Saux4008-Modeling and Analysis of Engine Components Lab (1)

7/24/2019 Saux4008-Modeling and Analysis of Engine Components Lab (1)

1/48

SAUX4008-MODELING AND ANALYSIS OF ENGINE COMPONENTS LAB

Exp. No .1

Introduction to ANSYS

Aim: To study the ANSYS package.

ANSYS, Inc. is an engineering simulation software provider founded by softwareengineer John Swanson. It develops general-purpose finite element analysis and computational

fluid dynamics software. While ANSYS has developed a range of computer-aided engineering

(CAE) products, it is perhaps best known for its ANSYS Mechanical and ANSYS Metaphysicsproducts. ANSYS Mechanical and ANSYS Metaphysics software are non-exportable analysis

tools incorporating pre-processing (geometry creation, meshing), solver and post-processing

modules in a graphical user interface. These are general-purpose finite element modeling

packages for numerically solving mechanical problems, including static/dynamic structuralanalysis (both linear and non-linear), heat transfer and fluid problems, as well as acoustic and

electro-magnetic problems. ANSYS Mechanical technology incorporates both structural and

material non-linearitys. ANSYS Metaphysics software includes solvers for thermal, structural,CFD, electromagnetics, and acoustics and can sometimes couple these separate physics together

in order to address multidisciplinary applications. ANSYS software can also be used in civil

engineering, electrical engineering, physics and chemistry. ANSYS, Inc. acquired the CFX

computational fluid dynamics code in 2003 and Fluent, Inc. in 2006. The CFD packages fromANSYS are used for engineering simulations. In 2008, ANSYS acquired Ansoft Corporation, a

leading developer of high-performance electronic design automation (EDA) software and added

a suite of products designed to simulate high-performance electronics designs found in mobilecommunication and Internet devices, broadband networking components and systems, integrated

circuits, printed circuit boards, and electromechanical systems. The acquisition allowed ANSYS

to address the continuing convergence of the mechanical and electrical worlds across a whole

range of industry sectors.Automotive

ToyotaPrius HEVaerodynamicsoptimization for fuel usage reduction

Red Bull Racingaerodynamics optimization for faster speed

Aerospace

Parker Aerospacehigh-performance computingfor faster simulation results

Astrobotic Technology andCarnegie Mellon Universityspacecraft structural analysis for

strength and stiffness[10]

Terrafugiaroadable aircraft for proof-of-concept testing[

Energy

Columbia Power wave energy device shape optimization to reduce maintenance costs and

breakdowns

Indar Electric permanent magnetwind turbine generatoroptimization for reliable operation

Electronics

University of Arizonaantenna performance optimization

Fujitsu Semiconductor Limited integrated circuit (IC) design optimization

Consumer products

Dysonbladeless fan airflow performance optimization
http://en.wikipedia.org/wiki/Toyotahttp://en.wikipedia.org/wiki/Toyotahttp://en.wikipedia.org/wiki/Aerodynamicshttp://en.wikipedia.org/wiki/Aerodynamicshttp://en.wikipedia.org/wiki/Aerodynamicshttp://en.wikipedia.org/wiki/Red_Bull_Racinghttp://en.wikipedia.org/wiki/Red_Bull_Racinghttp://en.wikipedia.org/wiki/High-performance_computinghttp://en.wikipedia.org/wiki/High-performance_computinghttp://en.wikipedia.org/wiki/High-performance_computinghttp://en.wikipedia.org/wiki/Carnegie_Mellon_Universityhttp://en.wikipedia.org/wiki/Carnegie_Mellon_Universityhttp://en.wikipedia.org/wiki/Carnegie_Mellon_Universityhttp://en.wikipedia.org/wiki/Ansys#cite_note-10http://en.wikipedia.org/wiki/Ansys#cite_note-10http://en.wikipedia.org/wiki/Ansys#cite_note-10http://en.wikipedia.org/wiki/Terrafugiahttp://en.wikipedia.org/wiki/Terrafugiahttp://en.wikipedia.org/wiki/Wind_turbine_designhttp://en.wikipedia.org/wiki/Wind_turbine_designhttp://en.wikipedia.org/wiki/Wind_turbine_designhttp://en.wikipedia.org/wiki/University_of_Arizonahttp://en.wikipedia.org/wiki/University_of_Arizonahttp://en.wikipedia.org/wiki/Dyson_(company)http://en.wikipedia.org/wiki/Dyson_(company)http://en.wikipedia.org/wiki/Dyson_(company)http://en.wikipedia.org/wiki/University_of_Arizonahttp://en.wikipedia.org/wiki/Wind_turbine_designhttp://en.wikipedia.org/wiki/Terrafugiahttp://en.wikipedia.org/wiki/Ansys#cite_note-10http://en.wikipedia.org/wiki/Carnegie_Mellon_Universityhttp://en.wikipedia.org/wiki/High-performance_computinghttp://en.wikipedia.org/wiki/Red_Bull_Racinghttp://en.wikipedia.org/wiki/Aerodynamicshttp://en.wikipedia.org/wiki/Toyota


2/48


SpeedoFASTSKIN3 Racing System drag reduction

Products

Simulation Technology:

Structural Mechanics, Multiphysics, Fluid Dynamics, Explicit Dynamics, Electromagnetics,

Hydrodynamics (AQWA).

