Altair Students Guides - Instructors Manual - A Designer's Guide To FEA

Student Project Summaries A Designer’s Guide To Finite Element Analysis
Contents
Introduction.............................................................................................2
Installation Instructions: .......................................................................2
FRF Analysis of a Cross Member................................................................3
Description of the Problem ....................................................................3
The Analysis Model ...............................................................................4
Results.................................................................................................5
Further Work ........................................................................................5
Summary .............................................................................................6
Thermal Expansion Of Screw Shaft............................................................7
Description of the Problem ....................................................................7
The Analysis Model ...............................................................................8
Results.................................................................................................9
Further Work ........................................................................................9
Summary ........................................................................................... 10
Transient Analysis Of Gun Barrel ............................................................. 11
Description of the Problem .................................................................. 11
The Analysis Model ............................................................................. 12
Results............................................................................................... 13
Further Work ...................................................................................... 13
Summary ........................................................................................... 14
Force & Stress Analysis of Engine Mechanism .......................................... 15
Description of the Problem .................................................................. 15
The Analysis Model ............................................................................. 16
Results............................................................................................... 17
Further Work ...................................................................................... 17
Summary ........................................................................................... 18
1
Introduction
This material is best used after reading the book A Designer’s Guide To
Finite Element Analysis.
Access to HyperWorks software is not essential for you, the instructor. Of

course, if you choose to solve the problem yourself before working with your
students, you will need HyperMesh and OptiStruct.
This book describes 4 assignment problems that highlight different

applications of HyperWorks. Each problem is independent, and is complete
in itself. Students may choose to do more than one, depending on their
interest.
To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player programme
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a server and accessed by clients.
You can customize the HTML files to suit your

requirements. After opening the file, double-
click on any text to edit it. Use the save changes
link on the left of your Browser window when
you are finished.
Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
edu.support@altair.india.com
2
FRF Analysis of a Cross Member

Areas covered:
• Geometry abstraction for FE modeling
• Automatic mesh generation
• Application of FRF loads
• Design interpretations of FE results
Software used:
• HyperMesh
• OptiStruct/Analysis
• HyperView
Description of the Problem

Vibration response plays an important part in
the design of vehicle frames. The range of
excitation is usually specified by the vehicle
designer for each sub-system.
In this project, a cross-member has been

proposed for a vehicle chassis. The purpose
of the analysis is to evaluate the response of
the component as the frequency is "swept"
through the given range - from 0 to 1000 Hz.
The starting point of the problem is the IGES

file of the CAD assembly. A frequency-domain
load is applied to simulate a frequency-
sweep: from 0 to 1000 Hz.
The student should be encouraged to

understand the modal-testing approach so
that the importance of the various data is
understood from a designer's perspective. The
vibration characteristics of the assembled
frame will be very different from that of the
single component, of course, but the
approach of setting requirements on
individual components is essential at the
preliminary design stage.
3
The Analysis Model

The model is characteristic of many sheet-
metal parts: small radii, flanges, bends, etc.
The element choice is easy - shell elements.
A shell element represents the "neutral"

surface of a thin shell. Except for a flat plate,
the neutral surface is not at the center. The
assignment discusses the relative benefits of
generating elements on the inner surface, the
outer surface or the mid-surface. The
discussion highlights the fact that if thin-shell
elements are justified, the difference is not
important from a mechanics point of view. It
is more important for convenience of
modeling. When working with assemblies,
considerable effort goes into extending or
trimming surfaces to ensure that they meet!
HyperMesh does a good job of mid-surface

extraction. We will use it simply because it
makes our meshing job easier, not because it
is more accurate than meshing the inner or
outer surfaces.
Since the model is small, we will not need to

worry much about the element size, though
the student must, of course, ensure that the
results are adequately accurate.
The choice of appropriate units is also

discussed. Analysis results and data are
specified in cycles-per-unit-time. The use of
SI units means we can work with Hz (cycles /
second).
The specifications call for an excitation

