FEM Lab-2

Frequency, Optimization, and

Thermal Analysis
R. S. Shaefer and C. Kang
MAE 162D
Mech. & Aerospace Engineering Dept.
UCLA
Winter 2014
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T1

FEM Lab-2 Assignment

T1: Frequency Tutorial (15 pts.)

P1

P1: Flywheel Frequency Analysis (15 pts.)

T2: Optimization Tutorial (20 pts.)

T2

P2: Flywheel Optimization (30 pts.)

P2

T3: Thermal Analyis (20 pts.)

500 N

T3

E3

E3: EXTRA CREDIT: Thermal Analysis (20 pts.)

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Frequency Analysis
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Frequency Study Background

A body disturbed from its rest position tends to vibrate at certain
frequencies called natural, or resonant frequencies. The lowest
natural frequency is called the fundamental frequency.
For each natural frequency, the body takes a certain shape called
mode shape.
Frequency analysis calculates the natural frequencies and the
associated mode shapes.
Excessive response occurs if a body is subjected to a dynamic
load vibrating at one of its natural frequencies. This
phenomenon is called resonance.
For example, a car with an out of-balance tire shakes violently at a certain speed
due to resonance. The shaking decreases or disappears at other speeds. Another
example is that a strong sound, like the voice of an opera singer, can cause a glass
to break.

Frequency analysis can help avoid failure due to excessive

stresses caused by resonance.

Frequency Study Tutorial ASSIGNMENT: T1 (10 pts.)

Open SW-Frequency Tutorials and open the shaft analysis

tutorial:

Place your name in the assembly or on a part (use large fonts).

Click on Simulation and go through the tutorial.

Save the resonance frequency list as an excel file and save

the 2nd mode shape as a jpeg file.

Repeat the tutorial, but change the shaft material from AISI1020 steel to Beryllium. Do not change the support material
(if you get an error when applying the Be-properties to the
shaft find a workaround, do not ask how!).

Calculate the first 5 resonance frequencies and plot both, the

steel shaft and the Be-shaft frequencies.

Again, save the resonance frequency list as an excel file and save the 2nd mode shape as a
jpeg file.

Make a plot that compares the frequencies and show a figure in which you compare the
mode shapes.

Give a reason for the difference in frequencies (1 sentence) and briefly discuss the different
mode shapes (what is different and why).

T1

Frequency Study Tutorial ASSIGNMENT: P1 (10 pts.)

Use the uploaded Flywheel model, or recreate it from the drawing and assign
316 SS
P1
(annealed)
material
properties.
Fix the inner
hub and find
the first 5
resonance
frequencies.
Mode

Fixed Inner
Hub (Hz)

3401

Fixed Outer
Rim (Hz)

Optimization Analysis
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Optimization Studies Background

Optimization studies search for the optimum design based on
optimization criteria (weight, size, cost, shape, material)
SW-Simulation is equipped with a technology to quickly detect
trends and identify the optimum solution using the least number
of runs.
Optimization studies require the definition of the following :
1.

Objective: State the objective of the study. For example, minimum

material.

2.

Design Variables or Geometry Constraints. Select the dimensions that

can change and set their ranges. For example, the diameter of a hole
can vary from 0.5 to 1.0 while the extrusion of a sketch can vary
from 2.0 to 3.0.

3.

Behavior Constraints. Set the conditions that the optimum design must
satisfy. For example, you can require that a stress component does not
exceed a certain value and/or that the natural frequency should be
within a specified range.
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Optimization Study Tutorial ASSIGNMENT: T2 (10 pts.)

Locate the knob optimization tutorial and set it up as instructed however,
prior to running it right click and suppress the following optimization variable:
Rib_thickness
Cut_Diameter T2
Cyl_Ht

Run the
optimization
analysis and
document the
optimum
Cut_Depth

Mark the know

with your Name
or other
identifiable logo
and present a
screenshot of
the optimized
result.
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Optimization Study ASSIGNMENT: P2 (30 pts.)

Optimize the Flywheel Thickness
You are to determine the
maximum thickness needed to
avoid yielding (< yield stress) of
two flywheels, one made of
1060-Alumimum and the other
of 316 stainless steel (annealed)
The wheel is resting on the
ground (same flywheel as in
P1).

P2

500 N

First run two static stress

analyses, one with 1060-Al and
one with 316 SS.
Your static analysis should
indicate that the wheel made
of 1060-Al will yield.
Document your results, by showing the Von Mises stress contours of both
analyses.
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Thermal Analysis
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Thermal Analysis:
Thermal studies calculate temperatures,
temperature gradients, and heat flow based
on heat generation, conduction, convection,
and radiation conditions.
Thermal studies can help you avoid
undesirable thermal conditions like
overheating and melting.

Create CAD Model

Apply Thermal
Loads
Apply Thermal
BCs
Temperatures

Thermal analysis of a coffee pot (Tmax=390 oC)

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Thermal Analysis ASSIGNMENT: T3 (30 pts.)

Melting a Copper Disk using a High Power Laser Beam
A friend claims that he has
developed a high power laser
beam and that it can melt
copper.

T3

Your friends laser beam will not be ready until next week, but you want to
investigate his claim using a thermal FEM analysis as follows:
Create a solid model of a 2 mm thick 316 SS disk with a diameter of 50 mm and
a 10 mm diameter insert (hole) for copper at its center.
Assume the following thermal loading conditions:

The beam is aimed at the center of the disk

The beam diameter (footprint) is 2-mm
The beam carries a heat flux of 1.5 MW/m2
The copper disk has a reflectivity of about 80%
A fan blows air at the back of the disk at a cooling rate of about 500 W/m2-K

Does the Cu-disk melt?

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Extra Credit: Thermal Analysis E1 (20 pts.)

Automobile Disk Brake

Disk Pads

http://carcraft.automotive.com/

http://www.khulsey.com/

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Extra Credit: Thermal Analysis E1 (20 pts.)

Problem Statement:
A person on a bike is coasting down a 30 hill at a constant velocity by
applying his brakes. The total heat flux from the brake pad to the brake disk is
10,000 W/m2. Cooling is facilitated by air blowing over the exposed brake disk
with a heat transfer coefficient of 746 W/m2-K. The following physical
specifications on the disk are also given:
-

Disk is solid with an outer diameter of 20 cm, an inner diameter of 2 cm and

a thickness of 0.7 cm
The material is stainless steel
There are two brake pads applied at opposite sides of the disk
The footprint of the brake pad on the disk has an inner diameter of 15 cm,
and outer diameter of 20 cm and extends over an angle of 60 degrees.

Find the Maximum temperature of the disk.

Assumptions:
- Outer rim and area of brake pad is also air cooled
- Ambient temperature is 298 K (25C)

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