Workflow Technology:ANSYS Workbench Platform, High-Performance Computing, Geometry Interfaces, Simulation

Process & Data Management.

FUNDAMENTALS OF ANSYS

Useful DefinitionsBefore delving into the details of the procedures related to the ANSYS program, we

define the following terms:

Jobname:

A specific name to be used for the files created during an ANSYS session. This name canbe assigned either before or after starting the ANSYS program.

Working Directory:A specific folder (directory) for ANSYS to store all of the files created during a session.

It is possible to specify the Working Directorybefore or after starting ANSYS.Interactive Mode:

This is the most common mode of interaction between the user and the ANSYS program.

It involves activation of a platform called Graphical User Interface {GUI), which is composed ofmenus, dialog boxes, push-buttons, and different windows. Interactive Mode is the

recommended mode for beginner ANSYS users as it provides an excellent platform for learning.

It is also highly effective for postprocessing.

Batch Mode:This is a method to use the ANSYS program without activating the GUI It involves an

Input File written in ANSYS Parametric Design Language {APDL), which allows the use ofparameters and common programming features such as DO loops and IF statements. Thesecapabilities make the Batch Mode a very powerful analysis tool. Another distinct advantage of

theBatch Mode is realized when there is an error/mistake in the model generation. This type of

problem can be fixed by modifying a small portion of the Input File and reading it again, savingthe user a great deal of time.

Combined Mode:

This is a combination of theInteractive andBatch Modes in which the user activates the

GUI and reads the Input File. Typically, this method allows the user to generate the model and

obtain the solution using the Input File while reviewing the results using the Postprocessor

within the GUL This method combines the salient advantages of the Interactive and Batch

Modes,

BEFORE AN ANSYS SESSION

The construction of solutions to engineering problems using FEA requires either the

development of a computer program based on the FEA formulation or the use of a commerciallyavailable general-purpose FEA program such as ANSYS. The ANSYS program is a powerful,

multi-purpose analysis tool that can be used in a wide variety of engineering disciplines. Before
http://en.wikipedia.org/wiki/Speedohttp://en.wikipedia.org/wiki/Speedohttp://en.wikipedia.org/wiki/Speedo


3/48


using ANSYS to generate an FEA model of a physical system, the following questions should be

answered based on engineering judgment and observations:

What are the objectives of this analysis? Should the entire physical system be modeled, or just a portion?

How much detail should be included in the model?

How refined should the finite element mesh be? In answering such questions, the computational expense should be balanced against the accuracyof the results. Therefore, the ANSYS finite element program can be employed in a correct and

efficient way after considering the following:

Type of problem. Time dependence.

Nonlinearity.

Modeling idealizations/simplifications. Each of these topics is discussed in this section.

ANALYSIS DISCIPLINEThe ANSYS program is capable of simulating problems in a wide range of engineering

disciplines. Structural Analysis: Deformation, stress, and strain fields, as well as reaction forcesin a solid body.

Thermal Analysis:

Steady-state or time-dependent temperature field and heat flux in a solid body.

Structural AnalysisThis analysis type addresses several different structural problems, for example:

Static Analysis:

The applied loads and support conditions of the solid body do not change with time.Nonlinear material and geometrical properties such as plasticity, contact, creep, etc., are

available.

Modal Analysis:

This option concerns natural frequencies and modal shapes of a structure.Harmonic Analysis:

The response of a structure subjected to loads only exhibiting sinusoidal behavior in time.

Transient Dynamic:The response of a structure subjected to loads with arbitrary behavior in time.

Eigenvalue Buckling:

This option concerns the buckling loads and buckling modes of a structure.Thermal Analysis

This analysis type addresses several different thermal problems, for example:

Primary Heat Transfer:

Steady-state or transient conduction, convection and radiation.Phase Change: Melting or freezing.

Thermo mechanical Analysis:

Thermal analysis results are employed to compute displacement, stress, and strain fields

due to differential thermal expansion.Time Dependence

The analysis with ANSYS should be time-dependent if:

The solid body is subjected to time varying loads. The solid body has an initially specified temperature distribution.


4/48


The body changes phase.

NONLINEARITYMost real-world physical phenomena exhibit nonlinear behavior. There are many

situations in which assuming a linear behavior for the physical system might provide satisfactory

results. On the other hand, there are circumstances or phenomena that might require a nonlinearsolution. A nonlinear structural behavior may arise because of geometric and materialnonlinearities, as well as a change in the boundary conditions and structural integrity. These

nonlinearities are discussed briefly in the following subsections.

