III B.

TECH II SEM CAE/CAM LAB R20

WEST GODAVARI INSTITUTE OF SCIENCE & ENGINEERING

(Approved by AICTE, New Delhi and Affiliated to JNTU, Kakinada)

An ISO 9001-2015 Certified College

AVAPADU, PRAKASARAOPALEM – 534 112, W.G.Dist., A.P

CAE & CAM LAB MANUAL-R20

DEPARTMENT OF MECHANICAL ENGINEERING

III B.TECH II SEMESTER

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

KAKINADA–533003, Andhra Pradesh, India

2022-23

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INTRODUCTION
Ansys is one of the Mechanical finite element analysis software is used to simulate computer
models of structures, electronics, or machine components for analyzing the strength, toughness,
elasticity, temperature distribution, electromagnetism, fluid flow, and other attributes..Ansys is
used to determine how a product will function with different specifications, without building test
products or conducting crash tests.
Most Ansys simulations are performed using the Ansys Workbench system, which is one
of the company's main products, Ansys users break down larger structures into small components
that are each modeled and tested individually. A user may start by defining the dimensions of an
object, and then adding weight, pressure, temperature and other physical properties. Finally, the
Ansys software simulates and analyzes movement, fatigue, fractures, fluid flow, temperature
distribution, electromagnetic efficiency and other effects over time.
Ansys also develops software for data management and backup, academic research and teaching.
Ansys software is sold on an annual subscription basis.

The finite element method (FEM) is a popular method for numerically solving differential
equations arising in engineering and mathematical modeling. Typical problem areas of interest
include the traditional fields of structural analysis, heat transfer, fluid flow, mass transport, and
electromagnetic potential
.FEA Applications :
 Mechanical/Aerospace/Civil/Automotive Engineering
 Structural/Stress Analysis
 Static/Dynamic
 Linear/Nonlinear
 Fluid Flow
 Heat Transfer
 Electromagnetic Fields
 Soil Mechanics
 Acoustics
 Biomechanics
The common steps involved in finite element analysis are
Step1:Modelling
Step 2: Material definition. The material properties are defined in this step.Step
3: Definition of loads.
Step 4: Boundary conditions.Step
5: Meshing.

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Step 6: Solution.
Step 7: Post-processing

Step 1: Modelling
The part is modeled omitting complicated geometrical features. This is the first and the most
crucial step in any analysis. This will provide you the insights to remove insignificant features from
our geometry eventually saving some computational time and unwanted complexity. Always
remember, simpler, the better.
Step 2: Material definition
The material properties are defined in this step. These material properties depend on the type of
analysis that needs to be carried out. Literature survey for similar problems could help you a lot in
tackling this step.
Step 3: Definition of loads
This step is about the definition of external forces acting on the part or the body force by virtue of
the weight of the component. We have to be careful about the force definition type in order avoid
encountering problems like singularities.
Step 4: Boundary conditions
This step is mainly done to reduce the complexity of the problem from an engineering sense. For
example, in some problems, the user might be knowing some initial conditions before starting an
analysis (like displacement of a point in the geometry). Such cases fall into the “Initial value problem”
category.

Step 5: Meshing
Our geometry is divided into smaller and simpler shapes called as finite elements. And then bind
in to a single element
Step 6: Solution
This step works after the definition of the simulation properties. It means that the partial
differential equations are converted into algebraic equations. Doing this helps the code to represent
equations in terms of matrices. Matrices of individual elements are assembled into global matrices for
the entire geometry which is then solved by solvers for unknown variables.
Step 7: Post-processing
Any FEM software will have some form of an indicator to show the user if the solution has been
completed successfully. Once the solver gives this message, the variables (Displacement, von Mises
Stress etc.) that have been calculated are presented in terms of contour plots or graphs.

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Utility Menu Contains functions which are available throughout the ANSYS session, such as file controls,
selecting, graphics controls, parameters, and exiting.
Toolbar Menu Contains push buttons for executing commonly used ANSYS commands and functions.Customized
buttons can be created.
Graphics Area Displays graphics created in ANSYS or imported into ANSYS.
Input Line Displays program prompt messages and a text field for typing commands. All previously typedcommands
appear for easy reference and access.
Main Menu Contains the primary ANSYS functions, organized by processors (preprocessor, solution,general
postprocessor, etc.)
Output Displays text output from the program. It is usually positioned behind the other windows andcan be
raised to the front when necessary.

