See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/363108874

"Ansys Software for Mechanical Engineering"

Technical Report · August 2022

DOI: 10.13140/RG.2.2.18076.97927

CITATION READS

1 6,213

1 author:

Akash Majeed
Manav Rachna Educational Institutions
6 PUBLICATIONS 1 CITATION

SEE PROFILE

All content following this page was uploaded by Akash Majeed on 30 August 2022.

The user has requested enhancement of the downloaded file.

 SUMMER INTERNSHIP-II REPORT

on

“Ansys Software for Mechanical Engineering”

Submitted in partial fulfillment of the requirement for the degree of

Bachelor of Technology
In
Mechanical Engineering

Submitted by:

Akash Majeed
(1/20/FET/BME/015)

Under the guidance of:

Ms. Seema Mahto

(Assistant Professor,
ME, FET)

Department of Mechanical Engineering, Faculty

of Engineering & Technology
Manav Rachna International Institute of Research and Studies Faridabad
NAAC ACCREDITED ‘A’ GRADE
August, 2022

1|Pa g e
 MANAV RACHNA INTERNATIONAL INSTITUTE OFRESEARCH
AND STUDIES

CANDIDATE'S DECLARATION

I “AKASH MAJEED” hereby declare that I have taken Summer Internship Training at
“INTERNSHALA” in partial fulfillment of requirements for the award of degree of
Bachelor of Technology in Mechanical Engineering at Faculty of Engineering &
Technology, Manav Rachna InternationalInstitute of Research and Studies. The work
presented in this training report, submittedto Department of Mechanical Engineering at
Faculty of Engineering & Technology, Faridabad is an authentic record of training work.

Name of Student: Akash Majeed

Roll No.: 1/20/FET/BME/015

Faculty Mentor: Ms Seema Mahto

Designation: Assistant Professor

Dr. Rajender Kumar

Assistant Professor and Industrial Training Coordinator
Department of Mechanical Engineering
Faculty of Engineering & Technology
Manav Rachna International Institute of Research and Studies

Dr. Manoj
Nayak

Professor
and HOD

Department of Mechanical
Engineering
Faculty of Engineering &
Technology
Manav Rachna International Institute of Research and Studies

2|Pa g e
3|Pa g e
 Acknowledgement

I would like to express my sincere gratitude to my supervisor Ms Seema Mahto Dept.

of Mechanical Engineering (FET, MRIIRS), for giving me the opportunity to work
on this software. It would never have been possible for me to take the work to this
level without their innovative ideas and their relentless support and encouragement.

I would take immense pleasure in thanking Dr. Rajender Kumar (Assistant Professor)
& B. Tech Internship Coordinator, Department of Mechanical Engineering, FET,
MRIIRS for the constant support provided throughout the program.

I would also like to thank Dr. Manoj Nayak Head, Department of Mechanical
Engineering, FET, MRIIRS, to facilitate us to provide an environment for smooth
dissertation process.

A thank is also due to Dr. Geeta Nijhawan, Associate Dean, FET, MRIIRS for
constant support and encouragement during this journey of B. Tech in MRIIRS.

I would like to express regards to Dr. Pradeep Kumar, PVC, Executive Director, and
Dean FET, MRIIRS, for his constant encouragement, to facilitate us to provide an
environment for smooth industrial training process, which helped us in understanding
the subject and methodology and completion of the work.

Akash Majeed

1/20/FET/BME/015

4|Pa g e
 ABSTRACT

Within the ANSYS ecosystem there are all options available to investigate the dynamic
behaviour of a structure in the most efficient way. Unified user interfaces help us to use the
method which is most appropriate. Being able to simulate how a product will look like is a
challenge that involves both geometrical factors and light-materials interaction. ANSYS
provides solutions to perform virtual measurements that can return photometric and
colorimetric values as well as the ability of simulate visual perception based on a physiological
human vision model. Simulation results are, to all intents and purposes, pictures containing
photometric data thanks to which you can take decisions on system performances, finally
reducing the number of physical porotypes and subjective opinions. If the “spectator” becomes
an electro-optical sensor like a camera or a Lidar, ANSYS enables you to simulate how the
image, or the infrared signal, will be perceived in different surrounding conditions paving the
way to a robust and safer autonomous vehicle development.

Beams, plates, and shafts are fundamental component parts of machines and structures often
encountered in daily life. These components must function properly and effectively, resisting
mechanical loadings. The integrity of these parts must be ensured by adequate strength design
to avoid excessive loads and deformation. The mechanics of materials can evaluate stresses and
deformations induced in components of interest, but can merely cover simple problems like a
slender bar subjected to bending, a plate under tension, a cylindrical bar twisted by torsional
moment, etc. The finite element method, however, can make analyses of stresses and
deformations in machines and structures in realistic forms subjected to complicated loadings.

The object of this report is to show how to carry out finite-element analyses of fundamental
types of component parts such as beams, plates, shafts, etc. subjected to loadings typical for
each type of component part. The validity of the results of the finite-element analyses is
discussed by comparing the results obtained by experiments or by the theory of elasticity.

This report provides a brief introduction to ANSYS as an engineering software suite. Using a
GUI (graphical user interface) approach, the most important and basic commands are briefly
outlined and illustrated. Easy, step-by-step guidance is given in order to illustrate all vital stages
of ANSYS analysis. This begins with launching the programme (naming the project, saving it
in an appropriate directory, using various menus available and exiting the programme), pre-
processing stage (construction of the model, selection of material, element type, meshing), the
solution stage (setting up boundary conditions, applying loads, and running the solution), and
finally the post processing stage (the general postprocessor, displaying results, error
estimation).