Geometric NonlinearityThere are two main types of geometric nonlinearity:

Large deflection and rotation:

If the structure undergoes large displacements compared to its smallest dimension and

rotations to such an extent that its original dimensions and position, as well as the loadingdirection, change significantly, the large deflection and rotation analysis becomes necessary. For

example, a fishing rod with a low lateral stiffness under a lateral load experiences large

deflections and rotations.Stress stiffening:

When the stress in one direction affects the stiffness in another direction, stress stiffening

occurs. Typically, a structure that has little or no stiffness in compression while having

considerable stiffness in tension exhibits this behavior. Cables, membranes, or spinningstructures exhibit stress stiffening.

Material Nonlinearity

A linear material response is a good approximation if the material exhibits a nearly linearstress-strain curve up to a proportional limit and the loading is in a manner that does not create

stresses higher than the yield stress anywhere in the body.

Nonlinear material behavior in ANSYS is characterized as:

Plasticity:Permanent, time-independent deformation.

Creep:

Permanent, time-dependent deformation.Nonlinear Elastic:

Nonlinear stress-strain curve; upon unloading, the structure returns back to its original

stateno permanent deformations.Viscoelasticity:

Time-dependent deformation under constant load. Full recovery upon unloading.

Hyper-elasticity: Rubber-like materials.

Changing-status NonlinearityMany common structural features exhibit nonlinear behavior that is status dependent.

When the status of the physical system changes, its stiffness shifts abruptly. The ANSYS

program offers solutions to such phenomena through the use of nonlinear contact elements and

birth and death options. This type of behavior is common in modeling manufacturing processessuch as that of a shrink-fit.

Practical Modeling Considerations

In order to reduce computational time, minor details that do not influence the resultsshould not be included in the FE model. Minor details can also be ignored in order to render the


5/48


geometry symmetric, which leads to a reduced FE model. However, in certain structures,

"small'* details such as fillets or holes may be the areas of maximum stress, which might prove

to be extremely important in the analysis and design. Engineering judgment is essential tobalance the possible gain in computational cost against the loss of accuracy.

ORGANIZATION OF ANSYS SOFTWAREThere are two primary levels in the ANSYS program,

Begin Level:

Gateway into and out of ANSYS and platform to utilize some global controls such aschanging ihQ jobname, etc.

Processor Level:

This level contains the processors (preprocessor, solution, postprocessor, etc.) that are

used to conduct finite element analyses. The user is in the Begin Level upon entering the ANSYSprogram. One can proceed to theProcessor Levelby clicking the mouse on one of the processor

selections in the ANSYSMain Menu,

ANSYS ANALYSIS APPROACHThere are three main steps in a typical ANSYS analysis:

Model generation:

Simplifications, idealizations.Define materials/material properties.

Generate finite element model (mesh).

Solution:Boundary conditions

Obtain the solution.

Review results:

Plot/list results.Check for validity.

Each of these steps corresponds to a specific processor or processors within theProcessor Level

in ANSYS. In particular, model generation is done in the Preprocessor and application of loadsand the solution is performed in the Solution Processor, Finally, the results are viewed in the

General

Postprocessor and Time History Postprocessor for steady-state (static) and transient (time-dependent) problems, respectively. There are several other processors within the ANSYS

program. These mostly concern optimization and probabilistic-type problems. The most

commonly used processors are described in the following subsections.

ANSYS PreprocessorModel generation is conducted in this processor, which involves material definition,

creation of a solid model, and, finally, meshing. Important tasks within this processor are:

Specify element type. Define real constants (if required by the element type).

Define material properties,

Create the model geometry. Generate the mesh.


6/48


Although the boundary conditions can also be specified in this processor, it is usually done in the

Solution Processor,

ANSYS Solution ProcessorThis processor is used for obtaining the solution for the finite element model that is generated

within thePreprocessor, Important tasks within this processor are:

Define analysis type and analysis options, Specify boundary conditions. Obtain solution.

ANSYS General PostprocessorIn this processor, the results at a specific time (if the analysis type is transient) over the

entire or a portion of the model are reviewed. This includes the plotting of contours, vector

displays, deformed shapes, and listings of the results in tabular format.

ANSYS Time History PostprocessorThis processor is used to review results at specific points in time (if the analysis type is

transient). Similar to the General Postprocessor, it provides graphical variations and tabularlistings of results data as functions of time.

ANSYS FILE STRUCTURE

Several files are created during a typical ANSYS analysis. Some of these files are inASCII format while the others are binary. Brief descriptions of common file types are given

below.

Database Fil e

During a typical ANSYS analysis, input and output data reside in memory until they are

saved in aDatabase File, which is saved in the Working Directory. The syntax for the name of

theDatabase File isjobname,db. This binary file includes the element type, material properties,

geometry (solid model), mesh (nodal coordinates and element connectivity), and the results if asolution is obtained. Once the Database File is saved, the user can resume from this file at any

time. There are three distinct ways to save and resume theDatabase File:

Use the Utility Menu.

Click on SAVE JOB orRESUMJDBbutton on theANSYS Toolbar.

Issue the command SAVE or RESUME in theInput Field.

Log F ile

TheLog File is an ASCII file, which is created (or resumed) immediately upon entering

ANSYS. Every action taken by the user is stored sequentially in this file in command format

(ANSYS Parametric Design Language (APDL)). The syntax for the name of the Log File, which

is also saved in the Working Directory, isjobname.log. If jobname.log already exists in theWorking Directory, ANSYS appends the newly executed actions instead of overwriting the file.