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EXPERIMENT -1(a) ANALYSIS ON TRUSS ELEMENT

AIM: Determine the nodal deflections and stress for the 2D and 3D truss system shown below (E =
200GPa, A = 3250 mm2).

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor

To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> Analysis on 2D Beam element
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

 Preprocessor >Element Type > Add/Edit/Delete >Add >Link > 3d finit stn 180 > OK > Close

Step 2(b): Define Geometric Properties

 Preprocessor > Real Constants > Add/Edit/Delete > Add >Ok > Cross Sectional area-3250 mm2 >
Ok > Close

Step 2(c) : Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear >
Elastic > Isotropic > EX(Young’s Modulus)- 2e5 >PRXY(Poissons Ratio)-0.3 > Ok > Close

Step 2(d) : To Model Element

 Preprocessor > Modeling > Create >Key points> In Active CS

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 Preprocessor > Modeling > Create > Lines > Lines > In Active Coord. > Select all key points
to get truss element

Step 2(e) : To Mesh Truss Element

 Preprocessor >Meshing > Size Cntrls>ManualSize> Lines > All Lines > No of element
divisions :1> Ok
 Preprocessor >Meshing > Mesh > Lines >Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK

Step 2(f): Assigning Loads and Constraints on element

 Preprocessor > Loads >Analysis Type > New Analysis > Static >Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On
Keypoint > Click on Keypoint 1 >Ok > All DOF > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On
Keypoint > Click on Keypoint 7 >Ok > UY > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 1 > Ok > Select FY (-280000) > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 3 > Ok > Select FY (-210000) > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 5 > Ok > Select FY (-280000) > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 7 > Ok > Select FY (-360000) > Ok
STEP 3: Solution

Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

Step 4(a): To View Nodal Deflection of Truss Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution > DOF
solution > Displacement Vector sum

 General Postprocessor > List results > Nodal Solution > Nodal Solution> DOF solution >
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Displacement Vector sum

Step 4(b): To View Stresses produced in Truss Element

 General Postprocessor > Element Table > Define Table> Add>User Label for item :SAXL>
click on By sequence Number > Click on LS > Enter LS,1> Ok > close
 General Postprocessor > Element Table > Plot Element table > Select SAXL > Ok
 General Postprocessor > Element Table > List Element table Select SAXL > Ok

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Result: Nodal deflections and stresses are determined for the 2D truss element

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EXPERIMENT -1(b) ANALYSIS ON BEAM ELEMENT

AIM: Determine the nodal deflections and stress for the 2D Beam as shown below (E = 200GPa,
Density=7800 kg/m3).

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor
To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> Analysis on 2D Beam element
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

 Preprocessor >Element Type > Add/Edit/Delete >Add > BEAM > 2 Node 188 > Ok.

Step 2(b) : Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear >
Elastic > Isotropic > EX(Young’s Modulus)- 2e11 >PRXY(Poissons Ratio)-0.3 > Ok
 Preprocessor >Material Props > Material Models > Double click on Structural>Density >
7800 > ok > close
Step 2(c) : To Select type of Section

 Preprocessor Sections > Beam > Common Sections > enter B- 0.01 and H- 0.01 > ok

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Step 2(d): To Model Element

 Preprocessor > Modeling > Create >Key points> In Active CS

Keypoint Coordinates (x,y)

1 (0,0)

2 (1,0)

 Preprocessor > Modeling > Create > Lines > Lines > In Active Coord. > Select all key points
to get Beam element

Step 2(e) : To Mesh Truss Element

 Preprocessor >Meshing > Size Cntrls>ManualSize> Lines > All Lines > No of element
divisions :10> Ok
 Preprocessor >Meshing > Mesh > Lines >Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(f): Assigning Loads and Constraints on element

 Preprocessor > Loads >Analysis Type > New Analysis > Static >Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On
Keypoint > Click on Keypoint 1 >Ok > All DOF > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 2 > Ok > Select FY (-100) > Ok
STEP 3: Solution

Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

Step 4(a): To View Nodal Deflection of Truss Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
DOF solution > Displacement Vector sum

 General Postprocessor > List results > Nodal Solution > Nodal Solution> DOF solution >
Displacement Vector sum

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Step 4(b): To View Stresses produced in Truss Element

 General Postprocessor > Element Table > Define Table> Add>User Label for item :SAXL>
click on By sequence Number > Click on LS > Enter LS,1> Ok > close
 General Postprocessor > Element Table > Plot Element table > Select SXAL > Ok
General Postprocessor > Element Table > List Element table >Select SXAL > Ok

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Result: Nodal deflections and stresses are determined for the 2D Beam element,

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EXPERIMENT -2
ANALYSIS ON RECTANGULAR PLATE WITH HOLE
AIM: Determination of deflections, principal and Von-mises stresses in plane Stress, plane Strain and Axi-
symmetric components.

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor
To Give Title for the Experiment and some Basic Requirements
 Utility menu bar > File > Change Title> Analysis on Rectangular plate with hole element
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

 Preprocessor >Element Type > Add/Edit/Delete >Add > Solid > 8 node 183 > ok >Options >
Elememt Behaviour(k3)- Plane Stress > ok > close.

Step 2(b) : Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear > Elastic >
Isotropic > EX(Young’s Modulus)- 2e5 >PRXY(Poissons Ratio)-0.3 > Ok > Close

Step 2(c): To Model Element

 Preprocessor > Modeling > Create >Ares >Rectangle > by 2 Corners

WP X 0
WP Y 0
WIDTH 200
HEIGH 100
T
 Preprocessor > Modeling > Create >Ares >Circle > Solid circle

WP X 100

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WP Y 50

RADIUS 20

 Preprocessor > Modeling > Operate > Booleans > Subtract > areas > Select total Rectangle > Ok in
New Open end Box > Ok > Double click on circle > Ok> Close.

Step 2(d) : To Mesh Truss Element

 Preprocessor >Meshing > Size Cntrls> Manual Size> areas > all areas > element edge
length > 10 > Ok
 Preprocessor >Meshing > Mesh >areas > free > Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(e): Assigning Loads and Constraints on the elemnt

 Preprocessor >Loads >Analysis type > New Analysis > Static >Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On lines >
Click on left side vertical line > Ok > All DOF > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Pressure> On Lines > Click
on Right side vertical line > Ok > VALUE Load PRES Value as -20 N/mm2> Ok
STEP 3: Solution

Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

Step 4(a): To View Nodal Deflection in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
DOF solution > Displacement Vector sum

 General Postprocessor > List results > Nodal Solution > Nodal Solution> DOF solution >
Displacement Vector sum

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Step 4(b): To View Principal Stresses in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> 1St Principal Stresses > Ok

 General Postprocessor > List results > Nodal Solution > Nodal Solution> Stress> 1St
Principal Stresses > Ok

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Step 4(b): To View Von Mises Stresses in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> Von Mises Stress> Ok
 General Postprocessor > List results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> Von Mises Stress> Ok

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Note: Similarly deflections, principal and Von-mises stresses for plane Strain and Axi-symmetric
components can be obtained using same process except by changing the element behaviour as plane strain or
axi symeetric,

Result: Deflections, principal and Von-mises stresses in plane Stress/ plane Strain /Axi-symmetric
components are determined.

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EXPERIMENT -3

ANALYSIS ON 3D BRACKET

AIM: Determination of stresses in 3D Bracket

G=200 GPa
t=20 mm

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor

To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> Analysis on Bracket
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

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 Preprocessor >Element Type > Add/Edit/Delete >Add > Solid > 8 node 183 > ok >Options >
Element Behavior(k3)- Plane Stress with thickness > ok > Close.