5|Pa g e
 LIST OF FIGURES

Figure 1 Concept of meshing 20

Figure 2. Example of Constraint 22

Figure 3. 1D Element 27

Figure 4. 2D Element 28

Figure 5. 3D Element 28

Figure 6. Problem figure 31-39

Figure 7. Cantilever Beam 43

Figure 8. Pneumatic Cylinder 44

Figure 9. LED T.V Stand 45

Figure 10. Clevis Pin Assembly 46

Figure 11. Flywheel assembly 47-48

Figure 12. Gear and Rack 49

Figure 13. Bookcase, or Bookshelf 50

Figure 14 Nut And Bolt 51

Figure 15 Plane Truss 52

Figure 16 High Rise Frames 53

Figure 17 1D+2D 54

Figure 18 Centrifugal Pump 55

Figure 19 Aero plane Wing 57

Figure 20 Bumper 58

Figure 21 composite slab 64

Figure 22 Finned tubes 65

Figure 23 Heating Element 66

Figure 24 solenoid valve 67

Figure 25 heat sink 70

Figure 26 Bi-morph 71

6|Pa g e
Figure 27 Pipe 74

Figure 28 Crankshaft 75

Figure 29 Meshed Geometry 83

Figure 30 C-Clamp 86

Figure 31 Simple Electronic Board 89

Figure 32 1U CubeSat Geometry 93-94

7|Pa g e
 TABLE OF CONTENTS
CANDIDATE'S DECLARATION 2
ACKNOWLEDGEMENT 4
ABSTRACT 5
LIST OF FIGURES 6
SECTION A 11
CHAPTER I: INTRODUCTION TO FEA 12
1.1 Basic Terms 12
1.2 Different types of Numerical Techniques to solve Engineering Problems 16
1.3 Degree of Freedom 18
1.4 Concept of Meshing 20
1.5 Applications of FEA 22
CHAPTER II: ANSYS SOFTWARE DETAILS 24
2.1 How to perform simulation 25
2.2 Inside Ansys workbench 30
SECTION B 39
CHAPTER I: STATIC STRUCTURAL ANALYSIS 42
1.1 Context for the structures that are used for the analysis ahead
1.2 Cantilever Beam
1.3 Pneumatic Cylinder
1.4 LED T.V Stand
1.5 Flywheel
1.6 Gear and Rack
1.7 Bookcase, or Bookshelf
1.8 Nut and Bolt
CHAPTER II: MODAL ANALYSIS 55
2.1 Context for the structures that are used for the analysis ahead
2.2 Aeroplane Wing:
2.3 Bumper
2.4 Machine frame
CHAPTER III: THERMAL ANALYSIS & THERMO-STRUCTURAL COUPLED 59
3.1 Context for the structures that are used for the analysis ahead
3.2 Composite slab
3.3 Finned tubes
3.4 A heating element or heating coil
3.5 Machine frame
3.6 Solenoid valve
3.7 Heat sink
3.8 Bi-morph
CHAPTER IV: BUCKLING ANALYSIS 72
4.1Context for the structures that are used for the analysis ahead
4.2 Pipe
4.3 Crankshaft
4.4 Bi-morph
SECTION C 77
CHAPTER I TRAINING ASSIGNMENTS QUESTIONS 78
CHAPTER II FINAL PROJECT ON 1U CUBESAT 93
 Simulation with different Materials
CONCLUSION 90
REFERENCES 105
8|Pa g e
 Section A

11 | P a g e
 INTRODUCTION

BASIC TERMS

CAD

The term CAD stands for Computer Aided Design. It can be easily explained in terms of the use of
computer systems to assist in the modelling, modification, and optimization of a design. The designs
may be mechanical, electrical, and of several other kinds of purposes. Computer Aided Design is a 3D
design tool for developing 2 and 3 dimensional models that can later be translated into a product. Even
in the fashion sector or chocolate manufacturing, CAD is used for automated pattern design and marker
making. Sometimes you may also hear the term CADD which stands for Computer Aided Design and
Drafting. This is also the same as CAD.

CAM

The term CAM refers to Computer Aided Manufacturing. It is nothing but the use of computers to help
in the planning, execution, and automation of the manufacturing processes. It will use the CAD models
to simulate and test the manufacturability of the design. Once the design passes through manufacturing
simulations then using CAM software’s we will be planning the production activity and also translate
the finalized CAD model into a set of instructions that the manufacturing personnel and machines can

12 | P a g e
understand. The best example is to create a CNC program for milling of components using the computers
instead of manually doing so.

CAE

The term CAE refers to Computer Aided Engineering. It can be simply understood as the use of
computers to solve engineering problems, even before a physical prototype has been created and tested.
CAE is used for analysing, validating and optimization of the performance of a product or a structure
under the effect of different operating environments. For this purpose, it will use the CAD data or model
as the input. If the digital prototype or simply the CAD model passes the CAE analysis then the same is
sent to the manufacturing phase where the use of CAM takes place, If the CAD model doesn't pass the
CAE phase then it is sent back to the CAD phase and design has to be Modified.

13 | P a g e
PRODUCT DESIGN

Product design can be described as a process of imagining, creating, and improving products of different
nature that provides the solution for end-user problems or address specific consumer wants in the
specified or considered market. It can be simply defined as the process of problem-solving, about
visualizing the needs of the user and bringing a solution

14 | P a g e
The product design process tries to improve the quality of life or solves a problem for the consumer. In
order to achieve the same, they follow different analytical and problem-solving approaches.

The product design approach is applied in many industries across several fields such as: Heavy
machinery, Automobile, Aerospace, Defence, Medical, tableware, jewellery, sports, fashion, food
preservation appliances, furniture, etc.

INDUSTRIAL DESIGN

Industrial design is a process of design applied to products that are to be manufactured through techniques
of mass production.
All manufactured products are the result of a design process, but the nature of this process can take many
forms. It can be conducted by an individual or a team, and such a team could include people with varied
expertise (e.g.: industrial designers, engineers, business experts, etc.) It can highlight creativity or
calculated scientific decision-making, and often emphasizes both. It can be influenced by factors as
varied as materials, production processes, business strategy, and prevailing social, commercial, or
aesthetic attitudes. Industrial design, as an applied art, most often focuses on a combination of aesthetics
and user-focused considerations, but also often provides solutions for problems of form, function,
physical ergonomics, marketing, brand development, sustainability, and sales.

