3 ARM ARTICULATED ROBOT DESIGN BY USING CAD TOOL

ABSTRACT
An articulated robot is a robot with rotary joints (e.g. a legged robot or an industrial robot).
Articulated robots can range from simple two-jointed structures to systems with 10 or more
interacting joints. They are powered by a variety of means, including motors. Some types of
robots, such as robotic arms, can be articulated or non-articulated; an articulated robot is a robot
which is fitted with rotary joints. Rotary joints allow a full range of motion, as they rotate
through multiple planes(x,y,z directions) and rotary motions also.

In this project by using CAD-tool (creo-2) we created circular arm robot and analysed with
real time boundary conditions with 3 different materials (steel, al-356, ARAMID epoxy). And
calculated results of deformation and stress, and shear stress and strain values. From all these
results here we are going to conclude which material has less weight and which material has
fewer amounts of stress values. From all these results we can get an idea which robot with which
material we should use for different conditions like less weight or less stress producing robots.

Tools were used:

Cad tool: creo-2

Cae tool: Ansys work bench

1. INTRODUCTION
An articulated robot is a robot with rotary joints (e.g. a legged robot or an industrial robot).
Articulated robots can range from simple two-jointed structures to systems with 10 or more
interacting joints. They are powered by a variety of means, including motors. Some types of
robots, such as robotic arms, can be articulated or non-articulated

A six-axis articulated welding robot reaching into a fixture to weld.

An articulated robot is a robot which is fitted with rotary joints. Rotary joints allow a full
range of motion, as they rotate through multiple planes, and they increase the capabilities of the
robot considerably. An articulated robot can have one or more rotary joints, and other types of
joints may be used as well, depending on the design of the robot and its intended function. With
rotary joints, a robot can engage in very precise movements. Articulated robots commonly show
up on manufacturing lines, where they utilize their flexibility to bend in a variety of directions.
Multiple arms can be used for greater control or to conduct multiple tasks at once, for example,
and rotary joints allow robots to do things like turning back and forth between different work
areas. These robots can also be seen at work in labs and in numerous other settings. Researchers
developing robots often work with articulated robots when they want to engage in activities like
teaching robots to walk and developing robotic arms. The joints in the robot can be programmed
to interact with each other in addition to activating independently, allowing the robot to have an
even higher degree of control. Many next generation robots are articulated because this allows for
a high level of functionality. At present, the main interest is to protect nuclear workers in highly
contaminated areas or hostile environments, robots can be used in nuclear power plants to reduce
human exposure not only to radiation, but also to hot, humid and oxygen-deficient atmosphere
researchers in the field of robotics are proposing a great variety of robots configurations and
functional capabilities to be used in nuclear power plants. Wheeled robots and tracked vehicles
are the common configurations for mobile robots. The robotic system is made up of three main
sub-systems: sensory head; teleportation and control panel; and mobile robot, vision, sound and
temperature cover 90% of all inspections tasks required in BWR nuclear power plants pan-tilt
mechanism. So it can be easily plugged into different mechanical robots. Video camera used
inspection purpose, stereo vision equipment, produced by stereo Graphics, has been integrated in
the tele-operation panel. This stereo system is of great use in guiding the mechanical robot
through cloistered areas. The tele-presence is completed with a stereophonic bidirectional audio
set, which also provides signals for sound inspection. To carry out close inspection tasks of the
vacuum vessel first wall using a long reach robot is called the “Articulated Inspection Arm”
(AIA). Significant stress and high deformations in bending and torsion occur in the structure. The
load depends on the articulated structure. The model has to be realistic to have a good knowledge
of the end-effectors position. The model of the complete robot is the assembly of the five
elementary models described before. It gives the deformation and position of the structure for any
given joint position and loads. The calculation is iterative due to the non-linearity induced by the
large displacements and the cumulative effect of the deformations.