Step 2(b): Define Geometric Properties

 Preprocessor > Real Constants > Add/Edit/Delete > Add > thickness- 20 mm >ok
Step 2(c) : Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear > Elastic >
Isotropic > EX(Young’s Modulus)- 2e5 >PRXY(Poissons Ratio)-0.3 > Ok > Close

Step 2(d): To Model Element

For Rectangle 1 :

 Preprocessor > Modeling > Create >Ares >Rectangle > by 2 Corners

WP X 0

WP Y 0

WIDTH 80

HEIGHT 100

For Big Circle 1:

 Preprocessor > Modeling > Create >Areas > Circle > Solid circle

WP X 80

WP Y 50

RADIUS 50

For small Circles 2 &3 :

 Preprocessor > Modeling > Create >Ares >Circle > Solid circle

Parameter Circle 2 Circle3

WP X 0 0

WP Y 20 80

RADIUS 20 20

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For Rectangle 2 :
 Preprocessor > Modeling > Create >Ares >Rectangle > by 2 Corners

WP X -20

WP Y 20

WIDTH 20

HEIGHT 60

 Preprocessor > Modeling > Operate > Booleans > add > areas > Pick all > Ok

For Bolt Holes:

 Preprocessor > Create > Areas > Circle > Solid Circle

Parameter Circle 1 Circle2 Circle 3

WP X 80 0 0

WP Y 50 20 80

RADIUS 30 10 10

 Preprocessor > Modeling > Operate > Booleans > Subtract > areas > Select total Rectangle > Ok in
New Openend Box > Ok > Ok > Double click on bolt circles > Ok >Close

Step 2(e) : To Mesh Element

 Preprocessor >Meshing > Size Cntrls> Manual Size> areas > all areas > element edge
length :10 > Ok
 Preprocessor >Meshing > Mesh >areas > free > Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(e): Assigning Loads and Constraints on the elemnt

 Preprocessor >Loads >Analysis type > New Analysis > Static >Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On nodes >
select circle option in window > select small top circle > Apply > all DOF > Ok > close
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On nodes
> select circle option in window > select small bottom circle > Apply > all DOF > Ok >
close

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 Preprocessor > Loads > Define Loads > Apply > Structural > force/ Moment > On Key
points > Click on bottom side of big circle > Select FY : -1000 > Ok

STEP 3: Solution
Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

Step 4(a): To View Nodal Deflection in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
DOF solution > Displacement Vector sum
 General Postprocessor > List results > Nodal Solution > Nodal Solution> DOF solution >
Displacement Vector sum

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Step 4(b): To View Principal Stresses in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> 1St Principal Stresses > Ok

 General Postprocessor > List results > Nodal Solution > Nodal Solution> Stress> 1St
Principal Stresses > Ok

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Step 4(b): To View Von Mises Stresses in Element

 General Postprocessor > Plot results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> Von Mises Stress> Ok
 General Postprocessor > List results > Contour Plot > Nodal Solution > Nodal Solution >
Stress> Von Mises Stress> Ok

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EXPERIMENT -4(a) MODAL ANALYSIS ON 2-D BEAM

AIM: Estimation of natural frequencies and mode shapes of 2-D Beam

E=200*109 N/m2
Procedure: Density=7800 kg/m3
The main steps to be involved are
1. Preferences Frequency=0 to 10000Hz
2. Pre Processor
3. Solution
4. General Post Processor

To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> Modal Analysis of 2D beam
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

 Preprocessor >Element Type > Add/Edit/Delete >Add > BEAM > 2 Node 188 > Ok.

Step 2(b) : Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear >
Elastic > Isotropic > EX(Young’s Modulus)- 2.068e11 >PRXY(Poissons Ratio) 0.3 > Ok
 Preprocessor >Material Props > Material Models > Double click on Structural>Density >
7800 > ok > close
Step 2(c) : To Select type of Section

 Preprocessor Sections > Beam > Common Sections > enter B- 0.01 and H- 0.01 > ok

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Step 2(d): To Model Element

 Preprocessor > Modeling > Create >Key points> In Active CS

Keypoint Coordinates (x,y)

1 (0,0)

2 (1,0)

 Preprocessor > Modeling > Create > Lines > Lines > In Active Coord. > Select all key points
to get Beam element

Step 2(e): To Mesh Truss Element

 Preprocessor >Meshing > Size Cntrls>ManualSize> Lines > All Lines > No of element
divisions :10> Ok
 Preprocessor >Meshing > Mesh > Lines >Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(f): Assigning Loads and Constraints on element