The Log File can be utilized to: Understand how an analysis was performed by another user.

Learn the command equivalents of the actions taken within ANSYS.

Error File

Similar to the Log File, the Error File is an ASCII file, which is created (or resumed)

immediately upon entering ANSYS. This file captures all warning and error messages issued byANSYS during a session. It is saved in the Working Directory with the following syntax for the


7/48


name:jobname.err. Ifjobname.err already exists in the Working Directory, ANSYS appends the

newly issued warning and error messages instead of overwriting the file. This file is particularly

important when ANSYS issues several warning and error messages too quickly during aninteractive session. The user can then consult the Error File to discover the exact cause(s) of

each of the warnings or errors.

Resul ts F il es

The results of an ANSYS analysis are stored in a separate Results File. This file is a

binary file and, depending upon theAnalysis Type, the file's extension takes a different form. The

following syntax applies to theResults File name for the selectedAnalysis Type:Structural analysis:jobname.rst

Thermal analysis:jobname.rth

Fluids analysis:jobname,rfl

DESCRIPTION OF ANSYS MENUS AND WINDOWSWhen using the ANSYS program in Interactive Mode, the Graphical User Interface

(GUT) is activated. The GUI has six distinct components:Utility Menu: Contains functions that are available throughout the ANSYS session, such as file

controls, selecting, graphic controls, and parameters. The ANSYS Help System is also accessible

through this menu.

Main Menu: Contains the primary ANSYS functions organized by processors (Preprocessor,Solution, General Postprocessor, etc.).

Toolbar: Contains push-buttons for executing commonly used ANSYS commands and functions.

Customized buttons can be created.Input Field: Displays a text field for typing commands. All previously typed commands are

stored in a pull-down menu for easy reference and access.

Graphics Window: Displays the graphical representation of the models/ meshes created within

ANSYS. Also, the related results are reviewed in this window.Output Window: Receives text output from the program. This window is usually positioned

behind other windows and can be raised to the front when necessary


8/48


USING THE ANSYS HELP SYSTEM

Information on ANSYS procedures, commands, and concepts can be found in the

ANSYS Help System. The importance of knowing how to use the Help System cannot beoveremphasized. It can be accessed within the Graphical User Interface (GUI) in three ways:

By choosing theHelp menu item under Utility Menu.

By pressing theHelpbutton within dialog boxes. By entering the HELP command directly in theInput Field.

TheHelp System is also available as a stand-alone program outside of ANSYS. The user

can bring up the desired help topic by choosing it from the system's table of contents or index,

through a word search, or by choosing a hypertext link. The Help System is built on the HTMLplatform in the form of web pages. As indicated in Fig. there are three tabs on the left of theHelp

Window: Contents, Index, and Search. The help pages are displayed on the right side of the Help

Window.


9/48


VERIFICATION MANUALAlthough all of the ANSYS Manuals included under the Contents Tab are important

sources of information, one particular Manual deserves special emphasis, the Verification

Manual. The purpose of this Manual is to demonstrate the capabilities of ANSYS in solving

fundamental engineering problems with analytical solutions. Another important feature of the

Verification Manual is its suitability as an effective learning tool. There is a corresponding InputFile for each of the verification problems included in this manual (in excess of 200). Asmentioned earlier, the input files contain ANSYS commands to be executed sequentially when

read from within ANSYS. Each of these commands corresponds to a specific action in the

Interactive Mode. Once the verification problem that is the closest to the problem at hand isidentified, the user can then study the corresponding Input File and learn the essential steps in

solving the problem using ANSYS. The Verification Manual also serves as an excellent tool for

learning to use ANSYS inBatch Mode


10/48


Exp.No:2

Thermal Analysis of Piston

Aim:To modeling and carry out thermal analysis of the given piston using the

analysis software ANSYS.

Procedure:

(I) Preference:

Preferences for GUI filtering > Thermal > OK

(II) Preprocessor:

(1) Element:

Element Types > Add/Edit/Delete > Add > Solid > Tet 10node 87

(SOLID 87) > OK

(2) Materials Props:

Material Models Available window:

Thermal > Conductivity > Isotropic > KXX = 16

Specific Heat = 500

Density = 8000

> OK

Materials Props > Temperature Units > Celsius click > OK

(3) Modeling:

Modeling > Create > keypoints>in active CS (keypoint name(x,y))

1(0.06,0)apply


11/48


2(0.07,0) apply

3(0.07,0.025)apply

4(0.065,0.025)apply

5(0.065,0.030)apply

6(0.070,0.030)apply

7(0.07,0.105)apply

8(0.065,0.105)apply

9(0.065,0.11)apply

10(0.07,0.11)apply

11(0.07,0.115)apply

12(0.065,0.115)apply

13(0,065,0.12)apply

14(0.07,0.12)apply

15(0.07,0.125)apply

16(0.065,0.125)apply

17(0.065,0.13)apply

18(0.07,0.13)

