MOS - CEP 1 Fahad

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DESIGN OF CANTILEVER BEAM UNDER

UNIFORM VARYING LOAD AND TORQUE

Fahad Iqbal 2020114

Faculty of mechanical engineering

GHULAM ISHAQ KHAN INTITUTE

ME314

MECHANICS OF SOLIDS

Submitted to Dr MASSAB JUNAID

Dated 28/12/2022
Contents
Problem Statement:.................................................................................................................................2
Design Limitations and Requirements: ....................................................................................................2
Assumption: .............................................................................................................................................3
Procedure: ...............................................................................................................................................3
Calculation: ..............................................................................................................................................3
Reaction forces on the Beam:..............................................................................................................3
Moment on the beam:.........................................................................................................................4
Equation for Shear force: .....................................................................................................................5
Equation for Bending Moment: ...........................................................................................................5
Equation for Deflection (θ): .................................................................................................................6
Equation for Displacement (y): ............................................................................................................7
First Moment of Inertia of point P: ......................................................................................................7
Second Moment of Inertia 𝑰𝒙𝒙: ..........................................................................................................8
Equation for Bending stress (𝝈): ..........................................................................................................8
Equation for Shear Stress (𝝉): ..............................................................................................................8
Equation for Torsional Stresses: ..........................................................................................................9
Equation for Total Shear stresses: .......................................................................................................9
Equation for Principal Stresses: ...........................................................................................................9
Equation for Maximum Shear stress: ................................................................................................10
Calculating Factor of Safety: ..............................................................................................................10
FINITE ELEMENT ANALYSIS (FEA): ..........................................................................................................11
Procedure: .........................................................................................................................................11
CAD Modelling: ..................................................................................................................................11
Geometry: ..........................................................................................................................................12
Conclusion:.............................................................................................................................................21

1
Problem Statement:
A Cantilever beam is to be designed, as shown in Figure 1, which is under torsion and non-uniform
distributed loading. The data provided is as follows:

• The beam is fixed on one end by solid surface and the other end is free to move.
• Total length of the beam is 3 m.
• Torsional load of 500 Nm is applied at the free end (at x=3m).
• Distributed load (𝑤𝑜 ) of 1 kN/m is applied over its top surface. The load is distributed as
follows:
➢ At x = 0 m, F = 0 N/m.
➢ At x = 3 m, F = 1 kN/m.

Figure 1 Cantilever Beam

The final design should include following parameters:

• Reaction Forces
• Cross-sectional dimensions
• Maximum stress value and location by distortion energy theory
• Maximum displacement value and location
• Factor of safety
• Strength to weight ratio
• Manufacturing drawing
• Finite Element Analysis (FEA).

Design Limitations and Requirements:


The design Limitations and requirements are as follows:

• Length (𝑙) of the beam is 3m.


• Allowable thickness of the beam is 1 mm or more, but thickness must not be in decimals.
• According to suitable failure criteria, minimum factor of safety is 2.0.
• Material is Aluminium Alloy 6061-T6 (SS) with following properties:
➢ Density: 2700 kg/m3.
➢ Yield Strength: 275 MPa.
➢ Ultimate Tensile Strength: 310 MPa.
➢ Poisson’s Ratio: 0.33

2
➢ Elastic Modulus: 69 GPa
• Maximum Strength to weight ratio (𝑋):
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔ℎ𝑡
𝑋= (1)
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑇ℎ𝑒 𝑏𝑒𝑎𝑚

Assumption:
Some assumptions are made to simplify the analysis of beam to design. It is follows:

• The material is Isotropic and Homogeneous (made up of one type of material).


