BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Analysis of stepped Bars

Exercise No. 1 a):

Determine nodal displacements, elemental stress and reaction force for the bar shown in
geometric model below. Take E=206 X103N/mm2 and Poisson’s ratio as 0.3.

Theory: Stepped shafts are widely used in drive trains. They are generally holding large
gears and cams, which are key elements in power transfer. Mostly supported by bearings at
the end, the shaft experiences bending loads, axial thrust and torsional loads. The shaft must
have greater strength to withstand these loads.

Exercise geometric Model:

FE Model:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

GUI (Graphical User Interface) Procedure:

1) File – Clear & Start New – Do not read File – Ok.

2) File-Save as - Select suitable Drive - enter file name as ‘Bar 1.db’- ok.
3) ANSYS Main Menu - Preferences – Structural – ok.
(Used to specify type of analysis)
Preprocessing steps:
4) ANSYS Main Menu - Preprocessor – Element type – Add/Edit/Delete – Add –
Link – 3D finit stn 180 – ok – Close.
(Used to select type of finite element)
5) Preprocessor – Material Props – Material Models – Structural (double click) –
Linear – Elastic – Isotropic
EX – 206e3 (in exponential form)
PRXY – 0.3 - ok – Material – Exit.
(Used to enter Young’s Modulus and Poisson’s ratio of the given material)

6) Preprocessor – Sections – link –add- add link with

ID = 1 – OK – SECTION NAME – A - Link area – 1962.5 mm2 - apply
ID = 2 – OK – SECTION NAME – B - Link area – 1256 mm2 - apply
ID = 3 – OK – SECTION NAME – C - Link area – 137.37 mm2 - OK

7) Preprocessor – Modeling – Create – Nodes – In Active CS –

Node number - 1
X, Y, Z location in active CS – 0 0 0 - Apply
Node number - 2
X, Y, Z location in active CS – 1000 0 0 - Apply.
Node number - 3
X, Y, Z location in active CS – 1000+600=1600 0 0 -
Apply.
Node number - 4
X, Y, Z location in active CS – 1000+600+400=2000 0 0 -
Ok.

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

8) Preprocessor – Modeling – Create – Elements – Element Attributes – Element type

– 1 LINK 180 – Material number – 1 – Section number 1 A – OK
Modeling – elements – Auto numbered – Through nodes – click curser on node I & 2
– ok (Line 1 will be created)
Preprocessor – Modeling – Create – Elements – Element Attributes – Element type –
1 LINK 180 – Material number – 1 – Section number 2 B – OK
Modeling – elements – Auto numbered – Through nodes – click curser on node 2 & 3
– ok (Line 2 will be created)
Preprocessor – Modeling – Create – Elements – Element Attributes – Element type –
1 LINK 180 – Material number – 1 – Section number 3 C – OK
Modeling – elements – Auto numbered – Through nodes – click curser on node 3 & 4
– ok (Line 3 will be created)
9) Preprocessor – Loads – Define loads – Apply – Structural – Displacement – On
nodes – [Select (click)1st node] – ok – (Select) All DOF – ok.
(Used to constraint nodes)
10) Preprocessor – Loads – Define loads – Apply – Structural – Force/Moment – on
Nodes – (select node 4) – ok –
Direction of force/moment FX
VALUE Force/moment value 50000 - Ok.
(Used to apply force or moments on nodes)

Processing:
11) Solution – Solve – Current LS –ok – Solution is done – Close.
(Used to solve the problem)
Post processing:
12) Result Viewer – DOF - Choose X component of displacement – Pot results –
ICON.
(Note down the maximum displacement of the node. (0.946385)
13) General Postproc – Element Table – Define Table – Add – (Scroll down and
select) by Sequence num – (select) SMISC – (enter in blank space) SMISC, 1
by Sequence num – (select) LS – (enter in blank space) LS,1
(SMISC specifies elemental force and LS specifies axial stress in the element)
14) General Postproc – List Results – Reaction Solu – Struct force Fx – OK.
(Displays the reaction forces at each constrained node)
15) PlotCtrls – Animate – Deformed Shape – Ok.

