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Swaybar-Shaft Assembly
Workshop 8
Bonded Contact
October 30, 2001
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8. Bonded Contact
Swaybar-Shaft Assembly
Description
• A swaybar-shaft assembly is subjected to a vertical force of 500 kgf at the right end of the swaybar. The objective is to determine the overall stresses in the assembly.
• Use bonded contact to simulate the assembly, and replace the right two-thirds of the swaybar with a "rigid region" (constraint equations).
• As a follow-up, join the two parts using a Boolean glue operation and redo the analysis.
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8. Bonded Contact
Swaybar-Shaft Assembly
Loads and Material Properties
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8. Bonded Contact
Swaybar-Shaft Assembly
1. Enter ANSYS in the working directory specified by your instructor using “bonded-contact” as the jobname.
2. Read input from the file “bonded-contact.inp” to 1) mesh the model, 2) create rigid links, and 3) apply constraints and loads:
– Utility Menu > File > Read Input from …
– Or issue:
/INP,bonded-contact,inp
3. Create the bonded contact elements between the shaft and the swaybar:
Procedure shown on following pages
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8. Bonded Contact
Swaybar-Shaft Assembly
3. (cont’d)a) Create the contact elements:
– Main Menu > Preprocessor > -Modeling- Create > Contact Pair > Contact Wizard … • Select “Flexible” and “Areas”, then [Pick Target …]• Pick area 48, then [OK]
HINT: drag mouse until Area 48 is selected or type 48 into the input window, then Enter
For ambiguous pick, hit NEXT until “48” is selected
• Pick [Next >]• Select “Areas”, then [Pick Contact …]• Pick area 22, then [OK]• Pick [Next >]• Pick [Optional settings …]• Set the “Normal Penalty Stiffness” to 100• Select “Bonded (always)” for
Behavior of contact surface• Select the “Initial Adjustment” tab• Select “Exclude everything” for
Initial penetration• [OK]• [Create >]• [Finish]
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8. Bonded Contact
Swaybar-Shaft Assembly
3. (cont’d)
b) select type 5 elements and their nodes and then plot the target surface contact elements:
– Utility Menu > Select > Entities ...
– Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair …
• Select “Target Surface” and check “normals shown” under Options
• [Display]
– Utility Menu > Plot > Elements
– Or issue:
ESEL,S,TYPE,,5
NSLE
/PSYMB,ESYS,1
/PNUM,TYPE,1
EPLOT
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8. Bonded Contact
Swaybar-Shaft Assembly
3. (cont’d)
c) Select type 6 elements and their nodes and then plot the contact surface contact elements:
– Utility Menu > Select > Entities ...
– Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair …
• Select “Contact Surface” and check “normals shown” under Options
• [Display]
– Utility Menu > Plot > Elements
– Or issue:
ESEL,S,TYPE,,6
NSLE
/PSYMB,ESYS,1
/PNUM,TYPE,1
EPLOT
d) Close the “View Contact Pair…” window• [Close]
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8. Bonded Contact
Swaybar-Shaft Assembly
4. Select everything, turn off all symbols except constraint equations, then plot elements:
– Utility Menu > Select > Everything
– Utility Menu > PlotCtrls >Symbols > For Individual : Miscellaneous > Constraint Equations
– Utility Menu > Plot > Elements
– Or issue:
ALLSEL
/PBC,CE, ,1
/AUTO,1
EPLOT
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8. Bonded Contact
Swaybar-Shaft Assembly
5. Enter the solution processor and turn off solution controls. Then choose the PCG solver, set the number of equilibrium iterations to one, and solve:
– Main Menu > Solution > Unabridged Menu
– Main Menu > Solution > -Load Step Opts- Solution Ctrl ..
• Set to “Off”, then [OK]
– Main Menu > Solution > -Analysis Type- Sol’n Control ...
• Pick the “Sol’n Options” tab
• Select “Pre-Condition CG”
• Pick the “Nonlinear” tab
• Enter “1” for the number of Equilibrium Iterations
• [OK]
• Read and then close yellow warning message window
– Pick the “SAVE_DB” button in the Toolbar (or select: Utility Menu > File > Save as Jobname.db)
– Main Menu > Solution > -Solve- Current LS
– Or issue:
/SOLU
SOLCONTROL,OFF
EQSLV,PCG
NEQIT,1
SAVE
SOLVE
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8. Bonded Contact
Swaybar-Shaft Assembly
6. Unselect element 8000 (MASS21 element), then enter POST1 and plot the nodal von Mises stresses:
– Utility Menu > Select > Entities ...
– Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ...
– Or issue:
ESEL,U,,,8000
/POST1
/AUTO,1
PLNSOL,S,EQV
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8. Bonded Contact
Swaybar-Shaft Assembly
7. Plot von Mises stresses for elements associated with volume component “v_bar”: – Utility Menu > Select > Comp/Assembly > Select Comp/Assembly …
– Utility Menu > Select > Everything Below > Selected Volumes
– Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ...
– Or issue:
CMSEL,S,v_bar
ALLSEL,BELOW,VOLU
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8. Bonded Contact
Swaybar-Shaft Assembly
8. Plot von Mises stresses for elements associated with volume component “v_shaft”:– Utility Menu > Select > Comp/Assembly > Select Comp/Assembly …
– Utility Menu > Select > Everything Below > Selected Volumes
– Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ...
– Or issue:
CMSEL,S,v_shaft
ALLSEL,BELOW,VOLU
PLNSOL,S,EQV
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8. Bonded Contact
Swaybar-Shaft Assembly
9. Now rerun the stress analysis, with the swaybar and shaft volumes glued together, by reading input from the file “swaybar-shaft-glued.inp”:
– Utility Menu > File > Read Input from …
– Or issue:
/INP,swaybar-shaft-glued,inp
10. After the solution completes, the nodal solution for SEQV is displayed for the swaybar (i.e. v_bar volume component):
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8. Bonded Contact
Swaybar-Shaft Assembly
11. Plot von Mises stresses for elements associated with volume component “v_shaft”:– Utility Menu > Select > Comp/Assembly > Select Comp/Assembly …
– Utility Menu > Select > Everything Below > Selected Volumes
– Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu ...
– Or issue:
CMSEL,S,v_shaft
ALLSEL,BELOW,VOLU
PLNSOL,S,EQV
12. Exit ANSYS.