Escolar Documentos
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Huei-Huang Lee
Contents 1
Contents
Preface 2
Section A. Sketching 5
Preface
ANSYS DesignModeler
ANSYS DesignModeler is a CAD program running under ANSYS Workbench environment. The DesignModeler can
create geometries as sophisticated as any other CAD programs. Yet, many engineers choose to create geometry
models using other CAD programs (e.g., Pro/Engineer, SolidWorks) and then import them into an ANSYS simulation
module (such as Mechanical) for simulations. One of the reasons may be that, other than the training materials
provided by the ANSYS Inc., there exist no tutorials in the bookstore. That is the main reason that I created this book.
The DesignModeler is designed specifically for creating models which can be seamlessly imported into an ANSYS
simulation modules (such as Mechanical). Therefore, if a geometry model is solely used for ANSYS simulations, I
strongly suggest that we create the model from scratch using DesignModeler, rather than other CAD programs, to
avoid any unnecessary incompatibilities.
Companion Webpage
A webpage dedicated to this book is maintained by the author:
http://myweb.ncku.edu.tw/~hhlee/Myweb_at_NCKU/ADM14.html
The webpage contains links to finished project files of each exercise and appendix. If everything works smoothly, you
do not need them at all. Every model can be built from scratch according to the steps described in the book. The
author provides these project files just in some cases you need them. For examples, if you have troubles to follow the
geometry details in the textbook, you may need to look up the geometry details from the project files.
Huei-Huang Lee
Associate Professor
Department of Engineering Science
National Cheng Kung University
Tainan, Taiwan
hhlee@mail.ncku.edu.tw
myweb.ncku.edu.tw/~hhlee
4
Section A. Sketching 5
Section A
Sketching
An assembly is a combination of parts. From manufacture point of view, a part is a basic unit for manufacturing
process. Many parts can be created by a two-step operation: drawing a 2D sketch on a plane and then generate a 3D
body by extrusion, revolution, sweeping, or skin/lofting.
The exercises in Section A are designed to introduce the 2D sketching techniques provided by the
DesignModeler. Each part created in Section A involves drawing a sketch and then extrude to generate a 3D solid
body representing the part.
Although it can be used as a general purpose CAD software, the DesignModeler is particularly designed for
creating geometric models to be analyzed (simulated) under the ANSYS environment. To let the readers understand
what it means by analysis (simulation) as early as possible, an exercise (Exercise 1a) is appended right after Exercise 1
to perform a structural analysis for the part created in Exercise 1. However, the reader has option to skip Exercise 1a
without affect the subsequent learning of geometric modeling.
6 Exercise 1. Arm
Exercise 1
Arm
1-1 Introduction
3 × D0.25
R0.25
[3] The global
2.25
coordinate
system. [2] Details of
the arm.
Unit: in.
Thickness: 0.125 in.
R0.5
Exercise 1. Arm 7
[7] Double-click
<Geometry> to start
up the DesignModeler.
[3] Click the plus sign (+) to
expand <Component
Systems>. The plus sign
becomes minus sign.
Speech Bubbles
1. In this book, each exercise is divided into subsections (e.g., 1-1, 1-2). In each subsection, speech bubbles are
ordered with numbers, which are enclosed by pairs of square brackets (e.g., [1], [2]). When you read, please follow
the order of speech bubble; the order is significant.
2. The square-bracket numbers also serve as reference numbers when referred in other text. When in the same
subsection, we simply refer to a speech bubble by its number (e.g., [1], [2]). When in the other subsections, we refer
to a speech bubble by its subsection identifier and its bubble number (e.g., 1-2[1]).
3. When a circle is used with a speech bubble, it is to indicate that mouse or keyboard ACTIONS are needed in that
step [1, 3, 4, 7, 9, 10]. A circle may be filled with white color [1, 4, 7] or unfilled [3, 9, 10]. A speech bubble without a
circle [2, 8] or with a rectangle [6] is used for commentary only, i.e., no mouse or keyboard actions are needed.
Workbench Keywords
A pair of angle brackets is used to highlight an Workbench keyword (e.g., <Component Systems> in [3]).
Sometimes, if the angle brackets do not add any clarity, they may be dropped (e.g., DesignModeler).
[8] Select
<Diameter> tool.
[9] Select the circle,
move the mouse
outward, and then click
[10] In the <Details to create a dimension.
View>, type 0.25 for Note that the circle turns
the diameter. blue, meaning the circle
has fully constrained
(fixed in the space).
Exercise 1. Arm 11
[3] Select
<Circle> tool.
[7] Select
<Dimension> toolbox
and then select
<Horizontal> tool.
[13] Select
<Vertical> tool.
1-12 Review
Workbench GUI
In the <Workbench GUI> (1-2[2]), you can create a system (1-2[4]) and start up DesignModeler (1-2[7]). Other
capabilities will be introduced later.
Project Schematic
Created systems appear on the <Project Schematic>, an area in the <Workbench GUI>.
DesignModeler GUI
Geometries are created entirely within the <DesignModeler GUI> (1-2[8]).
Length Unit
Before creating a model in the DesignModeler, you must choose a length unit (1-2[9, 10]). The length unit cannot be
changed thereafter.
Mouse Operations
Click -- Left-click the mouse button.
Select -- Left-click the mouse button.
Double-Click -- Left-click the mouse button twice.
Zoom In/Out -- Scroll the mouse wheel
Pan -- Move the mouse while holding control-left-button.
Other mouse operations will be introduced later.
Look At Face/Plane/Sketch
Clicking this tool to rotate the view angle so that you look at the current sketching plane (1-3[3]).
Ruler
The ruler (1-3[4, 5]) is to help you obtain a better feeling of the drawing scale. In this book, we always leave the ruler
off to make more sketching space.
Scrolling
In case you don't see a tool in a toolbox, scroll down/up to reveal the tool (1-4[2]). There is also a scrolling controller
for the <Details View>.
Auto Constraints
P -- The mouse cursor snaps to a point (or the origin) (1-4[4]).