Industrial Design Cycle.

15 | P a g e
 Different types of Numerical Techniques to solve Engineering Problems

⚫FEM (Finite Element Method)

⚫ FVM (Finite Volume Method)

⚫ FDM (Finite Difference Method)

⚫ BEM (Boundary Element Method)

Finite Element Method (FEM):

Finite element method (FEM) is a numerical method for solving a differential or integral equation.

Finite Element Analysis(FEA):

Finite Element Analysis or FEA is the simulation of a physical phenomenon using a numerical
mathematic technique referred to as the Finite Element Method, or FEM.

This process is at the core of mechanical engineering, as well as a variety of other disciplines

Why FEA/FEM?

FEA provides a way of virtually testing a product design. It helps users understand the designs and
implement appropriate design changes early in the product development process.

BEM (Boundary Element Method)

16 | P a g e
Just like the finite element method, it also requires nodes and elements, but as the name suggests it only
considers the outer boundary

of the domain. So, when the problem is of a volume, only the outer surfaces are considered. If the domain
is of an area, then only the outer periphery is considered. This way it reduces the dimensionality of the
problem by a degree of one and thus solving the problem faster.

FDM (Finite Difference Method)

In general, the Finite Difference Method is described as a way to solve differential equation. It uses
Taylor's series to convert a differential equation to an algebraic equation. In the conversion process,
higher order terms are neglected. It is used in combination with BEM or FVM to solve thermal and CFD
coupled problems.

FVM (Finite Volume Method)

The values are calculated at discrete volumes on a generic geometry. The unit volumes are considered in
Finite Volume Method like that of Finite elements that are considered in FEM. Variable properties
include pressure, velocity, area, mass...etc. It is based up on navier strokes equations (Mass, Momentum,
and Energy Conservation Equilibrium Equations)

17 | P a g e
Degree of Freedom (D.O.F): The minimum number of parameters (motion, coordinates, temperature,
etc.) required to define the position and state of any entity completely in space is known as degrees of
freedom (D.O.F).

18 | P a g e
19 | P a g e
20 | P a g e
21 | P a g e
22 | P a g e
 Applications of FEA

Mechanical Engineering:
Steady and transient structural analysis in solids and fluids

Steady and transient thermal analysis in solids and fluids

Automotive simulations and crash testing
Manufacturing process simulation.

Aerospace, Marine and Civil Engineering:

Structural analysis for natural frequencies, modes shapes, response analysis, aerodynamics and
hydrodynamics.

Electrical and Electronics Engineering:

Electrical network analysis
Electromagnetics
Insulation design analysis in high-voltage equipment's,

Dynamic analysis of motors

Heat analysis in electrical and electronic equipment's.
Nuclear engineering: Steady and dynamic analysis of reactor containment structures, viscoelastic
analysis reactor components, Steady and transient temperature distribution analysis of reactors and
related structures.

Metallurgical and chemical engineering:

In metallurgical engineering, FEM is used for the metallurgical process simulation, moulding and
casting.
In chemical engineering, FEM can be used in the simulation of chemical processes, transport processes
and chemical reaction simulations.

Bio-engineering:
Simulation of various human organs, blood circulation prediction and even total synthesis of human
body.

Geotechnical engineering:
Stress analysis, slope stability analysis, soil structure interactions, seepage of fluids in soils and rocks,
analysis of dams, tunnels, bore holes, propagation of stress waves and dynamic soil structure interaction.

23 | P a g e
 ANSYS SOFTWARE
ANSYS is a analysing software use for mechanical product design and civil structure designs. It uses
computer based numerical techniques to solve problems. It is a FEA software by ANSYS Inc. It is widely
used for analysing solutions in the industry. The range of problem it can solve is immense. It helps to
engineer and design complex, highly nonlinear and large models. It is used to stimulate computer models
of structures, electronics, or machine components for analysing strength, elasticity, temperature. Most of
its stimulation is performed using ANSYS Workbench system. It also develops software for data
management and backup.

BENEFITS OF ANSYS
ANSYS can import all kinds of CAD geometries (2D and 3D) from different CAD software’s
1. It has the capability of performing advanced engineering simulations accurately.
2. It has the capability to optimize various features like geometrical design, boundary conditions.
3. It has its own customized tool called ACT which uses python as a background scripting language
4. It has the ability to integrate various physics and perform analysis.
5. It uses certain inputs and evaluate the product behaviour to physics.
6. It is a general purpose software used to stimulate the interaction between physics like dynamic,
static, fluid.
7. It can import various geometric shapes from different CAD software and use them to perform
simulations

APPLICATIONS
The uses of ANSYS are numerous in number but finally all of them lead to one single concept called
profitability of organization.
1. Antenna design and placement: electromagnetic simulation of antenna design and its interaction
with the entire system.
2. Battery cell and electrode: It simulations accurately model electrochemistry before the
manufacturing process.
3. Battery simulation: It’s battery modelling and simulation use multiphysics to help maximize
battery performance.
4. Autonomous software development: Develop validate and auto generate autonomous vehicle
software.
5. Flight control: It’s tools are pivotal for driving the analysis, development
6. 3D design
7. Multiphysics
8. Electronics

24 | P a g e
 How simulation is performed

Important concepts for Analysis: Basic Material Properties

Density of a substance can be defined as its mass per unit volume. The symbol most often used for
density is ρ (the lower-case Greek letter rho), although the Latin Letter D can also be used.
Mathematically, density is defined as mass divided by volume:

where ρ is the density, m is the mass, and V is the volume. In some cases, (for instance, in the United
States oil and gas industry), density is loosely defined as its weight per unit volume, although this is
scientifically inaccurate – this quantity is more specifically called specific weight.