between 0 and 1000 Hz. We use the Lanczos
method to obtain mode shapes upto 3000 Hz.
We use the modal-analysis method, where

we approximate the transient behavior as a
weighted sum of the mode shapes. The
4
source of error lies in the choice of mode shapes, so to be safe we use

mode shapes upto 3000 Hz - thrice the excitation range.
Results
Interpreting the results of the optimization requires a good understanding of
the FRF approach.
Since the frequency-domain and time-domain

are entirely equivalent, the results can be
viewed either as phase-magnitude plots (i.e.
the frequency domain) or as animations or
time-histories (i.e. the time domain).
Depending on the output-control options,

either or both can be generated by OptiStruct
/ Analysis.
Further Work
The assignment brings home the advantages
of OptiStruct / Analysis:
• Excellent data import capabilities

• Quick, easy and convenient geometry
abstraction
• Powerful mesh generation
• Easy control over the solution process
• convenient reporting options with easy
viewing
Depending on their proficiency, students may

want to research
• the use of optimization to improve

response
• a comparison between the direct-
analysis method and the modal-
analysis-method
• the sensitivity of the results to mesh
size
• the sensitivity of results to the
solution parameters: FREQ1 options,
number of frequencies, etc.
5
• the response for multiple loads with a phase lag
Summary
By the end of this assignment, the student will know how to
• import IGES files
• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create collectors for materials, elements, forces and restraints
• measure distances and the diameter of circles
• generate mid-surfaces automatically
• use QI meshing
• find the centers of circles
• use consistent units
• check for different types of element-edges - free, shared, etc.
• fill and stitch surfaces
• use temp nodes
• apply frequency-domain loads
• use the modal-method for FRF analysis
• plot stress contours
• view deformed shapes
• check for warnings using the text output files
• view results in HyperView
6
Thermal Expansion Of Screw Shaft

Areas covered:
• Geometry abstraction for FE modeling
• Hex mesh generation
• Application of temperature loads
• Use of symmetry boundary conditions
• Use of contact in FE analysis
Software used:
• HyperMesh
• HyperView

Aircraft components go through stringent
testing before they are accepted. The testing
conditions are often more demanding than the
anticipated deployment conditions.
A design proposal has been received for a

subassembly, and the task is to simulate its
performance. The screw-shaft subassembly,
which fits into a housing, is manufactured to
very close tolerances. The dimensional
accuracy is measured in 10s of microns.
In the test chamber, the complete assembly is

cooled to -40 degrees Kelvin and tested. It is
subsequently raised to 135 degrees Kelvin and
tested again.
Will the sub-assembly function correctly? How

will the gap in the groove behave?
7
Since the entire assembly is "soaked" in the

testing-chamber to reach the uniform
temperature, we do not need to perform a
thermal analysis. Instead, we need to apply
the temperature field and calculate the
deformation of the components. In case there
is interference, we can then use contact
analysis to investigate stresses.
The Analysis Model

The model is characteristic of turned parts,
displaying axial symmetry.
The element choice is easy - solid elements
While tetrahedral elements are easy to create,

we will want to use hexahedral elements since
the clearances are very fine. We will use three
different facilities HyperMesh gives us to
create the hexahedral mesh on the shaft and
the plugs.
We must, of course, ensure that the results

are adequately accurate. A convergence study
is very important, particularly since the curved
faces of the grooves should be captured
adequately accurately.
We will want to use quite a fine mesh in our

final analysis, so we should take advantage of
symmetry. Since there are 4 plugs, we use
quarter symmetry to reduce the model size.
Since the differential expansion of the shaft

and the plugs is the likely source of design-
problems, the student should appreciate the
importance of the reference temperature and
the coefficient of thermal expansion.
Automeshing can be used if we are willing to