R -- The radius is the same as another circle (or arc) (1-4[5]).
C -- The mouse cursor is coincident to a line (or an axis) (1-5[4, 6]).
Other auto constraint features will be introduced later.
Color Codes
Greenish-blue -- Under-constrained (1-8[2])
Blue -- Fully constrained (fixed in the space) (1-4[9], 1-5[10,14]).
Red -- Over-constrained
Zoom To Fit
Click this tool to fit the entire sketch (in the <Sketching> mode) or entire model (in the <Modeling> mode) into the
graphics window (1-4[14]).
Extrude
This tool extrude a sketch by a specified depth to create a 3D body (1-10[1-5]). More exercises will be given later.
Isometric View
Click the little cyan sphere of the triad will rotate the view into an isometric view (1-10[3]). Other view controls will
be introduced later.
Display Plane
This tool is to toggle the display of current sketching plane and the sketches it contains (1-10[6]).
Exercise 1a. Structural Analysis of the Arm 21
Appendix:
Exercise 1a
Structural Analysis of the Arm
[6] Double-click to
[4] Drag <Geometry>... start up the
<Mechanical>.
Exercise 1a. Structural Analysis of the Arm 23
[4] Click
<Apply>.
Exercise 2
Ratchet Stop
R0.56 Y
40 [3] Details
p: of the
Slo ratchet stop.
6
0.1
0.125
R0.34
Unit: in.
R0.188
Thickness: 0.125 in. 0.57
Exercise 2. Ratchet Stop 29
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit (1-2[9, 10]).
[3] Draw a
[2] Rotate to
circle centered at
XYPlane view
the plane origin
(1-3[3])
(1-4[1-5]).
[1] Switch to
<Sketching
Mode> (1-3[2]).
[1] To specify an angle dimension, you need to select two lines (or axes).
When you select a line (or axis), the end near where you click become
the "arrow end" of the line. The angle is then measured from the first
line to the second line in a counter-clockwise fashion.
Wrap Up
Close DesignModeler, save the project as "Stop," and exit the
Workbench (1-11[1-3]).
34 Exercise 2. Ratchet Stop
2-9 Review
Context Menu
When you right-click the mouse, a menu pops up. The contents of the menu
depends on when and where you right-click the mouse. The menu is thus
called the <Context Menu> (2-5[5]). Try to right-click anywhere in the
graphics area, <Details View>, or <Tree Outline> (1-10[2]), to see the
contents of the <Context Menu>.
<Dimension/General> Tool
This tool can be used for any type of dimension. For a line, the default is to
create a <Length> dimension (2-4[2]). For a circle or arc, the default is to
create a diameter dimension. If the default is not what you want, right-click
anywhere in the graphics window to bring up the <Context Menu> [1] and
choose a dimension type.
<Dimension/Angle> Tool
To specify an angle dimension, you need to select two lines (or axes). When
you select a line (or axis), the end near where you click become the "arrow
end" of the line. The angle is then measured from the first line to the second
line in a counter-clockwise fashion (2-5[1-4]). [1] This is the
If you made mistakes (click on wrong ends or in a wrong order) and <Context Menu> when
the angle is not what you meant, right-click anywhere in the graphics window <Dimension/General> is
activated.
to bring up the <Context Menu> [2] and choose <Alternate Angle>. Repeat
this until the correct angle appears before you click to locate the angle
dimension (2-5[5]).
<Draw/Line> Tool
This tool draws a line by defining two end points (2-4[1])).
<Constraints/Tangent> Tool
This tool impose a <Tangent> constraint between two curves or between a
line and a curve (2-6[6, 12]).
Exercise 3
Ratchet Wheel
Y
60
15
[2] Details of
the ratchet
wheel.
1.00
D0.25
Unit: in.
Thickness: 0.25 in.
36 Exercise 3. Ratchet
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit.
[3] Draw
another line like
this.
[3] After
trimming, a single
tooth remains.
[3] Right-click
anywhere in the
graphics window to
bring up the
<Context Menu>, and
select <End/Use Plane
Origin as Handle>.
Now the tooth has
been copied to a
"clipboard."
[10] Type 90
(degrees) for the
rotating angle.
[11] Repeat
steps [5, 6].
Wrap Up
Close DesignModeler, save the project as "Ratchet," and exit
the Workbench.
Exercise 3. Ratchet 43
3-8 Review
<Modify/Replicate> Tool
<Replicate> is equivalent to a <Copy> followed by a <Paste>.
Ending a Tool
You can press <Esc> to end a tool (3-6[8, 12]). Besides, the <Context Menu> often provides an <End> option to end
a tool (3-6[5, 6]).
44 Exercise 4. Cover Plate
Exercise 4
Cover Plate
4-1 Introduction
2 × R0.188 2 × D0.201
8 × R0.15 Y
0.25
0.376
0.312 0.312 2.00
[1] Details of
the cover plate.
1.25
6 × R0.06
0.75
0.25
[2] Double-click
<Geometry> cell to start
up the DesignModeler.
Select <Inch> as the length
unit.
[1] Select
<Modify/Fillet>
and type 0.06 (in.)
for the <Radius>.
[4] Select
<Modify/Fillet>
again and type 0.15
(in.) for the
<Radius>.
50 Exercise 4. Cover Plate
Wrap Up
Close DesignModeler, save the project as "Cover," and exit the
Workbench.
Exercise 4. Cover Plate 53
4-8 Review
<Draw/Rectangle>
Draws a rectangle by defining two diagonally opposite points. The edges of the rectangle are either horizontal or
vertical. To draw a rectangle at an arbitrary orientation, please use <Draw/Rectangle by 3 Points>.
<Draw/Polyline>
This tool allows you to draw a series of connected lines, called a polyline. The polyline can be closed or open. After
defining the last point, choose <Open End> or <Closed End> from the <Context Menu>.