Young's modulus, the Young modulus or the modulus of elasticity in tension, is a mechanical property
that measures the tensile stiffness of a solid material. It quantifies the relationship between tensile stress

25 | P a g e
(force per unit area) and axial strain (proportional deformation) in the linear elastic region of a material
and is determined using the formula:

Young's moduli are typically so large that they are expressed not in Pascal’s but in gigapascals (G Pa ).

Shear modulus or modulus of rigidity, denoted by G, or sometimes S or μ, is a measure of the elastic

shear stiffness of a material and is defined as the ratio of shear stress to the shear strain.

The derived SI unit of shear modulus is the Pascal (Pa), although it is usually expressed in gigapascals
(GPa) or in thousand pounds per square inch (ksi)

Poisson's ratio (nu) is a measure of the Poisson effect, the deformation (expansion or contraction) of
material in directions perpendicular to the direction of loading. The value of Poisson's ratio is the negative
of the ratio of transverse strain to axial strain. For small values of these changes, is the amount of
transversal elongation divided by the amount of axial compression. Most materials have Poisson's ratio
values ranging between 0.0 and 0.5.

Stiffness is the extent to which an object resists deformation in response to an applied force.

Ultimate tensile strength (UTS), often shortened to tensile strength (TS), ultimate strength, and is the
maximum stress that a material can withstand while being stretched or pulled before breaking. In brittle
materials, the ultimate tensile strength is close to the yield point, whereas in ductile materials the ultimate
tensile strength can be higher.

26 | P a g e
Yield strength or yield stress is a material property and is the stress corresponding to the yield point at
which the material begins to deform plastically. The yield strength is often used to determine the
maximum allowable load in a mechanical component since it represents the upper limit to forces that can
be applied without producing permanent deformation.

Isotropic and Anisotropic

Isotropic: Properties of material are identical in all directions.

Anisotropic: Properties of a material depend on the direction; for example, wood. In a piece of wood,
you can see lines going in one direction; this direction is referred to as "with the grain". The wood is
stronger with the grain than "against the grain". Strength is a property of the wood and this property
depends on the direction; thus, it is anisotropic

Meshing inside Ansys workbench

27 | P a g e
28 | P a g e
29 | P a g e
30 | P a g e
Inside Ansys workbench:

31 | P a g e
32 | P a g e
33 | P a g e
34 | P a g e
35 | P a g e
36 | P a g e
37 | P a g e
38 | P a g e
39 | P a g e
 Section B

40 | P a g e
 STATIC STRUCTURAL ANALYSIS

Why Linear Static Structural Analysis?

⚫ 90% of the time the primary product structural behaviour can be understood using the Linear Static
Analysis. A linear static analysis is an analysis where a linear relation holds between applied forces and
displacements. In practice, this is applicable to structural problems where stresses remain in the linear
elastic range of the used material. In a linear static analysis, the model's stiffness matrix is constant, and
the solving process is relatively short compared to a nonlinear analysis on the same model. Therefore,
for a first estimate, the linear static analysis is often used prior to performing a full nonlinear analysis.

41 | P a g e
Applications of Linear Static Structural Analysis

• All aerospace,

automobile,

marine,

sports,

construction,

off shore structures...etc. All the fields where FEA is applied the starting point is the Linear static
analysis
42 | P a g e
 1. Static Structural Analysis PROBLEMS

Context for the structures that are used for the analysis ahead:

1. A Cantilever Beam is a member with one end projecting beyond the point of support, free to
move in a vertical plane under the influence of vertical loads placed between the free end and the
support.
Total Deformation

Subject: Cantilever beam

Date: Saturday, August 20, 2022

43 | P a g e
 2. A Pneumatic Cylinder is a mechanical device that creates a linear motion by converting energy
from compressed air. The pneumatic cylinder cover will be present at the end of the cylinder and
its operation is to prevent the leak of air which may cause the improper function of the pneumatic
cylinder.

Total Deformation

Subject: Pneumatic Cylinder

Date Thursday, August 4, 2022

44 | P a g e
 3. A LED T.V Stand is nothing but a mounting structure that we attached to the bottom of the LED
TV So that the LED monitor or T.V can be placed on any table or solid surface.

Directional Deformation

Subject: LED T.V Stand

Date Friday, August 5, 2022

45 | P a g e
 4. The clevis is a U-shaped piece that has holes at the end of the prongs to accept the clevis pin.
The clevis pin is similar to a bolt, but is either partially threaded or is unthreaded with a cross-
hole for a split pin. The tang is a piece that fits in the space within the clevis and is held in place
by the clevis pin. The combination of both clevis and pin is known as Clevis Pin Assembly.

Directional Deformation:

Subject: Clevis Pin Assembly

Date Monday, August 8, 2022

46 | P a g e
 5. A Flywheel is essentially a mechanical battery consisting of a mass rotating around an axis. It
stores energy in the form of kinetic energy and works by accelerating a rotor to very high speeds
and maintaining the energy in the system as rotational energy.

Radial stress

Subject: one forth flywheel

Date Monday, August 8, 2022

Full

flywheel analysis

47 | P a g e
 Equivalent Stress

Subject: flywheel

Date Monday, August 8, 2022

48 | P a g e
 6. A Gear and Rack is a type of linear actuator that comprises a circular gear (the pinion) engaging
a linear gear (the rack), which operate to translate rotational motion into linear motion. Driving
the pinion into rotation causes the rack to be driven linearly. Driving the rack linearly will cause
the pinion to be driven into a rotation.

Total Deformation

Subject: Gear and Rack

Date Thursday, August 11, 2022

49 | P a g e
 7. A Bookcase, or Bookshelf, is a piece of furniture with horizontal, shelves, often in a cabinet,
used to store books or other printed materials. Bookcases are used in private homes, public and
university libraries, offices and bookstores.