• The beam is initially straight with a constant cross section throughout.
• The material obeys Hooke's law.
• The beam has an axis of symmetry in the plane of bending.
• The beam is under static equilibrium. i.e, The sum of all forces and moment acting the body
is zero.
➢ ∑𝐹 = 0(𝑥, 𝑦, 𝑥)
➢ ∑𝑀 = 0(𝑥, 𝑦, 𝑥)

Procedure:
The problem-solving strategy adopted for the analysis can be put as follows:

1. Using equilibrium conditions to determine the reactions at the fixed end.


2. Use method of section to derive the general formula for shear force and bending moment as
a function of length,
3. Construct Shear force and Bending moment diagrams for the beam, and extract the point of
maximum shear force and bending moment.
4. Determine the equations for beam deflection and displacement.
5. Form equations for the following cross-sectional properties with keeping length and
thickness of cross section as variables.
➢ Second Moment of inertia, 𝐼𝑥𝑥
6. Using section properties form equations for
➢ Normal stress, σ𝑥𝑥
➢ Shear stress, τ𝑥𝑦 .
7. Use normal and shear stresses in the equation of von Mises theory to determine the
effective stress and Factor of Safety equations in form of iteration variables i.e., length and
thickness of the cross section.
8. Use all the equations formed to perform iterations and determine suitable design
parameters.

Calculation:
Reaction forces on the Beam:
Let 𝑹𝑨 is the reaction force acting on the beam at the fixed end A, W is the weight of the beam and
𝒘𝒐 is the distributed load acting on the beam in the downward direction. Applying the condition of

3
Figure 2 Free body diagram of the beam

equilibrium on the beam to find the reaction force 𝑹𝑨 . The free body diagram of the beam is shown
in the figure. In the free body diagram, the distributed load (𝒘𝒐 ) is shown as the concentrated

𝒘𝒐 𝒍
equivalent load ( ) at appropriate distance from the fixed end A.
𝟐

∑𝐹𝑦 = 0

𝑤𝑜 𝑙
𝑅𝐴 − 𝑊 − =0
2
Solve the equation for 𝑅𝐴 :
𝑤𝑜 𝑙
𝑅𝐴 = 𝑊𝑚 + (2)
2
Put 𝑤𝑜 = 1000 𝑁/𝑚 and 𝑙 = 3 𝑚 in equation (2), we get;

𝑅𝐴 = 𝑊𝑚 + 1500 (𝑖)

Moment on the beam:


Let 𝑴𝑨 is the moment acting on the beam about the z-axis at the fixed end. Condition of equilibrium
is applied on the free body diagram of the beam shown in the figure (1).

∑𝑀𝑧 = 0
𝑙 𝑤𝑜 𝑙 2𝑙
𝑀𝐴 − 𝑊 ( ) − ( )=0
2 2 3
Simplify the equation and solve for 𝑀𝐴 , we get;

𝑊𝑙 𝑤𝑜 𝑙2
𝑀𝐴 = + (3)
2 3
Put 𝑤𝑜 = 1000 𝑁/𝑚 and 𝑙 = 3 𝑚 in equation (3), we get;

𝑀𝐴 = (1.5 ∗ 𝑊) + 3000 (𝑖𝑖)

4
Equation for Shear force:
Using the method of sections and equilibrium conditions with the sign conventions, we will find the
equation for shear forces. The free body diagram of a section of the given beam is shown in the
figure (2).

Figure (3) Free body diagram of a section of the beam

𝑾𝒙 𝒘𝒐 𝒙𝟐
In the free body diagram, represent the weight of the beam per unit length, represent the
𝒍 𝟐𝒍
distributed load on the section and V represent the shear force.

Now applying the condition of equilibrium, the sum of all forces acting on the beam in the direction
of y- axis is zero. i.e

∑𝐹𝑦 = 0

𝑊 𝑤𝑜 𝑥 2
𝑅𝐴 − .𝑥 − −𝑉 =0
𝑙 2𝑙
𝑊𝑥 𝑤𝑜 𝑥 2
𝑉 = 𝑅𝐴 − −
𝑙 2𝑙
𝑤𝑜 𝑙
Substitute 𝑅𝐴 = 𝑊 + in the above equation:
2

𝑤𝑜 𝑙 𝑊𝑥 𝑤𝑜 𝑥 2
𝑉 = (𝑊 + )− −
2 𝑙 2𝑙
Simplifying the equation, we get;

𝑤𝑜 𝑙 𝑊𝑥 𝑤𝑜 𝑥 2
𝑉=𝑊+ − − (4)
2 𝑙 2𝑙
Equation for Bending Moment:
Let M is the bending moment acting on the beam. Using the method of sections and equilibrium
conditions with the sign conventions, we will find the equation for bending moment.