Auto Constraints
H -- Horizontal
V -- Vertical
Note:
For a comprehensive description of sketching tools, please refer to the following ANSYS on-line reference:
ANSYS Help System//DesignModeler User Guide//2D Sketching
54 Section B. Part Modeling
Section B
Part Modeling
As mentioned in the opening of Section A, many parts can be created by a two-step operation: drawing a 2D sketch on
a plane and then generate a 3D body by extrusion, revolution, sweeping, or skin/lofting.
A more complicated part often can be viewed as a series of the two-step operations; each two-step operation
either add material to the existing body or cut material from the existing body. The exercises in Section B are
designed to introduce the 3D modeling techniques for more complicated parts.
Exercise 5. Crank 55
Exercise 5
Crank
5-1 Introduction
In this exercise, we'll create a 3D solid model for a crank, of which the details are shown in the figure below. Note
that a global coordinate system is set up and shown in the figure.
The crank model can be viewed as a series of three two-step operations; each involves drawing a sketch on
XYPlane and then extrude the sketch to generate a material. The materials are either add to the existing body or cut
from the existing body.
Y Y
2 × D10
2 × R10
Unit: mm.
75
R10
X Z
R22
D30 65
D20 8
20
56 Exercise 5. Crank
[2] Double-click
<Geometry> cell to start
up DesignModeler.
[10] Click
[9] Click <Display Plane>
<Generate>. to turn off the
[3] Click plane display.
<Extrude>.
[14] The
<Extrude1> uses
<Sketch1> as the
base geometry.
[2] A new sketch (Sketch2) is created. Note that, for the first
sketch of a plane, you don't need to explicitly click <New
Sketch>. However, for additional sketches on the same plane,
you need to click <New Sketch>. Remember that the [4] Click <Look At
drawing entities always belong to the active sketch. Face/Plane/
Sketch>.
[2] Click
<Apply>.
[3] Type 20
[5] Click (mm).
<Generate>.
[7] <Sketch2> is
added under
[8] Click the XYPlane.
plus sign <+> to
expand
<Extrude2>.
[9] <Extrude2>
uses <Sketch2> as
the base
geometry. The
<Extrude2> is
simply a cylinder.
[2] Click
<Apply>.
[1] Click
<Extrude>. [3] Select <Cut
Material>.
[4] Select
<Through All>.
[5] Click
<Generate>.
[7] <Sketch3> is
added under
XYPlane.
Wrap Up
Close DesignModeler, save the project as "Crank," and exit the
Workbench.
Exercise 5. Crank 63
5-9 Review
Modeling Mode
In the modeling mode (5-4[4]), several modeling tools become available, including Extrude, Revolve, Sweep, Skin/Loft,
Thin/Surface, Blend, Chamfer, Point, etc. In addition, a <Tree Outline> is displayed.
Model Tree
<Tree Outline> (5-4[11]) contains an outline of the model tree, the data structure of the geometric model. Each branch
of the tree is called an object, which may contain one or more objects. At the bottom of the model tree is a part
branch, which is the only object that will be exported to <Mechanical>. By right-clicking an object and selecting a tool
from the context menu, you can operate on the object, such as delete, rename, duplicate, etc.
The order of the objects is relevant. <DesignModeler> renders the geometry according to the order of objects
in the model tree. New objects are normally added one after another. If you want to insert a new object BEFORE an
existing object, right-click the existing object and select <Insert/...> from the context menu. After insertion,
<DesignModeler> will re-render the geometry.
Exercise 6
Geneva Gear Index
6-1 Introduction
In this exercise, we'll create a 3D solid model for a Geneva gear index, of which the details are shown in the figure
below. Note that a global coordinate system is set up and shown in the figure.
Y Y
5× 0
5 × R0.63 .2
Unit: in.
29
1.5
X Z
D0.25
D0.5
D2.47
D1.25
0.25
0.44
Exercise 6. Geneva Gear Index 65
[8] Apply a
<Constraints/Tangent>
on the lower circle and
the horizontal line.
Exercise 6. Geneva Gear Index 67
[10] Click
<Generate>.
70 Exercise 6. Geneva Gear Index
[4] Click
<Generate>.
[9] Click
<Generate>.
6-7 Review
<Create/Pattern>
This tool allows you to create copies bodies in three types of pattern: Linear, Circular, and Rectangular (6-5).
<Create/Primitive/Cylinder>
This tool creates a cylinder by specifying its origin, axis, and radius (6-6). The origin and axis are defined by referring to
the active plane coordinate system (1-12).
72 Exercise 7. Yoke
Exercise 7
Yoke
7-1 Introduction
The yoke is a part of a universal joint [1]. In this exercise, we'll create a 3D
solid model for the yoke, of which the details are shown in the multiview
drawings below. Note that a global coordinate system is also shown in the
figure.
D1.20
Z
Y Y
Unit: in.
R1.00
3.55
X Z
1.50
D0.75
R1.00
2 × 0.75
Exercise 7. Yoke 73
[6] Use
<Dimensions/
General> to
specify a length of
2.50 (in.).
[12] Click
<Generate>.
[9] Click
<Extrude>.
[3] Click
<Apply>.
[3] Click
<Generate>.
[6] Select
<Reversed> for
<Direction>. Now,
the extrusion
direction is the -Z
direction.
Wrap Up
Close DesignModeler, save the project as "Yoke," and exit the Workbench.
78 Exercise 7. Yoke
7-7 Review
Extrude Direction
There are four options you can choose for the extrusion direction: <Normal>, <Reversed>, <Both -- Symmetric>, and
<Both -- Asymmetric>. In <Normal> case, the extrusion direction is the Z-direction of the sketching plane. When
<Reversed> is selected, the extrusion direction reverses to the -Z-direction (7-6[6]). For <Both -- Symmetric>, the
extrusion is along both +Z and -Z directions with the same depth (defined by <Depth>) (7-3[10]). For <Both --
Asymmetric>, the extrusion is along both +Z and -Z directions with the different depths (defined by <Depth> and
<Depth 2>).