HISTORY OF ROBOT:
Leonardo da Vinci created many robot-like sketches and designs in the 1500’s.The word robot
first appeared in print in the 1920 play R.U.R. (Rossum’s Universal Robots) by Karl Kapek, a
Czechoslovakian playwright. Robota is Czechoslovakian for worker or serf (peasant). Typical of
early science fiction, the robots take over and exterminate the human race. Isaac Asimov
popularized the term robotics through many science-fiction novels and short stories. Asimov is a
visionary who envisioned in the 1930’s the positronic brain for controlling robots; this pre-dated
digital computers by a couple of decades. Unlike earlier robots in science fiction, robots do not
threaten humans since Asimov invented the three laws of robotics: 1. A robot may not harm a
human or, through inaction, allow a human to come to harm. 2. A robot must obey the orders
given by human beings, except when such orders conflict with the First Law. 3. A robot must
protect its own existence as long as it does not conflict with the First or Second Laws. Joseph
Engleberger and George Devoe were the fathers of industrial robots. Their company, animation,
built the first industrial robot, the PUMA (Programmable Universal Manipulator Arm, a later
version shown below), in 1961.
ROBOTIC SYSTEMS:
Typically, robots are used to perform jobs that are difficult, hazardous or monotonous for
humans. They lift heavy objects, paint, and weld, handle chemicals, and perform assembly work
for days at a time without suffering from fatigue. Robots are defined by the nature of their
movement. This section describes the following.
CLASSIFICATIONS OF ROBOTS:

• Cylindrical
• Polar
• Articulated
• Scara
• Cartesian
ROBOT PARTS

TECHNICAL ROBOTICS TERMS SPEED

Speed is the amount of distance per unit time at which the robot can move, usually specified in
inches per second or meters per second. The speed is usually specified at a specific load or
assuming that the robot is carrying a fixed weight. Actual speed may vary depending upon the
weight carried by the robot.
LOAD BEARING CAPACITY
Load bearing capacity is the maximum weight-carrying capacity of the robot. Robots that carry
large weights, but must still be precise are expensive.
ACCURACY
Accuracy is the ability of a robot to go to the specified position without making a mistake. It is
impossible to position a machine exactly. Accuracy is therefore defined as the ability of the robot
to position itself to the desired location with the minimal error (usually 0.001 inch).
REPEATABILITY
Repeatability is the ability of a robot to repeatedly position itself when asked to perform a task
multiple times. Accuracy is an absolute concept, repeatability is relative. Note that a robot that is
repeatable may not be very accurate. Likewise, an accurate robot may not be repeatable.
WORK ENVELOPE
Work envelope is the maximum robot reach, or volume within which a robot can operate. This is
usually specified as a combination of the limits of each of the robot's parts. The figure below
shows how a work-envelope of a robot is documented.

LITERATURE REVIEW
Early research efforts in legged locomotion focused on statically stable gaits in which robot’s
centre of gravity is always kept over the polygon formed by the supporting feet [1]. Raibert,
around 1985, set the stage with his ground-breaking work on dynamic legged locomotion [2],
which resulted in one of the most advanced quadrupeds, Boston Dynamics’ BigDog that can
control its forward speed, and although it moves with static stable gaits, it can achieve a
dynamically balanced trot gait when moving at human walking speeds [3]. Boston Dynamics’
statically stable LittleDog, is a quadruped walking robot with 12 degrees of freedom, used as an
algorithm test bed. A different design and control approach is followed in Scout II [4] and in the
NTUA Quadruped Robot [5, 6], which use only one actuator and a spring per leg to realise
dynamically stable running with speed control. While the Scout requires a time-consuming trial-
and-error controller parameter determination to achieve a given speed, the NTUA quadruped
control algorithm does not need empirical gain tuning. Quadruped robots like Kotetsu [7] that
employ Central Pattern Generator (CPG) based controllers and KOLT [8] that uses a fuzzy
controller are different approaches towards achieving dynamic stable gaits. Recent research
efforts by the Autonomous System Lab at ETH [9] and the Advanced Robotics Department at IIT
[10] are aiming at making a step forward from LittleDog and BigDog respectively. Generally, the
tendency for the new robotic quadrupeds is to aim for very fast, rapidly accelerated, able to make
tight turns robots with flexible spine, articulated legs, possibly including head and tail, such as
the Boston Dynamics’ Cheetah concept. Lygorouas et al. [11] developed a computer-controlled
lightweight mechanical arm. This mechanical arm was a selfcontained, autonomous system
capable of executing high-level commands from a supervisory computer. The actuators of the
joints were permanent magnet type dc motors driven by servoamplifiers via Pulse Width
Modulation. Aung [12] designed and implemented a controller circuit based on PIC
microcontroller and H bridge circuit to control the motion of a Wheeled Mobile Robot (WMR).
He used MATLAB software for the modeling of the total system. Silva [13] applied fuzzy logic
at several hierarchical levels of a typical robotic control system. For controlling robotic
manipulators, Moosavian [14] used transpose jacobian (TJ) control. Arciniegas et al. [15]
developed neural network based adaptive control system to control the flexible robotic arm.
Tseng [16] developed a DSP based instantaneous torque controller to control the manipulator.
Rogers [17] designed a microcontroller circuit for interfacing joint sensor to control robotic arm.
A simple structured linked model of the articulated limb was developed where the model is
manipulated in simulation to ‘pull’ the end of the limb towards the desired destination position
and orientation [18]. Hisham [19] developed a PIC 16F877 microcontroller based system where
an articulated robot arm having six degrees of freedom was controlled [19]. In this present work,
an ATmega32L microcontroller based controller circuit has been designed to control the three
degrees of freedom of an articulated robot arm. The robot arm is actuated by the three DC
servomotors. A seven segment display and set of LEDs are used for indication purpose. Push
buttons are set to give the necessary input commands. Programming language C is used to
program the microcontroller which is written in AVR STUDIO 4 software.

