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Exercise 1. Arm

Exercise 1
Arm

1-1 Introduction
In this exercise, we will create a 3D
solid model for an arm, which is a
part of a clamping mechanism [1].
The clamping mechanism will be
introduced in Exercise 17 and
simulated in Exercise 17a.

The arm model consists of a
single solid body, which can be
generated by extruding a sketch by a
thickness of 0.125 inches [2].

Before creating a geometry
model, we must set up a global
coordinate system. For this exercise,
we arbitrarily choose the global
coordinate system as shown [3].
Note that the origin is on the back
surface of the part.

[1] The arm is a part


of a clamping
mechanism.

R0.313

1.375

R0.313

X
3 D0.25

[3] The global


coordinate
system.

2.25

R0.25

[2] Details of
the arm.

Unit: in.
Thickness: 0.125 in.

R0.5

Exercise 1. Arm

1-2 Start Up DesignModeler

[1] Launch ANSYS


Workbench.

[2] The <Workbench GUI>


(graphical user interface) shows up.

[3] Click the plus sign (+) to


expand <Component
Systems>. The plus sign
becomes minus sign.

[7] Double-click
<Geometry> to start
up the DesignModeler.

[5] A <Geometry> system


is created in the <Project
Schematic> area.

[4] Double-click to create


a <Geometry> system.

[6] You may click here to


show the messages from
ANSYS Inc. To hide the
message, click it again.

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Exercise 1. Arm

[8] <DesignModeler GUI>


shows up.

[9] Select <Inch> as


length unit.

[10] Click <OK>. Note


that, after clicking and
entering DesignModeler, the
length unit cannot be
changed anymore.

Speech Bubbles
1. In this book, each exercise is divided into subsections (e.g., 1-1, 1-2). In each subsection, speech bubbles are
ordered with numbers, which are enclosed by pairs of square brackets (e.g., [1], [2]). When you read, please follow
the order of speech bubble; the order is significant.
2. The square-bracket numbers also serve as reference numbers when referred in other text. When in the same
subsection, we simply refer to a speech bubble by its number (e.g., [1], [2]). When in the other subsections, we refer
to a speech bubble by its subsection identifier and its bubble number (e.g., 1-2[1]).
3. When a circle is used with a speech bubble, it is to indicate that mouse or keyboard ACTIONS are needed in that
step [1, 3, 4, 7, 9, 10]. A circle may be filled with white color [1, 4, 7] or unfilled [3, 9, 10]. A speech bubble without a
circle [2, 8] or with a rectangle [6] is used for commentary only, i.e., no mouse or keyboard actions are needed.

Workbench Keywords
A pair of angle brackets is used to highlight an Workbench keyword (e.g., <Component Systems> in [3]).
Sometimes, if the angle brackets do not add any clarity, they may be dropped (e.g., DesignModeler).

Clicking and Selecting


When we say "click" or "select," we mean left-click the mouse button.

Exercise 1. Arm

1-3 Prepare to Draw a Sketch on <XYPlane>

[1] By default,
<XYPlane> is the
current sketching
plane (active plane).

[3] Click <Look


At Face/Plane/
Sketch> to rotate
the view angle so
that you look at the
current sketching
plane.

[2] Click to switch to <Sketching


Mode>. Note that there are 5
toolboxes available: Draw, Modify,
Dimension, Constraints, and Settings.
<Draw> is the default toolbox.
[4] By default, the ruler is
on. In the next step, we will
turn off the ruler to make
more sketching space.

[6] This is the global


coordinate system.

[5] Select <View/


Ruler> to turn it off.
For the rest of this
book, we always leave
the ruler off.

[7] This is the plane


(local) coordinate
system.

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Exercise 1. Arm

1-4 Draw a Circle with Dimension


[6] As soon as you
begin to draw, a name
is assigned to the
sketch and it becomes
the active sketch.

[1] Select
<Circle> tool.

[7] Select
<Dimension>
toolbox.

