Stressed Bar

Problem:
This problem illustrates that the factor of safety for a machine element depends on the
particular point selected for analysis. Here you are to compare factors of safety, based
upon the distortion-energy theory, for stress elements at A and B of the member shown
in the figure. This bar is made of AISI 1006 cold-drawn steel and is loaded by the forces
F = 0.55 kN, P = 8.0 kN, and T = 30 N· m.

Joseph Shigley and Charles Mischke. Mechanical Engineering Design

5th ed. New York: McGraw Hill, May 2002.
 Stressed Bar
Overview

Anticipated time to complete this tutorial: 1 hour

Tutorial Overview
This tutorial is divided into six parts:
1) Tutorial Basics
2) Starting Ansys
3) Preprocessing
4) Solution
5) Post-Processing
6) Hand Calculations

Audience
This tutorial assumes minimal knowledge of ANSYS 8.0; therefore, it goes into moderate
detail to explain each step. More advanced ANSYS 8.0 users should be able to complete
this tutorial fairly quickly.

Prerequisites
1) ANSYS 8.0 in house “Structural Tutorial”

Objectives
1) Model the bar in ANSYS 8.0
2) Analyze the bar for appropriate stresses

Outcomes
1) Learn how to start Ansys 8.0
2) Gain familiarity with the graphical user interface (GUI)
3) Learn how to create and mesh a simple geometry
4) Learn how to apply boundary constraints and solve problems

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 Stressed Bar
Tutorial Basics
In this tutorial:
Instructions appear on the left.

Visual aids corresponding to the text

appear on the right.

All commands on the toolbars are

labeled. However, only operations
applicable to the tutorial are explained.

The instructions should be used as follows:

Bold > Text in bold are buttons,

options, or selections that the
user needs to click on

Example: > Preprocessor > Element

Type > Add/Edit/DeleteFile
would mean to follow the
options as shown to the right
to get you to the Element
Types window

Italics Text in italics are hints and

notes

MB1 Click on the left mouse button

MB2 Click on the middle mouse
button
MB3 Click on the right mouse
button

Some basic ANSYS functions are:

To rotate the models use Ctrl and MB3.

To zoom use Ctrl and MB2 and move the

mouse up and down.

To translate the models use Ctrl and MB1.

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 Stressed Bar
Starting Ansys
For this tutorial the windows version of
ANSYS 8.0 will be demonstrated. The path
below is one example of how to access
ANSYS; however, this path will not be the
same on all computers.

For Windows XP start ANSYS by either

using:
> Start > All Programs > ANSYS 8.0
> ANSYS
or the desktop icon (right) if present.

Note: The path to start ANSYS 8.0 may be different for

each computer. Check with your local network manager to
find out how to start ANSYS 8.0.

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 Stressed Bar
Starting Ansys
Once ANSYS 8.0 is loaded, two separate
windows appear: the main ANSYS
Advanced Utility Window and the ANSYS
Output Window.

The ANSYS Advanced Utility Window,

also known as the Graphical User Interface
(GUI), is the location where all the user
interface takes place. Graphical User Interface

Output Window
The Output Window documents all actions
taken, displays errors, and solver status.

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 Stressed Bar
Starting Ansys
The main utility window can be broken up
into three areas. A short explanation of each
will be given.

First is the Utility Toolbar:

From this toolbar you can use the command

line approach to ANSYS and access multiple
menus that you can’t get to from the main
menu.

Note: It would be beneficial to take some time and explore

these pull down menus and familiarize yourself with them.

Second is the ANSYS Main Menu as shown

to the right. This menu is designed to use a
top down approach and contains all the
steps and options necessary to properly pre-
process, solve, and postprocess a model.

Third is the Graphical Interface window

where all geometry, boundary conditions,
and results are displayed.

The tool bar located on the right hand side

has all the visual orientation tools that are
needed to manipulate your model.

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 Stressed Bar
Starting Ansys
With ANSYS 8.0 open select
> File > Change Jobname
and enter a new job name in the blank field
of the change jobname window.

Enter the problem title for this tutorial.

> OK

In order to know where all the output files

from ANSYS will be placed, the working
directory must be set in order to avoid using
the default folder: C:\Documents and
Settings.
> File > Change Directory > then
select the location that you want
all of the ANSYS files to be saved.

Be sure to change the working directory at

the beginning of every problem.

With the jobname and directory, set the

ANSYS database (.db) file can be given a
title. Following the same steps as you did
to change the jobname and the directory,
give the model a title.

