Pro Engineer 2001 Mechanica Structure Thermal

For University Use Only - Commercial Use Prohibited -
PTC Global Services
Fundamentals of Pro/MECHANICA Structure/Thermal

Release 2001 T741-320-01
Copyright
Copyright 2001 Parametric Technology Corporation. All Rights Reserved. This Fundamentals of Pro/MECHANICA Structure/Thermal Training Guide may not be copied, reproduced, disclosed, transferred, or reduced to any form, including electronic medium or machine-readable form, or transmitted or publicly performed by any means, electronic or otherwise, unless Parametric Technology Corporation (PTC) consents in writing in advance. User and training documentation from Parametric Technology Corporation (PTC) is subject to the copyright laws of the United States and other countries and is provided under a license agreement that restricts copying, disclosure, and use of such documentation. PTC hereby grants to the licensed user the right to make copies in printed form of this documentation if provided on software media, but only for internal/personal use and in accordance with the license agreement under which the applicable software is licensed. Any copy made shall include the PTC copyright notice and any other proprietary notice provided by PTC. This documentation may not be disclosed, transferred, modified, or reduced to any form, including electronic media, or transmitted or made publicly available by any means without the prior written consent of PTC and no authorization is granted to make copies for such purposes. Information described herein is furnished for general information only, is subject to change without notice, and should not be construed as a warranty or commitment by PTC. PTC assumes no responsibility or liability for any errors or inaccuracies that may appear in this document. The software described in this document is provided under written license agreement, contains valuable trade secrets and proprietary information, and is protected by the copyright laws of the United States and other countries. UNAUTHORIZED USE OF SOFTWARE OR ITS DOCUMENTATION CAN RESULT IN CIVIL DAMAGES AND CRIMINAL PROSECUTION. Registered Trademarks of Parametric Technology Corporation or a Subsidiary: Advanced Surface Design, CADDS, CADDShade, Computervision, Computervision Services, Electronic Product Definition, EPD, HARNESSDESIGN, Info*Engine, InPart, MEDUSA, Optegra, Parametric Technology, Parametric Technology Corporation, Pro/ENGINEER, Pro/HELP, Pro/INTRALINK, Pro/MECHANICA, Pro/TOOLKIT, PTC, PT/Products, Windchill, and the InPart logo. Trademarks of Parametric Technology Corporation or a Subsidiary 3DPAINT, Associative Topology Bus, Behavioral Modeler, BOMBOT, CDRS, CounterPart, CV, CVact, CVaec, CVdesign, CV-DORS, CVMAC, CVNC, CVToolmaker, DesignSuite, DIMENSION III, DIVISION, DVS, DVSAFEWORK, EDE, e/ENGINEER, Electrical Design Entry, e-Series, Expert Machinist, Expert Toolmaker, Flexible Engineering, ICEM, Import Data Doctor, Information for Innovation, i-Series, ISSM, MEDEA, ModelCHECK, NC Builder, Nitidus, PARTBOT, PartSpeak, Pro/ANIMATE, Pro/ASSEMBLY, Pro/CABLING, Pro/CASTING, Pro/CDT, Pro/CMM, Pro/COMPOSITE, Pro/CONVERT, Pro/DATA for PDGS, Pro/DESIGNER, Pro/DESKTOP, Pro/DETAIL, Pro/DIAGRAM, Pro/DIEFACE, Pro/DRAW, Pro/ECAD, Pro/ENGINE, Pro/FEATURE, Pro/FEM-POST, Pro/FLY-THROUGH, Pro/HARNESS-MFG, Pro/INTERFACE, Pro/LANGUAGE, Pro/LEGACY, Pro/LIBRARYACCESS, Pro/MESH, Pro/Model.View, Pro/MOLDESIGN,Pro/NC-ADVANCED, Pro/NC-CHECK, Pro/NC-MILL, Pro/NCPOST, Pro/NC-SHEETMETAL, Pro/NC-TURN, Pro/NC-WEDM, Pro/NC-Wire EDM, Pro/NETWORK ANIMATOR, Pro/NOTEBOOK, Pro/PDM, Pro/PHOTORENDER, Pro/PHOTORENDER TEXTURE LIBRARY, Pro/PIPING, Pro/PLASTIC ADVISOR, Pro/PLOT, Pro/POWER DESIGN, Pro/PROCESS, Pro/REPORT, Pro/REVIEW, Pro/SCAN-TOOLS, Pro/SHEETMETAL, Pro/SURFACE, Pro/VERIFY, Pro/Web.Link, Pro/Web.Publish, Pro/WELDING, Product Structure Navigator, PTC i-Series, Shaping Innovation, Shrinkwrap, The Product Development Company, Virtual Design Environment, Windchill e-Catalog, Windchill e-Series, Windchill ProjectLink, CV-Computervision logo, DIVISION logo, and ICEM logo.
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PRINTING HISTORY Document No. Date T741-320-01 11/10/01
Description Initial Printing of Fundamentals of Pro/MECHANICA Structure/Thermal for Release 2001
Order Number DT-741-320-EN Printed in U.S.A
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Training Agenda
Day 1
Introduction to Pro/MECHANICA Si mplif ying Models with Ideali zations Opti mi zing Models for Anal ysis
Day 2
Assi gning Material Properties Appl ying Constraints Si mulating Applied Loads
Day 3
Running and Evaluating Anal yses Anal ysis and Results: Examples
Day 4
Running Sensitivit y and Opti mi zation Studies Running Anal yses Advanced Exercises
Day 5
Fatigue Advisor Student Proj ects
Table of Contents
INTRODUCTION TO PRO/MECHANICA 1-1
OVERVIEW ...................................................................................................................... 1-2
Structure Simulation...........................................................................................................1-2
RUNNING ANALYSES.................................................................................................... 1-4

Analysis Design Scenario...................................................................................................1-4 Identifying the Design Requirements .................................................................................1-4 Creating the Bracket Design...............................................................................................1-5 Model Idealization..............................................................................................................1-6 Creating the Design Parameters .........................................................................................1-9 Running Sensitivity Studies .............................................................................................1-10 Running Optimization Studies..........................................................................................1-11
USER INTERFACE: INTEGRATED MODE I .............................................................. 1-12

Using the MECHANICA Menu .......................................................................................1-12 Using Toolbar Icons .........................................................................................................1-12 Accessing the Object Sensitive Menu from the MODEL TREE......................................1-13 Using the Icons in the Graphic Window...........................................................................1-14 EXERCISE 1: Create the Bracket Design ........................................................................1-15 EXERCISE 2: Assign the Material Properties .................................................................1-22 EXERCISE 3: Define Constraints....................................................................................1-23 EXERCISE 4: Define Loads ............................................................................................1-24 EXERCISE 5: Idealize the Model ....................................................................................1-27 EXERCISE 6: Define and Run a Static Analysis .............................................................1-29 EXERCISE 7: Display and Interpret the Results..............................................................1-32 EXERCISE 8: Defining Design Parameters Using Relations ..........................................1-37 EXERCISE 9: Investigating Parameters with Global Sensitivity Studies ........................1-42 EXERCISE 10: Design Optimization...............................................................................1-46
MODULE SUMMARY ................................................................................................... 1-53
SIMPLIFYING MODELS WITH IDEALIZATIONS
2-1
IDEALIZATIONS ............................................................................................................. 2-2

Using Shell Idealizations....................................................................................................2-2 Using Solid Model Idealizations ........................................................................................2-4
For University Use Only - Commercial Use Prohibited Creating Rigid Connections ............................................................................................... 2-4 Creating Connections......................................................................................................... 2-5
LABORATORY PRACTICAL ..........................................................................................2-6

EXERCISE 1: Using Mass, Spring, and Beam Idealizations............................................. 2-7 EXERCISE 2: Using Shell Idealizations ......................................................................... 2-12 EXERCISE 3: Using Solid Idealizations ......................................................................... 2-18 EXERCISE 4: Using Rigid Connections ......................................................................... 2-27 EXERCISE 5: Using End and Perimeter Welds .............................................................. 2-29
MODULE SUMMARY....................................................................................................2-36
OPTIMIZING MODELS FOR ANALYSIS
3-1
INTEGRATED MODE MODELING ................................................................................3-2

Solid Modeling................................................................................................................... 3-2 Modeling Shells ................................................................................................................. 3-2 Creating Regions................................................................................................................ 3-5 Structural Assemblies ........................................................................................................ 3-6 Modeling in 2-D................................................................................................................. 3-8
LABORATORY PRACTICAL ........................................................................................3-10

EXERCISE 1: Suppressing Structurally Insignificant Features....................................... 3-11 EXERCISE 3: Shell Modeling Using Auto Detect .......................................................... 3-21 EXERCISE 4: Creating Regions...................................................................................... 3-23 EXERCISE 5: Creating Volume Regions........................................................................ 3-28 Exercise 6: Structural Assemblies.................................................................................... 3-30 EXERCISE 7: Modeling a 2-D Plane Stress Plate........................................................... 3-32
MODULE SUMMARY....................................................................................................3-34
ASSIGNING MATERIAL PROPERTIES
4-1
BASIC MECHANICS OF MATERIALS ..........................................................................4-2

Young's Modulus ............................................................................................................... 4-2 Poisson's Ratio ................................................................................................................... 4-3
Systems of Units .................................................................................................................4-4 LABORATORY PRACTICAL ..........................................................................................4-5

EXERCISE 1: Assign Structural and Thermal Material Properties ................................... 4-5 EXERCISE 2: Adding New Materials to the Library ........................................................ 4-7 EXERCISE 3: Edit and Delete Materials........................................................................... 4-8
MODULE SUMMARY....................................................................................................4-10
APPLYING CONSTRAINTS
5-1
INTRODUCTION ..............................................................................................................5-2
For University Use Only - Commercial Use Prohibited LABORATORY PRACTICAL ......................................................................................... 5-8
EXERCISE 1: Using Fixed Edge Constraints ....................................................................5-8 EXERCISE 2: Using Point Constraints............................................................................5-10 EXERCISE 3: Using Surface Constraints ........................................................................5-14 EXERCISE 4: Constraining Shell Models .......................................................................5-15 EXERCISE 5: Using Coordinate System Constraints......................................................5-17 EXERCISE 6: Using Cyclic Symmetry Constraints ........................................................5-19
MODULE SUMMARY ................................................................................................... 5-21
SIMULATING APPLIED LOADS
6-1
INTRODUCTION.............................................................................................................. 6-2 LABORATORY PRACTICAL ......................................................................................... 6-3

EXERCISE1: Applying General Loads..............................................................................6-4 EXERCISE 2: Applying Spatial Load Variations ..............................................................6-8 EXERCISE 3: Varying Load Direction and Magnitude...................................................6-13 EXERCISE 4: Using Pressure and Gravity Loads ...........................................................6-15 EXERCISE 5: Creating Load Distributions .....................................................................6-19
MODULE SUMMARY ................................................................................................... 6-22
RUNNING AND EVALUATING ANALYSES
7-1
INTRODUCTION.............................................................................................................. 7-2
Analysis Options ................................................................................................................7-2
LABORATORY PRACTICAL ......................................................................................... 7-3

EXERCISE 1: Running a Structural Analysis....................................................................7-4 EXERCISE 2: Defining Thermal Analyses......................................................................7-18 EXERCISE 3: Running Combined Analyses ...................................................................7-21 EXERCISE 4: Combining Loads in Results ....................................................................7-25 EXERCISE 5: Comparing MPA to SPA..........................................................................7-29
MODULE SUMMARY ................................................................................................... 7-32
ANALYSIS AND RESULTS: EXAMPLES
8-1
INTRODUCTION.............................................................................................................. 8-2
Analyzing Models ..............................................................................................................8-2
LABORATORY PRACTICAL ......................................................................................... 8-3

EXERCISE 1: Analyzing Roller Mill Bearing Mechanical Properties ..............................8-4 EXERCISE 2: Analyzing Frying Pan Thermal Properties ...............................................8-12 EXERCISE 3: Analyzing a Tuning Fork..........................................................................8-21
MODULE SUMMARY ................................................................................................... 8-25
For University Use Only - Commercial Use Prohibited RUNNING SENSITIVITY AND OPTIMIZATION STUDIES 9-1
INTRODUCTION ..............................................................................................................9-2
Running Global Sensitivity Studies ................................................................................... 9-2 Running Local Sensitivity Studies ..................................................................................... 9-2 Running Optimizations ...................................................................................................... 9-3
LABORATORY PRACTICAL ..........................................................................................9-4

EXERCISE 1: Optimizing a Belt Clip ............................................................................... 9-5 EXERCISE 2: Running Sensitivity Studies ..................................................................... 9-15 EXERCISE 3: Optimizing the Clip.................................................................................. 9-21
MODULE SUMMARY....................................................................................................9-25
RUNNING ANALYSES
10-1
Model Description ............................................................................................................10-2
ADVANCED EXERCISES
11-1
INTEGRATED MODE CONTACT FUNCTIONALITY ...............................................11-2

Running Contact Analyses............................................................................................... 11-2 Defining Contact Regions ................................................................................................ 11-3 Defining Contact Analysis Measures............................................................................... 11-3 Setting Contact Analysis Options .................................................................................... 11-4
TRANSIENT THERMAL ANALYSIS ...........................................................................11-5

Fundamentals ................................................................................................................... 11-5
LABORATORY PRACTICAL ........................................................................................11-8

EXERCISE 1: Creating and Analyzing Spot Welded Sub-Assemblies ........................... 11-9 EXERCISE 2: Contact Problems ................................................................................... 11-14 EXERCISE 3: Running Transient Thermal Analyses.................................................... 11-21 EXERCISE 4: Analyzing Large Deformation ............................................................... 11-26
MODULE SUMMARY..................................................................................................11-36
FATIGUE ADVISOR
12-1
OVERVIEW .....................................................................................................................12-2 LABORATORY PRACTICAL ........................................................................................12-4

EXERCISE 1: Piston Fatigue........................................................................................... 12-4
MODULE SUMMARY..................................................................................................12-11
STUDENT PROJECTS
13-1
STUDENT PROJECTS ....................................................................................................13-2