[2] In case you don't


see the <Circle> tool,
scroll down to reveal
the tool.

[5] Move the mouse


away from the center and
then click the mouse to
create a circle with
arbitrary radius.

[4] Move the mouse


around the origin until
a <P> (Point) appears
and then click the
mouse to locate the
center of the circle.
The ability to "snap" a
point is a feature of the
DesignModeler, called
<Auto Constraints>.

[3] It gives you hints for


using the tool.

[11] It is possible that the circle


becomes too small. Select <Zoom to
Fit> tool to fit the sketch into the
graphics window. Now, we may need
to adjust (move) the position of the
dimension.

[8] Select
<Diameter> tool.

[10] In the <Details


View>, type 0.25 for
the diameter.

[9] Select the circle,


move the mouse
outward, and then click
to create a dimension.
Note that the circle turns
blue, meaning the circle
has fully constrained
(fixed in the space).

Exercise 1. Arm

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[14] Whenever necessary, select


<Zoom to Fit> tool to fit the
sketch into the graphics window.
[12] Select <Move> tool.
Remember to scroll
down to reveal a tool if
you don't see the tool.

[13] Select the


dimension, move to a
suitable position, and
then click again.

[15] Select <Display>


tool. You may need to
scroll down to reveal
the tool if you don't see
the tool.

[16] Click <Name> to


turn the dimension
name off. Note that
<Value> automatically
turns on.

[17] Instead of displaying dimension


name, now the dimension value is
displayed. For the rest of the book,
we always display dimension values
instead of name.

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Exercise 1. Arm

1-5 Draw Two More Circles

[2] Select <Draw>


toolbox.

[4] Move the mouse


around the horizontal
axis until a <C>
(Coincident) appears
and then click the
mouse to locate the
center of the circle.
This center is snapped
on the horizontal axis.

[1] Click anywhere in the


graphics window and then scroll
the mouse wheel down to zoom
out the sketch roughly like this.

[5] Move the mouse until an <R>


(Radius) appears and then click the
mouse. The radius dimension is
constrained to be the same as the
first circle. Note that the circle is
greenish-blue, meaning it is not
fully fixed in the space yet. A
horizontal location is needed to
fully defined the circle.

[3] Select
<Circle> tool.

[6] Create another circle in a


similar way. Make sure a <C> and
an <R> appear before clicking. A
vertical location is needed to fully
defined the circle.

Exercise 1. Arm

[8] Select the vertical


axis. Note that the shape
of the mouse cursor
changes when your mouse
is on the axis.

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[12] Remember that you


always can use <Zoom to Fit>
and scroll the mouse wheel [1]
to zoom in/out the view. Also,
to "pan" the view, simply move
the mouse while holding the
control-middle-button.
[10] Move the mouse upward roughly
here and click to locate a horizontal
dimension. Note that the circle turns
blue (fully constrained).

[7] Select
<Dimension> toolbox
and then select
<Horizontal> tool.
[11] In the <Details
View>, type 1.375 for
the horizontal
dimension.

[9] Select the center of


the circle. Note that the
shape of the mouse
cursor changes when your
mouse is on the point.

[13] Select
<Vertical> tool.

[16] Before going further, make sure you


familiarize the two most frequently used view
operations: scrolling the mouse wheel to zoom
in/out the view and moving mouse with
control-middle-button to pan the view.

[15] In the <Details


View>, type 2.25 for
the vertical
dimension.

[14] Select horizontal axis,


select the center of the lower
circle, move the mouse
leftward roughly here, and click
to locate a vertical dimension.
The circle turns blue.

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Exercise 1. Arm

1-6 Draw Three Concentric Circles

[2] Select the <Dimension/


Radius> tool, and create a
radius dimension for the
circle. In the <Details
View>, type 0.313 for the
radius.

[1] Select the <Draw/


Circle> tool, and draw a
concentric circle. Make sure
a <P> appears before
defining the center.

[4] With the <Draw/Circle>


tool still selected, draw a
concentric circle. Make sure a
<P> appears before defining
the center.