2. INTRODUCTION:
 CREO
2.1. CAD
Computer aided design (cad) is defined as any activity that involves the

effective use of the computer to create, modify, analyze, or document an engineering design.

CAD is most commonly associated with the use of an interactive computer graphics system,

referred to as cad system. The term CAD/CAM system is also used if it supports

manufacturing as well as design applications

2.2. Introduction to CREO

CREO is a suite of programs that are used in the design, analysis, and manufacturing of a

virtually unlimited range of product.

CREO is a parametric, feature-based solid modeling system, “Feature based”

means that you can create part and assembly by defining feature like pad, rib, slots, holes, rounds,

and so on, instead of specifying low-level geometry like lines, arcs, and circle& features are

specifying by setting values and attributes of element such as reference planes or surfaces

direction of creation, pattern parameters, shape, dimensions and others.

“Parametric” means that the physical shape of the part or assembly is driven

by the values assigned to the attributes (primarily dimensions) of its features. Parametric may

define or modify a feature’s dimensions or other attributes at any time.

For example, if your design intent is such that a hole is centered on a block, you

can relate the dimensional location of the hole to the block dimensions using a numerical

formula; if the block dimensions change, the centered hole position will be recomputed

automatically.
 “Solid Modeling” means that the computer model to create it able to contain all the

information that a real solid object would have. The most useful thing about the solid

modeling is that it is impossible to create a computer model that is ambiguous or physically

non-realizable.

There are six core CREO concepts. Those are:

 Solid Modeling

 Feature Based

 Parametric

 Parent / Child Relationships

 Associative

 Model Centric
2.3 Capabilities and Benefits:

1. Complete 3D modeling capabilities enable you to exceed quality arid time to arid time

to market goals.

2. Maximum production efficiency through automated generation of associative C tooling

design, assembly instructions, and machine code.

3. Ability to simulate and analysis virtual prototype to improve production performance

and optimized product design.

4. Ability to share digital product data seamlessly among all appropriate team members

5. Compatibility with myriad CAD tools-including associative data exchange and

industry standard data formats.

2.4 Features of CREO

 CREO is a one-stop for any manufacturing industry. It offers effective feature,

incorporated for a wide variety of purpose. Some of the important features are as follows:

 Simple and powerful tool

 Parametric design

 Feature-based approach

 Parent child relationship

 Associative and model centric

2.4.1. Simple and Powerful Tool

CREO tools are used friendly. Although the execution of any operation using the tool can

create a highly complex model

2.4.2. Parametric Design

CREO designs are parametric. The term “parametric” means that the design operations

that are captured can be stored as they take place. They can be used effectively in the future

for modifying and editing the design. These types of modelling help in faster and easier

modifications of design.

2.4.3. Feature-Based Approach

Features are the basic building blocks required to create an object. CREO wildfire models

are based on the series of feature. Each feature builds upon the previous feature, to create the

model (only one single feature can be modified at a time). Each feature may appear simple,

individually, but collectively forms a complex part and assemblies.

The idea behind feature based modelling is that the designer construct on object, composed

of individual feature that describe the manner in which the geometry supports the object, if its

dimensions change. The first feature is called the base feature.

2.4.4. Parent Child Relationship

The parent child relationship is a powerful way to capture your design intent in a model. This

relationship naturally occurs among features, during the modeling process. When you create a

new feature, the existing feature that are referenced, become parent to the feature.

2.4.5. Associative and Model Centric

CREO drawings are model centric. This means that CREO models that are represented in

assembly or drawings are associative. If changes are made in one module, these will

automatically get updated in the referenced module.