Total Deformation

Subject: Bookshelf

Date Friday, August 12, 2022

50 | P a g e
 8. A Nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction with
a mating Bolt to fasten multiple parts together. The two partners are kept together by a
combination of their threads' friction (with slight elastic deformation), a slight stretching of the
bolt, and compression of the parts to be held together.

A Bolt is a form of threaded fastener with an external male thread requiring a matching pre-
formed female thread such as a nut. Bolts are very closely related to screws

Total Deformation

Subject:

Date Saturday, August 20, 2022

51 | P a g e
 9. A Plane truss is defined as a two- dimensional framework of straight prismatic members
connected at their ends by frictionless hinged joints, and subjected to loads and reactions that act
only at the joints and lie in the plane of the structure.

Total Deformation

Subject: Plane truss

Date Friday, August 12, 2022

52 | P a g e
 10. High-rise frames are constructed of H-columns or box columns, (vertical-support members) and
H-beams (horizontal-support members). ... Use of steel makes it possible to create large, column-
free internal spaces; thus, these are particularly advantageous for open-plan offices and large
auditoriums and concert halls.

Total Deformation

Subject: High-rise frames

Date Friday, August 12, 2022

53 | P a g e
 11. 1D+2D

Equivalent Stress

Subject:

Date Friday, August 12, 2022

54 | P a g e
 MODAL ANALYSIS

55 | P a g e
56 | P a g e
 2. Model analysis PROBLEMS

Context for the structures used for teaching Modal Analysis.

1. Aero plane Wing: A wing is a type of fin that produces lift while moving through air or some
other fluid. As such, wings have streamlined cross-sections that are subject to aerodynamic forces
and act as airfoils. When this wing is attached and used with aircrafts that is nothing but the aero
plane wing. Here we have considered a simplified model of a small aircraft wing and studied how
to perform a modal analysis over on it.

Total Deformation

Subject:

Date Friday, August 12, 2022

57 | P a g e
 2. A bumper is a structure attached to or integrated with the front and rear ends of a motor vehicle,
to absorb impact in a minor collision, ideally minimizing repair costs. Here we use the bumper
model of an Audi Car. Each and every car has its own bumper style

Total Deformation

Subject: AUDI car bumper

Date Friday, August 12, 2022

58 | P a g e
 3. The machine frame, which is a structure that is the torsion-resistant and is used for supporting
all the parts of a machine. It is just like a skeleton to support the machinery or parts within the
machines.

Total Deformation

Subject: machine frame

Date Friday, August 12, 2022

59 | P a g e
 THERMAL ANALYSIS

Symbols used

60 | P a g e
61 | P a g e
62 | P a g e
63 | P a g e
 3. Thermal Analysis PROBLEMS

Context for the structures used for teaching Modal Analysis.

1. A composite slab is nothing a wall type of structure which is made up of different layers and
each layer will be made by using different kind of materials. This is the basic problem that is
taken as a standard to teach heat transfer through conduction.

Temperature

Subject: composite slab

Date Saturday, August 13, 2022

64 | P a g e
 2. Finned tubes are the main components of heat exchangers. They are a series of tubes where fins
have been added on the outside to increase the contact area with the outside fluid, to exchange
heat, and between the fluid inside the tube and the fluid outside the tube. Here as we considered
the Finned tube made from aluminum, that is the reason for the name.

Directional Heat Flux

Subject: Finned tubes

Date Saturday, August 13, 2022

65 | P a g e
 3. A heating element or heating coil converts electrical energy into heat through the process of
Joule heating. Electric current through the element encounters resistance, resulting in heating of
the element. Here if it is used in the bulbs it is going to emit light which is a form of heat transfer
through radiation as there will be a vacuum inside the bulb.

Total Heat Flux

Subject: heating element

Date Saturday, August 13, 2022

66 | P a g e
 4. A solenoid valve is an electrically controlled valve. The valve features a solenoid, which is an
electric coil with a movable ferromagnetic core (plunger) in its center. In the rest position, the
plunger closes off a small orifice. An electric current through the coil creates a magnetic field.
The magnetic field exerts an upwards force on the plunger opening the orifice. This is the basic
principle that is used to open and close solenoid valves.

Temperature

Subject: solenoid valve

Date Saturday, August 13, 2022

67 | P a g e
 Thermal-Structural Coupled Analysis

68 | P a g e
69 | P a g e
 4. Thermo-structural Analysis PROBLEMS

Context for the structures used for teaching Modal Analysis.

1. A heat sink is a passive heat exchanger that transfers the heat generated by an electronic or a
mechanical device to a fluid medium, often air or a liquid coolant, where it is dissipated away
from the device, thereby allowing regulation of the device's temperature.

Temperature

Subject: heat sink

Date Saturday, August 13, 2022

70 | P a g e
 2. A bimorph is a cantilever type like structure used for actuation or sensing which consists of two
active layers. It can also have a passive layer between the two active layers. In contrast, a
piezoelectric uni morph has only one active layer and one passive layer.

Equivalent Elastic Strain

Subject: bimorph

Date Sunday, August 14, 2022

71 | P a g e
 BUCKLING

72 | P a g e
73 | P a g e
 5. Buckling Analysis PROBLEMS

Context for the structures used for teaching Modal Analysis.

1. A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-
section, used mainly to convey substances which can flow — liquids and gases, slurries, powders
and masses of small solids.

Directional Deformation

Subject: pipe

Date Sunday, August 14, 2022

74 | P a g e
 2. A crankshaft is a shaft driven by a crank mechanism, consisting of a series of cranks and
crankpins to which the connecting rods of an engine are attached. It is a mechanical part able to
perform a conversion between reciprocating motion and rotational motion.