19(0.07,0.14)apply

20(0,0.14) apply

21(0,0.13) apply

22(0.055,0.13) apply

23(0.055,0.105) apply


12/48


24(0.06,0.1) ok

Modeling > Create >Line>straight line,[Joint all keypoint in sequence(1,2,3etc)]

Modeling > Create >Area>arbitrary>by lines [Joint all line in sequence (1,2,3..etc)

Modeling>operate>Extrude>Area>About Axix,

[select area> apply>select keypoint 20&21 ok]

Modeling > Create >Volume>Solid cylinder

[enter 0,0.065,0.007,+0.08 apply, 0,0.065,0.007,-0.08 OK]

Modeling>operate>Booleans>subtract>Volume

[select CYLINDER> apply>select two small solid ok]

(4) Meshing:

Meshing > Mesh Tool > Click on "Mesh" > In the dialog box of pick, click "Pick All" Click ok >

Click "Close" to close the Mesh Tool dialog box

(III) Solution:

(1) Analysis Type:

Analysis Type > New Analysis

For type of analysis select Steady-stateand select OK.

(2) Define Loads:

Main Menu >Solution >Define Loads >Apply >Thermal >Temperature >On Areas >Pick the

Bottom areaby mouse click (You can go to File Menu >PlotCtrls >Pan Zoom Rotate, to find

the area, check "Dynamic Mode" to rotate the model by mouse) >Click "ok" >Choose "Temp"

and put "500"as the value >Click "ok"

Main Menu >Solution >Define Loads >Apply >Thermal >Heat Flux >On Areas >Pick the

Top areaby mouse click >Click "ok">Input 3000into the value >Click "ok"


13/48


(3) Solve:

Main Menu >Solution >Current LS >Click "ok" >Click "close" after the solution is done and

close the window of commands.

(IV) General Post prop:

Plot Results > Contour Plot > Nodal Solu > DOF Solution >

Nodal temperature > Deformed shape only > OK

Animation:

Utility Menu > PlotCtrls > Animate > Deformed Results

Select the DOF solution > Temperature TEMP > OK

Result:

Thus the modeling and thermal analysis of the given piston was carried out

using the analysis software ANSYS.


14/48


Exp.No:3

Structural Analysis of Piston

Aim:To modeling and carry out structural analysis of the given piston using

the analysis software ANSYS

Procedure:

(I) Preference:

Preferences for GUI filtering > Structural > OK

(II) Preprocessor:

(1) Element:


(SOLID 87) > OK



> Structural > Linear > Elastic > Isotropic

The window titled Linear Isotropic

Properties for Material Number 1 now appears.

Enter 131e3 for EX (Young's Modulus) and

0.311 for PRXY (Poissions Ratio) > OK

(3) Modeling:


1(0.06,0)apply

2(0.07,0) apply

3(0.07,0.025)apply


15/48


4(0.065,0.025)apply

5(0.065,0.030)apply

6(0.070,0.030)apply

7(0.07,0.105)apply

8(0.065,0.105)apply

9(0.065,0.11)apply

10(0.07,0.11)apply

11(0.07,0.115)apply

12(0.065,0.115)apply

13(0,065,0.12)apply

14(0.07,0.12)apply

15(0.07,0.125)apply

16(0.065,0.125)apply

17(0.065,0.13)apply

18(0.07,0.13)

19(0.07,0.14)apply

20(0,0.14) apply

21(0,0.13) apply

22(0.055,0.13) apply

23(0.055,0.105) apply

24(0.06,0.1) ok



16/48





Modeling > Create >Volume>Solid cylinder

[enter 0,0.065,0.007,+0.08 apply, 0,0.065,0.007,-0.08 OK]

Modeling>operate>Booleans>subtract>Volume

[select CYLINDER> apply>select two small solid ok]

(4) Meshing:



(III) Solution:

(1) Analysis Type:


For type of analysis select static and select OK.

(2) Define Loads:

Define Loads > Apply> Structural >Displacement> On Area >

[select Gudgeon Pin Hole area ]>select All DOF> Click OK

Define Loads > Apply> Structural > Pressure> On Area > (select top area of piston > enter=18e6>

OK

(3) Solve:






17/48



Animation:


Result:

Thus the modeling and structural analysis of the given piston was carried outusing the analysis software ANSYS.


18/48


EXP: 4

Stress Analysis of Piston ring

Aim: To model and analyse the given piston-ring using ANSYS.

Procedure:

(I) Preference:


(II) Preprocessor:

(1) Element:

Preprocessor >Element Types > Add/Edit/Delete > Add > Beam > 3D Elastic 4 >ok

(2) Real Constants:

Preprocessor > Real Constants> Add/Edit/Delete

Select add to create a new set.

> Add

select Beam 4 as the element type.

> Type 1 Beam4 > OK

Cross-sectional area is 24,

Area moment of inertia IZZ is 72

Area moment of inertia IYY is 32.Enter the values into the table > OK> Close








(4) Modeling:


19/48


Preprocessor > Modeling> Create > Lines > Arcs> By Cent & Radius

Enter 0 and press enter on the keyboard. Then enter 40 and press enter on the keyboard.