<Blend/Fixed Radius>
This tool can be used to place rounds or fillets on a body (7-4). The fillets are specified on edges, while the rounds
can be specified on edges or faces. When faces are specified for rounds, the rounds are placed on the enclosing edges.
Exercise 8
Support
8-1 Introduction
The support is a part of the clamping
mechanism mentioned in Exercise 1 [1]. In
this exercise, we'll create a 3D solid model
for the support, of which the details are
shown in the multiview drawings below.
Note that a global coordinate system is also
shown in the figure.
Unit: in.
2 × R0.100
0.750
0.250
Y
Slo
pe
:4
R0.156
5
1.250
6 × D0.25
X Z
0.375 1.250
0.875
0.125
0.625
[11] Click
<Extrude>. [13] Click
<Generate>.
X
again until it is correct.
Z
[4] Click the
yellow area to
bring up <Apply/
Cancel> buttons.
[13] Click
<Extrude>.
[15] Click
<Generate>.
X
[6] Click <Generate>; a
<Plane5> is created.
Exercise 8. Support 85
[16] Click
<Generate>.
[12] Click
<Extrude>.
[14] The
<Direction>
automatically
becomes
<Reversed>.
[15] Select
<Through All>.
86 Exercise 8. Support
[5] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Support,"
and exit the Workbench.
Exercise 8. Support 87
8-7 Review
Appendix:
Exercise 8a
Structural Analysis of the Support
163 lbf
380 lbf
[6] Double-click to
[4] Drag <Geometry>... start up the
<Mechanical>.
90 Exercise 8a. Structural Analysis of the Support
[9] Click
<Apply>.
[2] Control-select
the three cylindrical
faces on the
horizontal plate.
[3] And
control-select
this face.
92 Exercise 8a. Structural Analysis of the Support
[7] Click
<Apply>.
[8] Type 0
(in.) for <Z
[5] Select <Supports/ Component>.
Displacement.
Wrap Up
Close <Mechanical>, save the project as "Support-a," and exit the
Workbench.
94 Exercise 9. Wheel
Exercise 9
Wheel
9-1 Introduction
The main purpose of this exercise is to introduce another modeling tool (than <Extrude>): <Revolve>, which takes a
sketch as the profile and revolves about an axis to create a 3D solid body.
We'll create a 3D solid model for a wheel, of which the details are shown in the multiview drawings below. A
global coordinate system is also shown in the figure.
Note that the wheel is axisymmetric. An axisymmetric body can be created by drawing a profile then revolting
about its axis to generate the 3D solid body.
45
Y
Unit: in.
X Z
D1.00
D1.50
D3.50
D4.00 0.25
0.50
0.75
Exercise 9. Wheel 95
[5] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Wheel," and exit the Workbench.
9-5 Review
Exercise 10
Transition Pipe
10-1 Introduction
The transition pipe is used to connect two pipe segments. In this exercise, we'll create a 3D solid model for the
transition pipe, of which the details are shown in the multiview drawings below. A global coordinate system is also
shown in the figure.
The main purpose of this exercise is to introduce another modeling tool: <Sweep>, which takes a sketch as the
path and another sketch as the profile; the profile then "sweeps" along the path to create a 3D solid body.
Note that it is possible to create the curved pipe by using of <Revolve> tool (Exercise 9), however, as an
exercise, we decide to create the curved pipe by using <Sweep>.
Y Y
R1/16"
2 × D3.50
2 × D2.50
8 × D0.25
R3.50
Unit: in.
D1.00
R1/8"
R2.50
2 × 0.25
X Z
Exercise 10. Transition Pipe 99
[1] Select
<ZXPlane> (or
click ZXPlane in [1] On the ZXPlane, draw two
the model tree). concentric circles like this. This
sketch will be used as the
profile of the curved pipe.
100 Exercise 10. Transition Pipe
[3] Click
<Generate>.
[1] Click
<Sweep> on the
<Toolbar>.
[2] Select <Sketch2>
(from the model tree)
for the <Profile> and
select <Sketch1> (from
the model tree) for the
<Path>.
[4] Click
<Extrude>.
[6] Click
<Generate>.
[6] Click
[3] Click the yellow <Generate>.
[5] Click color to bring up <Plane5> is
<Apply>. <Apply/Cancel> created.
buttons.
[8] Select
<Move>.
[9] Select the
existing end plate.
[12] Click
<Generate>.
Exercise 10. Transition Pipe 103
[4] Click
<Generate>.
[1] Select <Create/
Boolean>.
[2] Control-
select these two
edges.
[1] Select <Blend/
Fixed Radius>.
[4] Click
<Generate>.
104 Exercise 10. Transition Pipe
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Pipe," and exit
the Workbench.
Exercise 10. Transition Pipe 105
10-13 Review
Add Frozon
A body is either in a state of active or frozen. The default state is active. Two overlapped active bodies would
automatically join together to form a single body. If either of them is frozen, they wouldn't join together. Therefore,
the only way to avoid overlapped bodies joining together is to make at least one of them frozen. In 10-7, we create the
end plate as frozen body (separating it from the curved pipe), so that, in 10-8, we can copy the end plate alone without
the curved pipe.
<Body Operation/Move>
This tool moves a body (or a group of bodies) to another position and orientation in the same way that the source
plane is move to coincide with the destination plane (10-8). If the <Reserve Bodies?> option is <Yes>, it essentially
copies the bodies. This tool is useful for "assembling" parts together to form an assembly.
<Create/Boolean>
Using boolean operations, bodies can be united, intersected, and subtracted.
106 Exercise 11. C-Bar
Exercise 11
C-Bar
11-1 Introduction
[2] A strain gauge
is bonded to the
The C-shaped steel bar is used as a dynamometer, a device to surface here. The
measured strain is
measure the magnitude of a force P [1]. A strain gauge is bonded to
used to calculate
the surface of a location as shown [2]. The measured strain is then the force P.
used to calculate the force P.
The details are shown below; a coordinate system is also
included in the figure. In this exercise, we will create a 3D solid
model for the C-bar. Due to the symmetry, we will create the
upper half of the model and then complete the model by using a
"mirror" (copy) operation.