Designing a Flagpole ....................................................................................................... 13-2 Designing a Driveshaft..................................................................................................... 13-3
For University Use Only - Commercial Use Prohibited Designing a Wing Spar.....................................................................................................13-3 Designing a Valve Housing..............................................................................................13-5 Designing a Heat Sink ......................................................................................................13-7 Analyzing a Buckling Ring ..............................................................................................13-8 Analyzing a Beverage Can ...............................................................................................13-9
STUDENT PROJECT HINTS ....................................................................................... 13-12
USING PTC HELP
A-1
DEFINING THE PTC HELP FEATURES....................................................................... A-2 USING THE Pro/ENGINEER ONLINE HELP................................................................ A-2
Defining the PTC Help Table of Contents ........................................................................A-8
TECHNICAL SUPPORT
B-1
Locating the Technical Support Web Page ....................................................................... B-2 Opening Technical Support Calls via E-Mail.................................................................... B-2 Opening Technical Support Calls via Telephone .............................................................. B-3 Opening Technical Support Calls via the Web.................................................................. B-3 Sending Data Files to PTC Technical Support .................................................................. B-3 Routing Your Technical Support Calls.............................................................................. B-4 Technical Support Call Priorities ...................................................................................... B-5 Software Performance Report Priorities............................................................................ B-5 Registering for On-Line Support....................................................................................... B-5 Using the Online Services ................................................................................................. B-6 Finding Answers in the Knowledge Base.......................................................................... B-7
CONTACT INFORMATION ........................................................................................... B-9

Technical Support Worldwide Electronic Services ........................................................... B-9 Technical Support Customer Feedback Line..................................................................... B-9
TELEPHONE AND FAX INFORMATION .................................................................. B-10

North America Telephone Information ........................................................................... B-10 Europe Telephone Information........................................................................................ B-11 Asia and Pacific Rim Telephone Information ................................................................. B-15
ELECTRONIC SERVICES ............................................................................................ B-18
Module
Introduction to Pro/MECHANICA
In this module, you learn the basic Pro/MECHANICA structural simulation process.
Objectives
After completing this module, you will be able to: Create a Pro/ENGINEER model for simulation purpose. Setup the model for static analysis, including defining the model idealization, constraints, loads and material properties. Define and run the analysis. View and interpret the result. Optimization the design.
Page 1-1
NOTES
OVERVIEW
Structure Simulation
An important phase of most design cycles requires engineers to measure the stress and displacement distribution of new designs. This is necessary in order to validate the design and ensure it is suitable for its intended use. To further improve the design, engineers may also need to ascertain the key variables that control the design. This information is usually used to optimize designs. Pro/MECHANICA enables you to validate and optimize your designs by simulating their responses to various structural load types. Depending on the purpose of the simulation, the process may vary. There are two simulation process types: Integrated mode Pro/ENGINEER with integrated limited Pro/MECHANICA analysis features. Independent mode Stand along Pro/MECHANICA with comprehensive analysis features.
In the Integrated mode, a typical structural simulation consists of the design validation and optimization phases. These consist of twelve steps. The first eight steps comprise the Design Validation phase: 1. Create the ModelCreate the part or assembly that satisfies the design intent. 2. Idealize the Model Prepare the model for automatic mesh generation. This includes specifying appropriate idealization types and any required idealization properties. 3. Set Units and Material PropertiesSpecify the appropriate system of units and assign material properties. 4. Identify ConstraintsDefine realistic constraints that simulate how the model will function in the real world. 5. Set LoadsDefine loads to simulate how the model is loaded in the real world.
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F u n d am en t als o f P ro / M EC H A N IC A
NOTES
For University Use Only - Commercial Use Prohibited 6. Define the AnalysisDefine the appropriate analysis type (static, modal, and so on) based on the required results. You can also define the convergence settings. 7. Run the AnalysisRun the defined analysis. 8. View and Interpret the ResultsYou can generate graphs, fringe plots, and so on to visualize the converged results.
The last four steps comprise the Design Optimization phase: 9. Define the Design ParametersCreate Pro/MECHANICA parameters that specify how the model geometry can change. 10. Run Sensitivity StudiesPerform sensitivity studies on the parameters defined in the previous step. This will help you decide which parameters have the most influence on the design. 11. Run the OptimizationSpecify a goal, design constraints, and parameter ranges that constrain the solution boundaries. 12. Update the ModelYou can automatically or manually update the Pro/ENGINEER model.
I n t r o d u c t i o n t o P ro /M E CH A NI CA
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NOTES
RUNNING ANALYSES
This example illustrates a typical structural simulation process as run in the Integrated mode.
Analysis Design Scenario

Imagine you are an engineer designing large, industrial shelving systems. These systems are intended for warehouses and must support large loads. You will use Pro/MECHANICA to model and improve an existing bracket design. The bracket is used to connect the shelves to the vertical support rails.
Figure 1 Designing a shelving bracket
Identifying the Design Requirements

The objective is to find a design that is stronger and lighter than the existing system, yet still easy to assemble. This results in the following design requirements.
Objective
The design objective is to minimize the bracket mass.
Criteria
The design must support a 20 lbs. (pounds) load applied at a specific point. The following design criteria must be satisfied:
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NOTES
For University Use Only - Commercial Use Prohibited The maximum stress is less 93 N/mm2 (MPa). This maximum allowable stress is calculated using the tensile yield strength of the available steel (231 N/mm2) with a safety factor of 2.5. The maximum allowable displacement is 0.04 mm. This is necessary because a small deformation in the bracket can cause large displacement at the end of the rack it carries. The distance between the two bolt holes (30 mm) and sheet metal thickness (2.5 mm ) must remain fixed. This is necessary due to assembly constraints.
Creating the Bracket Design

The bracket design is created using Pro/ENGINEER. When constructing the model, the dimension scheme should reflect the design intent, and also provide enough design parameters for the design optimization. The following figure shows the desired design parameters.
Figure 2 Bracket design parameters.
Due to this consideration, the bracket is created using the specific dimensioning scheme shown in the following figure.
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NOTES
For University Use Only - Commercial Use Prohibited Note:

Relations can be used to capture the inter-relationship among the dimensions.
Figure 3: The bracket dimensioning scheme.
Note that the four rounds are created as two separate features: the inner and outer rounds. This dimensioning scheme provides the flexibility of altering each feature independently to improve the design. According to the design constraint, the dimensions of the hole will remain fixed during the optimization. The detailed instructions can be found in Exercise 1.
Model Idealization
Like other FEA and GEA simulation packages, Pro/MECHANICA performs computation at the individual elements. Because Pro/MECHANICA has extensive auto-meshing capability, most of the element generation is transparent. The only required step is to idealize the model. The AutoGEM will generate the appropriate element based on the model idealization. Various types of model idealization are available in Pro/MECHANICA to capture the characteristics of the model. For example, the default solid idealization
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NOTES
For University Use Only - Commercial Use Prohibited is perfect for simulating chunky geometry, and the shell idealization is suitable for thin geometry, such as the bracket.
Idealizing the Bracket as a Shell

To define a shell, you need to define the surface pairs. In this example, the front and back surface of the bracket model are defined as a surface pair. The surface pair will be compressed to form the mid-surface, as shown in the following figure. The detailed instructions can be found in Exercise 5.
Figure 4 Mid-surface compression.
Defining Material Properties

The material of the bracket is steel. The material properties are assigned to the bracket using the available properties in the library. The detailed instructions can be found in Exercise 2.
Defining Constraints
In reality, the top and bottom surface of the bracket are welded to other components. As a result, these surfaces need to be rigidly fixed in Pro/MECHANICA so that no movement is allowed. The following figure shows the constrained bracket model. The detailed instructions can be found in Exercise 3.
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NOTES
Figure 5 Constrain the bracket surfaces
Defining Loads
In this example, the bracket load must be calculated using realistic loading condition. In reality, a rack is attached to the bracket using two bolts. A 20 lbs. load is applied to a point as shown in the following figure.
Load
Figure 6 The rack assembly. Calculating the Bracket Bearing Load
A Free Body Diagram (FBD) can be created as shown in the next figure.
Ay Ax
Bx By
20 lbs (88.9 N)
Figure 7 The Free Body Diagram of the rack.
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NOTES
For University Use Only - Commercial Use Prohibited Since the system of equations is indeterminate, the assumption Ay = By is made. The static calculation yields the following result: Ax = -889 N; Ay = 44.5 N; Bx = 889 N; By = 44.5 N The force components of the bracket bearing load are equal and opposite. The detailed instructions can be found in Exercise 4.
Running the Analysis

The analysis type needs to be chosen depending on the type of problem. For this problem, a single pass adaptive static analysis is used. The summary file is used to monitor the progress of the analysis. The detailed instructions can be found in Exercise 6.
Displaying and Interpreting the Results

The result windows are created to show the stress and displacement of the model. In this example, three result windows are created: An animated fringe plot that shows the von Mises stress of the model. An animated fringe plot that shows the displacement of the model. An animated fringe plot that shows the principal stress of the model. A fringe plot used to dynamically query the stress of the model.
The results show that the design needs to be improved to satisfy the design requirements. Since most of the part had very low stress, this part is overdesigned. This indicates that further improvement can be made to reduce weight. The detailed instructions can be found in Exercise 7.
Creating the Design Parameters

Design parameters are variables of the model that can potentially affect the design objectives. Design parameters can be Pro/ENGINNER dimensions or model parameters. In a design optimization, the system changes the variables within a certain range to find the best values that satisfy the constraints and optimize the design goal. In this example, there are eight design parameters.
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NOTES
Maintaining Design Intent using Relations

In Pro/ENGINEER, relations can be created to capture the interrelationship among parameters and dimensions. In Pro/MECHANICA Integrated mode, these relations stay valid and active in the simulation process. Whenever a design parameter is changed, the system will re-evaluate the relations and regenerate the model. This ensure that the model satisfies the design intent. In this example, the basic shape of the model should be maintained. When varying the dimension ANG within the allowable range (from 45 degrees to 90 degrees), the dimension TOP should be adjusted accordingly. To capture this design intent a relation was created:
top = 62.5 + (45-ang) * 0.5
Due to this relation, when changing the dimension TOP from 45 to 90 degrees, the bracket model maintains its basic shape, as shown in the following figure. In Exercise 8, the relation is used to maintain design intent during a sensitivity study. As a result, eight independent design parameters are reduced to seven.
Figure 8 Maintain the basic shape of the bracket using relations.
Running Sensitivity Studies

Sensitivity studies are used to determine whether a certain characteristic or property of the model is sensitive to a design parameter. Specifically, the system calculates the changes in your model's measures (such as stress and displacement) when you vary a parameter over a specified range.
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NOTES
For University Use Only - Commercial Use Prohibited Sensitivity studies can be performed by varying the parameters within a range (Global sensitivity), or at a specific value (local sensitivity). Global sensitivity studies serve two primary purposes: To rule out the unimportant parameters in the upcoming optimization. To determine a good initial value for that parameter to use in the optimization.
Running Optimization Studies

In an optimization study, the system try to find a set of design parameter values within the specified ranges that satisfy all of the imposed constraints, at the same time, try to maximize/minimize certain properties of the model. There are several key elements that need to be defined in an optimization study. Goal: A goal is a certain property of the model that will be maximized/minimized in an optimization analysis. In this case, the goal is to minimize the mass of the bracket. Optimization Constraints: They are constraints that model parameters need to satisfy. In this case, the constraints are: The maximum von Mises stress is less 93 N/mm2 (MPa). The maximum allowable displacement is 0.04 mm. Optimization Variables: In an optimization study, the system changes the variables within a certain range to find the best values that satisfy the constraints and optimize the goal. In this case, there are 7 variables shown in Figure 2. The ranges for these variables can be found in Exercise 10.
Reviewing Optimization Results

The types of results you may want to review are the plots showing von Mises stress compared to optimization pass. You may also want to review total mass compared to optimization pass
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NOTES
USER INTERFACE: INTEGRATED MODE I

In the Integrated mode, there are four ways for you to access the Pro/MECHANICA commands: Commands located under the MECHANICA menu Icons in the toolbar located on the right of the graphic pane Object sensitive shortcut menu in the MODEL TREE Object sensitive shortcut menu accessed from graphic window
Using the MECHANICA Menu

Using Pro/MECHANICA, the user can perform simulation by navigating the menu structures.
Using Toolbar Icons

You can perform Pro/MECHANICA tasks using icons located on right of the graphic pane. The following tables list some commonly used icons.
Table 1 Structural Load Icons
Icon
Description
Create a point load. Create an edge/curve load. Create a surface load. Create a centrifugal load. Create a pressure load. Create a gravity load. Table 2 Structural Constraint Icons
Icon
Description
Create a point constraint. Create an edge/curve constraint. Create a surface constraint. Create a cyclic symmetry constraint.
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NOTES
For University Use Only - Commercial Use Prohibited Table 3 Structural Idealization Icons
Icon
Description
Define a beam idealization. Define a shell idealization. Define a mass idealization. Define a spring idealization.
Accessing the Object Sensitive Menu from the MODEL TREE

The MODEL TREE displays the entities exist in a simulation model, including the Simulation Features, Idealizations and Loads/Constraints, etc.
Figure 9 A typical top-level model tree.
You can expend the junction box to display the detailed list of the entities.
Figure 10 Navigate the Pro/MECHANICA model tree.
Selecting an entity in the MODEL TREE will highlight the entity in the graphic pane. After an entity is selected in the MODEL TREE, you can
Pag e 1 - 1 3
NOTES
For University Use Only - Commercial Use Prohibited access the object sensitive shortcut commands by clicking the right mouse button. The available commands are limited to the selected entity type.
Figure 11 Access the object sensitive menu from the MODEL TREE.
The SELECT_ACTION paradigm streamlines the workflow, increases the productivity.
Using the Icons in the Graphic Window