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

(Animates the given model according to applied boundary conditions)

16) PlotCtrls – Symbols – All BC’s.
(Displays the all applied boundary conditions)
17) PlotCtrls – Style –size & shape - window – Display of element - on - ok (you can
see the 3D VIEW of bar members)
18) File – Save as – Select the Directory – Bar 1.db– Ok.

Results:

NODAL SOLUTION- DISPLACEMENTS:

Node Number UX (mm) UY (mm) UZ(mm)

1 0 0 0
2 0.12368 0 0
3 0.23963 0 0
4 0.94638 0 0

ELEMENTAL SOLUTION- STRESSES:

Element No. Stress (MPa) Force (N)

1 25.478
2 39.809
3 363.98

REACTION SOLUTION:

Node No. FX FY FZ
1 -50000 0 0
2 0 0 0
3 0 0 0
4 0 0 0

Contour plot

Nodal displacement and stress in Elements:

School of Mechanical Engineering, VIT Vellore.
 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Inference:

Conclusions:

Exercise No. 1 b):

School of Mechanical Engineering, VIT Vellore.

 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Determine nodal displacements, elemental stress and reaction force for the bar shown below.

Geometric Model:

Data: EAl=70GPa, ESt=200X103 N/mm2, Ast=2400 mm2, AAl=600 mm2 , Poisson’s ratio
as 0.3.

FE Model:

GUI (Graphical User Interface) Procedure:

1) File – Clear & Start New – Do not read File – Ok.

2) File-Save as - Select suitable Drive - enter file name as ‘Bar2.db’- ok.
3) ANSYS Main Menu - Preferences – Structural – ok.
(Used to specify type of analysis)
Preprocessing steps:
4) ANSYS Main Menu - Preprocessor – Element type – Add/Edit/Delete – Add –
Link – 3D FINITE STN 180 – ok – Close.
(Used to select type of finite element)
5) Preprocessor – Material Props – Material Models – Structural (double click) –
Linear – Elastic – Isotropic
EX – 200e3 (in exponential form) (For Steel)
PRXY – 0.3 - ok.
New Model – Material model no.2 (For Aluminium) - Linear – Elastic – Isotropic
EX – 70e3 (in exponential form)
PRXY – 0.25 - ok – Material – Exit.

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

(Used to enter Young’s Modulus and Poisson’s ratio of the given material)
6) Preprocessor – SECTION – LINK ADD- add link with section ID – 1 – Ok –
screen – section name – Steel – Link area – 1200 – apply
Preprocessor – SECTION – LINK ADD- add link with section ID – 2– Ok –
screen – section name – Aluminium – Link area – 600 – apply

7) Preprocessor – Modeling – Create – Nodes – In Active CS –

Node number - 1
X, Y, Z location in active CS – 0 0 0 - Apply
Node number - 2
X, Y, Z location in active CS – 400 0 0 - Apply.
Node number - 3
X, Y, Z location in active CS – 400+300=700 0 0 - Ok.

(Used to create nodes depending on given geometry)

8) Preprocessor – Modeling – Create – Elements – Element Attributes – TYPE-
LINK 180 - MAT – 1 – SECNUM – 1 Steel - ok.
Preprocessor – Modeling – Create – Elements -Auto number – Through nodes – select
node 1 & 2 – apply. (first link is generated for steel)
Preprocessor – Modeling – Create – Elements – Element Attributes – TYPE- LINK
180 - MAT – 2 – SECNUM – 2 Aluminum - ok.
Preprocessor – Modeling – Create – Elements -Auto number – Through nodes – select
node 2 & 3 – apply. (second link is generated for Aluminium)

9) Preprocessor – Loads – Define loads – Apply – Structural – Displacement – On

nodes – [Select (click)1st and 3rd node] – ok – (Select) All DOF – ok.
(Used to constraint nodes)
10) Preprocessor – Loads – Define loads – Apply – Structural – Force/Moment – on
Nodes – (select node 2) – ok –
Direction of force/moment FX
VALUE Force/moment value 200e3N - Ok.
(Used to apply force or moments on nodes)

Processing:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

11) Solution – Solve – Current LS –ok – Solution is done – Close.