[3] Select the <Draw/Circle> tool,


and draw a concentric circle with the
same radius as the previous circle.
Make sure a <P> appears before
defining the center and an <R>
appears before defining the radius.

[5] Select the <Dimension/


Radius> tool, and create a
radius dimension for the
circle. In the <Details
View>, type 0.5 for the
radius.

Exercise 1. Arm

1-7 Draw Tangent Lines

[1] Select the <Draw/Line


by 2 Tangents> tool, and
then select the two circles
to be tangent to. A tangent
line is created.

[2] Create additional


three tangent lines in a
similar way.

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Exercise 1. Arm

1-8 Draw a Fillet


[1] Select the <Modify/
Fillet> tool, and type 0.25
for <Radius>.

[2] Select these two lines.


A fillet is created. Note
that the fillet is not bluecolored. We need to
specify the radius. The
radius typed in [1] is not
necessarily the final
dimension; it just serves as
a default dimension.

[3] Select the <Dimension/Radius>


tool, and create a radius dimension for
the fillet. You don't need to type in the
<Details View>, since the default value
[1] is automatically used. Note that the
color turns blue now.

Exercise 1. Arm

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1-9 Trim Away Unwanted Segments


[1] Select the <Modify/
Trim> tool, and turn on
<Ignore Axis>, meaning
that the axes will not serve
as trimming tools.

[3] Click to trim


away two other
arcs.

[2] Click the circle


roughly here to trim
away the arc. Note
that when you select
an edge (a line or a
curve), the remaining
edges will serve as
trimming tools.

[4] The sketch after


trimming.

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Exercise 1. Arm

1-10 Extrude the Sketch to Create the Arm


[1] Select
<Extrude> tool.

[6] Click <Generate>


to produce a 3D solid
body.

[3] Click the


little cyan sphere
to rotate the
view into an
isometric view.

[2] It automatically
switches to
<Modeling Mode>, in
which a <Tree
Outline> is
displayed, which will
be explained later.

[4] Type 0.125 for


the <Depth>.

[7] Click <Display


Plane> to turn off the
display of XYPlane (and
the sketches it contains).

[5] The active sketch is


automatically taken as
<Geometry>.

1-11 Save the Project and Exit Workbench

[2] In the <Workbench


GUI>, save the project
as "Arm."

[1] Select <File/Close


DesignModeler>. The
<DesignModeler GUI>
disappears.

[3] Select <File/


Exit> to quit
from the
Workbench.

Exercise 1. Arm

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1-12 Review
Global Coordinate System
Before creating a geometry model, you must set up a global coordinate system (1-1[3], 1-3[6]).

Workbench GUI
In the <Workbench GUI> (1-2[2]), you can create a system (1-2[4]) and start up DesignModeler (1-2[7]). Other
capabilities will be introduced later.

Project Schematic
Created systems appear on the <Project Schematic>, an area in the <Workbench GUI>.

DesignModeler GUI
Geometries are created entirely within the <DesignModeler GUI> (1-2[8]).

Length Unit
Before creating a model in the DesignModeler, you must choose a length unit (1-2[9, 10]). The length unit cannot be
changed thereafter.

Mouse Operations
Click

--  Left-click the mouse button.
Select

--  Left-click the mouse button.
Double-Click --  Left-click the mouse button twice.
Zoom In/Out --  Scroll the mouse wheel
Pan 

--  Move the mouse while holding control-left-button.
Other mouse operations will be introduced later.

Current Sketching Plane


Each sketch is stored in the current sketching plane (1-3[1]). Manipulating (switching, creating, etc.) sketching planes
will be introduced later.

Sketching Mode v.s. Modeling Mode


Tools for sketching are provided in the <Sketching> mode (1-3[2]), while tools for creating and manipulating bodies
are provided in the <Modeling> mode (1-10[2]). There are 5 toolboxes available: Draw, Modify, Dimension,
Constraints, and Settings. Tools in <Modeling> mode includes <Extrude> (1-10[1]). Some tools are available in both
modes, e.g., <Zoom To Fit> (1-4[11]).