 Preprocessor > Loads >Analysis Type > New Analysis > Modal >Ok
 Preprocessor > Loads > Define Loads > Analysis Options > ok> Block Lanczos >No of
modes to extract :5 > No of modes to Expand :5 > Ok > Start frequency : 0> End frequency:
10000> Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On
Keypoint > Click on Keypoint 1 >Ok > All DOF > Ok

STEP 3: Solution

Step 3(a): Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

Step 4(a): To View frequencies

General Postproc> Results Summary

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Step 4(b): To View First Mode shape

 General Postproc> Read Results > First Set

 General Postproc> Plot Results > Deformed shape >Def + undef edge

To View second Mode shape

 General Postproc> Read Results > Next Set

 General Postproc> Plot Results > Deformed shape >Def + undef edge

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To View Third Mode shape

 General Postproc> Read Results > Next Set

 General Postproc> Plot Results > Deformed shape >Def + undef edge

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To View Fourth Mode shape

 General Postproc> Read Results > Next Set

 General Postproc> Plot Results > Deformed shape >Def + undef edge

To View last Mode shape

 General Postproc> Read Results > last Set

 General Postproc> Plot Results > Deformed shape >Def + undef edge

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Result: Natural frequencies and mode shapes of 2-D Beam are done.

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EXPERIMENT -4(b)

HARMONIC ANALYSIS ON 2-D BEAM

AIM: Estimation of natural frequencies & Harmonic response of 2D beam

E=200*109 N/m2
Density=7800 kg/m3
Force:100 N

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor

To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> Harmonic response of 2D beam
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Structural>OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

 Preprocessor >Element Type > Add/Edit/Delete >Add > BEAM > 2 Node 188 > Ok.

Step 2(b): Element Material Properties

 Preprocessor >Material Props > Material Models > Double click on Structural > Linear >
Elastic > Isotropic > EX(Young’s Modulus)- 2e11 >PRXY(Poissons Ratio) 0.3 > Ok
 Preprocessor >Material Props > Material Models > Double click on Structural>Density >
7800 > ok > close
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Step 2(c): To Select type of Section

 Preprocessor Sections > Beam > Common Sections > enter B- 0.01 and H- 0.01 > ok

Step 2(d): To Model Element

 Preprocessor > Modeling > Create >Key points> In Active CS

Keypoint Coordinates (x,y)

1 (0,0)

2 (1,0)

 Preprocessor > Modeling > Create > Lines > Lines > In Active Coord. > Select all key points
to get Beam element

Step 2(e): To Mesh Truss Element

 Preprocessor >Meshing > Size Cntrls>ManualSize> Lines > All Lines > No of element
divisions :10> Ok
 Preprocessor >Meshing > Mesh > Lines >Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(f): Assigning Loads and Constraints on element

 Preprocessor > Loads >Analysis Type > New Analysis > Harmonic >Ok
 Preprocessor > Loads > Define Loads > Analysis Options > Solution Method : Full >Dof
Printout format:Real+imaginary> ok> Equation solver: sparse solver > Tolerance: 1e-
008>ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On
Keypoint > Click on Keypoint 1 >Ok > All DOF > Ok
 Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On
Keypoint > Click on Keypoint 2 > Ok > Select FY (-100) > Ok
 Preprocessor > Loads > Load Step Opts > Time/Frequency >Freq and Substps>harmonic
frequency range: 0 to 100 > number of sub steps :100 >
Ramped > ok
STEP 3: Solution

Step 3(a): Solution >Solve > Current LS> Ok

STEP 4: TimeHist Processor

Step 4(a): To View Harmo nic Response

 TimeHistPostpro> Variable Viewer > select add(+) > nodal solution > DOF solution >
Y-component of displacement > ok > enter node number 2 in Box > Ok

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 TimeHistPostpro> Variable Viewer > click list data button

 TimeHistPostpro> Variable Viewer > click graph data button

 Utility Menu >PlotCtrls> Style > Graphs > Modify Axis

 Thickness of axes: single > Number of y-Axis : single y-Axis > Y-axis scale :
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Logarithmic > Ok

 Utility Menu > Plot >Replot

Result: Natural frequencies & Harmonic response of 2D beam are observed.