2.5. CREO Basic Design Modes

When a design from conception to completion in CREO, the design information goes through three

basic design steps.

1. Creating the component parts of the design

2. Joining the parts in an assembly that records the relative position of the parts.

3. Creating mechanical drawing based on the information in the parts and the assembly.

2.6 Assembly in CREO:

Bottom-Up Design (Modeling):

The components (parts) are created first and then added to the assembly file. This technique

is particularly useful when parts already exist from previous designs and are being re-used.

Top-Down Design (Modeling):

The assembly file is created first and then the components are created in the

assembly file. The parts are build relative to other components. Useful in new designs

In practice, the combination of Top-Down and Bottom-Up approaches is used. As you often

use existing parts and create new parts in order to meet your design needs.

Degrees of Freedom:
An object in space has six degrees of freedom.

• Translation – movement along X, Y, and Z axis (three degrees of freedom)

• Rotation – rotate about X, Y, and Z axis (three degrees of freedom)

Assembly Constraints:

In order to completely define the position of one part relative to another, we must constrain all

of the degrees of freedom COINCIDENT, OFFSET

OFFSET

Two surfaces are made parallel with a specified offset distance..

COINCIDENT

Two selected surfaces become co-planar and face in the same direction. Can also be applied to

revolved surfaces. This constrains 3 degrees of freedom (two rotations and one translation). When

Align is used on revolved surfaces, they become coaxial (axes through the centers align).

CREO Modules:-

 Sketcher (2D)

 Part (3D)

 Assembly

 Drawing and Drafting

 Sheet Metal

 Surface modelling
 2.1 DESIGNING ROBOTS BY USING CREO-2
3d Model’s Developing by Using Creo-2:-
Open pro-e/creo

New enter namebase modelok

Base model dimensions:

 2d Sketch of Base Object
The above sketch should follow 3 conditions those are the sketcher should be closed and there
should be no open end there should be no over lapping. By following these conditions we have to
create our model. After completion of sketch click ok and we will get below model.

Extruded base model

The above model shows that base model extrusion length. And it has extrusion length is 8mm
and click on ok.

Side view dimensions

After creating above model here we have to create side walls, to create these walls select side
view of the model and create a sketch with 30mm height and width with 75mm.then click on ok.

Base side view extrude

After completion of sketcher click on ok then we will get above shape and in this window we can
adjust the thickness of the wall, and here we creating one wall with 10mm thickness. And to
create hole repeat same process but just click on remove material and then the material will
remove.

Base model with supporting

Modelling of first arm

To create first arm we repeating the same process for this model and completion of that model
creating one circle by using sketch tools and this sketch should also follow above 3 conditions.

Circular arm diameter values

After completion of base model select top view of base and create a sketch with circular diameter
40mm and inner circular diameter 30mm then click on ok.

Fi
rst Arm height
After completion of sketcher just click ok. Then we get the above model and create model with
150mm.

First arm model

COUPLINGS:
Here we are using couple joints to connect one arm to other arm and those dimensions are given
below. Here we are using 2 different couplings for different joints and those are

First Arm coupling dimensions:

First arm coupling diameter dimensions

Here we create coupling models to connect one arm to another arm. To create this model select
extrude and create a sketch circular diameter 14mm and click ok.

First arm coupling model extrusion

First arm coupled object

Second Arm Coupling Dimensions:

Second arm coupling dimension

2nd arm coupling extrude model.

 2nd coupling model
Circular rotor & second arm dimensions:
Circular rotor dimensions:

Here we creating 2nd arm model, to create this repeat same which we were used in first arm first
create a sketch with 60mm width and 45mm length. And follow all 3 conditions which we were
discussed in previous model.
The above model shows that base model extrusion length. And it has extrusion length is 8mm
and click on ok.

Circular robot rotor arm length with 80mm height

 2nd arm model side view sketcher

2nd arm model side view extrude model

 2nd arm model with holes

Circular arm

For second arm we are considering first arm dimensions only and repeat the same process for all
models and save them in one folder.
 2.1.1 CIRCULAR ROBOT ARM ASSEMBLY

Import all models into assembly window the first imported object should be in default position.
Then import other model and constraint them by requirement conditions.
First import base model into assembly window and place it in default condition. And import next
model place it in requirement condition. By using constraint option we can assemble all models.