Equivalent Stress

Subject: crankshaft

Date Saturday, August 20, 2022

75 | P a g e
 3. A bimorph is a cantilever type like structure used for actuation or sensing which consists of two
active layers. It can also have a passive layer between the two active layers. In contrast, a
piezoelectric uni morph has only one active layer and one passive layer.

Internal Heat Generation

Subject: bimorph

Date Sunday, August 14, 2022

76 | P a g e
 Section C

77 | P a g e
 Assignment problems with solution

1. Downloading and Installing Ansys Workbench Software, creating a new unit system, and

saving the workbench project files.

Problem Statement:

Your task is to download, install the Ansys Workbench software. Create a custom unit system with your
name and save the Ansys project files.

Desired Output:

Two Ansys files (one file with.wbpj file extension and other files is with .wbpz file extension) with the
custom unit systems crated and added inside Ansys workbench software.

Approach:

First, go to the Ansys website and download the latest version of Ansys workbench software. Then install
the Ansys Workbench software on your PC/Laptop. Then open the Ansys workbench and create a new
custom unit system with your name, this newly created custom unit system should have a mix of different
unit system values. For example, if the length is in the metric system, then the weight should be the
imperial unit system. Likewise, combine units from different unit systems and create your own custom
unit system and add it to the Ansys software. Then save the files in both the available formats.

Hints:

If you have any doubts on how to create, please check the lectures in the module.

Problem Solution:

78 | P a g e
Before Installing:

 Ensure that your computer meets the technical requirements necessary to run the
software. Please see the platform support document for details.
 Ensure that you have administrator privileges for the computer on which you are
installing this product.
 Uninstall any existing Ansys products present on your computer. The Ansys Student
installation will overwrite any existing installations.

Installation steps for the Ansys Student products from Release 18.0 onward:

 Extract (unzip) the downloaded installation files.

 Right-click on setup.exe and select Run as Administrator. (This will run setup.exe from
the extracted files.)
 Read and accept the click wrap to continue.
 Click the right arrow button to accept the default values throughout the installation.
 Click the exit button to close the installer.
 The Ansys Student software is now installed. Congratulations!

Reboot your machine and then run the Ansys Student product from your Start menu
by selecting Workbench.

79 | P a g e
 How to install Ansys Workbench

Step 1: Go to Ansys Workbench on Academic Software and click on the download button to download
the ZIP file. This may take a while due to the size of the file.

Step 2: Open the ZIP file and extract the three files.

Step 3: Right-click on ANSYS2022R1_WINX64_Disk1.iso. Under 'Open with' select Windows

Explorer to open the file as a virtual DVD.

Step 4: A new window will open with the contents of the ISO file, launch the 'setup.exe' file.

Step 5: Select 'Install Ansys Products'.

Step 6: Accept the licence terms and click on Next.

Step 7: Click on Next.

Step 8: Enter 20.101.140.82 in the Hostname field and click on Next.

Step 9: An additional Windows firewall screen will appear, make sure all three boxes are checked and
click on 'Allow access'.

Step 10: Select the components of the Ansys Workbench package that you wish to install and click on
Next.

Step 11: During installation you may be asked for the other two ISO files. Repeat step 3 for disk2.iso
and disk3.iso. Then use Browse to go to the correct virtual drive when the installation asks you to do so,
using the following box

Step 12: Once the installation has finished, click one last time on Next.

Step 13: Then click on Exit to close the installation program.

Step 14: In order to use the software, you must first press the Request button here. By doing so, you will
be allocated an online licence for one hour. So please come back here every time you want to use the
software to request your temporary access to a licence.

80 | P a g e
 2. Adding and creating new materials, model geometry, and meshing the created geometry.

Problem Statement:

Your task is divided into 3 minor steps.

1. Adding materials to the engineering data manager.

Add Silicon Anisotropic and Aluminum to the materials available for the current project. (These two
materials are from different material libraries)

2. Creating the geometric model.

Create the geometry by taking the dimensions from the image provided below.

3. Mesh the created geometric model with the global and local meshing.

 Mesh the geometry with the auto mesh settings and determine the number of elements and nodes
created.
 Mesh the geometry with the resolution levels of 7 settings and determine the number of elements
and nodes created.
 If you are using an older version, then use the refinement level of 100 and determine the number
of elements and nodes related.
 Along with that explore more options regarding the meshing and try to understand the formation
of mesh on the geometry files.

81 | P a g e
Desired Output:

Requested materials being added to the current project.

A geometry file from the design modeller module.

Meshed model with different settings from Ansys Mechanical.

Approach:

First, open the Ansys Workbench and add the static structural module to the project schematic. Then
open the engineering data manager and add the required materials. Then open the geometric modeller
and create the required geometry model. Finally, open the Ansys Mechanical module and perform the
required meshing operations.

Hints:

If you have any doubts on how to create, please check the lectures in the module.

Problem Solution

Mesh

Subject: meshing

Date Aug 15 2022

82 | P a g e
83 | P a g e
 3. Perform Structural analysis on a C-Clamp.
Instructions:

Before undertaking the assignment:

1. It is recommended to finish this project using the latest version of Ansys Workbench Software and
then use this data to answer the module and final test questions.

2. Use the coordinate system only and solve the problem and based on the same value, provide answers
to the module test and the final test questions.

3. Use the default mesh settings and solve the problem and based on the same value, provide answers to
the module test and the final test questions.

4. Once you answer the questions as per the requirement then, experiment with different mesh settings
and observe how the change in the mesh is affecting the results.

5. All the different possible cases cannot be simulated at the same time so after answering the required
question please do interact around with the software.

6. Please reach out to me at the forum for doubt clarifications.

7. For now, please ignore the error which might say that specific analysis is performed without turning
on large deflection theory. (e.g.: You have performed a pre-stress modal analysis with large deflection
effects turned off in the static analysis. For a more accurate modal solution, we recommend turning on
large deflection effects. Check results carefully.