Applying the condition for equilibrium on the beam, the sum of all moment acting on the beam
about z-axis is zero. i.e.

∑𝑀𝑧 = 0
From the free body diagram shown in the figure(2),

𝑤𝑜 𝑥 2 𝑥 𝑊𝑥 𝑥
𝑀𝐴 + 𝑀 − 𝑅𝐴 . 𝑥 + . + . =0
2𝑙 3 𝑙 2

5
𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀 = 𝑅𝐴 . 𝑥 − 𝑀𝐴 − −
6𝑙 2𝑙
𝑤𝑜 𝑙 𝑊𝑙 𝑤𝑜 𝑙2
Substitute 𝑅𝐴 = 𝑊 + and 𝑀𝐴 = + into the equation:
2 2 3

𝑤𝑜 𝑙 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀 = (𝑊 + )𝑥 − ( + )− −
2 2 3 6𝑙 2𝑙

𝑤𝑜 𝑙𝑥 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀(𝑥) = 𝑊𝑥 + − − − − (5)
2 2 3 6𝑙 2𝑙
Equation for Deflection (θ):
The formula for displacement and deflection is given by;

𝑑2 𝑦
𝐸𝐼 = 𝑀(𝑥) (6)
𝑑𝑥 2
Substituting equation (5) in equation (6):

𝑑2 𝑦 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑙𝑥 𝑊𝑥 2 𝑤𝑜 𝑥 3
𝐸𝐼 2 = − − + 𝑊𝑥 + − −
𝑑𝑥 2 3 2 2𝑙 6𝑙

By integrating the above equation with respect to dx, we get:

𝑑𝑦 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
𝐸𝐼 = − − + + − − + 𝐶1 (𝑎)
𝑑𝑥 2 3 2 4 6𝑙 24𝑙

𝑑𝑦
Since 𝑑𝑥 = θ, substitute it in equation (a) and solve for θ:

1 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
θ= (− − + + − − + 𝐶1 ) (𝑏)
𝐸𝐼 2 3 2 4 6𝑙 24𝑙

Using the boundary condition for cantilever beam, find the value of constant 𝐶1 .

At x=0, the value of θ=0. Substitute these values in equation (b), we get;

𝐶1 = 0

By putting the value of 𝐶1 in equation (b), the deflection equation of the given beam become as;

1 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
θ= (− − + + − − ) (7)
𝐸𝐼 2 3 2 4 6𝑙 24𝑙

6
Equation for Displacement (y):
In order to find the equation for the displace of the beam after deformation in the direction of y-
axis, integrate the equation (a) with respect to dx, we get:

𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
𝐸𝐼y = (− − + + − − + 𝐶2 )
4 6 6 12 24𝑙 120𝑙

1 𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
y= (− − + + − − + 𝐶2 ) (𝑐)
𝐸𝐼 4 6 6 12 24𝑙 120𝑙

Now using the boundary conditions for cantilever beam to find the value of constant 𝐶2 .

At x=3, the value of y=. Substitute these values in equation (), we get;

𝐶2 = 0

By putting the value of 𝐶2 in equation (c), the displacement equation of the given beam become as;

1 𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
y= (− − + + − − ) (8)
𝐸𝐼 4 6 6 12 24𝑙 120𝑙

First Moment of Inertia of point P:


The first moment of inertia of a cross section is given by;

𝑄 = 𝐴 × 𝑦̅

𝑎𝑡 𝑎
To find the value of 𝑸 at point P, Substitute 𝐴 = and 𝑦̅ = 2 in the above equation:
2