[1] The C-
bar is used to
Y measure a
P force P.
100
70 20
Y
20
D10
Unit: mm.
[3] The body has a
thickness of 5 mm.
everywhere.
30
R50
40
R10
120
X Z
40
[3] Click
<Generate>.
[1] Select
<XYPlane>
[3] Right-click
<Sketch1> and select
<Hide Sketch> from
the context menu.
Exercise 11. C-Bar 109
[5] Click
<Extrude>. [7] Click
<Generate>.
[4] Click
<Generate>.
110 Exercise 11. C-Bar
[2] <Mirror> is
the default
operation type.
[4] Select
<ZXPlane> from the
model tree.
Wrap Up
Close DesignModeler, save the project as "CBar," and exit the Workbench.
Exercise 11a. Deformation of the C-Bar 111
Appendix:
Exercise 11a
Deformation of the C-Bar
P
11a-1 Introduction
As described in Exercise 11, the C-shaped steel bar is used to measure the
magnitude of a force P [1]. A strain gauge is bonded to the surface of the location as
shown [2]. The location is chosen because the strain is relatively large and
distributed quite uniformly, so that the measured strain is not sensitive to the
variation of the location of the strain gauge. The measured strain ε is then used to [2] Strain
calculate the force P. The idea also relies on the fact that the strain is linearly gauge.
proportional to the force P, which is true when the deformation is small enough. In
other words, if the measured strain is doubled, then the force must be doubled.
In this section, we will assume a force of P = 2,000 N, and perform a simulation
to establish a relation between the force P and the strain ε .
[1]
Applied
force P.
11a-2 Start Up [5] The two systems P
share the same
<Geometry>. You can
edit up-stream cell
but not the down- [6] Double-click
stream cell. <Model> to start up
[2] Open the <Mechanical>
project "CBar," application.
which was saved
in Exercise 11.
[1] Launch
Workbench
112 Exercise 11a. Deformation of the C-Bar
[1] Highlight
<Mesh>.
Meshing
The process of dividing a body into small bodies is call meshing. The small bodies are called elements, or finite elements.
The simulation method is thus called finite element simulation. The basic idea of finite element methods is to divide a
body of rather complicated geometry into smaller elements of simple geometry, and the elements are assumed to be
connected to each other through nodes. The element's geometry is so simple that a set of equations may be
established easily for each element. All equations are then solve simultaneously for the displacements. Strains are then
calculated from the displacements. And stresses are in turn calculated from the strains.
In general, the finer the mesh, the more accurate the solution (and more computing time). In this exercise, we
control the mesh size by simply adjusting <Relevance Center> and <Relevance>.
Also, note that the Workbench will automatically generate a mesh right before it solves the problem if a mesh
doesn't exist.
[2] Select
<Supports/Fixed
Support>.
[1] Highlight
<Solution>.
[4] Click
<Probe>.
11a-7 Conclusion
The simulation results show that a force of P = 2,000 N produces a strain ε = 0.000296. We may establish a relation
between the force P and the strain ε as follows:
2000
P= ε
0.000296
For example, if the measured strain in the strain gauge is ε1 = 0.0001, then the force P1 is
2000
P1 = 0.0001= 676 N
0.000296
Wrap Up
Close <Mechanical>, save the project ("CBar"), and exit the Workbench.
Exercise 12. Threaded Shaft 119
Exercise 12
Threaded Shaft
Pitch p
p−H 8
H 8
H = ( 3 2)p = 0.0541266 in
60
H
Slo
H = ( 3 2)p
p − = 0.0557342 in
pe:
8
pe:
Slo
60
H
= 0.0135316 in
Major diameter d
4 H 4
120 Exercise 12. Threaded Shaft
[4] Click
<Generate>.
[3] Click
<Generate>.
[2] Right-click
<Sketch1> and select
<Hide Sketch>.
[10] Click
<Sweep>.
[11] Select
<Sketch2> (from the
model tree) as the
<Profile>.
[12] Select
<Sketch3> (from the
model tree) as the
<Path>.
Wrap Up
Close DesignModeler, save the project as "Shaft," and exit the Workbench.
124 Exercise 13. Lift Fork
Exercise 13
Lift Fork
13-1 Introduction
The lifting fork is used in an LCD (liquid crystal display) manufacturing factory to handle glass panels. In this section,
we will create a 3D solid model for the lift fork, of which the details are shown below.
The cross sections of the prongs (fingers) are not uniform along the length [1-3]. The tools <Extrude> or
<Sweep> cannot be used to created the prongs. This exercise introduces a modeling tool, <Skin/Loft>, which takes a
series of profiles from different planes and creates a 3D solid that fits through these profiles
0
240
Unit: mm.
Exercise 13. Lift Fork 125
Skin/Loft
Now we want to create a single prong, or finger. The prong is then duplicated to create other prongs. The prong's
cross section is not uniform. You cannot create the prong using <Extrude> or <Sweep>. A more general way to
create a solid or surface of different cross sections along its path is using <Skin/Loft>. <Skin/Loft> takes a series of
profiles from different planes and creates a solid that fits through these profiles.
You may view <Sweep> as a generalization of <Extrude>, and <Skin/Loft> as a generalization of <Sweep>.
[2] Create
<Plane4>, see
[3].
[4] Create
<Plane5>, see [5].
[6] Create
<Plane6>, see [7].
[3] Details of
[5] Details of <Plane4>.
[7] Details of <Plane5>.
<Plane6>.
Exercise 13. Lift Fork 127
[4] Click
<Generate>.
[3] Click
<Apply>.
[8] Click
[1] Select <Apply>.
<Create/
Pattern>.
[5] Select this
edge.
[10] Click
<Generate>.
Exercise 13. Lift Fork 129
[3] Control-select
all five bodies and
click <Apply>.
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Fork," and exit the Workbench.
130 Exercise 14. Caster Frame
Exercise 14
Caster Frame
14-1 Introduction
In this exercise, we'll create a 3D solid model for a caster frame, of which the details are shown in the multiview
drawings below. A coordinate system is also shown in the figure.