Enter 180 into the Arc length in degrees field.

> OK

(4) Meshing:

Meshing > Mesh Tool > Mesh > Pick All > OK

(III) Solution:

(1) Analysis Type:



(2) Define Loads:

Define Loads > Apply> Structural >Displacement> keypoints > (one side

outer circle select the keypoint) Click OK >

select All DOF.

> OK.

Define Loads > Apply> Structural > Force/Moment> keypoints > other end

keypoint> OK > Pick FY for the direction of the force.

Enter 5 in the Force/moment value field which will apply > OK

If you wish to view a 3D picture of your model select:

> Plot Controls > Style

> Size and Shape

The Size and Shape window opens. Click the check box next to Display of element to turn on the 3D

image

(3) Solve:

The next step is to solve the current load step that has been created. Select:


20/48


Solve > Current LS. The Solve Current Load Step window will appear. To begin the

analysis select OK.



Displacement vector sum > Deformed shape only > OK

Animation:


Select the DOF solution > USUM > OK

Result:

Thus the modeling and structural analysis of the given piston-ring was carried out using the



21/48


Exp:5

Date :

Thermal Analysis of Valve

Aim:To modeling and carry out thermal analysis of the given engine valve


Procedure:

(I) Preference:

Preferences for GUI filtering > Thermal > OK

(II) Preprocessor:

(1) Element:


(SOLID 87) > OK

(2) Materials Props:Material Models Available window:

Thermal > Conductivity > Isotropic > KXX = 16

Specific Heat = 500

Density = 8000

> OK

Materials Props > Temperature Units > Celsius click > OK

(3) Modeling:


1(0, 0) apply


22/48


2(0.02, 0) apply

3(0.02, 0.002) apply

4(0.015, 0.006) apply

5(0.006, 0.006) apply

6(0.006, 0.115) apply

7(0.005, 0.115) apply

8(0.005, 0.12) apply

9(0.006, 0.12) apply

10(0.006, 0.13) apply

11(0, 0.13)

ok





(5) Meshing:



(III) Solution:

(1) Analysis Type:


For type of analysis select Steady-stateand select OK.

(2) Define Loads:


23/48


Main Menu >Solution >Define Loads >Apply >Thermal >Temperature >On Areas >Pick the

Top areaby mouse click (You can go to File Menu >PlotCtrls >Pan Zoom Rotate, to find the

area, check "Dynamic Mode" to rotate the model by mouse) >Click "ok" >Choose "Temp" and

put "1000"as the value >Click "ok"

Main Menu >Solution >Define Loads >Apply >Thermal >Temperature>On Areas >Pick the

Bottom areaby mouse click >Click "ok">Choose "Temp" and put "3000"as the value >Click

"ok"

(3) Solve:






Animation:


Select the DOF solution > Temperature TEMP > OK


24/48


Result:

Thus the modeling and thermal analysis of the given engine valve was carriedout using the analysis software ANSYS.


25/48


Exp:6

Structural Analysis of Valve

Aim:To modeling and carry out structural analysis of the given engine valve


(I) Preference:

Preferences for GUI filtering > structural > OK

(II) Preprocessor:

(1) Element:


(SOLID 87) > OK



Preprocessor>Material prop>Material model> Structural > Linear > Elastic > Isotropic





(3) Modeling:


1(0, 0) apply

2(0.02, 0) apply


26/48


3(0.02, 0.002) apply

4(0.015, 0.006) apply

5(0.006, 0.006) apply

6(0.006, 0.115) apply

7(0.005, 0.115) apply

8(0.005, 0.12) apply

9(0.006, 0.12) apply

10(0.006, 0.13) apply

11(0, 0.13)

ok





(5) Meshing:



(III) Solution:

(1) Analysis Type:



27/48



(2) Define Loads:

Define Loads > Apply> Structural >Displacement> On Area >

[the valve is constrained at the top]>select All DOF> Click OK

Define Loads > Apply> Structural > Pressure> On Area > (The pressure is applied on the valve head

)

> enter=18e6> OK

(3) Solve:






Animation:



28/48


Result:

Thus the modeling and thermal analysis of the given engine valve was carriedout using the analysis software ANSYS.


29/48


Exp: 7

Stress Analysis of Piston Pin

Aim:To modeling and carry out structural analysis of the given engine piston-pin using the analysis software ANSYS.

Procedure:

(I) Preference:


(II) Preprocessor:

(1) Element:

Element Types > Add/Edit/Delete > Add > Solid > Brick 8node 45 > OK








(3) Modeling:


30/48


Preprocessor>modeling>create>volume>cylinder>hollow cylinder

Enter ( 0,0,0.005,0.0075,0.08) ok

(4) Meshing:


(III) Solution:

(1) Analysis Type:


For type of analysis select staticand select OK.

(2) Define Loads:

Define Loads > Apply> Structural >Displacementt> On Area > (one side

outer circle select the area) Click OK > Next click On Area > (another side

outer circle select the area) > click OK.