Object-sensitive shortcut menu can also be accessed by right-clicking the icons from the graphic window.
Figure 12 Using the shortcut menu in the graphic window.
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NOTES
LABORATORY PRACTICAL
Goal
Create a bracket model using Pro/ENGINEER. Set up a static structural analysis to simulate a loaded bracket. Optimize the bracket design.
EXERCISE 1: Create the Bracket Design
Figure 13 The finished bracket part.
Task 1.
Create a new part called BRACKET.
1. Set your working directory to the folder that corresponds to the name of the current module. 2. Set the environment settings. Click Utilities > Environment. Clear the Ring Message Bell and Spin Center check boxes. Click OK to close the dialog-box. 3. Create a new part model: Click [New file].
Select Part . Enter [bracket] as the name. Accept the default Use default template . Click OK .
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NOTES

In Pro/ENGINEER, the models created using the default templates will contain the information in the template model, such as the default datum planes and coordinate system.
4. Set up the units. From the PART menu. Click Set Up > Units . Select millimeter Newton Second(mmNs). Click Set . Accept the default Convert Existing Numbers (Same Size) . Click OK , followed by Close . Task 2. Create an extruded protrusion as the base feature.
1. From the INSERT pull down menu, click Protrusion > Extrude > One Side > Done . 2. Select the FRONT datum plane and click OK . 3. Select TOP from the Sket View menu and slect the TOP datum plane. 4. The system uses the system default feature creation options and enters the sketcher mode. Close the REFERENCE dialog box. 5. Sketch the section of the base feature as shown in the following figure. Note:
The dimensioning scheme captures the design intent, and provides flexibility for design optimization.
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Figure 14 The base protrusion section.
6. Click [Done] when finish. The system extrudes a default depth and displays the depth value. 7. Select Done . 8. Modify the depth. Double-click the depth dimension and enter [2.5]. Click OK . 9. Switch to the default view. Click View > Default Orientation . The model should look like the following figure. 10. Save the model.
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Figure 15 The base protrusion.
Task 3. Create one round on the two inner edges shown in the following figure. The round will have the radius of 5 mm.
Figure 16 Create one round on the two inner edges.
1. Click the
[Select Geometry] icon.
2. Select one inner edge. Press <Shift> and select the other edge. You may need to switch to hidden line mode to see the edges. 3. From the INSERT pull down menu, click Round . 4. A round is created with a temporary value, as shown in the following figure. You can use the drag handle to dynamically adjust the round size.
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5. Double click the dimension value. Enter [5]. 6. Click the background to implement the changes. Tips & Techniques
In Pro/ENGINEER to spin, zoom, or pan the model; Press <CTRL> key and use the three mouse buttons.
Task 4. Create another round on the outer edges, as shown in the following figure.
Figure 17 Create one round on the outer edges.
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For University Use Only - Commercial Use Prohibited 1. Use the same procedures in the previous task to create one round on the two outer edges. 2. Enter [5] as the round radius. Task 5. Create and dimension the two bracket holes.
1. From the INSERT pull down menu, click Hole . Accept the default Straight hole HOLE TYPE option. 2. Enter [12.5] for the diameter. 3. Select Thru All for the DEPTH ONE drop down list. 4. Define the hole placement: Select the front bracket surface as the PRIMARY REFERENCE. Accept the default Linear PLACEMENT TYPE option. Select RIGHT and TOP datum plane as the LINEAR REFERENCE. Enter [12.5] as the distance from the RIGHT datum plane. Enter [0] as the distance from the TOP datum plane. 5. Preview and close the HOLE dialog box by clicking The hole should appear as shown in the following. [Done].
Figure 18 Place a linear hole.
Task 6.
Create the second hole as an identical pattern
1. Click Feature > Pattern from the PART menu.

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For University Use Only - Commercial Use Prohibited 2. Select the hole you just created as the feature to be patterned. 3. Click Identical > Done . 4. Pick the 0.0 locating dimension as the pattern dimension for the first direction. 5. Enter [30] for the dimension increment. 6. Click Done from the EXIT menu. 7. Enter [2] for the number of instances. 8. Click Done from the EXIT menu. [Save]. The model should appear as 9. Save the model. Click the figure shown in the beginning of this exercise.
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EXERCISE 2: Assign the Material Properties

Task 1. Enter Pro/MECHANICA Structure Integrated mode.
1. From the APPLICATIONS pull down menu, click Mechanica . Click Continue in the UNIT INFO dialog box to confirm your system of units. 2. Click Structure from the MECHANICA menu. Task 2. Specify the material properties of the bracket. You will define the part as steel. 1. Assign the material steel to the bracket. Click Model > Materials . 2. Select STEEL and from MATERIALS IN LIBRARY list, add it to the MATERIALS IN MODEL list. 3. Select Part From the Assign drop-down list. 4. Select the bracket part and click Done Sel . 5. Close the MATERIALS dialog box.
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EXERCISE 3: Define Constraints

Task 1. Define how the part is constrained. In reality, the bracket is attached by welding the top and bottom edges to the adjoining hardware. 1. Create an edge constraint. Click constraint]. [Create an edge/curve
2. In the CONSTRAINT dialog box, enter [weld] as the name of the constraint. 3. Assign the constraint to a new constraint set. In the CONSTRAINT dialog box, click New next to the MEMBER OF SET to bring up the CONSTRAINT SET dialog box. In the CONSTRAINT SET dialog box, enter [weld] as the Constraint set name. Click OK to close the CONSTRAINT SET dialog-box. 4. Click the [Select] under the CURVE(S).
5. Select the front top edge and front bottom edge. Click Done Sel . 6. Fix all the DOFs (Degrees of Freedom). 7. Click OK to close the CONSTRAINT dialog-box. The constraint symbols appear on the model as shown in the following figure.
Figure 19 Constraint the bracket.
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EXERCISE 4: Define Loads

Task 1. Apply the bearing load on the top hole. [Bearing load].
1. Create the bearing load. Click
2. In the BEARING LOAD dialog box, enter [bearing_top] as the load name. 3. Assign the load to a new load set. In the BEARING LOAD dialog box, click New to bring up the LOAD SET dialog box. In the LOAD SET dialog box, enter [bearing_load] as the load set name. Click OK to close the LOAD SET dialog box. 4. In the BEARING LOAD dialog box, click [Select] under the HOLE(S). Select the front bottom edge of the top hole. Click Done Sel to finish. Note:
In this case, just like the constraint, the bearing load can be applied to the surface of the hole.
5. Accept the default option Components from the FORCE drop down list. 6. Enter [889] for the X component, enter [-44.5] for the Y component, keep Z as zero. 7. Click Preview . The system displays the load's distribution, as shown in the following figure.
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Figure 20 Preview the bearing load.
8. Click OK to finish. Task 2. Apply the bearing load on the bottom hole. [Bearing load].
1. Create another bearing load. Click
2. In the BEARING LOAD dialog box, enter [bearing_bottom] as the load name. 3. Accept the default load set. 4. In the BEARING LOAD dialog box, click [Select] under the HOLE(S). Select the front bottom edge of the lower hole. Click Done Sel to finish. 5. Accept the default option Components from the FORCE drop down list. 6. Enter [-889] for the X component, enter [-44.5] for the Y component, keep Z as zero. 7. Click Preview to see the load's distribution. 8. Click OK to finish. The model should appear as shown in the following figure.
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Figure 21 Apply the bearing load on both holes.
9. Click Done/Return from the LOADS menu.
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EXERCISE 5: Idealize the Model

Task 1. Idealize the model as a shell.
1. Select the model. 2. From the STRC MODEL menu, click Idealizations > Shells > Midsurfaces > New > Constant . 3. Select the front surface of the model. 4. Click Query Sel and select the back surface. 5. Click Done Sel to finish. Pro/MECHANICA highlights the pairs in red and yellow. Task 2. Verify the idealization and visualized the compressed model.
1. Test the mid-surface compression. Click Compress > Shells only . 2. Click Show Compress to see the created shell. The system displays only the mid-plane geometry, as shown in the following figure (displayed in yellow)
Figure 22 The compressed bracket mid-surface.
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NOTES

The AutoGEM functionality uses the surface to create triangular and quadrilateral shell elements. They can be visualized in the Independent mode.
3. Click Show Original to view the original part (displayed in green). 4. Click Show Both to display both the original part and the midsurface. 5. Click Done > Done Return > Done Return to finish.
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EXERCISE 6: Define and Run a Static Analysis

Task 1. Define a structural static analysis to determine the stress and strain caused by the applied loads. 1. Click Analyses from the MEC STRUCT menu to bring up the ANALYSES dialog box. 2. Create a new static analysis: Accept the default Static from m the NEW ANALYSIS type drop down list. Click New . The STATIC ANALYSIS DEFINITION dialog box appears. 3. In the STATIC ANALYSIS DEFINITION dialog box, Enter [bracket_static] for the name. Select weld for the Constraint Set. Select bearing_load for the Load Set. Unselect other load set as necessary. On Convergence tab, accept the default Single-Pass Adaptive . Click on the Output tab. Change Plotting Grid to 7 . Click OK to close the STATIC ANALYSIS DEFINITION dialogbox. 4. Close the ANALYSES dialog box. 5. Verify that Pro/MECHANICA treat your model as a shell model. From the MEC STRUCT menu, click Done/Return . From the MECHANICA menu, click Settings and verify that Use Pairs is checked. Note:
If you were to clear the Use Pairs check box, Pro/MECHANICA would treat your model as a solid, which will take longer to analysis. This setting is automatically checked when you define pairs.
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For University Use Only - Commercial Use Prohibited Task 2. Run the defined analysis.
1. Click Structure > Run . The RUN dialog box appears. 2. Verify that the analysis BRACKET_STATIC is selected. 3. Click Start . 4. Click Yes when asked "Do you want error detection?". Note:
Before starting the analysis, it is always helpful to have Pro/MECHANICA perform error checking on your model.
Task 3. Check to see how the run is progressing by monitoring the summary file. This file shows you details about each solver pass as the run progresses. 1. Click Summary . A summary window appears, displaying the report of the analysis run. 2. Scroll down a little. The report shows the following information: Principal System of Units. Model type and geometry information. Element information. 3. Scroll down a little further the report shows that the solver makes 2 passes. In the first pass all of the edges are set to p=3, which is usually referred to as third order polynomial. Based on the results of this pass, the final edge order for all the edges is determined between three and nine. This polynomial order distribution is applied to the model and a second pass is performed. Jot down the polynomial order of the second pass __________. 4. Scroll down a little further and review the error estimate. Jot down the value _______________. 5. Scroll down a little further. The report shows the constraint set and load set information. Check the values for the total load in X, Y and Z directions.
NOTES
For University Use Only - Commercial Use Prohibited 6. Scroll down a little further and review the values of the measures. Some measures of interest may be the max displacements and stress components. Note:
These values can be graphically displayed using the result interface.
7. Review the Memory and Disk Usage information. You can also find run time in this section. 8. At the end of the report, it indicates that the run is completed. 9. Click Close to exit the Summary window. Click Done to exit the RUN dialog box.
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EXERCISE 7: Display and Interpret the Results

Task 1. Create a RESULTS window to look at the distribution of von Mises stress in the model. 1. Create a RESULT window. Click Results from the MEC STRUCT menu. 2. Click No when prompted whether you want to save the model. The result interface is displayed. 3. Create a window to display the stress. Click [Insert result window].
Enter [Bracket_Max_VM] as the name. The DESIGN STUDY dialog box appears Click the bracket_static\ in the CURRENT DIRECTORY. Click Accept to finish. 4. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW MAX_PRINCIPAL dialog box, For the Title, enter [Maximum von Mises]. For Quantity, select Stress > Total > Von Mises . For Display, select Fringe and clear the Continuous Tone and Average . Select Deform . Accept the Deformed scale 10%. Select Animate . Change the number of frames to 16. Note:
More frames will result in smoother animation and take longer to generate.
Select Auto Start and Repeat . The dialog box should look like the following figure.
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Figure 23 The stress result window definition dialog box.
5. Click Accept and Show to finish the definition and display the result window. 6. Use following icons to control the result animation: [Stop]; Back] [Play] [Single Step]; [Single Step
7. Stop the animation when finish. Task 2. Create a result window to display the displacement by copying the existing window. 1. Click [Copy window].
2. Enter [Bracket_Displacement] as the name. 3. Fill out the dialog-box as shown in the following figure.
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Figure 24 The displacement result window definition dialog box.
4. Click Accept to finish. Task 3. Create a result window to display the Maximum Principal Stresses by copying the existing window. Maximum Principal Stress distinguishes tension from compression. 1. Click [Copy window].
2. Enter [Bracket_Principal] as the name. 3. Enter [Maximum Principal] as the title. 4. Select Max Principal from the drop-down list. 5. Keep other default settings. Click Accept to finish.
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For University Use Only - Commercial Use Prohibited Task 4. Create a Dynamic Query result window to further investigate the results. 1. Click [Copy window].
2. Enter [Bracket_vm_query] as the name. 3. Enter [Von Mises Query] as the title. 4. Unselect the Animate check box. 5. Keep other default settings. Click Accept to finish. Task 5. Display the result windows and examine the results. [Display Result Windows].
1. Click
2. In the display result window dialog box, click [Select all], followed by OK . The system starts to animate all animated windows. 3. Control individual window separately. Click one window to activate it. The borders of selected windows should be highlighted in yellow. Single step the animation. 4. Control multiple windows simultaneously. Press <Shift> and click all the animated windows. Note:
Red border indicates an inactivated window.
Task 6.
Interpret the result.
1. Jot down the following observations made in the MAX VON MISES window: Locations of the high von Mises stress ____________; 2. Jot down the following observations made in the BRACKET DISPLACEMENT window: Maximum displacement ____________; Location of the maximum displacement ____________;
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For University Use Only - Commercial Use Prohibited Does it satisfy the design requirement? _____________. 3. Stop the animation in all windows. Activate the VON MISES QUERY window. 4. Determine the von Mises stress and at any point on the model. Click Info > Dynamic Query. The QUERY dialog box appears. Move the mouse cursor over the fringe plot. Notice that in the dialog box, the value dynamically updates to show the stress level at the mouse location. Click a location of your interest to place a query tag. Click Done to close the QUERY dialog box. 5. Determine the maximum von Mises stress and its location. Click Info > Model Max to display the maximum stress location on the model. Jot down the value ____________. 6. Clear all query tags. Click Info > Clear All Query Tags . Click Yes when prompted Do you really want to clear all the values? . 7. Exit the result interface when you finish reviewing the result, Click File > Exit Results . Choose Yes when prompted to save the result window. Enter [Original] for the name. Click Accept to finish.
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EXERCISE 8: Defining Design Parameters Using Relations

