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UNIVERSITY OF HOUSTON
COMPUTER-AIDED DESIGN
MID-TERM
PROJECT 1
Spring 2017
TABLE OF CONTENT
INTRODUCTION: (3)
PROCEDURE: (4 - 8)
DISCUSSION: (9)
CONCLUSION: (10)
RESULTS:
Analytical Calculations (11 14)
Ansys: Maximum Shear Stress (15)
Ansys: Safety Factor (16)
Creo: Maximum Shear Stress (17)
Creo: Maximum Principle Stress (18)
Creo: Minimum Principle Stress (19)
Creo: Safety Factor (20)
Percent Error Analysis: (21)
DEFINTIONS: (22)
REFERENCES: (23)
APPENDICES: (24)
3
INTRODUCTION:
Shaft is to rotate at 900 rpm as it transmits 7000 Nm torque from a API 17D standard torque tool
to a generator and this is the only loading case on the shaft. The material specified in the design
is A500 Steel. To goal of this project is to determine/evaluate the following cases for the shaft.
a) Maximum shear stress on the shaft
b) Principal stresses on the shaft
c) Material yield criteria for selected material
4
PROCEDURE
To help visualize the effects of combined stress, it is helpful to know how an element of a
certain load carrying member combined with normal and shear stresses act. For this
project, we will consider a two-dimensional stress condition, as illustrated in Figure 1-1.
The x- and y-axes are aligned with corresponding axes on the member being analyzed.
Figure 1-1.
In this project, our model is undergoing a torsional load causing a Shear stress.
The double-subscript notation helps to orient the direction of shear stresses. For example,
indicates the shear stress acting on the element face that is perpendicular to the x-
axis and parallel to the y-axis.
The combination of the applied stresses that produce the minimum normal stress is called
the minimum principal stress, its magnitude can be computed from the following
equation.
5
Torsional Deformation
When a shaft experiences torque, it pursues a twisting motion in the shaft about a certain
axis, in this case the Z axis. Torsional deformation is also referred to as angle of twist
which is computed from the following equation
Holographic Analysis
We will study the effects of stress on an element undergoing torsional loading using
Holographic Anamorphous. One must understand the directions and magnitudes of each
stress acting on the element. To implement Anamorphosis one must see the model from a
unique perspective requiring the viewer to use a special device to observe from a specific
vantage point to reconstitute the element. This project was developed to calculate shear
stress, angle of twist and polar moment of inertia parameters of a shaft which is under
torsion.
Note that Torsion is causing the object to twist due to an applied load. When the shaft
twists, one end rotates relative to the other and shear stresses are produced. Shear stress is
zero on the axis passing through the center of a shaft under torsion and maximum at the
outside surface of a shaft. On an element where shear stress is maximum, normal stress is
zero.
Note that the shaft has a dimensional change in
its geometry. The location of various stresses is
most likely to concentrate at discontinuities in a
member. The ratio of peak stress near stress riser
to average stress over the member is called stress
concentration factor. For fillet in a stepped
circular shaft we refer to the chart shown in
Figure 1-2 to determine the stress concentration
factor known as "Kt". The value of "Kt" will be
used to determine the maximum shear stress
acting on the element.
Figure 1-2
6
For this project, I decided to use a free online CAD system called on shape. On shape is
the first and only full-cloud 3D Cad system that lets everyone on a design team work
together using any web browser, phone, or tablet.
To begin visit www.onshape.com and create a free account to sign in.
After signing in users have access to a dashboard shown in Figure 2.
Press create to begin the creation process. Select the sketch icon
adjust system units, select the icon located on the top tool bar
icon and enter a value of 10mm. Notice the reverse extrusion icon which allows
users to extrude in the opposite direction.
Once the body has been built we can now create the fillet by selecting the fillet icon
and entering a fillet radius of 5mm. Congrats we have completed the model. Once
satisfied with the design export the model as a IGES by proceeding to the lower part of
the screen and right clicking on the model tab to select export.
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ANSYS
In terms of loading, dynamic means energetic, an element that experiences a constant
loading and unloading in a repeated fashion, while static means stationary or fixed. In this
project, our model is stationary and fixed. To begin the analysis, select static structural
from the loading type menu on the left side of the screen.