Circular arm robot assembly

Circular arm assembly with 90 degrees

 Explode view
The above figure is complete exploding view of the object, and in this figure here we can see all
parts of the circular arm robot.
 3. INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz
method of numerical analysis and minimization of variational calculus to obtain approximate
solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R.
W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis.
The paper centered on the "stiffness and deflection of complex structures".
FEA consists of a computer model of a material or design that is stressed and analyzed for
specific results. It is used in new product design, and existing product refinement. A company is
able to verify a proposed design will be able to perform to the client's specifications prior to
manufacturing or construction. Modifying an existing product or structure is utilized to qualify
the product or structure for a new service condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet the new condition.
There are generally two types of analysis that are used in industry: 2-D modeling, and 3-D
modeling. While 2-D modeling conserves simplicity and allows the analysis to be run on a
relatively normal computer, it tends to yield less accurate results. 3-D modeling, however,
produces more accurate results while sacrificing the ability to run on all but the fastest computers
effectively. Within each of these modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave linearly or non-linearly. Linear
systems are far less complex and generally do not take into account plastic deformation. Non-
linear systems do account for plastic deformation, and many also are capable of testing a material
all the way to fracture.
FEA uses a complex system of points called nodes which make a grid called a mesh. This mesh
is programmed to contain the material and structural properties which define how the structure
will react to certain loading conditions. Nodes are assigned at a certain density throughout the
material depending on the anticipated stress levels of a particular area. Regions which will
receive large amounts of stress usually have a higher node density than those which experience
little or no stress. Points of interest may consist of: fracture point of previously tested material,
fillets, corners, complex detail, and high stress areas. The mesh acts like a spider web in that from
each node, there extends a mesh element to each of the adjacent nodes. This web of vectors is
what carries the material properties to the object, creating many elements.
A wide range of objective functions (variables within the system) are available for
minimization or maximization:
 Mass, volume, temperature

 Strain energy, stress strain

 Force, displacement, velocity, acceleration

 Synthetic (User defined)

There are multiple loading conditions which may be applied to a system. Some examples are
shown:
 Point, pressure, thermal, gravity, and centrifugal static loads

 Thermal loads from solution of heat transfer analysis

 Enforced displacements

 Heat flux and convection

 Point, pressure and gravity dynamic loads

Each FEA program may come with an element library, or one is constructed over time. Some
sample elements are:
 Rod elements

 Beam elements

 Plate/Shell/Composite elements

 Shear panel

 Solid elements

 Spring elements

 Mass elements

 Rigid elements
  Viscous damping elements

Many FEA programs also are equipped with the capability to use multiple materials within the
structure such as:
 Isotropic, identical throughout

 Orthotropic, identical at 90 degrees

 General anisotropic, different throughout

3.1 TYPES OF ENGINEERING ANALYSIS

Structural analysis consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Non-linear models consist of
stressing the material past its elastic capabilities. The stresses in the material then vary with the
amount of deformation as in.
Vibrational analysis is used to test a material against random vibrations, shock, and impact.
Each of these incidences may act on the natural vibrational frequency of the material which, in
turn, may cause resonance and subsequent failure.
Fatigue analysis helps designers to predict the life of a material or structure by showing the
effects of cyclic loading on the specimen. Such analysis can show the areas where crack
propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance of
the material.
Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or
structure. This may consist of a steady-state or transient transfer. Steady-state transfer refers to
constant thermo properties in the material that yield linear heat diffusion.
3. 2Results of Finite Element Analysis
FEA has become a solution to the task of predicting failure due to unknown stresses by showing
problem areas in a material and allowing designers to see all of the theoretical stresses within.
This method of product design and testing is far superior to the manufacturing costs which would
accrue if each sample was actually built and tested.
In practice, a finite element analysis usually consists of three principal steps:
1. Pre-processing: The user constructs a model of the part to be analyzed in which the geometry
is divided into a number of discrete sub regions, or elements," connected at discrete points
called nodes." Certain of these nodes will have fixed displacements, and others will have
prescribed loads. These models can be extremely time consuming to prepare, and commercial
codes vie with one another to have the most user-friendly graphical “preprocessor" to assist in
this rather tedious chore. Some of these preprocessors can overlay a mesh on a preexisting
CAD file, so that finite element analysis can be done conveniently as part of the computerized
drafting-and-design process.