X
64
10
Unit: mm.
Fillets and rounds: R3
D25 D17.5
Z
D35 Y
Y
50
10 R15
28
R10
X Z
10
10
92
D32
76 10 D21.5
13
126
Exercise 14. Caster Frame 131
[6] And
click
<Apply>.
[14] Click
<Generate>.
134 Exercise 14. Caster Frame
[20] Click
<Generate>.
[23] Click
<Generate>.
136 Exercise 14. Caster Frame
[26] Click
<Generate>.
Exercise 14. Caster Frame 137
[6] Control-select
these two edges.
[7] Click
<Generate>.
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Caster," and exit the Workbench.
144 Section C. Assembly Modeling
Section C
Assembly Modeling
An assembly consists of two or more parts. The DesignModeler assigns a color for each part in an assembly. Creating
a simple assembly is straightforward, but you have to take case so that parts are not bonded together. This usually can
be done by freezing the existing parts. Exercise 15 is an example of creating a simple assembly. Creating complex
assemblies involves transformations (translations, rotations, etc.) of parts to appropriate positions. Exercises 16 and 17
demonstrate these techniques.
Exercise 15. Threaded Shaft Assembly 145
Exercise 15
Threaded Shaft Assembly
0.3
75
Y D0
Unit: in. .75 X
0.1
875
0.7
5
D0
.75
.25
D0
0.1
25
3.0
00
63
5 5.0
D 0.2 6
.26
D0
00
2.0
19
0.2
Z
146 Exercise 15. Threaded Shaft Assembly
[2] Double-click
<Geometry> to start
up DesignModeler. Due
to the complexity of
the threads, it may take
a while to open the
model.
[3] Right-click
<Solid> and select
[4] Change the
<Rename> from the
part name to
context menu.
"Shaft."
Exercise 15. Threaded Shaft Assembly 147
[2] A <Freeze1>
object is inserted.
[10] Click
<Generate>.
[11] Right-click
"EndHinge" and select
<Hide All Other Bodies>
from the context menu.
[9] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project ("Shaft"), and exit
the Workbench.
152 Exercise 16. Universal Joint
Exercise 16
Universal Joint
16-1 Introduction
In this exercise, we'll create a universal joint shown in the figure below. The assembly consists of four kinds of parts
[1-4], of which the yoke [1] was created in Exercise 7. A coordinate system for the assembly is also shown in the
figure [5]. The assembly created in this exercise is simple enough that we will create all parts in a single <Geometry>
system. For more complicated cases (eg., Exercises 17), multiple <Geometry> systems may be a better management
scheme.
The universal joint is adapted from a working drawing in the book Technical Graphics Communication, by G. R.
Bertoline, E. N. Wiebe, C. L. Miller, and J. L. Mohler.
[1] 2 x Yoke
(created in
[5] Coordinate Unit: in. Exercise 7).
system for the
assembly.
[4] 4 x Pin.
D0.50, L1.35.
Z X
[2] Swivel.
OD1.00,
ID0.50, L2.15.
[3] 4 x Bushing.
OD0.75, ID0.50,
L0.60.
Exercise 16. Universal Joint 153
Coordinate Systems Y ,Y ′
There is a coordinate system for
the entire assembly, called a global
coordinate system; each part has
its own coordinate system, called a
local coordinate system.
Here, the coordinate system [5] The
set up in 16-1 is the global coordinate
coordinate system [4], and the system of the
part.
coordinate system defined in 7-1,
used to create the yoke, is a local
coordinate system [5].
In order to position the yoke [4] The
in the global coordinate system, we coordinate
system of the Z′
need to move the yoke upward (in
assembly. X′
Y direction) by 1.50 in.
Z X
154 Exercise 16. Universal Joint
[2] Select
"UpperYoke,"
either from the
model tree or
[3] Select <ZXPlane> from the graphics
from the model tree. window.
Click <Generate>.
[6] Select
<Rotate>.
[7] Select
"LowerYoke."
Selection Filters
By activating a selection filter [9],
you can make one of four types of
entities (points, edges, faces, and
bodies) selectable. By right-
clicking the graphic area, selection
filters can also be accessed
through the context menu, where
additional filters are available [15].
Multiple filters can be activated at
the same time.
[10] Right-click
anywhere in the
graphics window and
select <Show All
[8] Rename the Bodies>.
body as "Swivel."
158 Exercise 16. Universal Joint
[15] Control-select
the last 10 objects
and right-click-
select <Suppress>.
Wrap Up
Close DesignModeler, save the project ("Joint"), and exit the Workbench.
Exercise 16a. Dynamic Simulation of the Universal Joint 165
Appendix:
Exercise 16a
Dynamic Simulation of the
Universal Joint
[1] Lunch
Workbench and
open the project
"Joint," which was
saved in Exercise 16. [2] Double-click
<Geometry> to start
up <DesignModeler>.
[4] Double-click
<Model> to start
[2] A <Rigid up <Mechanical>.
Dynamics>
system is created.
[11] Click
<Apply>.
[4] Click
<Configure>.
[3] An environment
condition is inserted.
[1] Click
<Solve>.
[7] By clicking
[5] Click <Play> to [3] Click <Export Video File>,
[6] Click <Stop> to
animate the results. <Result the animation can be
stop the animation.
Sets>. save as an AVI file.
Wrap Up
Close <Mechanical>, save the project ("Joint"), and exit the Workbench.
176 Exercise 17. Clamping Mechanism
Exercise 17
Clamping Mechanism
0.75
mentioned in Exercises 1, 8, 12, and 15. Some parts that are
not created in the previous exercises are detailed in this page.
0.375
Comparing with previous exercises, this exercise is
rather complicated. For a complicated model like this, we 1.375
need more efficient way of handling multiple parts and
Part Name: Grip
transforming parts. We'll demonstrate how a geometry can
be exported from a <Geometry> system and imported to
another <Geometry> system. We'll also demonstrate a more D0.25 D0.312
general way of transformation parts. In this way, we need two
planes: a source plane and a destination plane. A part then
can be transformed just like the source plane is transformed
to the destination plane.
