MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

Scope: The take home assessment will examine the following content of the MECN5012/A course:

Finite Element Method (FEM): Overview over Typical Fields of Application; Significance of FEM;
Introduction to FEM; Typical Steps of a Finite Element Analysis (FEA) in Stress Analysis;
Experimental Stress Analysis; Outline of the Basic Concepts of FEM; Typical Finite Elements,
Bars/Trusses, Beams, Shells, and Solids; Definition of Finite Elements, Generation of Element
Stiffness Matrices, Assembly of Global Stiffness Matrix, FEM System of Equations, Imposition of
Boundary Conditions, Solving System of Equations, Calculation of Reaction Forces, Stresses, and
Strains, Finite Element Formulation for Elastodynamic Problems, Principle of Virtual Work;
Numerical Integration Method, Gauss Quadrature, Isoparametric Elements, Jacobian.

Modelling with Commercial Software of Two-Dimensional (axisymmetric, plane stress, plane strain)
Problems and Three-Dimensional Problems in Linear Structural and Thermal Analyses: Idealisation,
Modeling (pre-processing), CAD Geometry, Material Properties, Mesh Generation, Boundary
Conditions, Model Checking, Solution (processing, numerical analysis), Results Displaying (post-
processing), Results Evaluation, Model Revision and Optimisation, Documentation and
Presentation; Selected Topics: e.g. Contacts, Mesh Refinement, Stress Singularities, Error Estimation
and Accuracy, Convergence, Thermo-Structural Analysis; Applications of FEA to Practical Problems.

Format of the assessment:

The take home assessment consists of 6 parts, worth a total of 65 marks and contributes 20% towards
the course mark. This assessment is designed to be answered sequentially and can be written off-line
and then submitted online.

Special Instructions:
• The assessment is open-book and open-internet.

Assessment submission instructions: These instructions must be followed:

1. Students must write the following details on the top right side of each piece of paper submitted. A
5% penalty will be applied to each assessment part for every transgression.

a. Part number
b. Page number
c. Student number

2. Create a single pdf of your answer sheet/s

3. Submit the pdf using the assignment tool before the end of the submission time.

4. On‐line submission on MECN5012A Ulwazi Website.

5. Electronic format (*.pdf).

6. Name the file according to your student number and surname (ex: 181215_Skywalker.pdf).
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

IMPORTANT: Files not meeting these requirements will not be assessed!

Submission deadline: Thursday, 26th of May 2022 at 08h00 a.m.

During the assessment:

The lecturer will be always available on email during the period of the assessment. Any problem that is
experienced must be reported to the lecturer by email to allow enough time to be addressed. If any
problem with the assessment is reported that needs correction or explanation, the appropriate
information will be emailed to the affected students. Please monitor your email in case some important
information needs to be sent to you during the assessment.

Important notes regarding submission:

1. Late submissions will NOT be accepted.
2. If there is any problem experienced in uploading your work, it must be reported before the end of the
submission time. Upload issues must be reported with:
• An email reporting the issue as soon as it occurs to Yusuf.suder@wits.ac.za, and.
• A PC/device screen shot clearly indicating the time of the issue and showing evidence of the
uploading issue,

Honour pledge:
Every student has agreed to the following pledge:

I hereby promise that all submitted assessments are entirely my own, unaided work. I promise not to
consult with anybody else, including other students or websites offering help. I promise not to provide
or receive any unauthorised help on any assessment.

I acknowledge that if I am found to have cheated in any way or plagiarised other people’s work, I
will be subject to disciplinary action, which may lead to suspension or expulsion.

The school takes cheating very seriously.

MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 1 OF 6

Question 1

If you have to simulate the behaviour of a metal billet subject to a cold shape-rolling
operation, see Fig. 1, which type of Finite Element Analysis would you recommend?
Motivate your answer.
(3 marks)

Figure 1

Question 2

What would be the effect of a mechanical boundary condition in a thermal Finite Element
Analysis? Motivate your answer.
(3 marks)

Question 3

Summarise the conceptual shift between the structural calculation methods used before the
introduction of the Finite Element Method and the structural calculation method introduced
by the Finite Element Method.
(2 marks)

(Sub-Total: 8 Marks)
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 2 OF 6

Question 4

For a structural 1st order Pyramid Finite Element, sketch:

a) The possible shape before deformation
(1 mark)
b) The possible shape after deformation
(1 mark)
c) The position of the nodes
(1 mark)
d) The degree/s of freedom (DOF) for one node
(1 mark)
e) The possible variation of strain between nodes.
(1 mark)

Question 5

Which type/s of Finite Elements would you use for a possible Mapped (or partially
Mapped) Mesh of the following mechanical component, see Fig. 2?
(1 mark)

Figure 2
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

Question 6

Evaluate the interpolation functions (shape functions) in the X direction for a 2D plane
stress linear triangular Finite Element with nodes of coordinates:
- Node 1 (2, 0)
- Node 2 (0, 0)
- Node 3 (1, 1)
N.B. Show your
calculations.
(5 marks)
Sketch the geometry of a mechanical component for which it would be adequate to use 2D
Finite Elements with the given behaviour. Motivate your answer.

N.B. DO NOT use an example already reported in the course’s slides.

(2 marks)

(Sub-Total: 13 Marks)
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 3 OF 6

Question 7

For the following structural problem, see Fig. 3:

a) Define a simplified 2D Finite Element Model.