2. Analysis: The dataset prepared by the preprocessor is used as input to the finite
element

code itself, which constructs and solves a system of linear or nonlinear algebraic equations
Kijuj = fi

where u and f are the displacements and externally applied forces at the nodal points. The
formation of the K matrix is dependent on the type of problem being attacked, and this module
will outline the approach for truss and linear elastic stress analyses. Commercial codes may
have very large element libraries, with elements appropriate to a wide range of problem types.
One of FEA's principal advantages is that many problem types can be addressed with the same
code, merely by specifying the appropriate element types from the library.
3. Postprocessing: In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot spots
this way, and modern codes use graphical displays to assist in visualizing the results. A
typical postprocessor display overlays colored contours representing stress levels on
the model, showing a full field picture similar to that of photo elastic or moiré
experimental results
 4. INTRODUCTION TO ANSYS

4.1 INTRODUCTION
ANSYS is general-purpose finite element analysis (FEA) software package.  Finite Element
Analysis is a numerical method of deconstructing a complex system into very small pieces (of
user-designated size) called elements. The software implements equations that govern the
behaviour of these elements and solves them all; creating a comprehensive explanation of how
the system acts as a whole. These results then can be presented in tabulated, or graphical
forms.  This type of analysis is typically used for the design and optimization of a system far
too complex to analyze by hand.  Systems that may fit into this category are too complex due
to their geometry, scale, or governing equations.
ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at
many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics
and Chemistry departments. 
ANSYS provides a cost-effective way to explore the performance of products or processes in a
virtual environment. This type of product development is termed virtual prototyping.
With virtual prototyping techniques, users can iterate various scenarios to optimize the product
long before the manufacturing is started. This enables a reduction in the level of risk, and in
the cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to
ensure that users are able to see the effect of a design on the whole behavior of the product, be
it electromagnetic, thermal, mechanical etc
4.1.1 GENERIC STEPS TO SOLVING ANY PROBLEM IN ANSYS: 
Like solving any problem analytically, you need to define (1) your solution domain, (2) the
physical model, (3) boundary conditions and (4) the physical properties. You then solve the
problem and present the results. In numerical methods, the main difference is an extra step
called mesh generation. This is the step that divides the complex model into small elements
that become solvable in an otherwise too complex situation. Below describes the processes in
terminology slightly more attune to the software.

4.1.1.1 BUILD GEOMETRY

Construct a two or three dimensional representation of the object to be modelled and tested
using the work plane coordinates system within ANSYS.
4.1.1.2 DEFINE MATERIAL PROPERTIES
Now that the part exists, define a library of the necessary materials that compose the object (or
project) being modelled.  This includes thermal and mechanical properties.
4.1.1.3 GENERATE MESH
At this point ANSYS understands the makeup of the part.  Now define how the modelled
system should be broken down into finite pieces. 
4.1.1.4 APPLY LOADS
Once the system is fully designed, the last task is to burden the system with constraints, such
as physical loadings or boundary conditions.
4.1.1.5 OBTAIN SOLUTION
This is actually a step, because ANSYS needs to understand within what state (steady state,
transient… etc.) the problem must be solved.
4.1.1.6 PRESENT THE RESULTS
After the solution has been obtained, there are many ways to present ANSYS’ results, choose
from many options such as tables, graphs, and contour plots. 

4.2 SPECIFIC CAPABILITIES OF ANSYS:

4.2.1 STRUCTURAL 
Structural analysis is probably the most common application of the finite element method as it
implies bridges and buildings, naval, aeronautical, and mechanical structures such as ship
hulls, aircraft bodies, and machine housings, as well as mechanical components such as
pistons, machine parts, and tools. 
·         Static Analysis - Used to determine displacements, stresses, etc. under static loading
conditions. ANSYS can compute both linear and nonlinear static analyses. Nonlinearities can
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity, contact
surfaces, and creep. 

Modal Analysis
A modal analysis is typically used to determine the vibration characteristics (natural
frequencies and mode shapes) of a structure or a machine component while it is being
designed. It can also serve as a starting point for another, more detailed, dynamic analysis,
such as a harmonic response or full transient dynamic analysis.
Modal analyses, while being one of the most basic dynamic analysis types available in
ANSYS, can also be more computationally time consuming than a typical static analysis.  A
reduced solver, utilizing automatically or manually selected master degrees of freedom is used
to drastically reduce the problem size and solution time.
Harmonic Analysis - Used extensively by companies who produce rotating machinery,
ANSYS Harmonic analysis is used to predict the sustained dynamic behavior of structures to
consistent cyclic loading.  Examples of rotating machines which produced or are subjected to
harmonic loading are:
 Turbines