Task 1. Rename the dimensions in Pro/ENGINEER.
1. Return to Pro/ENGINEER. Click Applications > Standard . 2. Display the dimensions. Click Modify and pick on the base feature. 3. Rename the dimensions. From the MODIFY menu, click DimCosmetics > Symbol . 4. Click the 45 degrees angular dimension, enter [ang] as the name. 5. Click the 62.5 dimension from TOP datum plane to the tip of the nose, enter [top] as the name. 6. Click Info > Switch Dimensions to toggle dimension between the symbolic name and numerical value. The model should look like the following figure.
Figure 25 Rename two dimensions
Note:
The initial dimension names may be different due to different order of dimension creation.
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NOTES
For University Use Only - Commercial Use Prohibited Task 2. Create a relation. As the angle changes, the bracket tip must rotate to maintain the desired part shape. Create a relation that captures this design intent. 1. From the PART menu, click Relations > Add . 2. Enter the following relations in the message input window: Enter [if ang >= 45 & ang <= 90] Enter [top = 62.5 + (45-ang) * 0.5] Enter [endif] Click <Return> at a blank line to finish. 3. Pro/ENGINEER creates a file that contains the relations you entered. To display the file and make any corrections, click Edit Rel . To close the text editor, click File > Exit . Note:
The text editor may be different on different platform. You can change the text editor in the configuration file.
4. Test the relations. Click Modify from PART menu and select the base feature. Select the 45 degree angular dimension. Enter [90] in the message window. Click Regenerate from the PART menu. The model should look like the following figure. 5. Modify the angle back to 45 degrees and regenerate the model.
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For University Use Only - Commercial Use Prohibited Figure 26 Test the relation by modifying the angle.
Task 3. Define the design parameters in Pro/MECHANICA. First, you add a design parameter to vary the size of the inner fillets. 1. Click Applications > Mechanica > Dsgn Controls > Design Params > Create . The DESIGN PARAMETERS DEFINITION dialog box appears. 2. Click Create . The DESIGN PARAMETERS DEFINITION dialog box appears. 3. In the DESIGN PARAMETERS DEFINITION dialog box: Accept the default type Dimension . Click Select . Pick on one of the inner round in the model, the radius dimension with a value of 5 should appear. Click the radius dimension. Enter [inner_fillets] for the name of the parameter and any description you like. Define the range. Enter [2.5] for the minimum, and [12.5] for the maximum. 4. Click Accept > Done to finish. 5. Test this single design variable. Click Shape Animate from the DSGN CONTROLS menu. 6. In the shape animate dialog box: The inner_fillets check-box is selected by default. Change the NUMBER OF INTERVALS to 2. Click Animate . Press <RETURN> to continue to the next animation step. The model should change its shape as shown in the following figure.
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Figure 27 Define a design parameter for the inner round.
7. Click Yes to the message, Do you want to restore the model to its original shape? . Task 4. Define more design parameters and animate the shape.
1. Using the procedures in the previous task, create more design parameters shown in the Figure 2 at the beginning of this chapter. The name and range of the design parameters can be found in the following table.
Table 4: The design parameters. Name tab_width tab_top tab_bottom mid_curve ang outer_fillets Min 25.0 53.0 26.0 46.0 45 2.5 Current 50.0 62.5 62.5 50.0 45 5 Max 50.0 62.5 62.5 53.0 90 12.5
2. Select Done after creating the parameters. 3. From the DSGN CONTROLS menu, click Shape Animate . 4. In the SHAPE ANIMATE dialog box, Select all parameters. Change their settings as shown in the following table.
Table 5 Shape Animate settings.
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For University Use Only - Commercial Use Prohibited Parameter Name

tab_width tab_top tab_bottom mid_curve ang inner_fillets outer_fillets
Settings1:
50.0 62.5 62.5 53.0 45 2.5 2.5
Settings2:
25.0 53.0 26.0 46.0 90 12.5 12.5
Enter [2] for the NUMBER OF INTERVALS. Click Animate . Press <RETURN> to continue to the next animation step. The model should change its shape as shown in the following figure.
Figure 28 Two design parameter settings.
Note:
Shape Animate simulates what may happen to the geometry
during sensitivity and optimization studies, as the result of design parameters being updated. It is a good practice to use shape animate after creating design variables to test the validity of the geometry.
5. Click Yes to restore the model to its original shape.
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EXERCISE 9: Investigating Parameters with Global Sensitivity Studies

Task 1. Create a global sensitivity study. Change the inner_fillets radius within its range (2.5 to 12.5 mm). All other parameters will stay at their current position during the run. 1. Click Structure > DesignStudies . The DESIGN STUDIES DEFINITION dialog box appears. 2. In the DESIGN STUDIES DEFINITION dialog box: Enter [gs_tab] for the Study Name. Select Global Sensitivity for the type of study. For the description, Enter [Sensitivity of the bracket to inner fillet radius size ]. Verify that BRACKET_STATIC (STATIC) analysis is selected. Select INNER_FILLETS parameter and verify that the Start is Minimum and the End is Maximum . Enter [4 ] for the number of intervals. Check the Repeat P-Loop Convergence. The dialog box should appear as shown in the following figure.
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Figure 29 The DESIGN STUDIES DEFINITION dialog box.
Click Accept to create the design study. 3. Click Done to close the DESIGN STUDIES dialog box. Task 2. Run a global sensitivity study.
1. Click Run . The RUN dialog box appears. 2. Verify that GS_TAB (GLOBAL SENSITIVITY) is selected. 3. Reuse elements from an existing study. Click Settings . The RUN SETTINGS dialog box appears. Select Use Elements from an existing study check-box. Click Select and select BRACKET_STATIC. Click Accept to close the STUDY DIRECTORY WITH
ELEMENTS dialog box.
Click Accept to accept and close the RUN SETTINGS dialog box.
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For University Use Only - Commercial Use Prohibited 4. Click Start to start running the study. 5. Click Yes for error detection. 6. Click Summary to monitor the study's progress. 7. When the study is complete, click Close > Done . Task 3. Create a RESULTS WINDOW to graph the von Mises stress vs. inner_fillet radius. 1. Click Results from the MEC STRUCT menu. 2. Click No when prompted to save the current model. The system displays the result interface. 3. Create a window to display the stress. Click [Insert Result Window].
Enter [vm_sens] as the name. Click Accept . The DESIGN STUDY dialog box appears Click the gs_tab\ in the CURRENT DIRECTORY. Click Accept to finish. The DEFINE CONTENTS FOR RESULT WINDOW VM_SENS dialog box appears. 4. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW VM_SENS dialog box, For the TITLE, enter [Max von Mises Stress vs. inner_fillets radius]. In the QUANTITY section, click Select next to MEASURE. The SELECT A MEASURE dialog box appears. Scroll down through the list of PREDEFINED measures and select max_stress_vm from the list. Click Accept to return to the DEFINE CONTENTS FOR RESULT WINDOW VM_SENS dialog box. In the LOCATION section, click Select next to DESIGN VAR. Select INNER_FILLETS followed by Accept . Click Accept and Show .
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Figure 30 Max VM stress measure vs. inner_fillets dimension graph.
Task 4.
Review and interpret the results of a global sensitivity study.
1. The curve quantifies the impact that inner fillets have on stress in your model. 2. Jot down the INNER_FILLETS value that corresponds to the stress design constraint __________________. This value can be used as the initial value of INNER_FILLETS in the optimization. 3. Jot down the range of INNER_FILLETS that von Mises stress is sensitive to __________________. When there is computer hardware constraints, this range can be used in the optimization, instead of using the entire range. 4. Click File > Exit Results when finish. 5. Select No when prompted to save the result windows.
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EXERCISE 10: Design Optimization

Task 1. Create the optimization design study. The goal is to minimize total mass. In addition, there are two limits. Keep the Von Mises stress below 1. Click Design Studies from the STRUCTURE menu. 2. Click Create in the DESIGN STUDIES dialog box. 3. In the DESIGN STUDIES DEFINITION dialog box, define the name and type: Enter [tab_opt] for the study name. Select Optimization from the TYPE drop down list. For the description, Enter [Optimization study for the bracket]. 4. Set the optimization goal. Verify that GOAL is set to Minimize and that MEASURE is set to total_mass . 5. Define the optimization limits: Click Create underneath LIMITS ON MEASURES. The list of measures appears. Select both max_disp_mag and max_stress_vm from the list. These are the two limits you want the optimizer to track. Click Accept to return to the DESIGN STUDY DEFINITION dialog box. Set the max_disp_mag limit. Accept the default < sign. Enter [0.04] as the limit value. Set the max_stress_vm limit. Select the radio button next to max_stress_vm. Accept the default < sign. Enter [93] as the limit value. 6. Define the variables. In the PARAMETERS section, select all seven buttons under Parameters. You can use the scroll bar in the PARAMETERS area to display all the parameters. Verify that the MIN is Minimum and the MAX is Maximum for all parameters.
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For University Use Only - Commercial Use Prohibited Assign the parameters initial values. Enter the INIT value listed in the following table
Table 6: Set the parameter range and initial values Parameter inner_fillets outer_fillets tab_width tab_top tab_bottom mid_curve ang Min Minimum Minimum Minimum Minimum Minimum Minimum Minimum Init 3.75 3.75 50.00 62.50 62.50 50.00 45 Max Maximum Maximum Maximum Maximum Maximum Maximum Maximum
Enter [2] as the OPTIM CONVERGENCE (%). Accept the remaining default values. The dialog box should look like the following figure.
Figure 31 Optimization design study definition dialog box.
7. Click Accept , followed by Done to finish the optimization design study definition.
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For University Use Only - Commercial Use Prohibited Task 2. Using the pre-run result, create a result window to display the graph of von Mises stress vs. Optimization pass. The graph shows how the stress was reduced during the optimization. 1. Click Results from the MEC STRUCT menu. 2. Click No when prompted to save the current model. The system displays the result interface. 3. Create a result window to display the graph of von Mises stress vs. optimization pass: Click [Insert Result Window].
Enter [vm_history] as the name. Click Accept . The DESIGN STUDY dialog box appears. The pre-run design study result is in the subdirectory Fund_structure_320/Integrated/results, navigate to the directory, select Results from the list and click Change Directory . Double-click on tab , select tab_opt from the list of studies. Click Accept to finish. The DEFINE CONTENTS FOR RESULT WINDOW VM_HISTORY dialog box appears. 4. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW VM_ HISTORY dialog box, Enter [Max Von Mises Stress vs. Optimization Pass] for the title. In the QUANTITY section, select Measure from the list. Click Select next to MEASURE. The SELECT A MEASURE dialog box appears. Scroll down through the list of PREDEFINED measures and select max_stress_vm from the list. Click Accept to return to the DEFINE CONTENTS FOR RESULT WINDOW VM_ HISTORY dialog box. Click Accept and Show .
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For University Use Only - Commercial Use Prohibited Task 3. Create a RESULT window to displays the graph of mass vs. optimization pass by copying an existing window definition 1. Click [Copy window]. The COPY RESULT WINDOW: VM_HISTORY appears.
1. Enter [mass_history] as the name the new window followed by Accept . The DEFINE CONTENTS FOR RESULT WINDOW MASS_HISTORY dialog box appears. 2. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW MASS _ HISTORY dialog box, Enter [Total Mass vs. Optimization Pass] for the title. In the QUANTITY section, select Measure from the list. Click Select next to MEASURE. The SELECT A MEASURE dialog box appears. Scroll down through the list of PREDEFINED measures and select total_mass from the list. Click Accept to return to the DEFINE CONTENTS FOR RESULT WINDOW MASS _ HISTORY dialog box. Click Accept and Show . 3. Jot down the following information: Initial mass _______________; Final mass ________________. 4. Exit the result interface when you finish reviewing the result, Click File > Exit Results . Choose Yes when prompted to save the result window. Enter [bracket_optimization] for the name.
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Figure 32 The optimization graphs. Task 4. Replay the optimization process and update the design.
1. Change the working directory to where the optimization design study is located. Click File > Working Directory . Navigate to the RESULTS sub-directory. Click OK . 2. From the MEC STRUCT menu, click Model > Dsgn Controls > Optimize Hist > Search Study . 5. Animate the optimization process. Select the BRACKET_OPT. Press <Enter> when prompted to review the next step. Repeat to advance to the next step. 6. Update the design parameters so that the model remains at the optimized state. Press <Enter> when prompted Leave the model at the optimized shape?. The model should look like the following figure.
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Figure 33 The optimized bracket model.
Task 5. Create a results window to show the von Mises Stress fringe plot of the optimized model. 1. Change the working directory back to
FUND_STRUCTURE_320/INTEGRATED.
Click File > Working Directory . Navigate to the FUND_STRUCTURE_320/INTEGRATED subdirectory. Click OK . 2. From the MEC STRUCT menu, click Results . 3. Click No when prompted whether you want to save the model. The result interface is displayed. 4. Create a window to display the stress. Click [Insert Result Window].
Enter [vm_final] as the name. The DESIGN STUDY dialog box appears Click the bracket_opt\ in the CURRENT DIRECTORY. Click Accept to finish. 5. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW VM_FINAL dialog box,
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For University Use Only - Commercial Use Prohibited For the Title, enter [Von Mises Stress Optimized Shape]. For Quantity, select Stress > Total > Von Mises . For Display, select Fringe . Clear Continuous Tone and
Average .
Select Deformed and accept the Deformed scale 10%. Select Animate . Change the number of frames to 16. Select Auto Start and Reverse . Click Accept and Show to finish and display the RESULTS window. 6. Jot down the following information: Maximum von Mises stress ________________; Maximum Displacement __________________. 7. Calculate how much the mass has been reduced ___________. 8. Exit the result interface when you finish reviewing the result, Click File > Exit Results . Choose Yes when prompted to save the result window. Enter [final] for the name. 9. Switch to the standard application. Save and erase the model.
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MODULE SUMMARY
You have learned: How to setup the model appropriately for static analysis, including defining the model idealization, constraints, loads and material properties. Define and run the analysis. View and interpret the result. Optimization the design.
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Module
Simplifying Models with Idealizations