settle for tetras. HyperMesh makes it very easy
to do this. Since we want hexahedral
elements, however, we use a different
approach. First, since the shaft has an axis of
8
symmetry, we mesh one face with

quadrilaterals and "spin" these to get hexas.
Next, we focus on one of the plugs. We create
a 2D mesh on one face, and use HyperMorph
to map these to another face. Once we have
this, the Linear Solid option generates hexas
between the element sets. Finally, we "drag"
elements along a line to generate the stub-
handle on the plug.
The "Position" option quickly lets us move an

entire mesh from one position to another,
completing our mesh.
Results
Interpreting the results of the optimization
requires some care. In the initial analysis, we
are trying to decide whether or not a more
expensive contact analysis is required or not.
So the focus is on the deformation pattern of
the shaft and the plugs.
If contact is necessary, a subsequent analysis

with contact yields the actual deformation
pattern.
Further Work

abstraction
viewing
You may choose to assign further

investigations to your students based on their
level of proficiency on CAD, the time available,
etc.
9
Some of the areas that could include
• the use of contact to assess stresses

• the use of spring supports on the exterior,
to simulate the flexibility of the housing
• an investigation into the sensitivity to mesh
size
• a study of possible alternate steel-alloys
for the plugs
Summary
By the end of this assignment, the student will
know how to
• import IGES files
• create material collectors
• create component collectors
• create load collectors
• create loadcases
• measure distances
• work with different types of edges
- free, shared, etc.
• fill and stitch surfaces
• measure the diameter of circles
• find the centers of circles
• use temp nodes
• use autocleanup to do all of the
above
• create restraints or SPCs
• apply symmetry BCs
• use HyperMorph to map elements
to a geometry
• use the Linear Solid option to
generate hex elements
• check for warnings using the text
output files
• view deformation plots and stress
contours
10
Transient Analysis Of Gun Barrel

Areas covered:
• Hexahedral Mesh Generation
• Direct-integration for short-time response
• Generation of plots for parametric studies
Software used:
• HyperMesh
• HyperView

An artillery system is being designed to allow
for four barrels, and the goal is to understand
the impact of the firing order on the
deflection of the barrel tips. When the shell
leaves a barrel, the tip of the barrel
experiences a disturbance. As a result, all 4
barrel tips vibrate. If the amplitude of the
vibration has not died down before the next
shell is fired, accuracy will suffer.
Our design problem is to estimate the

amplitudes of vibration of the barrel tips
under different firing orders. if we number the
barrels 1-2-3-4, several choices are available
to the artillery designer: the order could be
1/2/3/4, or 1/3/2/4, etc.
Since the gun is still at the design stage, the

load characteristics are not frozen. The
simulation should also cast light on the
sensitivity of the proposed configuration and
firing order to the amplitude-versus-time
variation of the load.
A Finite Element model is used, with the

direct-integration approach, to carry out the
simulation. A series of analyses will be carried
out to generate graphs of the displacement
characteristics of the barrel-tips under
11
different firing orders, and under different

amplitude-time variations of the impulse load.
The Analysis Model

We will want to carry out the analysis for a
few second after the excitation has ceased.
The graphs we obtain of amplitude vs. time
can be used by the designer to estimate when
it is safe to fire the next round.
Beam elements would yield a very quick

model, but the problem lies in connecting the
baffle plates to the barrels. Shell elements are
a possible choice for the baffles, but shells
and solids are incompatible elements - shells
have 6 dof / node while solids have 3.
In a geometry like this, hexahedral elements

are almost as easy to create as tetrahedra.
Accordingly there is no justification to use the
less-accurate tetras. Therefore we use
hexahedral elements for all components. We
take care to ensure that nodes match up at
the junctions of the baffles and the barrels,
since as per the assembly instructions the
baffles are press-fitted. We assume perfect
transmission of forces from the barrels to the
baffles.
We use the different facilities HyperMesh

gives us - linear solid, ruled-surface meshing,
etc.- to create the hexahedral mesh.
First, for the barrels, we use the "ruled"