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EXPERIMENT -5

STEADY STATE HEAT TRANSFER ANALYSIS

AIM: To perform Steady state heat transfer Analysis of plane and Axisymmetric components

Problem Description:

The Simple Conduction Example is constrained as shown in the following figure. Thermal
conductivity (K) of the material is 10 W/m*C and the block is assumed to be infinitely long.

Procedure:
The main steps to be involved are
1. Preferences
2. Pre Processor
3. Solution
4. General Post Processor

To Give Title for the Experiment and some Basic Requirements

 Utility menu bar > File > Change Title> steady state heat transfer analysis
 Utility menu bar > File > Save as> Give file name and Location
 Utility Menu > Plot > Replot (For quick visibility of Title and all )

STEP 1: Preferences

 Preferences > Thermal >OK

STEP 2: Pre Processor

Step 2(a): Define the Type of Element

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 Preprocessor >Element Type > Add/Edit/Delete >Add > Solid >Quad 4 Node 55 > Ok.

Step 2(b): Element Material Properties

 Preprocessor >Material Props > Material Models > Thermal > Conductivity > Isotropic > KXX
= 10(Thermal conductivity)

Step 2(c): Create geometry

 Preprocessor > Modeling > Create > Areas > Rectangle > By 2 Corners > X=0, Y=0,
Width=1,Height=1.

Step 2(d): To Mesh Truss Element

 Preprocessor > Meshing > Size Cntrls>ManualSize> Areas > All Areas > 0.05
 Preprocessor >Meshing > Mesh > Areas> Free >Pick All > Ok
 Utility Menu > PlotCtrls > Numbering > Node Numbers –ON > OK
Step 2(f): Assigning Loads and Constraints on element

 Preprocessor > Loads >Analysis Type > New Analysis > Steady-State >Ok
 Preprocessor > Loads > Define Loads > Apply > Thermal > Temperature > On
Nodes >Click the Box option and draw a box around the nodes on the top
line>ok>Temp: 500>ok
 Preprocessor > Loads > Define Loads > Apply > Thermal > Temperature > On
Nodes >Click the Box option and draw a box around the nodes on the left
line>ok>Temp: 100>ok
 Preprocessor > Loads > Define Loads > Apply > Thermal > Temperature > On
Nodes >Click the Box option and draw a box around the nodes on the right
line>ok>Temp: 100>ok
 Preprocessor > Loads > Define Loads > Apply > Thermal > Temperature > On
Nodes > Click the Box option and draw a box around the nodes on the bottom
line>ok>Temp:100>ok

STEP 3: Solution

Step 3(a): Solution >Solve > Current LS> Ok

STEP 4: General Postprocessor

 General Post proc > Plot Results > Contour Plot > Nodal Solu > DOF solution > Nodal
Temperature

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Result: Steady state heat transfer Analysis on Axisymmetric component is done.

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DEFINITION OF CAD/CAM/CAE

Computer Aided Design – CAD

CAD is technology concerned with using computer systems to assist in the creation, modification, analysis, and
optimization of a design. Any computer program that embodies computer graphics and an application program
facilitating engineering functions in design process can be classified as CAD software.

The most basic role of CAD is to define the geometry of design – a mechanical part, a product assembly, an
architectural structure, an electronic circuit, a building layout, etc. The greatest benefits of CAD systems are that
they can save considerable time and reduce errors caused by otherwise having to redefine the geometry of the
design from scratch every time it is needed.

Computer Aided Manufacturing – CAM

CAM technology involves computer systems that plan, manage, and control the manufacturing operations
through computer interface with the plant’s production resources.

One of the most important areas of CAM is numerical control (NC). This is the technique of using programmed
instructions to control a machine tool, which cuts, mills, grinds, punches or turns raw stock into a finished part.
Another significant CAM function is in the programming of robots. Process planning is also a target of
computer automation.

Computer Aided Engineering – CAE

CAE technology uses a computer system to analyze the functions of a CAD-created product, allowing designers
to simulate and study how the product will behave so that the design can be refined and optimized.