In this module, you learn how to use idealizations in Pro/MECHANICA. Idealizations are the mathematical approximation of your model's geometry that Pro/MECHANICA uses to simulate the behavior of your design.
Objectives
After completing this module, you will be able to: Describe the purpose of using idealizations to simplify your designs. Describe the types and applications of idealizations. Define rigid connection idealizations. Define end- and perimeter-weld idealizations.
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IDEALIZATIONS
You can use idealizations as simplifications of your designs when running analyses. During analysis, Pro/MECHANICA calculates stress and other values in each model idealization. There are different types of idealizations available in Pro/MECHANICA. It is important to understand the following idealization types and how they affect the results you will get for any given analysis. Mass- Used to represent a concentrated or point mass without a specified shape (Structure only). Spring- Used to represent a linear elastic (six degrees-of-freedom) spring connection (Structure only). Beam- Used to model a structure that is relatively long compared to its thickness and width, with a constant cross section. Shell- Used to model a structure with a constant thickness which is thin compared to its length and width. Solid- Used to model a structure that is as thick and wide as it is long. Its cross section and thickness can vary.
When deciding on which idealization to use, consider the structure you are modeling and how that structure behaves, rather than the geometry. This will help you select the type of element for your model.
Using Shell Idealizations

You would typically use a shell model when your part is relatively thin compared to its length and width. Shells are 3-D idealizations that have length, width, and thickness. Shell models run faster and require less disk space than solid models without sacrificing accuracy.
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For University Use Only - Commercial Use Prohibited To meet Pro/MECHANICA's criteria for shell models, your part must have a constant or multi-constant thickness. In other words, you can not shell model a tapered part, but your part can have multiple constant thickness areas. The thickness of the shell idealization is always distributed symmetrically about the surface on which it is placed. For this reason, it is important that this surface actually represent the mid-plane of the model.
Creating the Mid-Surface

By default, Pro/MECHANICA treats all Integrated Mode models as solid models. You can direct Pro/MECHANICA to treat your part as a shell model by defining mid-plane surfaces. The focus of this chapter is to teach you how to compress a solid model to a shell model. To model your part as a shell model, you must use the following procedure: 1. Define Shell Pairs The first step is to define pairs of solid surfaces which will be compressed to form the mid-surface of the model. A surface/shell pair consists of two or more parallel surfaces on opposite sides of a volume. 2. Test the Pairs Compression Once the pairs have been defined, Pro/MECHANICA attempts to compress all the pairs to a continuous surface model representing the middle of the part. You should review this mid-surface model to ensure that it has compressed to the desired form, i.e. you should test the compression. 3. Verify the Use Pairs Setting To ensure that Pro/MECHANICA treats the model as a shell, you should verify that the Use Pairs setting is selected.
Creating Shells
It is important to note that the procedure described above is used only to define the mid-surfaces on which shell elements will be placed. In the Integrated Pro/Mechanica interface these shell elements are not manually created by the user. Rather, they are automatically created when an analysis is run. In Integrated Mode, all elements are created by the Mechanica auto-mesher, known as the AutoGEM utility. The most important difference between Integrated Mode and Independent Mode is that elements can be manually created in the Independent Mode.
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Using Solid Model Idealizations

A solid model is a part that you model using solid elements like tetrahedral, bricks, or wedges. In Integrated Mode, Pro/MECHANICA uses only tetrahedrals for solid modeling. You use solid modeling when your part is as thick and wide as it is long. Your part's thickness, however, can vary non-uniformly. There are three different shapes a solid element can take. The three different solids can be remembered by the number and type of faces that it takes to define them.
Table 1 Solid element types. Solid Type Brick Description Two opposite Quad faces, (total of 8 points)
Wedge
Two opposite Tri faces, (total of points)
Tetra
One Tri faces and one opposite point, (total of points)
Creating Rigid Connections

A rigid connection connects geometric entities, such as surfaces, curves and points, so that they remain rigidly connected during an analysis. When you connect entities in this way,
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For University Use Only - Commercial Use Prohibited They move together as if part of a single rigid body They do not deform, but the rigid body can move as a whole.
Because Pro/MECHANICA uses linear constraint equations to enforce the rigid rotations, rather than equations with trigonometric functions (such as sine and cosine), you should use rigid connections only for small rotation angles of rigidly connected entities. Use rigid connections in this way, even if you intend to use them in a large deformation analysis. Pro/MECHANICA supports rigid connections for 3-D models only.
Creating Connections
A connection is the point of contact between two or more parts or subassemblies. In Pro/MECHANICA, you can use two kinds of connectionsend welds and perimeter welds.
End Welds
Use end welds in assembly models to connect plates. Plates can be curved and placed at oblique or right angles, such as T or L configurations. Using the end weld, the shell mesh from one plate is extended to meet the mesh from the base plate. You can use end welds to join: Two thin wall components at a right angle. Two thin wall components at an oblique angle. Two offset thin wall components mated at a right angle with a gap between the compressed surfaces of the components. Two offset thin wall components mated at an oblique angle with no contact between the components.
Perimeter Welds
Use perimeter welds in assembly models to connect parallel plates, which may be curved, along the perimeter of another plate. During mesh generation, a sequence of surfaces is automatically created to connect the selected edges of the top plate to the base plate. Pro/MECHANICA creates shell elements on the selected surfaces. A series of welds on one or more of the perimeter edges of the top plate connects it to the base plate. In this case, the components are touching. The resulting compressed surfaces, however, are parallel to one another and do not touch. For this type of geometry, you should use a perimeter weld to connect the two plates.
Simp lif ying Model s with I d e ali zati ons
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Goal
To use idealizations to simplify a design.
Method
In Exercise 1 you examine mass, spring and beam idealizations. The model you will be working on is a truss. Since you will be defining the beam section properties (I-beam, solid circle, etc.) in Pro/MECHANICA, all you need to create for the geometry is the datum curve framework to set up beam idealizations. In Exercise 2 you learn how to direct Pro/MECHANICA to treat your part as a shell model by automatically defining mid-plane surfaces. You create the two intersecting pipes. In Exercise 3 you learn how the Integrated Mode automatically meshes solid models using the T-Bracket. In Exercise 4 you will learn how to define rigid connections. In Exercise 5 you will learn how to create end and perimeter welds.
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EXERCISE 1: Using Mass, Spring, and Beam Idealizations
Figure 1 A truss structure made up of datum curves.
Task 1.
Create the truss structure.
4. Set your working directory to the folder that corresponds to the name of the current module. 5. Click File > New . 6. Select Part from the dialog box. Enter [truss] for the part name. 7. Leave the Use Default Template check box selected. The new part will have three defaults, datum planes, and a csys. 8. Turn off the spin center and bell if necessary. Click Utilities > Environment . Clear both the spin center and ring message bell check boxes. 9. Change units from Pro/Engineer default to mm N s. Click Setup > Units . Select mm Ns and click Set . Accept Same Size option. Click OK > Close . 10. Create a sketched datum curve.
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For University Use Only - Commercial Use Prohibited Click [Insert a sketched datum curve] on the right. Select the default. Select the FRONT datum plane, click OK . Close the REFERENCES dialog box. 11. Sketch the datum curve as shown in the following figure.
Figure 2 Sketch the datum curves.
Note:
With Intent Manager, constraints are established while you sketch. In addition, your sketch automatically snaps to the references you specified. When you finish sketching, Intent Manager creates a default dimensioning scheme. To override the default weak dimensions, simply create new dimensions.
12. Click Task 2.
[Done] to finish and then click OK .
Create the beams.
1. Enter Pro/MECHANICA Structure. Click Mechanica from the APPLICATION menu. 2. Click Continue in the UNIT INFO window. Click Structure .
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For University Use Only - Commercial Use Prohibited 3. Accept the default Model from the MEC STRUCT menu. Click Idealizations > Beams > New . The BEAM DEFINITION dialog box appears. 4. Enter [hollow_tube] for the name. 5. Select Edge/Curve from REFERENCE drop-down menu. Click [Select]. Select all the curves in the model. Click Done Sel. 6. Click More next to the MATERIAL. MATERIALS dialog box appears. Select Steel . Click the right arrows to assign to the model. Click OK . 7. From the Y DIRECTION menu, select Vector in WCS and enter [ 0,0,1] respectively for the X, Y and Z directions. 8. Click More next to SECTION. The BEAM SECTION dialog box appears. Click New . The BEAM SECTION DEFINITION dialog box appears. 9. Select Hollow Circle from SECTION TYPE drop-down list. 10. Enter [12.5] for R and [8.75] for Ri. Click Review > OK . 11. Click OK > OK . Do not define Beam Orientation and Beam Release. They will be discussed later. Click OK . 12. Click Done/Return. 13. Click View > Default Orientation . Notice that Beam Section icons appear at intervals along each beam. This gives you a visual idea of the size and shape of the hollow tubing.
Mass and Spring Idealizations
Task 3. Attach a weight (mass) to the tip of the truss and model a flexible support (spring) attached at the center of the truss and the ground. Note:
These Mass and Spring idealizations are placed at datum points on your model. You will create a datum point in Pro/MECHANICA.
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For University Use Only - Commercial Use Prohibited 1. Switch to the front view. Click the Saved Views icon followed by Front . 2. Create a datum point at the right most vertex of your model. Click [Create a datum point]. Click On Vertex. 3. Click the vertex on the top right of the truss, corresponds to the PNT0 shown in the following figure, followed by Done Sel > Done . 4. Create another datum point, PNT1, using on vertex as shown in the following figure.
Figure 3 The Truss Model
5. Create a mass at the point that you just created. Click Idealizations > Masses > New . 6. Accept the default name. Click [Select] and select PNT0 followed by Done Sel . Accept the default type. Enter [100] as the mass followed by OK . The Mass icon appears. 7. Create a spring between PNT1 and the ground. Click Springs > New . 8. Accept the default name. Select To Ground from the Type drop[Select] and select PNT1 , followed by Done down list. Click Sel . 9. Click More next to PROPERTIES. Click New to create a spring property. 10. In the SPRING PROPERTIES DEFINITION dialog box, enter the [10, 1000, 10] for Kxx, Kyy and Kzz respectively and accept other defaults. 11. Click OK > OK > OK . The spring icon appears.
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Figure 4 The truss model with beam, mass and spring idealizations.
Task 4.
Blank the idealization icon display.
1. Click Simulation Display from the VIEW pull-down menu. Then click Visibilities . 2. Clear Beam Sections , Masses and Springs , followed by OK . The model now is ready for applying load and defining analyses. 3. Select Done > Return from the IDEALIZATIONS menu. 4. Save and erase the model when finished. Note:
The model is displayed without the Beam Section icons since it may interfere with visibility when you are working on a complex model. Adjust these as necessary for ease of use in Pro/MECHANICA.
Tips & Techniques