o Gas Turbines for Aircraft and Power Generation

o Steam Turbines

o Wind Turbine

o Water Turbines

o Turbopumps

 Internal Combustion engines

 Electric motors and generators

  Gas and fluid pumps

 Disc drives

A harmonic analysis can be used to verify whether or not a machine design will successfully
overcome resonance, fatigue, and other harmful effects of forced vibrations.
·         Transient Dynamic Analysis - Used to determine the response of a structure to
arbitrarily time-varying loads. All nonlinearities mentioned under Static Analysis above are
allowed. 
·         Buckling Analysis - Used to calculate the buckling loads and determine the buckling
mode shape. Both linear (eigenvalue) buckling and nonlinear buckling analyses are possible.  
In addition to the above analysis types, several special-purpose features are available such as
Fracture mechanics, Composite material analysis, Fatigue, and both p-Method and Beam
analyses.  
4.2.2 THERMAL 
ANSYS is capable of both steady state and transient analysis of any solid with thermal
boundary conditions. 
Steady-state thermal analyses calculate the effects of steady thermal loads on a system or
component. Users often perform a steady-state analysis before doing a transient thermal
analysis, to help establish initial conditions. A steady-state analysis also can be the last step of
a transient thermal analysis; performed after all transient effects have diminished. ANSYS can
be used to determine temperatures, thermal gradients, heat flow rates, and heat fluxes in an
object that are caused by thermal loads that do not vary over time. Such loads include the
following: 
·         Convection
·         Radiation
·         Heat flow rates
·         Heat fluxes (heat flow per unit area)
·         Heat generation rates (heat flow per unit volume)
·         Constant temperature boundaries
A steady-state thermal analysis may be either linear, with constant material properties; or
nonlinear, with material properties that depend on temperature. The thermal properties of most
material vary with temperature. This temperature dependency being appreciable, the analysis
becomes nonlinear. Radiation boundary conditions also make the analysis nonlinear. Transient
calculations are time dependent and ANSYS can both solve distributions as well as create
video for time incremental displays of models.

4.2.3 FLUID FLOW

The ANSYS/FLOTRAN CFD (Computational Fluid Dynamics) offers comprehensive tools
for analyzing two-dimensional and three-dimensional fluid flow fields.  ANSYS is capable of
modeling a vast range of analysis types such as: airfoils for pressure analysis of airplane wings
(lift and drag), flow in supersonic nozzles, and complex, three-dimensional flow patterns in a
pipe bend.  In addition, ANSYS/FLOTRAN could be used to perform tasks including:  
·         Calculating the gas pressure and temperature distributions in an engine exhaust
manifold
·         Studying the thermal stratification and breakup in piping systems
·         Using flow mixing studies to evaluate potential for thermal shock
·         Doing natural convection analyses to evaluate the thermal performance of chips in
electronic enclosures
·         Conducting heat exchanger studies involving different fluids separated by solid regions 
 4.2.4 ACOUSTICS / VIBRATION
ANSYS is capable of modeling and analyzing vibrating systems in order to that vibrate in
order to analyze  
Acoustics is the study of the generation, propagation, absorption, and reflection of pressure
waves in a fluid medium. Applications for acoustics include the following:  
·         Sonar - the acoustic counterpart of radar
·         Design of concert halls, where an even distribution of sound pressure is desired
·         Noise minimization in machine shops
·         Noise cancellation in automobiles
·         Underwater acoustics
·         Design of speakers, speaker housings, acoustic filters, mufflers, and many other similar
devices.
·         Geophysical exploration
Within ANSYS, an acoustic analysis usually involves modelling a fluid medium and the
surrounding structure. Characteristics in question include pressure distribution in the fluid at
different frequencies, pressure gradient, and particle velocity, the sound pressure level, as
well as, scattering, diffraction, transmission, radiation, attenuation, and dispersion of
acoustic waves. A coupled acoustic analysis takes the fluid-structure interaction into account.
An uncoupled acoustic analysis models only the fluid and ignores any fluid-structure
interaction.
The ANSYS program assumes that the fluid is compressible, but allows only relatively small
pressure changes with respect to the mean pressure. Also, the fluid is assumed to be non-
flowing and inviscid (that is, viscosity causes no dissipative effects). Uniform mean density
and mean pressure are assumed, with the pressure solution being the deviation from the mean
pressure, not the absolute pressure.