𝑎𝑡 𝑎
𝑄= ×
2 2
𝑎2 𝑡
𝑄= (9)
4

7
Second Moment of Inertia 𝑰𝒙𝒙 :
The moment of inertia of a square cross section about the 𝑥-axis is given by:
1
𝐼𝑥𝑥 = 𝑏ℎ3
12
To find the second moment of the cross section having thickness (𝑡) and length (𝑙), subtract the
moment of inertia of the inner square from the outer square:
1 1
𝐼𝑥𝑥 = ( 𝑎. 𝑎 3 ) − ( (𝑎 − 2𝑡)(𝑎 − 2𝑡)3 )
12 12
1 4 1
𝐼𝑥𝑥 = ( 𝑎 ) − ( (𝑎 − 2𝑡)4 )
12 12
1 4 1 4
𝐼𝑥𝑥 = ( 𝑎 )− (𝑎 − 8𝑎 3 𝑡 + 24𝑎 2 𝑡 2 − 32𝑎𝑡 3 + 16𝑡 4 )
12 12
By simplify the above equation, we get;
2 3 7 4
𝐼𝑥𝑥 = 𝑎 𝑡 − 2𝑎 2 𝑡 2 + 𝑎𝑡 3 − 𝑡 4
3 3 3
1
𝐼𝑥𝑥 = (2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 ) (10)
3

Equation for Bending stress (𝝈):


The bending stress is given by,
𝑀𝑐
𝜎=
𝐼
𝑎
We know that bending stress is maximum at point most distant from the neutral axis i.e., 𝑐 = 2 , and
the value of 𝐼𝑥𝑥 we calculate in the previous section. So substitute these values in the above
equation:
𝑎
𝑀. 2
𝜎𝑥𝑥 =
1
(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )
3
3𝑀. 𝑎
𝜎𝑥𝑥 =
2(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )
3𝑀. 𝑎
𝜎𝑥𝑥 = (11)
(4𝑎 3 𝑡 − 12𝑡 2 + 14𝑎𝑡 3 − 8𝑡 4 )

Equation for Shear Stress (𝝉):


The shear stress is given by;
𝑄𝑉
𝜏1 = (𝑑)
𝐼𝑡
To calculate the shear stresses at point P, put equation(4) and equation (9) in equation (d), we get;

8
𝑎2 𝑡
𝜏1 = 4 𝑉
1
(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )𝑡
3
3𝑎 2 𝑡𝑉
𝜏1 =
4(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )𝑡
3𝑎 2 𝑉
𝜏1 = (12)
(8𝑎 3 𝑡 − 24𝑡 2 + 28𝑎𝑡 3 − 16𝑡 4 )

Equation for Torsional Stresses:


The torsional stress which is pure shear stress is given by:
𝑇
𝜏2 =
2𝑡 × 𝑚𝑒𝑎𝑛 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟 𝑎𝑟𝑒𝑎

Where,

T= Applied Torque

t= Thickness of the beam

As the mean perimeter of the hollow square cross section have thickness 𝑡 is (𝑎 − 𝑡)2 , then the
torsional stresses became as;

𝑇
𝜏2 =
2𝑡(𝑎 − 𝑡)2
T
𝜏2 = (13)
2a2 t − 8at 2 + 8t 3
Equation for Total Shear stresses:
There are two shear stresses in the beam, i.e one shear stress (𝜏1 ) is due to the distributed load and
the second shear stress (𝜏2 ) is due to the applied torque (T). The net shear stresses in the beam is
given by.

𝜏 = 𝜏1 + 𝜏2
3𝑎 2𝑉 T
Substitute 𝜏1 = (8𝑎3 and 𝜏2 = in the equation to get equation for
𝑡−24𝑡 2+28𝑎𝑡 3 −16𝑡 4) 2a2t−8at2+8t3
total shear stresses:

3𝑎 2 𝑉 T
𝜏= + (14)
(8𝑎 3 𝑡 − 24𝑡 2 + 28𝑎𝑡 3 − 16𝑡 4 ) 2a2 t − 8at 2 + 8t 3

Equation for Principal Stresses:


The general Equation for calculating the principal stresses is
𝜎𝑥𝑥 + 𝜎𝑦𝑦 𝜎𝑥𝑥 − 𝜎𝑥𝑥 2
𝜎1,2 = ( ) ± √( ) + 𝜏𝑥𝑦 2 (𝑑)
2 2

9
Substitute equation (11) and equation (14) in equation (d), we get;

3𝑀. 𝑎
𝜎1,2 = ( )
2(4𝑎 3 𝑡 − 12𝑡 2 + 14𝑎𝑡 3 − 8𝑡 4 )