Items, such as Loads/ Constraints, Simulation features are displayed together with Pro/ENGINEER features in the Model Tree. You can use the Model Tree as a shortcut to manipulate these items. Right-click an object in the Model Tree. A pop-up menu will appear. You can then manipulate these items.
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EXERCISE 2: Using Shell Idealizations
Figure 5 Idealize the intersecting pipe as a shell.
Task 1.
Create two intersecting pipes.
1. Click File > New . 2. Select Part . Enter [pipes] for the part name. Use the default template. 3. Change units from Pro Engineer default to mm N s. Click Setup > Units . Select mm Ns and click Set . Accept Same Size option. Click OK > Close . 4. Create a solid protrusion to represent the first pipe. Click Insert > Protrusion > Extrude > Done . Select the TOP datum plane and click Okay . Select Default from SKET VIEW. 5. Sketch a circle that is 250 mm in diameter. For a blind depth, enter [750] mm. 6. Change the default attribute to both side protrusion. Right-click the protrusion in the MODEL TREE and choose Redefine .
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For University Use Only - Commercial Use Prohibited Double-click the Attribute . Select Both Side > Done > Done . Accept the depth value, followed by OK . The protrusion should appear as shown in the following figure.
Figure 6 Finished base protrusion.
7. Repeat the preceding procedures to create a second solid protrusion with 200m diameter and 750mm depth to represent the second pipe. Use FRONT as the sketching plane. Use Both Side option. 8. Insert a round at the intersection of the two cylinders with a radius of 25 mm. 9. Click Insert > Round . 10. Click Simple > Done . 11. Click Done to accept the defaults Constant and Edge Chain . Click the two edges that represent the intersection of the two cylinders, followed by Done Sel . Enter [25] as the radius. 12. Click OK to finish. The model should appear as shown in the following figure.
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Hidden Surfaces to remove Surfaces to remove
Figure 7 Unshelled pipe.
13. Shell the pipes with a thickness of 6.25. Click Insert > Shell . 14. Select the four pipe ends as the surfaces to remove, as shown in the previous figure. Click Done Sel > Done Refs . 15. Enter [6.25] as the thickness. Click OK to complete the shell. 16. Save the model.
Task 2.
Create the mid-surface of the shell model.
1. Enter Pro/MECHANICA. Click Applications > Mechanica . Read the unit information and click Continue . 2. Click Structure > Model > Idealizations > Shells . 3. Turn off the Datum Planes , Axes , and Coordinate Systems by toggling the icons on the toolbar. 4. Shade the model using the icons in the toolbar. 5. Click Midsurfaces > Auto Detect .
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Note:
Pro/MECHANICA highlights one set of surfaces in red and the opposing surfaces in yellow. The red surface acts as a point of reference for the pair. Pro/MECHANICA uses this surface as a view point when determining which opposing surfaces in the model are part of the pair.
6. From the SHELLS menu, click Compress > Shells only > Show Compress to test the mid-plane compression. The pairs get compressed and display in yellow as shown in the following figure. 7. Click Done/Return > Done/Return > Done/Return .
Figure 8 Compressed pipe. Create Shells
Now you will examine the shell element mesh in Independent Mode. This is NOT a require step. Normally, you will set up an analysis and then run it without ever leaving the Integrated interface. When you run an analysis in Integrated Mode, the AutoGEM auto mesher will create the elements.
Task 3.
Transfer to Independent mode to manually AutoGEM.
1. From the MECHANICA menu, click Settings . 2. Notice that the Use Pairs option is turned on automatically, as a result of shell idealization. This setting tells Pro/MECHANICA to place shell elements on the midsurfaces you just defined. If you
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For University Use Only - Commercial Use Prohibited want to model this part as a solid instead, you would turn off this setting. 3. Click Indep MEC > Structure to quit Integrated mode, and enter the Independent mode STRUCTURE. 4. Confirm to exit Pro/ENGINEER. Click OK to close the information window. 5. Save the model with a new name when prompted. Enter [pipes_2] as a new name. Click Accept . 6. Change the model view to isometric. Click View > Iso > Done . 7. When the model displays, click Settings from the DISPLAY pull down menu to change the settings. 8. Select the DISPLAY TYPE Smooth Shade , the DISPLAY QUALITY Fine , and the SHADE Geometry . Select Display Edges , accept other defaults and click Accept . 9. Notice that only the midsurface geometry was imported into Independent Pro/MECHANICA. Task 4. AutoGEM the midsurface.
1. Click Model > Elements > AutoGEM > Surface > All , followed by <Return>. 2. When you mesh the model, AutoGEM creates shell elements. The type of idealization determines the types of elements that AutoGEM will create. 3. Read the SUMMARY window and click OK to finish. 4. Change to an isometric view. Click View > Iso > Done . 5. Adjust the element display settings. Click Display > Settings from the DISPLAY menu: Shade the elements. Select Smooth Shade from the DISPLAY TYPE drop-down list. Select Elements from the SHADE drop-down list. Select Shrink All Elements check box with a factor of 0.2. Click Accept
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For University Use Only - Commercial Use Prohibited 6. Visually examine the model. The model should look like the following figure.
Figure 9 The meshed pipe part.
Task 5. Verify the mid-surface thickness. It is automatically defined during the shell idealization in the Integrated mode. 1. To verify that the correct part thickness was automatically assigned, click Edit > Property > Shell Property > Surface . 2. Click the surface mesh lines of any surface. Note that the shell thickness properties have been assigned. 3. Click Cancel to finish, followed by <Return>. 4. Exit Pro/MECHANICA. Click File > Quit . Answer Yes to whether or not you want to quit, and No to the saving the model prompt.
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EXERCISE 3: Using Solid Idealizations
Figure 10 The finished geometry.
Task 1.
Create the base for the t_bracket.
1. Start a new Pro/ENGINEER session. Set the current working directory as directed by your instructor. 2. Create a part called t_bracket. Click File > New . Enter [t_bracket] for the name. Use the default template. 3. Set mm Ns as units. Click Set Up > Units . Select mm Ns . Click Set > Same Size > OK > Close . 4. Create the base of the T-Bracket using a thin protrusion. Click Insert > Thin Protrusion > Both Sides > Done . 5. Pick FRONT as the sketching plane and click Okay . Pick TOP as a horizontal reference, and select the TOP datum plane. 6. Sketch the T-Bracket's base as shown in the following figure. Since the base is symmetrical about DTM1, use a vertical centerline on the RIGHT datum plane.
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Figure 11 Sketch a horizontal line symmetric about RIGHT.
7. Click
[Done].
8. Select Both from the THIN OPT menu. Enter [25] for the thin feature width. 9. Click Blind > Done in the SPEC TO menu. Enter [250] as the extrusion depth. 10. Click OK to complete the feature. Task 2. Task 2. Create the rib for the t_bracket.
1. The vertical rib can also be created as a thin protrusion. Click Insert > Thin Protrusion > Extrude > Both Sides > Done . 2. Click Use Prev , followed by Okay . 3. Select RIGHT and the top surface of the first protrusion as references. 4. Sketch the t-bracket's vertical rib as shown in the following figure.
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For University Use Only - Commercial Use Prohibited Figure 12 Sketch a vertical line on RIGHT.
5. Click
[Done].
6. Click Both from the THIN OPT menu. Enter [25] for the thin feature width in the message window. 7. Click Blind > Done in the SPEC TO menu. Enter [250] as the extrusion depth. 8. Click View > Default > Preview . The part should appear as shown in the following figure. Click OK to complete the feature.
Figure 13 The finished T-bracket geometry.
9. Save the model. Click File > Save , followed by <Enter> Task 3. Task 3. Transfer the part to the Independent mode and manually AutoGEM it. Note:
This optional step is performed to illustrate the meshed model.
1. Start Independent session of Pro/MECHANICA. Click

Applications > Mechanica
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For University Use Only - Commercial Use Prohibited 2. Click Continue in the UNIT INFO window. Click Indep MEC > Structure . 3. Confirm to exit Integrated mode when prompted. 4. Confirm to save the model with a new name when prompted. 5. Enter [t_bracket_2] as a new name. Click Accept . 6. To get a better view of your part, click View in the upper right hand corner, followed by Iso > Done . The model should like the following figure.
Figure 14 Visualize the T_bracket in the Independent mode.
Task 4.
Task 4. Generate the elements.
1. Create the elements by using AutoGEM. Click Model > Elements > AutoGEM > Volume > All from the DESIGN menu. Click <RETURN> . 2. A dialog box indicating the number of solid tetrahedral elements that AutoGEM created will appear. Review the statistics and record the number of elements and the time below. #Elements_________ Time_________ Click OK to finish. 3. To get a better view of the elements, turn off the visibility of all the entities except the solid elements. Click Display > Master Visibilities from the DISPLAY menu.
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For University Use Only - Commercial Use Prohibited Click All Off from the bottom of the form. Select Solids from the ELEMENTS column and click Accept . 4. Change the element display. Click Display > Settings from the DISPLAY menu. Select Smooth Shade from the DISPLAY TYPE drop-down list. Select Fine from DISPLAY QUALITY drop-down list. Select Elements from the SHADE drop-down list. Select Shrink All Elements . Set the shrink factor to 0.2. 5. Accept the settings. Your mesh should resemble the following figure.
Figure 15 The bracket part meshed with Tetra solid elements.
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For University Use Only - Commercial Use Prohibited Task 5. Task 5. Create brick idealizations. Delete the existing Tetra mesh and all extra points. Note:
For cases where solution time is critical, it is sometimes quicker to create idealizations by hand. You hand mesh with fewer elements than AutoGEM produces, and thus, reduce your solution time drastically.
1. Re-display all the entities. Click Display > Master Visibilities > All On > Accept . 2. Delete all the elements you just created. Click Edit > Delete > Entity . 3. Click Solids > All , followed by <Return>. 4. Click Points > All , followed by < Return>. Click OK when prompted. 5. Click Main > Geometry > Point > Single Points > Near . Note:
The Near option places a point on a specified entity near a projection point.
6. Click the bottom curve of the t_bracket. Then click the point directly above it, as shown in the following figure.
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Pick this reference point after selecting the curve
Pick this curve first
Figure 16 Create a point for hand mesh.
7. Repeat this process to create three more points - your model should look like the one shown in the following figure.
Figure 17 Create 3 more points.
8. Manually create elements. Click Main > Model > Elements > Solid > Brick > Curve . 9. Select the curves shown in the following figure to create the first face of the solid brick element.
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Pick these two curves
First face defined from curves.
Figure 18 Create the first face of the solid brick element.
10. Select the opposing curves. A solid brick element appears. 11. Create the element in the middle. Select Point from the menu. Select the 8 points consecutively to form the element in the middle. 12. Create the rest of the solids using either the Point or Curve option. When you are completed your model should look like the following figure. 13. Quit the application when finished. Click File > Quit > Yes > No .
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Figure 19 The finished hand mesh.
In the hand-created mesh, you have only four elements as compared to sixty created by AutoGEM. Which one do you think will solve faster?
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EXERCISE 4: Using Rigid Connections
Figure 20 A symmetric plastic container is cut in half.
Task 1.
Retrieve the container assembly and create a rigid connection.
1. Start Pro/ENGINEER. Set your working directory to the folder that corresponds to the name of the current module. 2. Retrieve the RIGID_CONNECTION.ASM located in the current working directory. The model is symmetric. All external load and constraints are also symmetric about the same center plane. 3. Click Application > Mechanica . Click Continue in the UNIT INFO dialog box. 4. Click Structure from the MECHANICA menu. 5. Click Idealizations from the STRC MODEL menu followed by Rigid Connections > Create . 6. In the Rigid Connection dialog box, accept the default name. 7. Click the Select icon under SURFACE(S) and select the both halves of the two holes surfaces as shown in the following figure.
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Select these surfaces
Figure 21 Select the indicated surfaces to create the rigid connection.
1. Click Done Sel > OK to finish. 2. Repeat the procedure on the other pair of tabs. The system displays the rigid connection icons as shown in the following figure.
Figure 22 The rigid connection icon.
3. Click Done/Return to finish. 4. Save and erase the model.
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EXERCISE 5: Using End and Perimeter Welds
Figure 23 The trailer frame assembly.
Task 1. Retrieve the frame assembly and create an assembly cut. Because the model is symmetric, the analysis can be performed on one quarter of the model. 1. Retrieve the FRAME.ASM located in the current working directory. 2. From the ASSEMBLY menu, click Insert > Cut > Extrude > Both Sides > Done . 3. Specify ASM_TOP as the sketching plane by selecting Sel by Menu . Pick ASM_TOP from the SELECTION TOOLS dialog box and hit the Select button. Select Okay. 4. Click Right and select ASM_RIGHT as the reference plane by selecting Sel by Menu . Pick ASM_RIGHT from the SELECTION TOOLS dialog box and hit the Select button. Select Okay . 5. Specify the appropriate references and sketch the section, as shown in the following figure.
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Select as four references and Sketch these 4 lines
Figure 24 Sketch the cut section.
6. Click
[Done] to finish.
7. Click Flip > OK to remove the geometry outside of the rectangular section. 8. Select Thru All > Done for depth option of both sides. 9. Click AutoAdd > OK so that the cut intersect all the components based on the depth definition. 10. Click OK to finish cut definition. Task 2. mode. Compress the mid-surface of the assembly in the ASSEMBLY
1. Enter Pro/MECHANICA Structure. Click Mechanica from the APPLICATION menu. Click Continue in the UNIT INFO window. 2. Click Structure > Model > Idealizations > Shells > Midsurfaces > Compress > Shell only .
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For University Use Only - Commercial Use Prohibited 3. The system highlights the MID_BAR.PRT and informs you that the shell model is not defined in this component. 4. Click Yes > ShowCompress . The system displays the shell models except the MID_BAR.PRT. Note:
The shell models have been created in all components except the MID_BAR.PRT. In the ASSEMBLY mode, you can compress shell models that have been previously created in PART mode. However you cannot create the shells in the ASSEMBLY mode.
Task 3.
Create the mid-surface of the shell model in part mode.
1. Retrieve the MID_BAR.PRT. 2. Enter Pro/MECHANICA Structure. Click Mechanica from the APPLICATION menu. Click Continue in the UNIT INFO window. Click Structure . 3. Click Model > Idealizations > Shells > Midsurfaces > Auto Detect > Compress > Shell only > ShowCompress . 4. Click Done/Return > Done/Return > Done/Return . Task 4. Compress the mid-surface of the assembly in the ASSEMBLY mode again. Because all the shell models have been created in all the components in the part mode, the system compresses and shows all components. 1. Activated the frame assembly window. Click Window > FRAME.ASM . 2. Click Structure > Model > Idealizations > Shells > Midsurfaces > Compress > Shell only > ShowCompress . 3. Reorient to the TOP view and zoom in on the area indicated in the following figure. Notice that there is a gap between the mid_bar shell and the cross_bar shell. 4. Click Done > Done/Return .
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For University Use Only - Commercial Use Prohibited Zoom in to this area.
Figure 25 The gap between two shell models.
Task 5. Create end welds at one end of a sheetmetal part, as shown in the following figure. Most end welds have been created for your convenience. 1. Reorient to the DEFAULT view and zoom in on the area indicated in the following figure.
Create end welds at this end.
Figure 26 Create end welds at one end of a sheetmetal part.
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For University Use Only - Commercial Use Prohibited 2. From the IDEALIZATIONS menu, click Connections > End Welds . 3. Specify the end weld surfaces: Select the hidden end surface of the sheetmetal MID_BAR.PRT, as shown in the following figure by using Query Sel . Select the other surface, as shown in the following figure.
Select these two surfaces
Figure 27 Select the end weld surfaces.
4. Create 3 more end welds on the end of the MID_BAR.PRT, using the same procedures. The system displays the weld icons as shown in the following figure. 5. Click Done/Return .
Figure 28 Create end welds on all 4 surfaces of the sheetmetal part.
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For University Use Only - Commercial Use Prohibited Task 6. Task 6. Compress the mid-surface of the assembly in the
ASSEMBLY mode again to verify the end weld connections.
1. From the IDEALIZATIONS menu, click Shells > Midsurfaces > Compress > Shell only > ShowCompress . 2. Notice that the mid_bar shell and the cross_bar shell are now connected. However, if you change your view to RIGHT there is a gap between the bracket part and the cross bar, as shown in the following figure.
Gap
Figure 29 The shell models of the bracket and the cross bar is not connected.
3. Click Done > Done/Return . Task 7. Task 7. Create a perimeter weld.
1. From the IDEALIZATIONS menu, click Connections > Perim Welds . 2. Specify the perimeter weld property. Click Current Props > Thickness . Accept the default. 3. Click New and specify the end weld surfaces: Select the hidden end surface of the bracket part as the doubler surface, as shown in the following figure using Query Sel . Select the edges of doubler to define weld location, as shown in the following figure. Click Done / Sel . Select the base surface, as shown in the following figure.
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Select these edges.
Select this surface as the Select the hidden bracket base surface surface as the doubler surface
Figure 30 Create the perimeter welds.
4. Click Done/Return . 5. Compress the model again to verify the connections. Click Done / Return > Done / Return . 6. Save and erase the model.
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MODULE SUMMARY
In this module you learned: How to simplify a design using with idealizations. How to simplify a design using shell models. How to AUTOGEM elements in Independent mode. How to define rigid connections. How to define end and perimeter welds.
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Module
Optimizing Models for Analysis