Since we have created a model we can easily import the IGES file into Ansys. Right click
geometry and select browse to search for the location of the IGES file. After imported
double click on engineering data to edit the material properties. The material used is AISI
1137 Cold-Drawn steel with a yield strength of 565 and an ultimate stress of 656.
Other properties such as Young's modulus and poisons ratio can be set but for structural
steels these usually remain the same. Once we have completed our property settings and
successfully imported our model we can now add the loading conditions to analyze the
shaft. By right clicking on "model" select edit to open the "mechanical" window where
we will first generate a mesh to closely approximate the geometries domain. Click mesh
and look below to edit "element size". For this project, I chose an element size of 0.1
mm. As you edit the element size notice the network of wire and thread becomes closure
the smaller the element size. Right click and select "generate mesh" to complete mesh
settings. Next in our procedure we must tell Ansys where we would like our model to be
fixed. As shown in Figure 1-3 our model is attached to the torque tool by six bolts but for
simulation purposes we will only select the outer surfaces of the larger diameter circle to
simulate its fixture. Right click on static structural and select insert/support/fixed and
while holding the shift key select the end surface and outer surface. On the left side of the
window Confirm selection by finding the highlighted geometry selection and click apply.
We have now successfully added fixed supports to our model. Using the same process,
we will add a moment to the opposite end of the shaft. In the same fashion right click
static structural and select insert/loads/moment and click the surface of the smaller
cylindrical as shown in Figure 1-4. On the left side of the window Confirm selection by
finding the highlighted geometry selection and click apply. Next scroll down a bit in the
same window to enter the applied torque load of 7000 Nm. Now that we have indicated
our stress conditions we can now tell Ansys what to solve. For this project, we are
solving for maximum stress, normal stress and a safety factor for this material. Right
click solution and choose insert/stress/maximum stress. Repeat and select
insert/stress/normal stress. Repeat and select insert/stress/stress tool. As you select these
solutions you can see them appear as nodes under solution tree. Now we are ready to
solve by right clicking solution and selecting solve to begin the solving process.
8
DISCUSSION:
As a student of mechanical engineering who is trained to solve problems using analytical
and computational methods. In most cases students can only imagine the actual size of a
structure or element that is being designed. With holographic Anamorphosis this is no
longer an excuse. To explain how holographic Anamorphosis relates to mechanical
engineering Figure 3 shows a holographic representation of the shaft we made earlier in
its actual dimensions. The shaft is to rotate at 1900 RPM as it transmits 7000 Newton
meters of torque from a 17D API standard Torque tool. The material specified in the
design is AISI 1137 Cold-Drawn steel. As shown in Figure 3 the diameters we made in
Creo and Ansys have been transferred to our holographic simulation. With these
diameters, we can calculate Modulus of Rigidity, power requirements, polar Moment of
Inertia, Normal Shear Stress, Angle of twist, Maximum Principle Stress, Minimum
Principle, Angle o Principle Stress, Angle of Maximum Shear Stress, stress concentration
factor, and Safety Factor. Figure 3
CONCLUSION:
In conclusion, we learned that stress is largely dependent on the materials property. Depending
on the Young's modulus of a material the modulus of rigidity may change, you can examine this
change using the Finite element analysis I created. By changing the modulus of rigidity, the
angle of which the material may twist due to a torsional load will change. These are matters that
are not always clear during lectures of a college class room, the ability to think of these very
small but essential elements of a design.
During my studies with Ansys I ran in to a problem with node limitations. Depending on the type
of license a user owns Ansys may choose to reject a engineers simulation if it is over a certain
number of nodes. To fix this problem I found that I needed to lower the modulus of rigidity to fit
the limits of the simulation. Because the results of a tensile test aren't always the same yielding a
different modulus of rigidity may results in a small variance in the simulated results vs hand
calculated results.
11
RESULTS
12
13
14
15
Figure 4
21
PERCENT ERROR
22
DEFINITIONS:
Homogeneous Material: Material that has the same material properties.
Modulus of elasticity (Youngs modulus): The rate of change between tensile or compressive
stress with respect to a elements tensile or compressive strain. Mostly studied for one direction
Modulus of rigidity (modulus of elasticity in shear): The rate of change in shear stress with re-
spect to shear strain for an element undergoing pure shear. Typical values Aluminum 6061-T6:
Poissons ratio: The ratio between vertical strain and horizontal strain under the condition of uni-
Stress Concentration Factor: The ratio of peak stress near stress riser to average stress over the
Maximum Shear Stress Angle: The angle of maximum in-plane shear stress at some point.
Shear stress: A form of a stress that acts parallel to the cross section.
23
REFERENCES
Budynas.R , Nisbett.K . (2014) . Shigley's Mechanical Engineering Design . 10th edi-
tion. McGraw-Hill
Pilkey, W. D..(2005). Formulas for Stress, Strain, and Structural Matrices .2nd Edition John Wiley
& Sons
Young, W. C., Budynas, R. G.(2002). Roark's Formulas for Stress and Strain .7nd Edition
McGraw-Hill
Pilkey, W. D..(2005). Formulas for Stress, Strain, and Structural Matrices .2nd Edition John Wiley
& Sons
24
APPENDICES:
Figure 5
25