2 2
3𝑀. 𝑎 3𝑎 2 𝑉 T
±√ ( 3 2 3 4 ) + ( + 2 )
2(4𝑎 𝑡 − 12𝑡 + 14𝑎𝑡 − 8𝑡 ) (8𝑎 𝑡 − 24𝑡 + 28𝑎𝑡 − 16𝑡 ) 2a t − 8at 2 + 8t 3
3 2 3 4

Equation for Maximum Shear stress:


The equation for calculating maximum in plane shear stress is;

𝜎𝑥𝑥 − 𝜎𝑥𝑥 2
𝜏𝑚𝑎𝑥 = √( ) + 𝜏𝑥𝑦 2
2
Substitute equation (11) and equation (14) in above equation, we get;

2 2
3𝑀.𝑎 3𝑎2𝑉 T
𝜏𝑚𝑎𝑥 =√(2(4𝑎3𝑡−12𝑡 2+14𝑎𝑡 3 −8𝑡 4) ) + ((8𝑎3𝑡−24𝑡 2+28𝑎𝑡 3 −16𝑡 4) + 2a2t−8at2+8t3) (15)

Calculating Factor of Safety:


As specified in the design Requirements, we use Tresca Criteria for calculating the factor of safety
(n). The equation for Tresca Criteria is given as.
𝑌
𝑛(𝜏𝑚𝑎𝑥 ) =
2
Solve the equation for 𝑛:
𝑌
𝑛= (16)
2(𝜏𝑚𝑎𝑥 )

The following beam is selected based upon the design requirements as discussed in Section 2.

10
Property Value

Cross section 0.13350 m

Thickness 0.001 m

Volume 0.00159 𝑚3

Weight 42.11433 N

Second Moment of Inertia 1.55089× 10−6 𝑚4

Maximum Normal Stress 131.8382621 MPa

Maximum Shear Stress 68.5121279 MPa

Factor of Safety 2.006943942

Strength 7360914.919 Pa/N

FINITE ELEMENT ANALYSIS (FEA):


The CAD modelling is done using Dassault System’s Solidworks 2021 SP0, and the Finite Element
Analysis was performed using ANSYS 2022 student R2.

Procedure:

The procedure used for modelling and simulation is discussed in this section.

CAD Modelling:

1. Cross Section of beam was constructed on Right plane


2. Extrude command was used to give length to the beam of 3000 mm
3. The model was saved in format appropriate for Ansys
4. The model was imported to ansys workbench
5. Material was applied i.e Aluminium Alloy 6061-T6 (SS)
6. Geometry was loaded
7. Fixed point was added
8. The load was distributed using pressure distribution
9. Torque was applied at the free end.
10. The simulations were run and the results are as follows

Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius


Angle Degrees
Rotational Velocity rad/s
Temperature Celsius
Table 1

11
Geometry:
TABLE 2 Model (B4) > Geometry Imports
Object Name Geometry Imports
State Solved
Model (B4) > Geometry Imports > Geometry Import (B3)
Object Name Geometry Import (B3)
State Solved
Definition
Source C:\Users\izhar\Documents\Fahad Cep Mos\Part2.STEP
Type Step
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Independent
Parameter Key ANS;DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Analysis Type 3-D
Mixed Import Resolution None
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint Geometry Yes
Enclosure and Symmetry Processing Yes
Geometry
TABLE 4
Model (B4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source C:\Users\izhar\Documents\Fahad Cep Mos\Part2.STEP
Type Step
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 3. m

12
Length Y 0.1335 m
Length Z 0.1335 m
Properties
Volume 1.59e-003 m³
Mass 4.4043 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 3360
Elements 1656
Mesh Metric None
Update Options
Assign Default Material No
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Independent
Parameter Key ANS;DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Analysis Type 3-D
Mixed Import Resolution None
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint Geometry Yes
Enclosure and Symmetry Processing Yes
TABLE 5 Model
(B4) > Geometry > Parts
Object Name Part2-FreeParts|Boss-Extrude1
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No

13
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Aluminum Alloy
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 3. m
Length Y 0.1335 m
Length Z 0.1335 m
Properties
Volume 1.59e-003 m³
Mass 4.4043 kg
Centroid X 1.5 m
Centroid Y -2.273e-017 m
Centroid Z 0. m
Moment of Inertia Ip1 2.5776e-002 kg·m²
Moment of Inertia Ip2 3.3161 kg·m²
Moment of Inertia Ip3 3.3161 kg·m²
Statistics
Nodes 3360
Elements 1656
Mesh Metric None
TABLE 6 Model (B4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 1
Material Assignments 0