Look At Face/Plane/Sketch
Clicking this tool to rotate the view angle so that you look at the current sketching plane (1-3[3]).

Ruler
The ruler (1-3[4, 5]) is to help you obtain a better feeling of the drawing scale. In this book, we always leave the ruler
off to make more sketching space.

Plane Coordinate System


Every plane has its own coordinate system (1-3[7]); it is also called a local coordinate system. The plane coordinate
system will be explained further later.

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Exercise 1. Arm

Scrolling
In case you don't see a tool in a toolbox, scroll down/up to reveal the tool (1-4[2]). There is also a scrolling controller
for the <Details View>.

Tools in <Draw> Toolbox


Circle


Line by 2 Tangent

-- Draw a circle, giving the center and the radius (1-4[1, 3-5]).
-- Draw a line tangent to two curves (including circles and arcs) (1-7[1, 2]).

Tools in <Dimension> Toolbox


Radius

Move

Display 



Horizontal



Vertical 




-- 
-- 
-- 

-- 

-- 


Specify a radius dimension by selecting a circle (1-4[6, 8-10]) or an arc (1-8[2]).


Move (relocate) a dimension name/value by dragging the name/value (1-4[12, 13]).
This tool is to toggle the display of dimension name and the dimension value (1-4[15-17]).
In this book, we always turn off the dimension name and turn on the dimension value.
Specify a horizontal dimension by first selecting a or a point (or a vertical line) and
then a second point (or a vertical line) (1-5[7-10]).
Specify a vertical dimension by first selecting a or a point (or a horizontal line) and
then a second point (or a horizontal line) (1-5[13, 14]).

Tools in <Modify> Toolbox


Fillet 
Trim 

-- 
-- 

Create a fillet by selecting two lines or curves (1-8[1-3]).


Trim away unwanted segments (1-9[1-4]).

Auto Constraints
P --  The mouse cursor snaps to a point (or the origin) (1-4[4]).
R --  The radius is the same as another circle (or arc) (1-4[5]).
C --  The mouse cursor is coincident to a line (or an axis) (1-5[4, 6]).
Other auto constraint features will be introduced later.

Color Codes
Greenish-blue -- 
Blue 

-- 
Red 

-- 

Under-constrained (1-8[2])
Fully constrained (fixed in the space) (1-4[9], 1-5[10,14]).
Over-constrained

Zoom To Fit
Click this tool to fit the entire sketch (in the <Sketching> mode) or entire model (in the <Modeling> mode) into the
graphics window (1-4[14]).

Extrude
This tool extrude a sketch by a specified depth to create a 3D body (1-10[1-5]). More exercises will be given later.

Isometric View
Click the little cyan sphere of the triad will rotate the view into an isometric view (1-10[3]). Other view controls will
be introduced later.

Display Plane
This tool is to toggle the display of current sketching plane and the sketches it contains (1-10[6]).

Exercise 1a. Structural Analysis of the Arm

Appendix:

Exercise 1a
Structural Analysis of the Arm
1a-1 Introduction
Although it can be used as a general purpose
CAD software, the DesignModeler is
particularly designed for creating geometric
models to be analyzed (simulated) under the
ANSYS environment. The purpose of this
exercise is to let the readers understand what
it means by analysis (simulation). However, the
reader has option to skip this exercise without
affect the subsequent learning of geometric
modeling.

In this exercise, we will perform a static
structural analysis for the arm created in
Exercise 1. The objective is to find the
deformation and stresses under the working
loads.

The clamping mechanism is entirely
made of steel and is designed to withstand a
clamping force of 450 lbf [1]. After a
structural analysis of the entire mechanism [2]
(also see Exercise 17a), the results show
shows that, to withstand a clamping force of
450 lbf, the arm is subject to external forces as
shown [3] (also see 17a-13). Note that the
external forces are in a state of static
equilibrium.

