Week 10 - Lecture Nonlinear Structural Analysis

ME 24-688 Introduction to CAD/CAE Tools

Product Lifecycle Week 10

Requirements

Portfolio Management

Conceptual Design

Product Engineering
Manufacturing Engineering Simulation & Validation Build & Produce

Disposal & Recycling

Maintenance & Repair

Sales & Distribution

Test & Quality

ME 24-688 Introduction to CAD/CAE Tools

Goals of Simulation
Validate Designs
Predict Product Performance

Optimize Designs

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Replicate the Physical World

The more closely a simulation conforms to what happens in the physical world, the more value it has to offer.
Analysis Parameters and Type Materials Model Geometry Loads and Constraints Contacts and Relationships

ME 24-688 Introduction to CAD/CAE Tools

Materials
The available material selection is vast and changing everyday.
The material properties and material model control the behavior under operating conditions.

To compare designs select a consistent material for each test that closely represent the real material.
ME 24-688 Introduction to CAD/CAE Tools

Force Estimation Methods

Experience
Engineers reply on past experience from similar projects to estimate forces. Often results in an over designed product.

Rigid-Body Dynamics
Leverage the 3D design data to perform a motion simulation using rigid bodies to gain insights into force values.

Physical Experimentation
Experiment with prototypes or past products to obtain accurate force values.

ME 24-688 Introduction to CAD/CAE Tools

Linear vs. Nonlinear Analysis

Linear
Structure returns to original form No changes in loading direction or magnitude Material properties do not change Small deformation and strain

Nonlinear

Focus for this week

Geometry changes resulting in stiffness change Material deformation that may not return to original form Supports changes in load direction and constraint locations Support of nonlinear load curves

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Nonlinear Analysis
Design Engineer Belief
Too Complicated Time Consuming Software Access Design away nonlinearities

Reality (Obtainable)
Nonlinearities are Commonplace Advances in FEA Software Advances in Computing Hardware

ME 24-688 Introduction to CAD/CAE Tools

Types of Nonlinearity
Nonlinear Material
Materials that do not have a complete linear stress strain curve as seen in plastic and rubber materials for example.

Nonlinear Boundary Condition

Boundary conditions that involve components in contact with one another often produce disproportionate changes in deformation.

Nonlinear Geometry
The changing shape of a model when large deformations exists provide nonlinear changes in the components stiffness.

ME 24-688 Introduction to CAD/CAE Tools

Materials Types
Hard and Brittle

Hard and Strong

Force

Area

Hard and Tough Soft and Tough

Stress =

Strain =
ME 24-688 Introduction to CAD/CAE Tools

Change in Length

Original Length

Polymeric Material Example

Elastic Region

Plastic Region Failure

Force

Area

Yield Limit

Stress =

Proportional Limit

Youngs Modulus

Strain =
ME 24-688 Introduction to CAD/CAE Tools

Change in Length

Original Length

Nonlinear Boundary Condition

Component contacts produce stresses and friction that result in disproportionate changes in deformation.

ME 24-688 Introduction to CAD/CAE Tools

Nonlinear Geometry
Changing shape triggers nonlinear changes in stiffness of the part model.

ME 24-688 Introduction to CAD/CAE Tools

Event Simulation
Event simulation allows for the entire event of a condition not just a static solution. In mechanical engineering the static case often doesnt dictate the design. Designs must consider the worst-case scenario which often occurs after loading.

ME 24-688 Introduction to CAD/CAE Tools

Event Simulation Example

F
Linear static solution would have the entire load carried by vertical member.
ME 24-688 Introduction to CAD/CAE Tools

Event Simulation Example

F
With an event simulation the horizontal members would carry some of the load.
ME 24-688 Introduction to CAD/CAE Tools

Nonlinear Example
Unbending and bending a paperclip back into position has nonlinear material and geometry effects.
Plastic Stresses

Residual Stresses

ME 24-688 Introduction to CAD/CAE Tools

Everyday Nonlinear Requirements

ME 24-688 Introduction to CAD/CAE Tools

Autodesk Simulation
Autodesk Simulation helps designers and engineers make decisions earlier and predict product performance.
Linear and Nonlinear Static Stress Fatigue Analysis Linear Dynamic Mechanical Event Heat Transfer CFD Multiphysics

ME 24-688 Introduction to CAD/CAE Tools

Element Types
The following are some of the element types available in Autodesk Simulation
Beam Spring Brick Shell Truss Special (Actuator) Special (Membrane) Special (Slider)

ME 24-688 Introduction to CAD/CAE Tools

Load Curves
Load curves control the load value through a multiplier over a time period. Each specific load can follow a different load curve.

ME 24-688 Introduction to CAD/CAE Tools

Six Flags Theme Parks - Case Study

Challenge
Maintain and renovate hundreds of thrill rides with minimal downtime.

Results
New, in-house design of antirollback mechanism to modernize a wooden roller coaster, the Texas Giant Better collaboration with fabricators through use of high-quality drawings and documentation Improve quality by increasing reliability of high-wear parts.
Our primary concern is safety. Inventor and Autodesk Simulation allow us to study real-world loading scenarios so we can be sure we have appropriate safety factors in our designs. Mike Neuzil Corporate Engineer Six Flags Theme Parks, Inc. United States

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Howden - Case Study

Challenge
Reduce the time taken to produce tenders with technically and economically competitive proposals, while taking account of increasingly detailed customer requirements

Results
Substantial reduction in total design time. Faster response to customer design requirements. Simulation allows investigation and validation of new design approaches.
Flexibility, adaptability and reliability are the key benefits that we enjoy with Autodesk Simulation products. Laurent Tisserand Technical Director Howden France

Weight reduction through design optimization brings reduced costs.

ME 24-688 Introduction to CAD/CAE Tools

Computer-Cluster Projects (CP10)

ME 24-688 Introduction to CAD/CAE Tools

Guided Lab Project 1

Guides instructions for completing a static stress linear simulation in Autodesk Simulation.

ME 24-688 Introduction to CAD/CAE Tools

Guided Lab Project 2

Guided instructions for completing a mechanical event nonlinear analysis in Autodesk Simulation.

ME 24-688 Introduction to CAD/CAE Tools

Guided Lab Project 3

Guided instructions for completing a snap fit nonlinear analysis on a medical device in Autodesk Simulation.

ME 24-688 Introduction to CAD/CAE Tools

Problem Set Assignment

Analyze the electrical switch snap fit mounting to determine force required and design quality.

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Demo Topics

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User Interface
Setup tab Stress Analysis browser Graphical display

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Mesh Panel and Settings

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Simulation Browser
Multiple simulations Analysis Type Constraints and Loads Part Element Type Element Definition

Material Surfaces Contacts

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Assign Materials

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Assign Constraints

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Assign Loads

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Contacts

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Analysis Parameters
Duration Capture Rate Load Curves

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Selection Panel

Selection Shape Select Type Subentites of Selection

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Run Simulation

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Results User Interface

Results Contours tab Stress Analysis browser Legend Graphical display

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Results Contours / Results Inquire

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Graph Results

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