In this module, you learn how different geometry creation techniques used in Pro/Engineer integrate with Pro/MECHANICA. You also learn Pro/Engineer techniques that reduce calculation time in Pro/MECHANICA while maintaining accurate results.
Objectives
After completing this module, you will be able to: Create Pro/ENGINEER models for analysis. Use shell elements, solid elements, and regions. Model structural assemblies. Create 2-Dimensional models.
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INTEGRATED MODE MODELING

The first step in the Pro/MECHANICA analysis process is part creation. You need to build a part before Pro/MECHANICA can analyze and optimize it. The feature creation techniques you use when you build your part will have a significant positive or negative influence on your modeling experience. The integrated mode of Pro/MECHANICA unites geometry creation with analysis. Consequently, you need to take into consideration downstream activities such as analysis, sensitivity, or optimization as you build your part. You need to think modeling, not just geometry, and you need to plan ahead to increase efficiency. To promote a flexible approach to part modeling, Pro/MECHANICA enables you to define your model as either a solid or shell. The way you define your model determines the type of elements Pro/MECHANICA uses to model your part.
Solid Modeling
A solid model is a part that you model using solid elements like tetrahedrals, bricks, or wedges. In Integrated Mode, Pro/MECHANICA uses only tetrahedrals for solid modeling. As a rule, you use solid modeling when your part is as thick and wide as it is long. Your parts thickness, however, can vary non-uniformly. In Integrated Mode, element creation is automatic and transparent, with analysis beginning immediately after the mesh is created. Although rare, there are times when you may want to investigate the mesh.
Modeling Shells
A shell model is a part that you model using shell elements like triangles and quadrilaterals. Typically, you use shell modeling when your part is relatively thin compared to its length and width. To meet Pro/MECHANICAs criteria for shell models, your part must have either a constant or a semi-constant thickness
Defining Midsurfaces
Pro/MECHANICA does not support shell elements that vary non-uniformly in thickness (tapered), but your part can have multiple constant uniform thickness areas.
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NOTES
For University Use Only - Commercial Use Prohibited Using shell elements can result in models with fewer elements that will run faster and require less disk space than a solid model. For Pro/MECHANICA to treat your part as a shell model, you typically need to complete a three-step procedure. The purpose of this procedure is to direct Pro/MECHANICA to treat the part as a shell model and to specify how shell elements are constructed. The following is a summary of the procedure:
Defining shell pairs The first step is to define pairs of solid
surfaces which will be compressed to form the mid-surface of the model. A surface/shell pair consists of two or more parallel surfaces on opposite sides of a volume.
Test the pairs compression Once the pairs have been defined,
MECHANICA attempts to compress all the pairs to a continuous surface model representing the middle of the part. You can and should review this mid-surface model to ensure that it has compressed to the desired form, i.e. you should test the compression.
Verify the Use Pairs setting To ensure that Pro/MECHANICA treats
the model as a shell, you should verify that the Use Pairs setting is clicked. Pro/MECHANICA uses this setting to determine whether to perform solid or shell modeling.
Figure 1 A shell model.
Optimi zing Mod els fo r Anal ysi s
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NOTES
For University Use Only - Commercial Use Prohibited Automatically Create the Midsurfaces
If you use feature creation methods that implicitly contain a thickness dimension, you can pair these surfaces automatically using the Auto Detect option. Feature creation methods that implicitly contain thickness type dimensions are: Shells Ears Sheet Metal Ribs Thin Protrusions
Suppressing Cosmetic Features

Pro/ENGINEER allows you to create parts with great detail and precision. However, there are many features in a model that are irrelevant in analysis computations. For instance, a part may include a company logo etched on the surface; although this detail is important for cosmetic purposes and drawings, it has virtually no effect on stress in the model. Sending features like this to Pro/MECHANICA serves only to increase solution time and disk space requirements because AutoGEM has to generate many extra elements to capture these structurally insignificant features. These features should be suppressed before you run an analysis.
Preparing Your Part for Static Analysis
To help reduce the number of elements that AutoGEM makes, you can de-feature a model. Features that you might typically suppress are: Small Cuts and Grooves Locating Holes and Small Counterbores Logos Rounds and Chamfers Ejection Bosses
Whether the features in a part are purely cosmetic or structurally significant; AutoGEM gives them equal importance and will create elements to capture every small detail. Normally, these types of features can be removed from the part before the start of a run. This can result in a drastic improvement in analysis performance, such as faster run times and smaller disk space requirements without affecting the solutions accuracy. Usually it is obvious which features are important to the analysis and which are purely cosmetic. However, it is up to the user to determine which features are truly significant to the analysis.
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NOTES
For University Use Only - Commercial Use Prohibited Geometric Symmetry
Another way to drastically reduce run time and disk requirements is to take advantage of symmetry. It is important to note that your model must not only have symmetrical geometry, but the loads and constraints must be symmetric about the cutting plane as well. When this is the case, it is a good idea to prepare your geometry before you begin the analysis process. In Pro/ENGINEER, you simply cut away the symmetric portions of the model. Many models can be cut into halves, quarters, or even smaller sections if the parts geometry, constraints, properties and loads are all symmetric about a cutting plane. Another time saving type of symmetry supported by Pro/MECHANICA is Cyclic Symmetry. Cyclic symmetry is fairly specialized and is often used for analysis of rotating machinery such as turbine blades, pump impellers etc.
Creating Regions
Regions are used to apply loads and constraints to particular footprints on a model. Surface Regions may be created in Pro/MECHANICA to apply loads and constraints to specific localized surface areas. Surface region creation is a two step process.
Defining the region boundary
is accomplished either by creating a datum curve to represent the boundary or by sketching the boundary on the fly. A separate datum curve feature must be created for each region that you wish to define. You cannot define multiple boundaries with one datum curve feature. consists of splitting the model surface into regions using the boundary
Creating the region
As of Release 2000i, features such as Datum Points, Curves and Coordinate Systems can be created either in Pro/MECHANICA or in Pro/ENGINEER. You must create your regions before defining Mid Surfaces for Shell Modeling, because assigning regions can invalidate existing shell pairs. While Surface Regions may be created in Pro/MECHANICA to apply loads and constraints to specific localized surface areas, similar functionality allows solids to be split into three-dimensional regions. This is done by creating Volume regions. Creation of the Volume Region simulation feature is similar to that of the Cut feature in Pro/ENGINEER. It can be created in
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NOTES
For University Use Only - Commercial Use Prohibited part or assembly models and inherits the material properties from the solid geometry within which they are created. Since results may be viewed by volume, these regions are beneficial in preparing a model for postprocessing, making it easier to view internal stresses, strains, etc. Since elements must be created within a volume region, they can also be used as an effective means of increasing mesh density when required.
Structural Assemblies
While understanding how parts behave individually is important, many times these parts are bolted or welded to other parts in an assembly. Their interaction may require analyzing the parts joined together in a structural assembly. You must understand how to prepare an assembly for a shell model and for a solid model, as well as how to take advantage of the differences between shell and solid models.
Layers and Groups
Layer functionality is fundamental to organization and working efficiently in Pro/Engineer. When a model is transferred to independent Pro/MECHANICA you have the option of transferring Pro/E layers to Pro/MECHANICA groups. The advantages of groups in independent mode are numerous. Groups allow ease of use when clicking or manipulating entitiesespecially elements. This is very useful in both model preparation, as well as in post-processing. For example, if you want to view the stress fringe results for only one part in an assembly (as opposed to viewing the results on the entire assembly), you can view results by group.
Mixed Meshing
In some cases, you combine different element types. This is done simply by providing Pro/MECHANICA with the geometry associated with the desired element type and by verifying settings. When MECHANICA, Settings , Use Pairs is checked on, any existing shell pairs will be meshed with shell elements, while any remaining unpaired part geometry will be meshed with solid elements. This functionality works as well on single parts that are partially paired. Mixing element types is sometimes critical in balancing time savings with required accuracy.
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NOTES
For University Use Only - Commercial Use Prohibited Interfacing Solids and Shells
How does Pro/MECHANICA handle the intersection of the shell and solid elements? When the analysis is run in Integrated mode, AutoGEM will automatically place Links on the edges where shell and solid elements intersect. Links ensure identical displacements at these locations. If you were to view a mixed-meshed model in Independent mode, the interface between the shells and solids would appear as shown in the following figure.
Figure 2 A mixed-meshed model.
The solids are the dark gray, the shell element on the gusset is light gray, and the links are shown as dotted lines at the intersection of the shells and solids. They can be created automatically or manually in Independent modes. The links are very convenient and are used commonly, but do cause an increase in run time and can affect accuracy. Therefore, there is an alternative to links when combining solids and shells, or beams and shells for that matter. The alternative is to create transition elements between the shells and solids. This is known as masking. Usually the mask elements are made of the same material as the solids they interface with. They need to be very thin so they do not add significant stiffness to the model.
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NOTES
Modeling in 2-D
It is possible to define 2-D model types in Pro/MECHANICA Integrated mode. For Structure, the available model types are Plane Strain, Plane Stress, and 2-D Axisymmetric. For the Thermal module the available model types are 2-D Plate, 2-D Unit Depth, and 2-D Axisymmetric. The default model type is 3D. The suggested procedure to define a model to be used in a 2-D analysis using Integrated mode is as follows:
Define a reference coordinate system - To prepare the model for a 2-
D analysis, a reference coordinate system must be created before the model type is changed. The coordinate system can be created in Pro/ENGINEER or in Pro/MECHANICA.
Select the model type - The model type should be selected before any
loads, constraints, or material properties are defined on the model. Changing the model type from 3-D to 2-D causes all modeling entities to be deleted. The available model types are:
3-D - Use this option if any aspect of the model goes out of the
WCS XY plane. Most of your models will be 3D. This is the default model type.
Plane Stress (Structure) or 2-D Plate (Thermal) - Model
should be thin and all modeling entities (properties, constraints, loads, and geometry) must lie in the XY plane of the reference coordinate system.
Plane Strain (Structure) or 2-D Unit Depth (Thermal) -
Model should be sufficiently long such that strains in the transverse z direction are negligible. All modeling entities must lie in the XY plane of the reference coordinate system.
2-D Axisymmetric - Geometry and all modeling entities should
be symmetric about an axis. All modeling entities must lie in the positive x portion of the XY plane of the reference coordinate system. Select the geometry and reference coordinate system - Once a model type is selected, the user is required to select the geometry and reference coordinate system for the model. If either selection is invalid, the model type will not be changed.
Define loads and constraints - Once the model type has been
selected, the loads and constraints can be defined. The model should only be loaded in the XY plane.
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NOTES
For University Use Only - Commercial Use Prohibited

Define shell properties - For a Plane Stress or 2-D Plate model, shell
properties must be defined to assign a thickness to the model. This step is not necessary for other 2-D model types unless shell elements will be used. If shell properties are not assigned to the plane stress surface, an error will be found during error checking.
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Goal
To learn effective techniques for preparing thick and thin parts for analysis.
Method
In Exercise 1, you suppress the purely cosmetic features on your part in preparation for analysis. In Exercise 2, You create a shell model from a T-bracket and create the midsurfaces both manually and automatically. In Exercise 3, you use Auto Detect to shell model the handle part. In Exercise 4, you create simple sketched and projected regions in order to understand regions and their affects on pairing. In Exercise 5, you prepare an assembly for a shell model and for a solid model.
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NOTES
EXERCISE 1: Suppressing Structurally Insignificant Features
Figure 3 A realistic handle.
Task 1.
Open the part handle.
1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open the HANDLE.PRT. The model should appear as shown in the figure above. Task 2. Create and review the elements in the Independent Mode. Send the fully featured model to Independent Pro/MECHANICA and use AutoGEM to find out how many elements are needed to mesh the part. This will give you an indication of how model complexity can affect the number of elements, and consequently solution time, and disk space requirements for a fully detailed part. 1. Click Applications > Mechanica . Click Continue in the UNIT INFO window
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NOTES
For University Use Only - Commercial Use Prohibited 2. Before enter the Independent mode, verify that the Use Pairs setting is turned off. Recall that this is found under Settings . 3. Enter the Independent mode. Click Independ MEC > Structure . Confirm when prompted. 4. Save the model with a new name when prompted. Enter [handle_2] as a new name. Click Accept . 5. Click View > Iso >Done . The model should appear as shown in the following figure. 6. Note that all the features were transferred, and that you have a clean single volume part ready for AutoGEM. To confirm that you have a single volume, click Review > Model Summary from the tool bar and verify that there is only one volume. Click OK when finish.
Figure 4 Handle part in the Independent mode.
Task 3.
Mesh the part using AutoGEM.
1. Generate the elements, click Model > Elements > AutoGEM > Volume > All . Then press <RETURN>. 2. Record the number of elements and how long it took from the AUTOGEM SUMMARY dialog box,.
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NOTES
For University Use Only - Commercial Use Prohibited The number of elements_______________ Time _______________ Element type ______________ Reason for generating this type of element ____________ Click OK to finish. 3. To get a better view of the elements, turn off the visibility of all the entities except the solid elements. Click Display > Master Visibilities from the DISPLAY pull-down menu. 4. Click All Off from the bottom of the form. 5. Select Solids from elements. Click Accept . 6. Shade the elements. Click Display > Settings from the DISPLAY pull-down menu. Select Smooth Shade for the DISPLAY TYPE. Select Fine for the Display Quality. Select Elements for the SHADE. Select Shrink All Elements check box. Set the Shrink Factor to 0.2. 7. Accept the settings. 8. Click File > Quit from the top tool bar. Do not save the model.
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NOTES
For University Use Only - Commercial Use Prohibited Locator Holes
Name Plate recess
Chamfers
Figure 5 Suppress these features.
Task 4.
Suppress the structurally insignificant features.
1. Start Pro/ENGINEER and set the working directory to the folder that corresponds to the name of the current module. 2. Retrieve the handle part. 3. Suppress the locator pin holes, the chamfers, and the recess. Click Feature > Suppress > Clip , select the chamfer from the MODEL TREE, followed by Done . The system suppresses all the subsequent features. Task 5. Transfer to Independent Mode and AutoGEM.
1. Repeat earlier steps to transfer the part to Independent Pro/MECHANICA and AutoGEM it. Rename it in MECHANICA to any name you want. Record the number of elements and time to mesh. Number of Elements ________ Time to mesh ___________. 2. Compare this mesh to the previous result.
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NOTES
For University Use Only - Commercial Use Prohibited 3. Click File > Quit. Do not save the model. Note:
When performing a thermal or modal analysis, the round and the holes may become insignificant and can be suppressed as well, further reducing the element count.
Task 6. Reduce the element count by removing symmetric geometry. This technique is only valid under symmetric situations, which will be discussed in detail in later chapters. 1. Start Pro/ENGINEER and set the working directory to the folder that corresponds to the name of the current module. 2. Retrieve the handle part. Notice that the features remain suppressed. 3. Restore all the suppressed features. Click Feature > Resume > All > Done . 4. Close examination of the part shows that it is symmetric about DTM3. When the load and constraints are also symmetric about DTM3, the model can be cut in half. 5. Cut the part in half at DTM3. Click Insert > Cut > Extrude > One Side > Done . 6. Sketch on the bottom horizontal surface of the handle, with DTM3 as the TOP horizontal reference plane. 7. Sketch a rectangle to encompass the redundant geometry, as shown in the following figure. 8. Click [Done] to exit the sketching environment.
9. Click Flip if necessary, so that the arrow points to the inside.
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NOTES
Figure 6 Sketch the rectangle to cut away the geometry.
10. Select Thru All for the Depth, then click Done> OK . The model should appear as shown in the following figure.
Figure 7 Half of the handle.
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NOTES