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 Stressed Bar
Preprocessing
To begin the analysis, a preference needs to
be set.
> Main Menu > Preferences

Place a check mark next to the Structural

box. This determines the type of analysis
that will be performed in ANSYS.
> Ok

The ANSYS Main Menu should now be

opened. Click once on the “+” sign next to
Preprocessor.
> Main Menu > Preprocessor

The Preprocessor options currently avail-

able are displayed in the expansion of the
Main Menu tree as shown to the right.

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 Stressed Bar
Preprocessing
As mentioned previously, the ANSYS Main
Menu is designed in such a way that one
should start at the top and work towards the
bottom of the menu in preparing, solving,
and analyzing your model.

Note: This procedure will be shown throughout the tuto-

rial.

Select the “+” next to Element Type or click

on Element Type. The extension of the
menu is shown to the right.
> Element Type

Select Add/Edit/Delete and the Element

type window appears. Select add and the
Library of Element Types window appears.
> ADD/EDIT/DELETE > Add

In this window, select the types of elements

to be defined and used for this problem.

For this model Pipe16 elements will be used.

> Pipe > Elast straight16
> Ok

In the Element Types window Type 1

Pipe16 should be visible signaling that the
element type has been chosen.

Close the Element Types window.

> Close

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 Stressed Bar
Preprocessing
The properties for the pipe 16 elements need
to be chosen. This is done by adding Real
Constants.
> Preprocessor > Real Constants
> Add/Edit/Delete

The Real Constants window should appear.

Select add to create a new set.
> Add

The Element Type for Real Constants win-

dow should appear. From this window,
select Pipe16 as the element type.
> Type 1 Pipe16 > OK

The Real Constant Set Number 1, for

PIPE16 window will appear. From this win-
dow you can interactively customize the ele-
ment type.

The problem states that the outside diame-

ter of the first shaft should be 0.02 meter.
Since the pin is a solid, the thickness of the
elements should be equal to the radius of
the outside diameter (.01 meter).

Enter the values into the table, as shown to

the right.
> OK

Close the Real Constant window.

> Close

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 Stressed Bar
Preprocessing
The material properties for the Pipe16 ele-
ments now need to be defined.
> Preprocessor > Material Props
> Material Models

The Define Material Models Behavior win-

dow should now be open.

This window has many different possibili-

ties for defining the materials for your
model. We will use isotopic linearly elastic
structural properties.

Select the following from the Material

Models Available window:
> Structural > Linear > Elastic
> Isotropic

The window titled Linear isotropic

Properties for Material Number 1 now
appears.

Enter 209e9 (209 Gpa) in for EX (Young's

Modulus) and 0.3 for PRXY (Poisson’s
Ratio).
> OK

Close the Define Material Model Behavior

window.
> Material > Exit

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 Stressed Bar
Preprocessing
The next step is to define the keypoints
(KP’s) where loads and constraints will be
applied:
> Preprocessor > Modeling > Create
> Keypoints > In Active CS

The Create Keypoints in Active CS win-

dow will now appear. Here the KP’s will be
assigned numbers and their respective
(XYZ) coordinates.

Enter the KP numbers and coordinates for

the pin definition. Select Apply after each
KP has been defined.

Note: Be sure to change the keypoint number every time

you click apply. If you don’t it will overwrite the last key-
point you entered with the new coordinates.

This tutorial will use a different coordinate

notation than the one shown in the problem
statement.

KP # 1: X = 0, Y = 0, Z = 0
> Apply

KP # 2: X = 0, Y = 0, Z = .1

Select Ok when completed.

If a mistake was made in creating the key-

points, select:
> Preprocessor > Modeling > Delete
> Keypoints

Select the inappropriate KP’s and select Ok.

The created KP’s should look similar to the

example to the right except the KP’s could
be labeled with the KP numbers.

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 Stressed Bar
Preprocessing
At times it will be helpful to turn on the key-
point numbers.
> PlotCtrls > Numbering > put a
checkmark next to keypoint
numbers > OK

Other numbers (for lines, areas, etc..) can be

turned on in a similar manner.

The next step is to create lines between the

KP’s.
> Preprocessor > Modeling
> Create > Lines > Lines
> Straight Lines

The Create Straight Lines window should

appear. You will create 1 line. Create line 1
between the two keypoints.

For line 1: MB1 KP1 then MB1 KP 2.

Verify that the line only goes between the

specified keypoints. When you are done
creating the line click OK in the Create
Straight Lines window.
> Ok

If you make a mistake, use the following to

delete the lines:
> Preprocessor > Modeling > Delete
> Lines Only

Select the inappropriate line and select Ok.

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 Stressed Bar
Preprocessing
Now that the model has been created, it
needs to be meshed. Only meshed models
can be run to find a solution.