(Used to solve the problem)
Post processing steps:
12) General post processor – Result viewer - - choose a result items – nodal solutions
– DOF solutions – X component – icon plot results – capture image to Lab
report – close the window.
13) General post processor – Plot results – contour plots – nodal solutions – DOF
solutions – X – Component of displacement – ok (capture the image for
report) & tabulate the maximum displacement 0.27-27 mm)
14) General Postproc – Element Table – Define Table – Add – (Scroll down and
select) by Sequence num – (select) SMISC – (enter in blank space) SMISC, 1
– apply
General Postproc – Element Table – Define Table – Add – (Scroll down and
select) by Sequence num – (select) LS – (enter in blank space) LS, 1 – ok –
close the window.
(SMISC specifies elemental force and LS specifies axial stress in the element)
15) General Postproc – List Results – Nodal solutions – DOF solutions - X-
component of displacement - ok
(Lists the displacements at each node)
16) General Postproc – List Results – Elemental table data – (select both SMISC and
LS) – ok.
(Displays the stress of each element)
17) General Postproc – List Results – Reaction Solu – Struct force Fx – OK.
(Displays the reaction forces at each constrained node)
18) PlotCtrls – Animate – Deformed Shape – Ok.
(Animates the given model according to applied boundary conditions)
19) PlotCtrls – Symbols – All BC’s.
(Displays the all applied boundary conditions)
PlotCtrls – Style – sixze & shape – 3D View of BAR structure. (Capture to
report)
20) File – Save as – Select the Directory – Bar 2.db – Ok.

Tabulate the nodal displacements, stresses & Reaction forces:

Results:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

NODAL SOLUTION- DISPLACEMENTS:

Node Number UX (mm) UY (mm) UZ(mm)

1 0 0 0
2 0.11494 0 0
3 0 0 0

ELEMENTAL SOLUTION- STRESSES:

Element No. Stress (MPa) Force (N)

1 68966. 57.471
2 -45977. -76.628

REACTION SOLUTION:

Node No. FX FY FZ
1 -0.13793E+006 0 0
3 -62069. 0 0

Contour plot

Nodal displacement and stress in Elements:

School of Mechanical Engineering, VIT Vellore.

 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Inference:

Conclusions:

School of Mechanical Engineering, VIT Vellore.

 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Exercise No. 1c: Determine nodal displacements, elemental stress and reaction force for the
bar shown below. Take E=2 X105N/mm2 and Poisson’s ratio as 0.3. A 1=1000 mm2,
A2=500mm2

Theory: Machine tapered shaft is a shaft with a difference between left and right diameter,
and any difference of diameter will cause the formation of taper as shown in below figures.
For ease of hydraulic fit assembly and disassembly, all shafts and coupling hubs are tapered.
The process of taper measurement involves measurement of taper angle of the given drafted
surface. Since, there is no direct method available for measuring this angle, we use the ratio
of two different lengths concerning the taper angle and then with the use of trigonometry, the
required angle can be obtained.

Geometric Model:

Equivalent Geometric Model: Tapered bar is modified into stepped bar as shown below:

(1000+500)/2= 750mm2
A1Eq=(1000+750)/2=875 mm2
A2Eq=(750+500)/2=625 mm2

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

FE Model:

GUI (Graphical User Interface) Procedure:

1) File – Clear & Start New – Do not read File – Ok.

2) File-Save as - Select suitable Drive - enter file name as ‘Bar 6.db’- ok.
3) ANSYS Main Menu - Preferences – Structural – ok.
(Used to specify type of analysis)
Preprocessing steps:
4) ANSYS Main Menu - Preprocessor – Element type – Add/Edit/Delete – Add –
Link – 3D finit stn 180 – ok – Close.
(Used to select type of finite element)
5) Preprocessor – Material Props – Material Models – Structural (double click) –
Linear – Elastic – Isotropic
EX – 2e5 (in exponential form)
PRXY – 0.3 - ok – Material – Exit.
6) Preprocessor – SECTIONS – Add – Add link section – ID – 1 – OK, Section name
- first section – Link area- 875 – apply,
Preprocessor – SECTIONS – Add – Add link section – ID – 2 – OK, Section name -
second section – Link area- 625 – ok.

