAD MODEL IMAGE The floor panel geometry: QUALITY CRITERIA Target Element Length = 5mm S.No Quality…