First, the element size will be specified.

> Preprocessor > Meshing
> Size Cntrls > Manual Size
> Lines > All Lines

The Element Sizes on All Selected Lines

window should appear. From this window,
the number of elements per line segment
can be defined along with the Element edge
length.

Approximately 20 elements along the

length of the line will produce reasonable
results.

Enter 20 into the No. of element divisions

field
> Ok

Note: you could change the No. of element divisions after

completing the tutorial to a different value and rerun the
solution to see how it affects the results.

With the mesh parameters complete the

lines representing the pin can now be
meshed. Select:
> Preprocessor > Meshing > Mesh
> Lines

From the Mesh Lines window select Pick

All.
> Pick all

This will select all the line segments and

mesh them all at the same time.

The meshed line should appear similar to

the one shown to the right.

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 Stressed Bar
Solution
We will now move into the solution phase.

Before applying the loads and constraints to

the bar, you will select a new static analysis
> Solution > Analysis Type
> New Analysis

For type of analysis select static and select

Ok.

The constraints will now be added.

For this problem, KP 1 needs to be con-

strained in all six degrees of freedom.

To apply constraints select:

> Solution > Define Loads > Apply
> Structural > Displacement
> On Keypoints

Select the Key point in need of constraints.

Select KP 1 in the graphics window.
> Ok

The Apply U, ROT on KP’s large window

should appear. From this window the
degrees of freedom can be specified.

To the right of DOFs to be constrained

select ALL DOF.
> Apply.

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 Stressed Bar
Solution
The constraints now appear at keypoint 1.

The loads will now be applied to the bar.

> Solutions > Define Loads > Apply
> Structural > Force/Moment
> On Keypoints

The Apply F/M on KP’s window should

appear.

Select KP 2 in the graphics window.

> Apply

The expanded Apply F/M on KP’s window

should appear. From this window the direc-
tion of the force and magnitude can be spec-
ified.

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 Stressed Bar
Solution
Select FY for the Direction of force/moment.
Select Constant value for Apply as.

Enter -550 in the Force/moment value field

which will apply a 550 N force downward.

Verify that all the fields match those of the

figure shown to the right.
> Apply

Select FZ and enter 8000.

> Apply

Select MZ and enter 30.

> Ok

The fully loaded and constrained model

should appear similar to the picture shown
on the right.

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 Stressed Bar
Solution
Before solving the problem, display the ele-
ment in three dimensions.
> Plot Controls > Style
> Size and Shape

The Size and Shape window opens. Click

the check box next to Display of element to
turn on the 3D image.

The next step in completion of the tutorial is

to solve the current load step that has been
created. Select:
> Solution > Solve > Current LS

The Solve Current Load Step window will

appear. To begin the analysis select Ok.

The analysis should begin and when com-

plete a Note window should appear that
states the analysis is complete.

Close both the Note window and /STATUS

Command window.

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 Stressed Bar
Post Processing
From the problem statement, we will esti-
mate the maximum stress at point A (on
top of the bar) point B (on the side of the
bar). To obtain the stress, select Nodal
solution from the drop down menu, Stress
and Von Mises stress.
> Preprocessor > Results Viewer
> Nodal solution > Stress
> Von Mises stress

Select the contour icon and look at the

stress value at point A

Notice that (as expected) there is a max at

point A labeled MX. The numerical value
is shown at the value on the far right of the
scale and also is labeled SMX in the upper
left corner of the screen. The value is 101
MPa.

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 Stressed Bar
Post Processing
To find the stress at Point B, we will look at
the stress in the x direction. Change the
item in results viewer from Von Mises to X-
component of stress at replot the contours.
Noticed that near point B is a minimum
stress value labeled MN. This value is also
shown in the upper left as SMN. The value
is 44.6MPa.

For AISI 1006 cold-drawn steel Sy = 330

MPa.

The safety factor n = Sy/Smax.

For A, n = 330/101.56 = 3.25.

For B, n = 330/44.6 = 7.19.

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 Stressed Bar
Hand Calculations

To find the factor of safety of the element A and B:

At A:

σ x = 95.5 MPa
τ xz = 19.1MPa

[ ] = 101Mpa
1
σ = (95.5 ) + 3(19.1)
1 2 2 2

Sy = 330Mpa
n = 330 / 101 = 3.27

At B:

σ x = 25.5 MPa
τ xy = 21.4.1MPa

[ ] = 45.0Mpa
1
σ 1 = (25.5 ) + 3(21.4)
2 2 2

Sy = 330Mpa
n = 330 / 45.0 = 7.33

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