option to generate elements between curves.
We then use the linear-solid option to create
hexas. Next, we copy elements from one
barrel to another, filling all 4 with elements.
When meshing the baffles, the elements on

the barrels must match those on the holes in
the baffles. This ensures continuity of forces.
12
Clamps at the specified locations are best

represented by SPCs. The loads are a little
more complicated. For the first analysis, we
assume the load-vs-time curve is triangular:
going from 0 to 200N in 1 second and falling
back to 0 in the next second. We specify the
curve using the TABLED1 card. The DAREA
card specifies the amplitude of the excitation,
and the TLOAD1 card puts the curve and the
amplitude together.
We then specify the time-integration method,

by choosing delta-t, which is the time-step size
and the number of time steps.
Results
Animated plots can be viewed, but graphs of
amplitude vs. time are more useful in this
case.
The assignment shows how to evaluate results

as time-history plots, and how to export these
to files for use in subsequent reports.
Further Work

abstraction
viewing

investigations to your students based on their
level of proficiency on CAD, the time available,
etc.
13
• the use of spring supports at the base, to simulate the flexibility of

the support system
• an investigation into the sensitivity to mesh size
• a study of possible alternate steel-alloys for the baffles
• an investigation into the response if perforated baffle plates are
used, which is likely to be the case when the design evolves
Summary
By the end of this assignment, the student will know how to
• import IGES files of assemblies into HyperMesh
• delete unwanted imported data
• create and edit component collectors
• create restraints or SPCs
• measure distances
• apply time-variant loads as (time,amplitude)
• perform an analysis and obtain baseline results
• check for warnings using the text output files
14
Force & Stress Analysis of Engine

Mechanism
Areas covered:
• Geometry Abstraction for FE modeling
• Automatic Mesh Generation
• Modeling for MBD
• Use of Component Mode Synthesis
Software used:
• HyperMesh
• OptiStruct
• HyperView

An assembly model for the engine of a
model aircraft has been proposed. The
designers want to know at what speed the
engine can be run without the stress in the
connecting rod exceeding the permissible
stress for the material.
This problem involves more than just an

"FEA for stress analysis". Forces and
restraints are not supplied. The designer
has to estimate these and then perform the
stress-analysis. The components move as a
mechanism so the first task is to calculate
the forces in the components as the engine
reciprocates. These forces should then be
used to calculate the dynamic stresses in
the component of interest - the connecting
rod.
The first task involves a rigid-body analysis,

while the second involves a flexible-body
analysis. The approach taken in this
assignment makes use of the capability of
OptiStruct / Analysis to mix both forms of
analysis using component-mode synthesis
(CMS).
The assignment explores the use of
15
"bodies" and "joints" together with

"elements".
The Analysis Model

The assignment involves continuum
mechanics for stress analysis, and rigid
body dynamics for calculation of forces.
The latter does not require 3D geometry.

The mass and inertial properties are
adequate. However the availability of the
3D geometry makes it easier to understand
the results of the analysis. Also, the use of
CMS means that the "flexibility" as
calculated by the finite element method can
be used to calculate dynamic stresses
easily.
A "traditional" analysis would require that

• the properties be calculated using a 3D
model, typically a CAD model
• these properties be transferred to a
motion-simulation tool that can perform
"dynamic" analysis, not simple
"kinematic" analysis
• the dynamic simulation be carried out
and forces obtained as output
• forces be transferred to a Finite
Element model
• the stress analysis be performed using
the Finite Element model
With the integrated approach, the various