The clamping mechanicsm is adapted from a working 0.375
drawing in the book Technical Graphics Communication, by G. 0.75
R. Bertoline, E. N. Wiebe, C. L. Miller, and J. L. Mohler.
Part Name: Pin A
0.3
75 Unit: in. D0.312
0.2 D0.25
5
0.7
5
Grip
0.75
1.125
Part Name: Pin B
Pin A D0.312
D0.25
0.375
Pin C
1.125
Pin B
Part Name: Pin C
Exercise 17. Clamping Mechanism 177
[2] Double-click
<Geometry> to start
up DesignModeler.
[3] In DesignModeler,
select <File/Export...>.
[10] Double-click
<Geometry> to start
up DesignModeler.
[8] Click <No>.
[11] In DesignModeler,
select <File/Export...>.
[18] Double-click
<Geometry> to start
up DesignModeler.
[19] In DesignModeler,
select <File/Export...>.
[5] Double-click
<Geometry> to start
up DesignModeler.
[4] Double-
click to create a
<Geometry>
system.
[2] Click <No>.
[2] Select
"Support1."
[3] Select
<XYPlane> from the
model tree and click
<Generate>.
Now, we want to translate the shaft assembly such that the part "MidHinge" is at its correct position. Calculation of
the amount of translation is not a easy task. We now demonstrate a general way of transformation parts. In this way,
we need two planes: a source plane and a destination plane. The shaft assembly will be transformed just like the source
plane is transformed to the destination plane.
Y
[9] Select <Yes> for
<Reverse Normal/Z-
Axis>. Click
<Generate>.
X
9.273
46.775
186 Exercise 17. Clamping Mechanism
[4] Bring up
<Apply/Cancel>
[4] Bring up
<Apply/Cancel>
[7] If necessary,
click here to
reverse the
direction.
[3] Select
<XYPlane> from the
model tree and click
<Generate>.
[5] Click
<Apply>.
[6] Select<Yes>
for <Preserve
Bodies?>
Wrap Up
Close DesignModeler, save the project ("Clamp") and exit the Workbench.
Exercise 17a. Simulation of the Clamping Mechanism 197
Appendix:
Exercise 17a
Simulation of the Clamping
Mechanism
17a-1 Introduction
The clamping mechanism created in Exercise 17 is designed to provide clamping forces up to 450 lbf [1]. In this
exercise, we'll perform a simulation to make sure that, under the clamping force of 450 lbf, the stresses everywhere are
within the allowable stress of the steel, which is 30,000 psi. Remember that the clamping mechanism is entirely made
of steel, which is the default material used in <Mechanical>.
We'll assume an initial configuration such that the grip merely contacts the clamped object and the clamping
force is zero [2, 3]. As the handle rotates to increase the distance between two hinges, the clamping force also
increases, until the clamping force reaches 450 lbf [4-6].
[2] Double-click
<Geometry> to start
up DesignModeler.
[12] Double-click
<Geometry> to start
up <DesignModeler>.
[13] Select
<Import2>, which is
the shaft assembly.
[14] Double-click
<Source>.
[19] Control-select
"Support1," "Support2,"
"PinB1," "PinB2," and
"PinC," and right-click-
select <Form New Part>.
[21] Control-select
"Grip" and "PinA," and
right-click-select <Form
New Part>.
[23] Close
DesignModeler.
202 Exercise 17a. Simulation of the Clamping Mechanism
There are 8 revolute joints to be created: [1] PinA to Arm1, [2] PinA to Arm2, [3] EndHinge to Arm1, [4] EndHinge to
Arm2, [5] MidHinge to Support1, [6] MidHinge to Support2, [7] PinC to Arm1, and [8] PinC to Arm2.
[12] While
<Connections> is
highlighted, click to
activate <Body Views>.
[7] Select
<Frictionless
Support>.
[1] Highlight
<Equivalent Stress>.
379.95
225.04
379.94
163.13
379.94 62.045
225.03
Wrap Up
Close <Mechanical>, save the project as "Clamp-a", and exit the Workbench.
Section D. Concept Modeling 215
Section D
Concept Modeling
As mentioned, although it can be used as a general purpose CAD software, the DesignModeler is particularly designed
for creating geometric models to be analyzed (simulated) under the ANSYS environment. So far, we've created many
3D solid models; each can be imported into an analysis application, such as <ANSYS Mechanical>. 3D solid models are
not the only models that <ANSYS Mechanical> can analyze. Often, due to the efficiency (computing time and solution
accuracy), we prefer using simplified models, such as 2D solid models, surface models, or line models. This section
provides exercises for creating such simplified model.
216 Exercise 18. 2D Solid Modeling (Arm)
Exercise 18
2D Solid Modeling (Arm)
18-1 Introduction
When the geometric characteristics in a certain dimension (e.g., the thickness in Z-dimension) can be parameterized
and the rest of the geometric characteristics (and the loads) can be expressed in a 2D space (in this example, XY-
space), we often simplify the model into a 2D solid model, to facilitate the simulation task. The benefits of using a 2D
solid model (over a 3D solid model) include reduced modeling time, reduced computing time, increased accuracy,
increased post-processing efficiency.
In this exercise, we will create a 2D solid model for the arm, which has been modeled as s 3D solid model in
Exercise 1
[3] Select
<Sketch1> from
the model tree.
Wrap Up
Close DesignModeler, save the project as "Arm-2D" and exit the Workbench.
Exercise 18a. Structural Analysis of the Arm Using 2D Model 219
Appendix:
Exercise 18a
Structural Analysis of the Arm
Using 2D Model
18a-1 Introduction
In this exercise, we will perform a static structural analysis for the 2D model created in Exercise 18. We'll use the
same boundary conditions (loads and supports) as in Exercise 1a (1a-1[3]). The results (stresses) should be the same
as those obtained in Exercise 1a, except that a 2D model is computationally much more efficient.
