Swaybar-Shaft Assembly

Workshop 8

Bonded Contact

October 30, 2001

Inventory #001572

W8-2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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.

October 30, 2001

Inventory #001572

W8-3

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

8. Bonded Contact

Swaybar-Shaft Assembly

Loads and Material Properties

October 30, 2001

Inventory #001572

W8-4

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-5

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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]

October 30, 2001

Inventory #001572

W8-6

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-7

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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]

October 30, 2001

Inventory #001572

W8-8

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-9

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-10

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-11

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

PLNSOL,S,EQV

October 30, 2001

Inventory #001572

W8-12

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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

October 30, 2001

Inventory #001572

W8-13

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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):

October 30, 2001

Inventory #001572

W8-14

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

INTR

OD

UC

TIO

N T

O A

NS

YS

6.0

- Part 2

Workshop Supplement

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.