TABLE 7
Model (B4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Coordinate System Program Controlled
APDL Name
Suppressed No
Origin
Origin X 0. m 1.5 m
Origin Y 0. m 6.675e-002 m
Origin Z 0. m

14
Define By Geometry Selection
Geometry Defined
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ] [ 0. 0. -1. ]
Z Axis Data [ 0. 0. 1. ] [ 0. 1. 0. ]
Principal Axis
Axis X
Define By Global X Axis
Orientation About Principal Axis
Axis Z
Define By Global Y Axis
Transformations
Base Configuration Absolute
Transformed Configuration [ 1.5 6.675e-002 0. ]
Mesh
TABLE 8
Model (B4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 3.0059 m
Average Surface Area 0.31811 m²
Minimum Edge Length 0.1315 m
Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Element Quality Default (5.e-002)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition

15
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 3360
Elements 1656
TABLE 9 Model (B4) > Mesh > Mesh Controls
Object Name Patch Conforming Method Body Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Body
Definition
Suppressed No
Method Tetrahedrons
Algorithm Patch Conforming
Element Order Use Global Setting
Type Element Size
Element Size 9.e-002 m
Advanced
Defeature Size Default
Behavior Soft

TABLE 13 Model (B4) > Static Structural (B5) >


Loads
Object Name Fixed Support Pressure Moment
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 4 Edges 1 Face 4 Edges
Definition
Type Fixed Support Pressure Moment
Suppressed No
Define By Normal To Components
Applied By Direct
Loaded Area Deformed

16
Magnitude Tabular Data
Coordinate System Global Coordinate System
X Component -500. N·m (ramped)
Y Component 0. N·m (ramped)
Z Component 0. N·m (ramped)
Behavior Deformable
Tabular Data
Independent Variable X
Coordinate System Global Coordinate System
Graph Controls
X-Axis X
Advanced
Pinball Region All

TABLE 18 Model (B4) > Static Structural (B5) > Solution (B6) > Normal Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. -1.4806e+008 1.4199e+008 310.37

17
Maximum Shear Stress

TABLE 19 Model (B4) > Static Structural (B5) > Solution (B6) > Maximum Shear Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. 4.5898e+006 6.8572e+007 2.5002e+007

18
FIGURE 8 Model (B4) > Static Structural (B5) > Solution (B6) > Stress Intensity

TABLE 20
Model (B4) > Static Structural (B5) > Solution (B6) > Stress Intensity
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. 9.1797e+006 1.3714e+008 5.0003e+007

19
Model (B4) > Static Structural (B5) > Solution (B6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1. 2.0416 15. 7.5292

Figure 4 Shear force diagram

20
Figure 5 Bending moment diagram

Figure 6 Shear Force diagram Due to Torsion

Conclusion:
A hollow square cantilever beam was to be designed with multiple design constraints as discussed in
the above sections. After analysing the beam with multiple cross section dimensions, following
parameters are selected which could provide a strength to weight ratio of 7360914.919 Pa/N and a
factor of safety (n) 2.006943942.

• cross section width: 133.5 mm


• cross section thickness: 1 mm

21
The results obtained from FEA analysis and manual calculations are approximately same with
relative error calculated as follows,

Theoretical FEA Calculations Error(%)


Calculations
Cross section 0.1335 m 0.1335 m 0
Thickness 0.001 m 0.001 m 0
Volume 0.00159 𝑚3 1.59e-003 m³ 0
Weight 42.11433 N 43.16214 2.51
Maximum Normal 131.8382621 MPa 1.4199e+008 6.86
Stress
Maximum Shear Stress 68.5121279 MPa 6.8572e+007 0.087
Displacement 61.35 mm 60.668mm 1.09

Factor of Safety 2.006943942 2.0416 1.98

• The error in the normal stress can be due to the factor that the load was applied in
ANSYS in terms of pressure and the torsional stress calculated manually may not be
accurate as there is no correct form of formula available.

22

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