(1 mark)

b) Define the Finite Elements: selection of elements type/s, numbering of elements, numbering of
nodes.
(2 marks)

c) Define the vector of DOFs of the model.

(2 marks)

d) Define the vector of nodal forces of the model.

(1 mark)
e) Define the boundary conditions of the model.
(1 mark)

f) List all the model’s unknowns.

(2 marks)

Figure 3

(Sub-Total: 9 Marks)
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 4 OF 6

Question 8

Briefly describe, in your own words, the general meaning of the following equation.

Then state the name and explain briefly the physical meaning of equation’s matrices E and N.

 (x, y, z ) = E   = E  B  N  u el
(3 Marks)
Question 9

Briefly explain, in your own words, how the following equation influences the FEA results?

u  N  u el
(2 Marks)

Question 10
The following function is defined within a quadrilateral 2D element:
F(x, y)= x2-4y2+2xy+3
Using this function F:
a) Evaluate its Gaussian Quadrature Integral using 1 Sampling Point, showing your
calculations.
(1 Mark)
b) Evaluate its Gaussian Quadrature Integral 2 Sampling Points in each direction, showing
your calculations.
(3 Marks)
c) Explain, in your own words, what is the Gaussian quadrature numerical integration method
used for in Finite Element Analysis?
(2 Marks)

(Sub Total: 11 Marks)

MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 5 OF 6

Question 11

Briefly describe how the geometry of an isoparametric linear hexahedral 3D Finite Element
can be represented.
(2 Marks)

Question 12
A “Frictionless Support” has to be defined on the two cylindrical surfaces, denoted by A, see Fig.
4. How can you represent this boundary condition using a “Displacement Support” in ANSYS
Workbench 2022 R1? Motivate your answer.
(2 Marks)

Figure 4

(Sub-Total: 4 Marks)
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

PART 6 OF 6

Bicycle brakes perform the obvious vital function of slowing or stopping a bike. Over the years
there have been many different designs of bicycle brakes.

Rim brakes, in general, are the most effective and have been the most popular for many years,
since they provide adequate braking power without too much maintenance.
Rim brakes are controlled by hand levers which are attached to the actual brake by a cable. When
the rider pulls on the brake lever the cable moves the brakes and two pads, one on each side,
press against the rim causing the wheel to slow down.
Naturally, a rider needs brakes that are not only in good working order, but that are also designed
to work for their specific riding conditions.

Your company is designing and manufacturing rim brakes for several bikes companies and it is
continuously increasing the range of its available products.

Caliper brakes are normally installed on road bikes as for this use they provide quite adequate
stopping power: they attach directly onto the bike frame by one bolt, just above the tire, and the
two caliper arms reach down to either side of the wheel.

There are various types of caliper brakes, but they all work using the same principle. The brake
center-fixing bolt attaches the 2 calipers arms to the bike frame and each arm can move
independently, see Fig. 5. The cable transmits force from the brake lever, and the caliper design
splits this force equally between the 2 calipers arms. The two brake pads are of friction material
and these make contact with the wheel rim.

The side-pull caliper brakes have the cable to one side. In the mono pivot side-pull caliper
brakes both the left and right caliper arms pivot at the centre-fixing bolt.

Figure 5 - Mono Pivot Side-Pull Caliper Brake

MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

You are in charge of developing a Finite Element (FE) analysis of a new Mono Pivot Side-Pull
Caliper Brake model, made of high quality aluminium alloy, for road bikes.

Question 13

Describe step-by-step the full setup of the FE analysis for this new brake model, see Fig. 5, using
ANSYS Workbench 2021 R1, starting from the ANSYS Workbench project schematic shown in
Fig. 6.

Figure 6 – Ansys Workbench Project Schematic Page

In particular, in your proposed FE analysis, you have to address the following listed points from
(a) to (j).
Use explanatory sketches if needed and indicate clearly all your assumptions.
Pre-processing Phase
a) Briefly justify which type of FE analysis you would select from the ANSYS Workbench project
schematic.
(1 Mark)
b) Sketch your proposed simplified FE geometry and motivate your choice/s.
(3 Marks)

c) Briefly outline the FE material/s requirements. It is not requested that you research the specific
mechanical characteristics of the model material/s.
(1 Mark)

d) Clearly define the necessary contact pair/s using the geometry sketch and select their contact
behavior/s. Justify your selection.
(3 Marks)
e) Clearly define FE support/s using the geometry sketch and motivate your selection.
(3 Marks)

f) Clearly define the FE load/s using the geometry sketch and justify your selection.
(2 Marks)
MECN5012/A – FEA Assessment I 23 MAY 2022

MECHANICS OF SOLIDS

g) Determine which type/s of FE elements are needed and which local mesh control/s you would
recommend. Justify your selection.
(3 Marks)
Solution Phase
h) Briefly motivate if your proposed FE analysis is linear elastic or non-linear elastic.
(1 Mark)
Post-processing Phase
i) Briefly discuss which specific FE outputs are required to evaluate the performance of the new
brake model.
(2 Marks)
j) Briefly discuss one strategy that could be implemented to evaluate the quality of the results
and, eventually, to increase it.
(1 Mark)

(Sub-Total: 20 Marks)

[TOTAL: 65 MARKS]

END