Computer Aided Engineering with Ansys: The Final Project Description

Hossein Talebi Timon Rabczuk , May 18, 2010

Abstract In this manuscript we explain the nal project titles oered for the Computer Aided Engineering(CAE) with ANSYS course. It is also explained how the nal report should be organized and presented. It is highly recommended that the instructions here are followed carefully. KEY WORDS: Computer Aided Engineering, ANSYS, Final Project, Finite Elements

Introduction

In this semester, we have oered the a course named Computer Aided Engineering with ANSYS in which the basics of using nite element methods using two commercial software are taught. The software are ANSYS for linear/nonlinear nite element calculations with implicit dynamics and LS-DYNA as the linear/nonlinear for explicit dynamic nite element and meshfree methods. The nal evaluation and grading for this course is based on the report of nal project and an oral presentation. The description of the format of the nal reports and project titles are brought here. It is crucial to follow this manuscript step by step in order to write a descent nal report. The nal grading will be based on the report itself(organization and formatting),the results you obtain, how you approach the problem and your oral presentation
Institute of Structural Mechanics, BauhausUniversitat Weimar, Marienstrasse 15, D-99423 Weimar, Germany; email: [email protected] Institute of Structural Mechanics, BauhausUniversitat Weimar, Marienstrasse 15, D-99423 Weimar, Germany; email:[email protected]

quality. You can use any commercial software such as ABAQUS in order to do the project. However, knowing he ANSYS and LS-DYNA will be sucient to nish the task.

2
2.1

The Final Report

The deadline of the nal report is on Wednesday 25th August 2010 at 4pm and it will not be extended. You will have the option of presenting your reports before 5th August in order to get an initial evaluation. This initial evaluation has no inuence on you nal grade and it is only for your advantage. It will take one week for the initial evaluation.

2.2

Format

The nal report should be presented with the following characteristics: 1. Language: English 2. Paper size: A4 3. Number of pages: minimum of 10 pages, there is no maximum limit 4. Color: black and white only 5. Margins: at least 1in from each side 6. Spacing: double spaced 7. Font : Arial or Times New Roman 8. Font size: 11pt The paper should nally look like a scientic paper. It is recommended to type the report in LATEX. I will share this manuscript later on and thus you will have a LATEX template for your reports.

2.3

Organization

The nal report should include the following sections and the corresponding order: The title, the author, the aliation, the abstract, introduction, methodology, result and discussion, conclusion and references. In the introduction, you need to briey explain the problem in hand, dierent aspect of the problem, how you approach the problem and possibly some literature review. This literate review will briey reviews the work of other people and their main achievements. The literature review must contain at least 20 related citations. The references must be listed at the end of the report in the References section. The methodology section may be divided into few subsections with respect to the problem. In this section, you need to explain the problem in detail, the methods that you use to solve the problem like element types, material parameters and so on. All the data that you borrow from some other sources like articles, reports, thesis etc. must be referenced. In the result section, you will present the results in terms of gures and graphs and discuss what you have obtained, the errors and whatever you think it is necessary. Moreover, you need to start the result section with the validation of your model. The validation for example can be the convergence test of some initial problem.

2.4

Citation

As I mentioned earlier, you need to bring references in several parts of the report. The reference list must have a standard format and must be consistent everywhere. Refer to online sources for description of the standard reference formats. A sample of citation is like this [1, 2]

The Oral Presentation

After submitting the nal report, we will have an oral presentation where everybody presents his work in 12+3 minutes. We might invite external audience from ISM as well. The exact date and venue of the presentations will be announced in the near future. The presentation will have one third of the whole grade.

Figure 1: Schematic representation of rubber pad forming process and the studied model (in mm).

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4.1

Project Description
Project 1: Finite Element Modeling of Flexible Forming Process

Flexible forming enables the production of sheet metal parts with complex contours and bends by utilizing a exible medium, such as natural or synthetic rubber, as one half of a conventional die set. This project is concerned with nite element simulation of this process. A 2D schematic representation of the problem is illustrated in Fig.1. The forming process is performed as follows: The polyurethane chamber advances the form block and the exible rubber will form the blank. The blank can be made of Steel or Aluminum. Both the blank and rubber will undergo large deformation which for the case of blank it is plastic as well. You need to model the physical system in 3D with solid elements. There are of course contact among the components which has to model accordingly. There is also friction between the surfaces which plays an important on the outcome. Material Properties: The blank is modeled as Elastoplastic multilinear material. The elasticity moduli (E) and Poissons ratios () are 71 and 200 GPa, and 0.334 and 0.3 for Aluminium and steel specimens, respectively. The stress versus strain graphs for Steel and Aluminum are shown in the Fig.2 as well. Two types of rubber pad is used here and both are modeled as Monney-Rivlin material with the properties listed in the Table 1. The form block