The analysis for the entire clamping
mechanism will be perform in Exercise 17a. In
this exercise, we will only perform a analysis
on the arm. The purpose is to make sure the
stresses are within the allowable stress of the
steel, which is 30,000 psi.

The analysis task cannot not be
performed in DesignModeler. Rather, it is
carried out with <Mechanical>, another
Workbench application program.

[2] This is the deformed


structure under the design
loads. The wireframe is the
underformed configuration.
Note that, for visual effects,
the deformation has been
exaggerated.

281 lbf

[1] The clamping


mechanism is
designed to withstand
a clamping force of
450 lbf.

[3] The external


forces on the arm.
These forces are
calculated
according to
17a-13.

264 lbf

77 lbf

407 lbf

126 lbf

187 lbf

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Exercise 1a. Structural Analysis of the Arm

1a-2 Start Up <Mechanical>

[1] Launch ANSYS


Workbench.

[2] Open the project "Arm,"


which was saved in Exercise 1.

[3] Double-click to create


a <Static Structural>
analysis system.

[5] And drop here. A link


is created, indicating that
both <Geometry> share
the same data.

[4] Drag <Geometry>...

[6] Double-click to
start up the
<Mechanical>.

Exercise 1a. Structural Analysis of the Arm

[7] This is the <Mechanical> GUI. Note


that the model is automatically brought
into <Mechanical>. By default, the body
is assumed to be made of steel.

[8] Make sure the length


unit is <in.>. If not,
select the right unit from
the pull-down menu
<Units> (see [9]).

[9] If the length unit is not <in.>,


select <Units/U.S. Customary (in,
lbm, lbf, F, s,V, A)>. Unlike
DesignModeler, the units can be
changed any time as you like in
<Mechanical>.

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Exercise 1a. Structural Analysis of the Arm

1a-3 Specify Loads


[2] Select <Loads/
Force>.

[3] A <Force> object is


inserted under the <Static
Structural> branch.

[1] Click to highlight


<Static Structural>.

[4] Select this


cylindrical face.

[5] Click <Apply>.

[6] Select <Components>.

[7] Type -187 (lbf) for <X


Component>, and 126 (lbf)
for <Y Component>.

[8] Select <Loads/


Force> again.

[9] A <Force 2> object


is inserted.
[10] Select this
cylindrical face.
[11] Click
<Apply>.
[12] Select <Components>.

[13] Type 264 (lbf) for <X


Component>, and 281 (lbf)
for <Y Component>.

Exercise 1a. Structural Analysis of the Arm

1a-4 Specify Supports


[1] Select <Supports/
Fixed Support>.

[2] A <Fixed Support> is


inserted.

[3] Select this


cylindrical face.

[4] Click
<Apply>.

1a-5 Insert Result Objects

[2] Select <Stress/


Equivalent (von-Mises)>.

[1] Click to highlight


<Solution>.

[3] A solution object is


inserted under the
<Solution> branch.

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26

Exercise 1a. Structural Analysis of the Arm

1a-6 Solve the Model

[1] Click <Solve>.

[4] Select <Edges/


Show Undeformed
WireFrame>.

[6] For visual


effect, the
deformation is
automatically
enlarged 49 times.

[3] The maximum stress


is 29,690 psi, slightly below
the allowable stress
(30,000 psi). Note that the
maximum stress can be
reduced by increasing the
radius of the fillet.

[5] Undeformed
shape.
[2] Click the Z-axis
to rotate the view so
that you look into the
<XYPlane>.

[7] Click to close the


<Message> window.

[8] Click <Play> to


animate the
deformation.

[9] Click <Stop> to


stop the animation.

Exercise 1a. Structural Analysis of the Arm

1a-7 Save the Project and Exit Workbench

[2] In the <Workbench


GUI>, save the project as
"Arm-a".

[1] Select <File/Close


Mechanical>. The
<Mechanical GUI>
disappears.

[3] Select <File/


Exit> to quit from
the Workbench.

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