Problem Statement:

84 | P a g e
Your task is to perform conduct Static Structural Analysis on a simple C-Clamp.

Geometry: The geometry file is already provided to you. Please download the same by clicking on the
button below.

Boundary Conditions to be used:

The Gripping Face 1 is to be fixed and a Load of 950N is to be applied on the Gripping Face 2.

Desired Output:

A solution file with the results depicting the Stress, Strain, Total Displacement, and vertically downward
directional displacement.

Approach:

First Import the geometry model and then create the new material. Then perform the required 3D static
structural analysis and get the results.

Hints:

If you have any doubts on how to create please check the lectures in the module.

Materials to be used:

Material: CAST Carbon Steel

Property Value
Density 7800 Kg/m3
Young’s Modulus 200 GPa
Poisson’s Ratio 0.28
Tensile Strength 513.613 MPa

Problem Solution:

Total Deformation

85 | P a g e
Subject: C-Clamp

Date 2022

86 | P a g e
 4. Perform Thermo-Structural, Thermal-Buckling and Pre-Stressed Modal Analysis on a

Simple Electronic Board

Instructions:

Before undertaking the assignment:

1. It is recommended to finish this project using the latest version of Ansys Workbench Software and
then use this data to answer the module and final test questions.

2. Use the coordinate system only and solve the problem and based on the same value, provide answers
to the module test and the final test questions.

3. Use the default mesh settings and solve the problem and based on the same value, provide answers to
the module test and the final test questions.

4. Once you answer the questions as per the requirement then, experiment with different mesh settings
and observe how the change in the mesh is affecting the results.

5. All the different possible cases cannot be simulated at the same time so after answering the required
question please do interact around with the software.

6. Please reach out to me at the forum for doubt clarifications.

7. For now, please ignore the error which might say that specific analysis is performed without turning
on large deflection theory. (e.g.: You have performed a pre-stress modal analysis with large deflection
effects turned off in the static analysis. For a more accurate modal solution, we recommend turning on
large deflection effects. Check results carefully.

87 | P a g e
Problem Statement:

Your task is to perform Thermal, Thermo-mechanical, Thermal-buckling, and Pre-Stressed Modal

Analysis on a simple electronic board.

Geometry: The geometry file is already provided to you. Please download the same by clicking on the
button below.

Materials to be used:

Aluminium Alloy for Fins

Copper Alloy for Chip and Processor

Silicon Anisotropic for Board

Boundary Conditions to be used:

Initial temperature of the entire system is 20°C.

24e4 W/m3 is the amount of internal heat that is being generated in the processor,

Convection is applied to the boundaries with h = 5 W/m2 ·˚C and to = 20°C

The board bottom surface is well insulated.

For all the other types of analysis except the thermal analysis the board bottom surface is fixed.

Desired Output:

A solution file with the results depicting the temperature distribution and heat flux distribution from
thermal analysis, thermal stresses and strains from thermo-structural analysis, and 10 natural frequencies
from pre-stressed modal analysis due to thermal loading from modal analysis and bulking load multiplier
due to the thermal loading from buckling analysis.

Approach:

First, define Import the geometry model and then first perform the thermal analysis. Once the thermal
analysis is completed the next stage is to add the structural analysis system to the thermal analysis
systems and perform the thermo-structural analysis. Then couple the Modal and Buckling analysis to the
thermo-structural analysis. This way you perform all the required analysis and get the results required.

88 | P a g e
Hints:

If you have any doubts on how to create please check the lectures in the module.

Problem Solution

Total Deformation

89 | P a g e
 Final Project CubeSat

90 | P a g e
91 | P a g e
 5. Project Guidelines: Introduction to the Nasa CubeSat Project

Before getting started make sure you have understood the following and download the resources from
the tab below:

 It is recommended to finish this project using the latest version of Ansys Workbench Software.
Ensure that you complete this project as its data will be required to answer the module and final test
questions.
 Use the coordinate system to solve the problem and based on the same value.
 Use the default mesh settings and solve the problem and based on the same value.
 Once you answer the questions as per the requirement then, play around with different mesh settings
and observe how the change in the mesh is affecting the results.
 All the different possible cases are not possible to simulate at the same time so after answering the
required question please, play around with the software.
 Try as many changes as possible, this will help you get multiple questions and doubts. If you are
unable to resolve them yourself, please feel free to contact me for clarifications.
 Also, perform the project with the other 2 materials.
 For now, please ignore the error which might say that specific analysis is performed without turning
on large deflection theory.
 (e.g.: You have performed a pre-stress modal analysis with large deflection effects turned off in the
static analysis. For a more accurate modal solution, we recommend turning on large deflection
effects. Check results carefully.)

92 | P a g e
Static Structural

Subject:

Date Tuesday, June 29, 2021

93 | P a g e
 GEOMETRY

94 | P a g e
Total Deformation

Subject: 1U CubeSat

Date Tuesday, June 29, 2021

Material: Structural Steel

Structural Steel
Fatigue Data at zero mean stress comes from 1998 ASME BPV Code, Section 8, Div 2, Table 5-110.1

Density 7.85e-06 kg/mm³

Structural

Isotropic Elasticity
Derive from Young's Modulus and Poisson's Ratio
Young's Modulus 2e+05 MPa
Poisson's Ratio 0.3
Bulk Modulus 1.6667e+05 MPa
Shear Modulus 76923 MPa
Isotropic Secant Coefficient of Thermal Expansion 1.2e-05 1/°C
Compressive Ultimate Strength 0 MPa
Compressive Yield Strength 250 MPa
Strain-Life Parameters 0.0e+01.0e+1-5.4e+0-6.6e-1
log(10)1.0e+06.0e+0MPa
S-N Curve
log(10)1.9e+03.6e+0
Tensile Ultimate Strength 460 MPa
Tensile Yield Strength 250 MPa
Thermal