Table 1: Mechanical properties of rubber pad materials used in the simulations Polyurethane Mooney-rivlin Mooney-rivlin G(MPa) E(MPa) Poissons rubber constants constants ratio() C10(MPa) C01(MPa) Type 1 0.382 0.096 0.956 2.868 0.49997 Type 1 0.736 0.184 1.839 5.517 0.49997

Figure 2: True stresstrue strain diagrams for Aluminium and Steel blank materials. material is assumed to be steel with a modulus of elasticity of 200 GPa and a Poissons ratio of 0.3. Contact:Assume simple Colombs friction between the contacts with a value of 0.2 and 0.1 for lubricated case. Advance the chamber for 5mm and compute the deformation and stresses in the model. The simulation has to be done with dierent friction coecients and two types of blank material.

4.2

Project 2: Finite Element Simulation of Magnesium Alloy Stamping

In this project we would like to simulate sheet metal forming of magnesium alloy under certain temperature conditions. This certain conditions is a special deep-drawing technique with heating at the ange and cooling at the die-throat and punch part. There is some experimental data from the literature and you need to form a FE simulation according to the experiment and nally compare your results to the experiments.

4.2.1

Experimental condition The deep-drawing

Deep-drawing machine with local heating and cooling system:

experiment was carried out using a universal testing machine (maximum load: 100 kN). The equipment apparatus can locally heat the ange of the blank and the drawn-cup wall can be cooled directly by injected water. A schematic illustration of the local heating and cooling deep-drawing set-up is shown in Fig.3. Table 2 shows the dimensions of the punch and die used. Material: A magnesium alloy sheet (AZ31-O) of 0.5mm thickness was used in the experiment. Fig.4 shows the material properties obtained from a tensile test. The direct injection of cooling water was carried out simultaneously with punch cooling. The punch speed was 200 mm/min. Graphite grease was applied as a lubricant on the die side of the blank only. The blank was heated to about 400 C at the ange. Cooling was carried out only by direct injection of water to the drawn-cup without punch cooling. 4.2.2 FE simulation conditions

Table 3 shows the nite element material model denition for punch, blank holder, die and blank material that you need to use in your simulation. You need to model the magnesium material using shell elements with circular sheet of outer radius of 118.8mm (drawing ratio, DR = 3.6)and thickness of 0.5 mm. You also need to simulate the process in the case of the heated and cooled material. The properties of the magnesium alloy can be modeled as bilinear isotropic with properties that change with temperature. The punch, blank holder and die must also be modeled using shell elements and given the material properties of mild steel, and their shape and dimensions corresponded to actual experimental conditions from the tensile stressstrain curves obtained. The friction coecient between the material and punch, and die and blank holder is 0.1. You ultimately need to predict possible fracture of the blank. To make the FE simulation easier, you might start with a 2D axisymmetric model with constant temperature and later enhance the model to 3D with temperature gradients.

4.3

Self-dened Projects

You may dene you own project to present it for your nal project. If you do so, you need to write the detailed description of your project and get my approval before attempting to do it.

Figure 3: Schematic of circular-cup deep-drawing system with local heating and cooling.

Table 2: Dimensions of punch and die used in the experiment Punch shoulder radius, rp (mm) 4 Punch diameter, Dp (2Rp )(mm) 33 Die shoulder radius, rd (mm) 3 Die inner diameter, Dd (2Rd )(mm) 36.5

Figure 4: Eect of forming temperature on material properties of magnesium alloy used (F is the principal stress at fracture).

Table 3: FE simulation conditions Punch, die, blank holder Shell elements Rigid 8.19E 6 0.3 210 Blank

Element Material model Density (kg/mm3) Poissons ratio Temperature (C) Yield stress (GPa) Youngs modulus (GPa) Tangent modulus

Bilinear isotropic 1.66E 6 0.3 100 0.065 32.5 2.636

200 0.098 49 1.625

300 0.49 24.5 0.812

Please kindly note that unapproved projects will not be considered.

References
[1] T. Belytschko and T. Black, Elastic crack growth in nite elements with minimal remeshing, International Journal for Numerical Methods in Engineering 45 (1999), no. 5, 601620. [2] T. Rabczuk and T. Belytschko, Cracking particles: A simplied meshfree method for arbitrary evolving cracks, International Journal for Numerical Methods in Engineering 61 (2004), no. 13, 23162343.