18a-2 Start Up
[3] Right-click
<Geometry> and
select <Properties>.
[9] Click
<Apply>.
[4] Click
<Apply>.
[6] Highlight
<Mesh>.
[7] There are 779 nodes in the model; that means a total
degrees of freedom is 1558 (2x779; for 2D problems, each
node has 2 degrees of freedom). The degrees of freedom
is an indication of problem size, and it is in turn an
indication of computing time.
224 Exercise 18a. Structural Analysis of the Arm Using 2D Model
[2] Highlight
<Mesh>.
[7] There are 890 nodes in the model; that means a total
degrees of freedom is 2667 (3x890; for 3D problems,
each node has 3 degrees of freedom). The ratio of the
problem size between the 2D model and the 3D model
is 0.58 (1558/2667). That means, in this case, only
approximately 58% of computing time is need for the 2D
model, to achieve the same solution accuracy.
Wrap Up
Close <Mechanical> and exit the Workbench.
Exercise 19. Surface Modeling (Support) 225
Exercise 19
Surface Modeling (Support)
19-1 Introduction
When a body in 3D space is thin enough, we often simplify the body into a surface body, to facilitate the simulation
task. The benefits of using a 3D surface model (over a 3D solid model), similar to a 2D solid over 3D solid, include
reduced modeling time, reduced computing time, increased accuracy, increased post-processing efficiency.
In this exercise, we will create a 3D surface model for the support, which has been modeled as a 3D solid model
in Exercise 8.
[4] Click
<Generate>.
[11] Click
<Generate>.
[1] Activate
<ZXPlane>.
[4] Click
<Generate>.
Wrap Up
Close DesignModeler, save the project as "Support-Surface" and exit the Workbench.
230 Exercise 19a. Structural Analysis of the Support Using Surface Model
Appendix:
Exercise 19a
Structural Analysis of the
Support Using Surface Model
19a-1 Introduction
In this exercise, we will perform a static structural analysis for the surface model created in Exercise 19. We'll use the
same boundary conditions (loads and supports) as in Exercise 8a (8a-1[3, 4]).
19a-2 Start Up
[4] Click
<Apply>.
[8] Click
<Apply>.
[9] Type 0
(in.) for <Z
Component>.
Exercise 19a. Structural Analysis of the Support Using Surface Model 233
Wrap Up
Close <Mechanical>, save the project as "Support-Surface-a," and exit the Workbench.
234 Exercise 20. Line Modeling (Space Truss)
Exercise 20
Line Modeling (Space Truss)
20-1 Introduction
Consider a space truss subject to design loads as shown [1-4]. Note that each truss member and each connection
node (spherical joint) is given an identification number. This example is adapted from a problem in the book Vector
Mechanics for Engineers: Statics, by F. P. Beer, E. R. Johnston, and E. R. Eisenberg. The member forces calculated by the
textbook are shown in the table below [5]. Note that a plus sign is used to indicate a tensile member force and a
minus sign to indicate compressive member force.
The truss is a statically determinate structure, that is, the member forces can be solved using static equilibrium
equations without any cross-sectional information. Here, we assume that all members have a circular cross-section of
diameter 10 mm.
In this exercise, we'll create a line model for this space truss. In the Exercise 20a, as an appendix, we'll perform a
structural analysis to calculate the member forces using this line model.
1m
[4] This node is 4 [3] This node is
supported in Z- supported in Z- [5] Member
direction. direction. forces.
3
4 3
[1] This node is Member Member
supported in Y- Force
direction. 8 9
1 1 +400 N
7 2
-600 N
1m
1 2
5 -100 N
3
2
6 4 -200 N
0.5 5
Z X 0
m 200 N 5
0.5 1m 6 -1342 N
m
[2] This node is
supported with a 7 +1500 N
hinge, i.e.,
1200 N displacements in all +300 N
8
directions are
restricted. -566 N
9
Exercise 20. Line Modeling (Space Truss) 235
20-2 Start Up
[3] Double-click
<Geometry> to start
up <DesignModeler>.
Select <Meter> as
length unit.
[1] Launch
<Workbench> and
save the project as
"Truss."
[3] Type
coordinates.
[1] Select
<Create/Point>.
[4] Click
<Generate>.
236 Exercise 20. Line Modeling (Space Truss)
5 0.5 m 0m 1m
[6] Click
<Generate>.
Exercise 20. Line Modeling (Space Truss) 237
7 Point3 Point5
8 Point4 Point5
9 Point1 Point3
8
2
5 1
7
20-5 Create and Assign Cross Section for the Line Bodies
Wrap Up
Close DesignModeler, save the project ("Truss") and exit the Workbench.
240 Exercise 20a. Structural Analysis of the Space Truss
Appendix:
Exercise 20a
Structural Analysis of the Space
Truss
20a-1 Introduction
In this exercise, we will perform a static structural analysis using the line model created in Exercise 20. We'll use the
boundary conditions (loads and supports) described in Exercise 20 (20-1[1-4]). The resulting member forces should
be consistent with those given by 20-1[5].
20a-2 Start Up
[2] Double-click
<Model> to start up
<Mechanical>.
Exercise 20a. Structural Analysis of the Space Truss 241
[1] Highlight
<Connection>.
[3] Click
<Vertex>.
[7] Select
<Deformable>.
[11] Select
<Deformable>.
Now, we've set up a spherical joint at node 1. We'll repeat the above steps to set up the other spherical joints at
nodes 2, 3, 4, and 5. When you click a node, make sure all selection panes representing involved vertices show up; if
not, click again until all panes show up. Remember to leave the leftmost pane as <Reference> body and the other
panes as <Mobile> bodies.
[2] Select
<Vertex>.
[5] Click
<Apply>.
[11] Select
this node.
[1] Click
<Solve>.
[7] Click
<Probe>.
Wrap Up
Close <Mechanical>, save the project as "Truss-a,"
and exit the Workbench.