4.2.5 COUPLED FIELDS

 A coupled-field analysis is an analysis that takes into account the interaction (coupling)
between two or more disciplines (fields) of engineering. A piezoelectric analysis, for example,
handles the interaction between the structural and electric fields: it solves for the voltage
distribution due to applied displacements, or vice versa. Other examples of coupled-field
analysis are thermal-stress analysis, thermal-electric analysis, and fluid-structure analysis.
Some of the applications in which coupled-field analysis may be required are pressure vessels
(thermal-stress analysis), fluid flow constrictions (fluid-structure analysis), induction heating
(magnetic-thermal analysis), ultrasonic transducers (piezoelectric analysis), magnetic forming
(magneto-structural analysis), and micro-electro mechanical systems (MEMS).
 5. ANSYS PROCESS

IMPORTING THE COMPONEENT FROM CAD (CREO) TOOL TO CAE TOOL (ANSYS):

STRUCTURAL ANALYSIS:-
1. Click on Ansys workbench
Static structural

3. Engineering dataright click enter values

FOR
Steel
Ex: - 200*10^9 Pa
Poison ratio: 0.30
Density: 7850 Kg/m^3
Yield strength: 250 Mpa

AL-356
Ex: 72.4*10^9 Pa
Poison ratio: 0.33
Density: 2670 kg/m^3
Yield strength: 165 Mpa

ARAMID EPOXY
Young’s modulus in x-direction: 130e9pa
Young’s modulus in y-direction: 11e9pa
Young’s modulus in z-direction: 5.5e9pa
Poison ratio in x-direction: 0.04
Poison ratio in y-direction: 0.32
Poison ratio in z-direction: 0.34
Density: 1600 kg/m^3
Yield strength: 2000Mpa
. Geometry right click import geometry import iges format model

Model imported from pro-e tool in IGES format.

Meshing: - Volume Mesh - Tetmesh.

Tet Volume Mesh.

Select geometry assign material properties
Click on static structural  supports fixed supports
 Loadspressure 2*10^6 pa apply
 Loads  force 100 N

 Inertia rotational velocity select first arm1250 RPM

 Inertia rotational velocity select second arm1250 RPM

. Solutiondeformationsolve
Repeat same process for von-misess stress, factor of safety then solve
 5.1. CIRCULAR ARTICULATED ROBOT ARM RESULTS
Material: steel
Deformation

Stress
Shear stress

Material: al-356
Deformation
Stress

Shear stress
Material: ARAMID EPOXY
Deformation

Stress
Shear stress

6. RESULTS & DISCUSSION

Circular arm robot

STEEL AL-356 ARAMID EPOXY

Deformation(mm) 0.099402 0.12171 1.4472
Stress(Mpa) 117.63 51.715 170.67
Shear stress(Mpa) 61.987 27.234 86.4

Graphs
Deformation

Deformation(mm)
1.6
1.4
1.2
1 Deformation(mm)
0.8
0.6
0.4
0.2
0
STEEL AL-356 ARAMID EPOXY

Stress

Stress(Mpa)
160
120 Stress(Mpa)
80
40
0
STEEL AL-356 ARAMID EPOXY

Shear stress
 Shear stress(Mpa)
80
40
0 Shear stress(Mpa)
L 6 XY
EE -3
5 O
ST AL EP
ID
A M
AR

Weight estimation table:

Circular arm robot (Kg)
STEEL 4.0945
Al-356 1.3927
ARAMID EPOXY 0.80

from all materials ARAMID epoxy has very less amount of weight compare to other but it is
expensive and we can use these robots when cost doesn’t matter only weight is matter (for
example: Airplane usage) . And among all steel has more weight and al-356 has less weight
and also it has very less stress values.
 7. CONCLUSION
In this project by using CAD-tool (creo-2) we created circular arm robot and analysed
with real time boundary conditions with 3 different materials (steel, al-356, ARAMID epoxy).
And calculated results of deformation and stress, and shear stress values for 3 materials
While analysing models with different materials we got different weights and different
stress and different shear stress values. From all these results we can say, in ARAMID epoxy
produces much more stress compare with other 2 materials. And we know that composite
materials generally high strength materials and also expensive. And from all materials ARAMID
epoxy has very less amount of weight compare to other but it is expensive and we can use these
robot when cost doesn’t matter only weight is matter (for example: Airplane usage) . And among
all steel has more weight and al-356 has less weight and also it has very less stress values.

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