"transfers" of data are eliminated, making
the process easier and faster and reducing
scope for error.
The modeling focus is on creation of joints

and bodies. OptiStruct / Analysis requires
that the two grids be used to define
revolute and translational joints - one grid
on each of the bodies. The grids that define
the joints need to be on the axis of
rotation, for a revolute joint. Since there
may not be elements at the desired
16
location, we make liberal use of "rigid"

elements. This approach allows us to define
the grids for the joints at locations that are
correct from the point of view of the multi-
body solver.
The use of "ground" bodies means we do

not need any restraints on the FEA model.
We provide an initial velocity to the piston,
to simulate the effect of a "kick-start".
Unlike an FEA solution, the time-integration
scheme used by the MBD solver embedded
inOptiStruct / Analysis calculates the step-
size for time-integration internally.
Running OptiStruct/Analysis is easy, but

errors can occur and can be diagnosed
using the text otput file and the "fem" file
Results
The motion of the bodies is best interpreted
using animations. These are different from
the animated plots of a more "traditional"
FEA. In this case, the deformations are
large. HyperView allows us to view the
animation, to superimpose stresses on the
animated displays, and to plot graphs of
forces at points of interest.
Further Work
The assignment brings home the
advantages of OptiStruct / Analysis:

abstraction
viewing

investigations to your students based on
17
their level of proficiency on CAD, the time

available, etc.
• the use of a higher-quality mesh

• application of a constant angular
velocity motion to the crank
• use of the Flexible Body definition
option (PFBODY) for the connecting rod
• an investigation of the variation of the
stress in the connecting rod with
changes in the rpm of the engine
Summary
By the end of this assignment, the student
will know how to
• import IGES files of assemblies
into HyperMesh
• create component collectors
• define units for the MBD solver
• mix flexible and rigid bodies in
the same model
• create flexible bodies, rigid
bodies and grounded bodies
• apply initial motion to bodies
• define revolute and
translational joints
• check for warnings using the
text output files
• view animated plots of stresses
• view animated plots of the
mechanism’s motion
18

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Student Project Summaries A Designer’s Guide To Finite Element Analysis

Access to HyperWorks software is not essential for you, the instructor. Of

This book describes 4 assignment problems that highlight different

You can customize the HTML files to suit your

FRF Analysis of a Cross Member

Description of the Problem

In this project, a cross-member has been

The starting point of the problem is the IGES

The student should be encouraged to

The Analysis Model

The element choice is easy - shell elements.

A shell element represents the "neutral"

HyperMesh does a good job of mid-surface

Since the model is small, we will not need to

The choice of appropriate units is also

The specifications call for an excitation

We use the modal-analysis method, where

source of error lies in the choice of mode shapes, so to be safe we use

Since the frequency-domain and time-domain

Depending on the output-control options,

• Excellent data import capabilities

Depending on their proficiency, students may

• the use of optimization to improve

• the response for multiple loads with a phase lag

Thermal Expansion Of Screw Shaft

Description of the Problem

A design proposal has been received for a

In the test chamber, the complete assembly is

Will the sub-assembly function correctly? How

Since the entire assembly is "soaked" in the

The Analysis Model

The element choice is easy - solid elements

While tetrahedral elements are easy to create,

We must, of course, ensure that the results

We will want to use quite a fine mesh in our

Since the differential expansion of the shaft

Automeshing can be used if we are willing to

symmetry, we mesh one face with

The "Position" option quickly lets us move an

If contact is necessary, a subsequent analysis

• Excellent data import capabilities

You may choose to assign further

Some of the areas that could include

• the use of contact to assess stresses

Transient Analysis Of Gun Barrel

Description of the Problem

Our design problem is to estimate the

Since the gun is still at the design stage, the

A Finite Element model is used, with the

different firing orders, and under different

The Analysis Model

Beam elements would yield a very quick

In a geometry like this, hexahedral elements

We use the different facilities HyperMesh

First, for the barrels, we use the "ruled"

When meshing the baffles, the elements on

Clamps at the specified locations are best

We then specify the time-integration method,

The assignment shows how to evaluate results

• Excellent data import capabilities

You may choose to assign further

Some of the areas that could include

• the use of spring supports at the base, to simulate the flexibility of