Isotropic Thermal Conductivity 0.0605 W/mm·°C

Specific Heat Constant Pressure 4.34e+05 mJ/kg·°C
Electric

Isotropic Resistivity 0.00017 ohm·mm

Magnetic

Isotropic Relative Permeability 10000

95 | P a g e
96 | P a g e
Total Deformation

Subject:

Date Tuesday, June 29, 2021

Material: AI 5052-H32

Al 5052-H32
Density 2.68e-06 kg/mm³
Structural

Isotropic Elasticity
Derive from Young's Modulus and Poisson's Ratio
Young's Modulus 70300 MPa
Poisson's Ratio 0.33
Bulk Modulus 68922 MPa
Shear Modulus 26429 MPa
Tensile Yield Strength 193 MPa

97 | P a g e
Total Deformation

Subject:

Date Tuesday, June 29, 2021

Material: AI 6061-T6

Al 6061-T6
Density 2.7e-06 kg/mm³
Structural

Isotropic Elasticity
Derive from Young's Modulus and Poisson's Ratio
Young's Modulus 68900 MPa
Poisson's Ratio 0.33
Bulk Modulus 67549 MPa
Shear Modulus 25902 MPa
Tensile Yield Strength 276 MPa

98 | P a g e
Total Deformation

Subject:

Date Tuesday, June 29, 2021

Material: AI 7075-T6

Al 7075-T6
Density 2.81e-06 kg/mm³
Structural

Isotropic Elasticity
Derive from Young's Modulus and Poisson's Ratio
Young's Modulus 71700 MPa
Poisson's Ratio 0.33
Bulk Modulus 70294 MPa
Shear Modulus 26955 MPa
Tensile Yield Strength 503 MPa

99 | P a g e
 Units

TABLE 1
Unit System U.S. Customary (ft, lbm, lbf, s, V, A) Degrees rad/s Fahrenheit

Angle Degrees

Rotational Velocity rad/s

Temperature Fahrenheit

Model (B4, D4, E4)

TABLE 2
Model (B4, D4, E4) > Geometry Imports
Object Name Geometry Imports

State Solved

TABLE 3
Model (B4, D4, E4) > Geometry Imports > Geometry Import (B3, C3, D3, E3)
Object Name Geometry Import (B3, C3, D3, E3)

State Solved

Definition

C:\Users\AAKASH\Desktop\word file solutions\Ansys_Final_Project\Final

Source
Project Solution____files\dp0\SYS\DM\SYS.agdb

Type DesignModeler

Basic Geometry Options

Parameters Independent

Parameter Key

Advanced Geometry Options

Compare Parts
No
On Update

100 | P a g e
 Analysis Type 3-D

Geometry

TABLE 4
Model (B4, D4, E4) > Geometry
Object Name Geometry

State Fully Defined

Definition

C:\Users\AAKASH\Desktop\word file
Source solutions\Ansys_Final_Project\Final Project
Solution____files\dp0\SYS\DM\SYS.agdb

Type DesignModeler

Length Unit Meters

Element Control Program Controlled

Display Style Body Colour

Bounding Box

Length X 0.32808 ft

Length Y 0.37238 ft

Length Z 0.32808 ft

Properties

Volume 3.7225e-003 ft³

Mass 0.62281 lbm

Scale Factor Value 1.

Statistics

Bodies 1

Active Bodies 1

101 | P a g e
 Nodes 26174

Elements 11616

Mesh Metric None

Update Options

Assign Default
No
Material

Basic Geometry Options

Parameters Independent

Parameter Key

Attributes Yes

Attribute Key

Named Selections Yes

Named Selection
Key

Material Properties Yes

Advanced Geometry Options

Use Associativity Yes

Coordinate Systems Yes

Coordinate System
Key

Reader Mode Saves

No
Updated File

Use Instances Yes

Smart CAD Update Yes

102 | P a g e
 Compare Parts On
No
Update

Analysis Type 3-D

Import Facet Quality Source

Clean Bodies On
No
Import

Stitch Surfaces On
None
Import

Decompose Disjoint
Yes
Geometry

Enclosure and
Symmetry Yes
Processing

103 | P a g e
 CONCLUSION

Summary of Training

This training program was designed to equip students with sound knowledge and skills, and
understanding of the how simulation works inside workbench. ANSYS is time saving and cost efficient
tool that helps in simulation and gives satisfactory results using discrete approach. Every component of
the software is nothing but a numerical algorithm which solves a system of equations. The software has
the capability to optimize various features like the geometrical design, boundary conditions and analyze
the behavior of the product under various criterion's. the preexisting knowledge ANSYS ACT allows
you to customize your workflow, add functionality and improve the simulation process ensures the
efficiency of a company in this compete world. After the training was over I was able to boost my
technical as well as my cad skills. ANSYS helps you to study your design in details even before you
make it in real. It helps you to identity the fault lines within your design. It provides wide range of
application like CFx, Fluent, structural mechanics, heat analysis, flow analysis, transient structural and
heat mechanics etc. Additionally, I improved my workbench abilities, which will greatly aid me in laying
the groundwork for simulation and designing.

104 | P a g e
REFERENCES

1. Identification of shear cracks in reinforced beams using finite element method

2. https://forum.ansys.com/forums/forum/discuss-simulation/structures/

3. https://www.researchgate.net/publication/304248421_Identification_of_shear_cracks_in_reinf
orced_beams_using_finite_element_method

4. https://courses.ansys.com/index.php/courses/getting-started-with-ansys-mechanical/

5. https://www.sciencedirect.com/topics/engineering/finite-element-
analysis#:~:text=Finite%20element%20analysis%20(FEA)%20is,structural%20analysis%20a
nd%20fluid%20flow.

6. Finite Element Analysis Applications a Systematic and Practical Approach Book • 2019

105 | P a g e
View publication stats