7) Preprocessor – Modeling – Create – Nodes – In Active CS –

Node number - 1
X, Y, Z location in active CS – 0 0 0 - Apply
Node number - 2

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

X, Y, Z location in active CS – 187.5 0 0 - Apply.

Node number - 3
X, Y, Z location in active CS – 375 0 0 - OK.
(Used to create nodes depending on given geometry)

8) Preprocessor – Modeling – Create – Elements – Element Attributes – TYPE- 1

LINK180- MAT – 1 – SECTION NUM – 1 FIRST SECTION – Ok
Preprocessor – Modeling – Create – Elements -Auto number – Through nodes – select
node 1 & 2 – apply.

8) Preprocessor – Modeling – Create – Elements – Element Attributes – TYPE- 1

LINK180- MAT – 1 – SECTION NUM – 2 SECOND SECTION – Ok
Preprocessor – Modeling – Create – Elements -Auto number – Through nodes – select
node 2& 3 – apply. (link two is generated)
(Used to assign the area 1to step 1 of the given bar.)

9) Preprocessor – Loads – Define loads – Apply – Structural – Displacement – On

nodes – [Select (click)1st node] – ok – (Select) All DOF – ok. (Used to
constraint nodes)
10) Preprocessor – Loads – Define loads – Apply – Structural – Force/Moment – on
Nodes – (select node 3) – ok –
Direction of force/moment FX
VALUE Force/moment value 1000 - Ok.
(Used to apply force or moments on nodes)

Processing:
10) Solution – Solve – Current LS –ok – Solution is done – Close.
(Used to solve the problem)
Post processing steps:
11) General post processor – Plot results – contour plots – nodal solutions – DOF
solutions – X – Component of displacement – ok (capture the image for
report) & tabulate the maximum displacement 0.002571 mm)
12) General post processor – Result viewer - - choose a result items – nodal solutions
– DOF solutions – X component – icon plot results – capture image – close the
window.

School of Mechanical Engineering, VIT Vellore.

 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

13) General Postproc – Element Table – Define Table – Add – (Scroll down and
select) by Sequence num – (select) SMISC – (enter in blank space) SMISC, 1
- apply
by Sequence num – (select) LS – (enter in blank space) LS,1 – ok – close the
window.
(SMISC specifies elemental force and LS specifies axial stress in the element)
14) General Postproc – List Results – Nodal solutions – DOF solutions - X-
component of displacement - ok
(Lists the displacements at each node)
15) General Postproc – List Results – Elemental table data – (select both SMISC and
LS) – ok.
(Displays the stress of each element)
16) General Postproc – List Results – Reaction Solu – Struct force Fx – OK.
(Displays the reaction forces at each constrained node)
17) PlotCtrls – Animate – Deformed Shape – Ok.
(Animates the given model according to applied boundary conditions)
18) PlotCtrls – Symbols – All BC’s.
(Displays the all applied boundary conditions)
19) PlotCtrls – Style – sixze & shape – 3D View of BAR structure. (Capture image to
report)
20) File – Save as – Select the Directory – Bar3.db – Ok.

Tabulate the nodal displacements, stresses & Reaction forces:

Results:

NODAL SOLUTION- DISPLACEMENTS:

Node Number UX (mm) UY (mm) UZ(mm)

1 0 0 0
2 0.10714E-002 0 0
3 0.25714E-002 0 0

ELEMENTAL SOLUTION- STRESSES:

Element No. Stress (MPa) Force (N)

1 1000 1.1429
2 1000 1.6

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

REACTION SOLUTION:

Node No. FX FY FZ
1 -1000 0 0

Contour plot

Nodal displacement and stress in Elements:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Inference:

Conclusions:

School of Mechanical Engineering, VIT Vellore.