CAE tools are available for a number of different types of analyses. For example, kinematic analysis programs
can be used to determine motion paths and linkage velocities in mechanisms. Dynamic analysis programs can
be used to determine loads and displacements in complex assemblies such as automobiles. One of the most
popular methods of analyses is using a Finite Element Method (FEM). This approach can be used to determine
stress, deformation, heat transfer, magnetic field distribution, fluid flow, and other continuous field problems
that are often too tough to solve with any other approach.

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CNC PROGRAMMING
Basic CNC input data:

It is used to identify each block with the CNC program and provides a means by which CNC commands may be
rapidly located. Some control units requires that sequence numbers be input in ascending order where has other
system allow any three digit numbers appear after symbol N eg: N05 Y25 Z0

Coordinate function:

The coordinates of the tooltip are programmed for generating a given component geometry. The coordinates are
specified by using word addresses X,Y,Z,U,V,W etc..

Feed function:

The feed state for slider displacement or spindle field rate is expressed in mm/min and a threedigit number prefixed
by a letter F that indicates feed rate.

Once the feed rate is programmed in a block it remains enforce in all the subsequent blocks till it is replaced by
another F value.

Speed function:

The spindle is expressed in Rev/minute and is a three digit number prefixed by letter for example S1000 indicates
the spindle speed is 1000 rpm

Tool function:

The tool function is used in conjunction with the miscellaneous function for tool change (M06) and has a means of
addressing the new tool

Preparatory functions:

The preparatory functions are represented by a two digit number prefixed by the letter G. The purpose of the
preparatory function is to command the machine tool to perform function represented by the selected code number.

G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G17 X Y plane selection
G18 Z X plane selection
G19 Y Z plane selection
G28 Return to reference position

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G30 2nd, 3rd and 4th reference position return

G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation + direction
G44 Tool length compensation – direction
G49 Tool length compensation cancel
G53 Machine coordinate system selection
G54 Workpiece coordinate system 1 selection
G55 Workpiece coordinate system 2 selection
G56 Workpiece coordinate system 3 selection
G57 Workpiece coordinate system 4 selection
G58 Workpiece coordinate system 5 selection
G59 Workpiece coordinate system 6 selection
G68 Coordinate rotation
G69 Coordinate rotation cancel
G73 Peck drilling cycle
G74 Left-spiral cutting circle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring cycle
G82 Drilling cycle or counter boring cycle
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G90 Absolute command
G91 Increment command
G92 Setting for work coordinate system or clamp at maximum spindle speed
G98 Return to initial point in canned cycle

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G99 Return to R point in canned cycle

Miscellaneous functions:

Miscellaneous functions involve actions that are necessary for machining i.e (spindle on/off and coolant on/off).
These are used to designate a particular mode of operation for a CNC machine tool.

M code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M06 Tool change
M07 Coolant ON – Mist coolant/Coolant thru spindle
M08 Coolant ON – Flood coolant
M09 Coolant OFF
M19 Spindle orientation
M28 Return to origin
M29 Rigid tap
M30 End of program (Reset)
M41 Low gear select
M42 High gear select
M94 Cancel mirrorimage
M95 Mirrorimage of X axis
M96 Mirrorimage of Y axis
M98 Subprogram call
M99 End of subprogram

Program number:

The symbol used for the program number is 0 or: followed by number. For example 0123 or :123 the program does
not interfere with the execution of a CNC program.

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Exp:-1 Step Turning (CNC TURNING)

Aim: - To write a program to simulate step turning operation on a work piece as shown in the figure on a

TURNING MACHINE. (Length-50mm, diameter -30mm)

Code:

G21 G98
G28 U0 W0
M06 T02
M03 S1500
G00 X30 Z2
G90 X29 Z-35 F100
X28
X27
X26
X25
X24
X23
X22 Z-18
X21
X20
X19
X18
X17
X16
X15
G28 U0 W0
M05
M30

Result: - Simulation for step turning operation on a TURNING MACHINE completed

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Exp:-2 Circular Interpolation (CNC TURNING)

Aim: - To write a program to simulate required circular interpolation operation on a work piece as shown in the

figure on a TURNING MACHINE. (Length-50mm, diameter -30mm)