Define Loads > Apply> Structural > Force/Moment> On nodes > (Center Point click > OK> Pick FY for the direction of the force.

Enter -1000 in the Force/moment value field which will apply > OK

(3) Solve:


31/48



Solve > Current LS. The Solve Current Load Step window will appear. To begin the analysis

select OK.




Animation:




32/48


Result:

Thus the modeling and structural analysis of the given piston-pin was carried

out using the analysis software ANSYS.


33/48


Exp : 8

Buckling Analysis of Connecting Rod

Aim:To model and carry out Buckling Analysis of Connecting rodusing the


Procedure

(I) Preference:


(II) Preprocessor:

(1) Element:

Element Types > Add/Edit/Delete > Add > Solid > Quad 4node 42 > Apply

> Brick 8node 45 > OK .



Structural > Linear > Elastic > Isotropic > EX = 30e6

PRXY = 0.3

> OK

(3)Modeling:


34/48


Define four new keypoints:

Main menu>preprocessor>modeling>creat>keypoints>In Active CS

1stKP,X=2.5,Y=0.5 [Apply]

2nd

KP,X=3.25,, Y=0.4 [apply]

3rd

KP, X=4,Y=0.33 [apply]

4

th

KP, X=4.75, Y=0.28 [OK]

Create two circular area:

Main menu>preprocessor>modeling>create>area>circle>by dimension.

Rad1=1.4, Rad2=1,THETA1=0,THETA2=180, [Apply] next set

(1.4,1,45,180) [OK]

Offset working plane to XYZ location (6.5)

Utility menu>workplane>offset WP to> XYZ Location

Enter 6.5 [OK]

Utility menu>workplane>change Active CS to> working plane


35/48


Create two circular areas:

Main menu>preprocessor>modeling>create>area>circle>by dimension.

Rad1=0.7, Rad2=0.4,THETA1=0,THETA2=180, [Apply] next set

(0.7,0.4,135,180) [OK]

Separate overlaps on each area group:

Main menu>preprocessor>Modeling>operate>Booleans>Overlap>Area

Frist select left group of areas, [Apply]

Next, select right group of areas, [OK]

Create a single line from a spline fit to a series of keypoints:

Utility menu>workplane>change Active CS to> Global Cylindrical

Main menu> preprocessor>modeling>create>lines>Splines>spline thru KPs

[Pick in order the six keypoints]

Create a straight line between keypoints:

Main menu> preprocessor>modeling>create>lines>Straight line>

Pick the two keypoints as shown


36/48


Utility menu>Plot ctrls>Numbering..set line numbers on, [OK]

Utility menu>Plot> Lines.

Create area bounded by lines:

Main menu> preprocessor>modeling>create>Areas Arbitrary> By lines

Pick the four lines(6,1,7,25) [OK]

Add all areas together to form one single area:

Main menu>Preprocessor>Modeling>operate>add>Areas

[Pick All]

Utility menu>workplane>change Active CS to> Global Cartesian

Reflect the area about the X-Z Plane:

Main menu>Preprocessor>Modeling>Reflect>Areas

[Pick All]

Select X-Z plane,[OK]

Add all areas together to form one single area:

Main menu>Preprocessor>Modeling>operate>Boolean>add>Areas

[Pick All]

Extrude the Area:


37/48


Main menu>Preprocessor>Modeling>operate>Extrude>Area>Along

Normal> [select area, Apply, length of Extrusion=0.5]

Save Data:

(4) Meshing:

Meshing > Mesh Tool > click the Mesh" > In the dialog box of pick, click "Pick All".

(III) Solution:

(1) Analysis Type:


For type of analysis select Staticand select OK.

*Solution> Unabridged Menu > Click

(2) Define Loads:

Main Menu >Solution >Define Loads >Apply >Structural >Displacement>On Areas >Pick

the Bottom area (two side)by mouse click (You can go to File Menu >PlotCtrls >Pan Zoom

Rotate, to find the area, check "Dynamic Mode" to rotate the model by mouse) >Click "ok" >

Choose All DOF>Click "ok"

Main Menu >Solution >Define Loads >Apply >Structural >Pressure>On Areas >Pick the

Top areaby mouse click (You can go to File Menu >PlotCtrls >Pan Zoom Rotate, to find the

area, check "Dynamic Mode" to rotate the model by mouse) >Pressure Value = 31500>"ok"


38/48


(3) Solve:



** Note: Two times Solution and solve the Analysis.

(1) Analysis Type:


For type of analysis select Eigen Bucklingand select OK.

Analysis Type > Analysis Option > No. of modes to extract = 5 > OK

(2) Load Step Opts:

Expansion Pass >Single Expand >Expand Modes >

No. of modes to expansion = 5 > OK.

(3) Solve:




39/48



Read Results > First > Utility Menu > PlotCtls > Animate >

Deformed Results > Select USUM only > OK

Result:

Thus the modeling and Buckling Analysis of Connecting rod was carried out


For REFERENCE


40/48


Exp :9

Stress Analysis of

Balancing Weight of Crankshaft

Aim:To model and analyse the given crankshaft using ANSYS.

Procedure:

(I) Preference:


(II) Preprocessor:

(1) Element:

Element Types > Add/Edit/Delete > Add > Solid > Quad 4node 42 >

Apply > Brick 8node 45 > OK








(3) Modeling:



41/48


1(0, -0.025) apply

2(0.06,-0.025) apply

3(0.03, 0.01) apply

4(0.03, 0.06) apply

5(0.0, 0.06) apply

6(-0.03, 0.06) apply

7(-0.03, 0.01) apply

8(-0.06, -0.025) apply

ok

Modeling > Create >Line>straight line

[Joint all keypoint in sequence(1,2,3etc)]

Modeling > Create >Line>Arc>by Center&Radius

[select KP1 apply select KP8 , 180 OK]

[select KP5 apply select KP4 , 180 OK]

Modeling > Create >Area>arbitrary>by lines

[Joint all line in sequence (1,2,3..etc)

Modeling>operate>Extrude>Area>Along Normal,

[select area> apply>0.02 ok]

Utility menu> Work plane>offset WP by increment>

(0, 0, 0.02) enter [OK]

Modeling > Create >Volume>Cylinder>Solid Cylinder>

(0, 0.06, 0.02, 0.03) [OK]

Modeling>copy>volume>

Select Web-volume [OK] Z-offset in active CS=0.05 [OK]


42/48



(0, 0, 0) enter [OK]


(0, 0, 0.02, -0.03) [OK]


(0, 0, 0.07) enter [OK]


(0, 0, 0.02, 0.03) [OK]

Modeling>Operate>Booleans>Add>Volume>

Pick All [OK]

(4) Meshing:


(III) Solution:

(1) Analysis Type:


For type of analysis select staticand select OK.

(2) Define Loads:

Define Loads > Apply> Structural >Displacement> On Area > (one side

outer circle select the area) Click OK > Next click On Area> (another side

outer circle select the area) > click OK.

Define Loads > Apply> Structural > Force/Moment> On nodes > (Center Point click > OK

> Pick FY for the direction of the force.


43/48


Enter -1000 in the Force/moment value field which will apply > OK

(3) Solve:



select OK.




Animation:Utility Menu > PlotCtrls > Animate > Deformed Results


Result:

Thus the modeling and Stress Analysis of Balancing Weight of Crankshaft was

carried out using the analysis software ANSYS.


44/48


Exp:10

Vibration Modal Analysis of Camshaft

Aim:To model and carry out Vibration Modal Analysis of Camshaftusing the


Procedure:

First create the Catia software modeling the Camshaft and file name and type save the x_t format.

Utility Menu> File > Import > Para > file name (camshaft .x_t) >

Geometry type (All Entities) > Allow Scaling click > OK

(I) Preference:


(II) Preprocessor:

(1) Element:

Element Types > Add/Edit/Delete > Add > Solid > Quad 4node 42 >

Apply > Brick 8node 45 > OK



> Structural > Linear > Elastic > Isotropic > EX = 30e6

PRXY = 0.3

Density = 8.3e-5

> OK

(3) Modeling:



45/48


1(0, 0) apply

2(2.5, 0) apply

3(1, 3) apply

4(0, 4) apply

5(-1, 3) apply

6(-2.5, 0) OK

Modeling > Create >Line>Arc>by Center&Radius

[Select KP1 apply select KP6 , 180 OK]

Modeling > Create >Line>splines>splines thru KPS

[Select KP2,3,4,5,6 apply OK]

Modeling > Create >Area>arbitrary>by lines

[Joint all line in sequence (1,2,3..etc)

Modeling>operate>Extrude>Area>Along Normal,

[Select area> apply>2 ok]


(0, 0, 2) enter [OK]


(0, 0, 2, 2) [OK]


Select Cam-volume [OK] Z-offset in active CS=4[OK]


Select circular-volume [OK] Z-offset in active CS=4[OK]


(0, 0, 8) enter [OK]



46/48


(0, 0, 2.5, 2) [OK]


Select circular-volume [OK] Z-offset in active CS=4[OK]


Select 1circular-volume [OK] Z-offset in active CS=-6[OK]


Select Big-circular-volume [OK] Z-offset in active CS=-8[OK]

Repeat steps for Number of cylinder

(4) Meshing:


(III) Solution:

(1) Analysis Type:


For type of analysis select Modaland select OK.

Analysis Type > Analysis Options > click Block Lanczos >

No. of modes to extract = 5 > No. of modes to expand = 5 > OK

(2) Define Loads:

Define Loads > Apply> Structural >Displacement t> On Area > (two side

select the area) Click OK


47/48


*Note: Force / Moment & Pressure not applicable.

(3) Solve:



select OK.




Animation:



Result:


48/48


Thus the modeling and Vibration Modal Analysis of Camshaftwas carried out


Date post:	21-Feb-2018
Category:	Documents
Upload:	stanlyd15
View:	214 times
Download:	0 times

Saux4008-Modeling and Analysis of Engine Components Lab (1)

Documents