Code:

G21 G98
G28 U0 W0
M06 T02
M03 S1500
G00 X30 Z3
G71 U0.5 R0.5
G71 P1Q2 U0.1 W0.1 F100
N1 G01 X0 Z0
G03 X16 Z-8 R8
G02 X20 Z-12 R4
G01 X23
G01 Z-22
G02 X30 Z-26 R4
N2 G01 Z-36
G70 P1 Q2
G28 U0 W0
M05
M30

Result: - Simulation for circular interpolation operation on a TURNING MACHINE completed

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Exp:-3 Profile (CNC MILLING)

Aim: - Write a Milling program to simulate & machine a Following-Section on top face of a billet of size 90*90*12
mm.

Code:

N00 T02 D2 M06

N01 G00 X0 Y0 Z2
N02 M03 S500
N03 G01 X30 Y10
N04 G01 Z-1 F50
N05 G01 X60 Y10
N06 G01 X80 Y30
N07 G01 X80 Y60
N08 G03 X60 Y80 R20 F30
N09 G01 X10 Y80
N10G01 X10 Y30
N11 G02 X30 Y10 R20 F30
N12 GO1 Z10
N13 G28 X0 Y0
N13 M05
N14 M30

Result: - For a closed section Simulation and machining completed on milling machine.

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Exp:-4 C-Section (CNC MILLING)

Aim: - Write a Milling program to simulate & machine a C-Section on top face of a billet of size 90*90*12 mm.

Code:

N10 T02 D2 M06

N20 M03 S1000
N30 G00 Z100
N40 X5 Y5
N50 G01 Z-1 F30
N60 X85 Y5
N70 X85 Y20
N80 X20 Y20
N90 X20 Y70
N100 X85 Y70
N110 X85 Y85
N120 X5 Y85
N130 X5 Y5
N140 G40 G80
N150 G00 X5 Y5 Z2
N160 G28 X0 Y0
N170 M05
N180 M30

Result: - For a C- section Simulation and machining completed on milling machine.

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Exp:-5

Simulation of Fused Deposition Modelling (FDM) process

Aim: To simulate the Fused Deposition Modelling (FDM) process.

Theory:

In FDM process, thermoplastic material in the form of filament is unwound from a spool and is fed into a extruder
assembly where it is melted in liquefier and this semi-liquid material is laid down on the build platform by extrusion
process through a nozzle according to computer-controlled paths, where it cools and solidifies.

In this manner a cross section of an object is 3d printed each layer at a time. The solid portion of the incoming
filament serves as a “plunger” to extrude the material through a nozzle. The extrusion nozzle or the 3d printed
object (or both) are moved along 3 axis by a computer-controlled mechanism.

Stepper motors are employed for all these movements, as well as for pushing the filament into the extruder. Layer
height determines the quality of the 3D print.

Some FDM 3D printers can have two or more print heads that can print in multiple different colors and use support
for overhanging areas of a complex 3D print.

Medical sciences has made many breakthroughs with the support of FDM technology, today we are capable of
replicating functional human organs and implant artificially.

Procedure:

1) Click on 'Base'. Base and Build Platform will be displayed on the left side of the screen.
2) Click on 'Extruder' then extruder and extruder nozzle will be displayed.
3) Click on 'Material Spool' then material spool will be shown.
4) Click on 'Filament' then filament will be added.
5) Click on 'Start Process' to begin the process.
6) After the process is complete click on 'Stop Process' to view product generated using FDM process.

Applications:

1) Education
2) Modelling & Prototyping
3) Medical
4) Space Technology

Advantages:

1) FDM machines are safe, reliable, easy to use, and office friendly.
2) Minimum material wastage.
3) Varieties of engineering polymers are available commercially with different strengths and mechanical
properties.

Limitations:

1) FDM material needs to be made in filament form of required diameter.

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2) As the parts are built by depositing extruded rasters, the mechanical properties of the parts are not the same
in all directions.
3) To change extruder nozzle, it is require to Disassemble complete extruder assembly. Thus, it is very difficult
to change extruder nozzle in FDM.

Result: To studied the Fused Deposition Modelling (FDM) 3d printing process.

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