When you AutoGEM this fully featured half model, you would get about half the number of elements. Using these simple, but powerful, techniques will drastically reduce analysis time.
Task 7. (Optional) Automesh in the Independent Mode and compare the element count. 1. Repeat earlier steps to transfer the part to Independent Pro/MECHANICA and AutoGEM it. Record the number of elements and the time below. 2. Number of Elements ________ Time to mesh _________. 3. Click File > Quit from the top tool bar. Do not save the model.
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NOTES
EXERCISE 2: Shell Modeling by Defining Midsurfaces

Task 1. Retrieve the T-Bracket. Manually create the first set of pairs. Define the pairs for the base of the bracket. 1. Start Pro/ENGINEER and set the working directory to the folder that corresponds to the name of the current module. 2. Retrieve the T_BRACKET.PRT. 3. Enter MECHANICA. Click Applications > Mechanica . Click Continue > Structure . 4. To prepare the model for shell creation. Click Model > Idealizations > Shells . 5. Click Midsurfaces > New , accept the default Constant . Select the two surfaces, shown in the following figure to define the first and second set of pairs. Use Query Sel as necessary.
Pair #2
Pair #1
Figure 8 Create two surface pairs.
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NOTES
For University Use Only - Commercial Use Prohibited Task 2. Test the midsurface compression to verify that you have defined the pairs correctly. 1. Click Compress from the MIDSURFACES menu, then click Shells only . 2. To display the midsurface geometry, click ShowCompress . The pairs get compressed to their midsurfaces and displayed in yellow.
Figure 9 The midsurface.
3. To display the original geometry, click ShowOriginal . 4. Click Show Both to display both the original geometry and the compressed midsurface simultaneously. 5. Click Done/Return twice when finished. The meshed model can be visualized in the Independent Mode, as shown in the following figure.
Figure 10 Midsurface in the Independent Mode.
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NOTES
For University Use Only - Commercial Use Prohibited Task 3. Use the Auto Detect option to generate midsurfaces in the T Bracket. 1. Delete all existing pairs. Click Model > Idealizations > Shells > Midsurfaces > Delete > Select All > Yes . 2. To automatically create the pairs, click Auto Detect from the MIDSURFACES menu. 3. Pro/MECHANICA highlights the pairs that it was able to automatically create. One surface in each pair is red and the other is yellow. 4. Test the compression. Click Compress > Shells only > ShowCompress from the MIDSURFACES menu. 5. The midsurface displays in yellow.
Figure 11 Midsurface compressed from Auto Detect.
6. Display the original geometry as necessary. 7. Click Done > Done/Return> Done/Return . 8. Save and erase the file. Click File > Save. Click Applications > Standard > File > Erase > Current > Yes .
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NOTES
EXERCISE 3: Shell Modeling Using Auto Detect

Task 1. Retrieve the handle part and attempt to Auto Detect and compress the surface pairs. 1. Open the HANDLE.PRT. Resume all the suppressed features. 2. Click Applications > Mechanica > Structure > Model > Idealizations > Shells > Midsurfaces . 3. Click Auto Detect > Compress > Shell Only . The system informs the unpaired geometry. 4. Click Done/Return twice. Task 2. Suppress the counterbores.
1. Click Applications > Standard . Display the MODEL TREE if necessary. 2. Suppress the unpaired geometry. Click Feature > Suppress > Clip , select the HOLE ID 221 from the MODEL TREE, followed by Done . The system suppresses all the subsequent features. The handle should appear as shown in the following figure.
Figure 12 The handle without unpaired surfaces.
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NOTES
For University Use Only - Commercial Use Prohibited 3. Enter MECHANICA and Auto Detect the midsurfaces. Note that not all the surfaces paired. The unpaired geometry are the two separately created rounds. 4. Manually pair the inner and outer rounds. Click New from the MIDSURFACES menu. Accept the default Constant , then select the inner and outer round surfaces. 5. Compress again. The model should appear as shown in the following figure.
Figure 13 The compressed handle.
6. Click Done/Return twice. 7. Switch to the standard application. Save and erase the model.
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NOTES
EXERCISE 4: Creating Regions

In order to constrain or load a specific portion of a parts surface, you need to create a region on the surface. You will use the simple 254 x 254 x 25.4 steel plate and create circular regions on each side of the plate where you want to apply loads.
Figure 14 Create regions for applying the load.
Task 1.
Create the first datum curve.
1. Open the REGIONS.PRT. 2. Enter Pro/MECHANICA Structure. Click Application > Mechanica > Continue > Structure . 3. Create the datum curve on the top of the plate. Click Model > Features > Datum Curve > Create > Sketch > Done . 4. Select the top surface of the plate as the sketching plane. 5. Flip the arrow so it points out of the plate, followed by Okay. 6. Click Bottom , and pick the bottom side of the plate as the horizontal reference. 7. Select the top side and the left side for sketching references and sketch the section as shown in the following figure.
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NOTES
Figure 15 The sketched section.
8. Finish the curve and switch to the default view. Click followed by OK . Task 2. Create the second datum curve.
[Done],
1. Create a second datum curve on the bottom of the plate. From the SIM FEAT OPER menu, click Create > Sketch > Done . 2. Select the bottom surface of the plate as the sketching plane. 3. Specify the appropriate sketching references and sketch the section as shown in the following figure.
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NOTES
Figure 16 Sketch another curve on the other side.
4. Click OK to complete the curve. Task 3. Use the datum curves you to define the regions.
1. Create a surface region. From the SIMULAT FEATS menu, click Surf Region > Create > Select > Done . 2. Select the top datum curve. 3. Select the top surface as the surface to split, followed by Done Sel >
Done > OK.
4. Follow the same procedure to create the bottom region. 5. Verify the defined regions. From the VIEW drop-down list, click Model Setup > Mesh Surface . Select the top and bottom circular regions. The model should appear as shown in the following figure. Note:
Mesh surface in the previous step is a Pro/ENGINEER functionality for visualizing surfaces. It has nothing to do with element generation.
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NOTES
Figure 17 Visualize the surface regions.
6. Close the MESH dialog box and repaint the screen. Task 4. Manually define the midsurface.
1. Click Done/Return . From the STRC MODEL menu, click Idealizations > Shells > Midsurfaces > new . 2. Ensure that the model is shaded. Select the top surface of the model using Query Sel (outside the circular region). 3. Select the bottom surface of the model (outside the circular region). 4. Click Done Sel when finished. 5. Test the compression. Click Compress > Shells only . Notice the error message in the message box regarding unpaired surfaces, and also that the COMPRES MDL menu looks different than it usually does. Note:
When you created the regions, you actually split the surfaces. The top and bottom faces now each consist of two surfaces. You need to include all four surfaces in the pair definition.
6. From the Midsurfaces menu click Edit > Edit Pair . Pick either the top or bottom surface. Shade the model as necessary.
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NOTES
For University Use Only - Commercial Use Prohibited 7. Click Add Surface . The unpaired surfaces are not displayed in red and yellow. 8. Select the top circular region and the bottom circular region. Notice the color change. 9. Click Done/Return from the EDIT PAIR menu. 10. Test the compression. Click Midsurface > Compress > Shells only > Show Compress . The entire model should appear as shown in the following figure.
Figure 18 The compressed shell midsurface.
Task 5. Automatically define the Midsurface. The plate was created as a thin feature, you can automatically create the pairs. 1. Delete the existing shell. From the MIDSURFACES menu, click Delete > Select All to delete the surface pairs that you have already manually defined. 2. Confirm when prompt. 3. From the MIDSURFACES menu, select Auto Detect to automatically pair the part. 4. Test the compression. Notice how Auto Pair automatically included the regions you defined. 5. Return to the top-level menu. Switch to Pro/ENGINEER. 6. Save and erase the model.
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NOTES

You will see how Pro/MECHANICA interprets loads and constraints that are applied to overlapping regions in later sections. But for the time being, you just need to know how to define them.
EXERCISE 5: Creating Volume Regions

Volume regions can be created in part or assembly models. They inherit the material properties from the solid geometry within which they are created. Since results may be viewed by volume, these regions are beneficial in preparing a model for post-processing, making it easier to view internal stresses. strain, etc.
Task 1.
Open the part VOLUME_REGION.PRT.
1. Open VOLUME_REGION.PRT. 2. Enter Pro/MECHANICA Structure. Click Applications > Mechanica > Continue > Structure . Task 2. Create a volume region.
1. Click Model > Features > Volume Region > Create > Extrude > Done . 2. Select either end face of the shaft as a sketching plane. 3. Click OK to accept the direction of feature direction into the cylinder, followed by Default . 4. In Sketcher, click [Use edge]. Click both semi-circular edges to form a circular sketch. 5. Click [Done].
6. Click Done to accept the default depth option Blind . Enter [10]. 7. Click OK to finish the definition. Switch to hidden line if necessary, to see the created region. 8. Verify the defined region. Click View > Model Setup > Mesh Surface .
NOTES
For University Use Only - Commercial Use Prohibited Select the surfaces of the created region. The system meshes the selected surfaces. Click Close when finished. 9. Save and erase the model.
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NOTES
Exercise 6: Structural Assemblies
Figure 19 the Gusset Assembly
Task 1.
Idealize the GUSSET.PRT as a shell.
1. Open the GUSSET.PRT. 2. Enter Pro/MECHANICA Structure. Click Applications > Mechanica > Continue > Structure . 3. Select surface pair to create the midsurface. Click Model > Idealizations > Shells > Midsurfaces > New > Constant . Select the paired surfaces. Spin the model as necessary. 4. Click Done/Return > Done/Return > Done/Return . 5. Switch to the standard application. 6. Save the model. Task 2. Retrieve the gusset assembly.
1. Retrieve the gusset assembly. This model is created using assembly constraints, such as MATE and ALIGN. The GUSSET.PRT has been idealized as shell. The plate is not idealized as shell, hence a solid.
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NOTES
For University Use Only - Commercial Use Prohibited 2. Verify that the assembly units have been set to mm N s as necessary. Click SetUp > Units , select mm N s , click Set . Task 3. Mix idealize the model.
1. Enter Pro/MECHANICA Structure. Click Applications > Mechanica > Continue > Structure . 2. Click Model > Idealizations > Shells > Midsurfaces > Compress > Shells and Solid > Show Compress . The model should appear as shown in the following figure.
Figure 20 An assembly with mixed idealizations.
3. The interface between the shell GUSSET.PRT and the plate parts are handled by the system. Had you created and run an analysis in the Independent mode, then the system will create links between the solid and shell idealization. 4. Switch to Pro/ENGINEER and erase the model.
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NOTES
EXERCISE 7: Modeling a 2-D Plane Stress Plate

Task 1. Define the PLATE_2D.PRT as a plane stress model.
1. Open the PLATE_2D.PRT. 2. Switch to the default view. Notice that the back surface of the model lies in the X-Y plane. 3. Enter Pro/MECHANICA Structure. Click Applications > Mechanica > Continue > Structure . 4. Specify the model type. Click Model > Model Type . 5. In the MODEL TYPE dialog box, click Plane Stress . The Select Geometry and Select Coordinate System option becomes available. 6. Try to define the Plane Stress model using the front surface. Click Select Geometry . Select the front surface of the model, followed by Done Sel . Click the Select Coordinate System . Select the only available coordinate system, followed by Done Sel . Click OK to finish. The system informs that the surface does not lie in the X-Y plane. Close the information window. 7. Define the Plane Stress model using the back surface. Click Select Geometry> Unsel Last . Select the front surface of the model to remove. Select the back surface of the model, followed by Done Sel . Click the Select Coordinate System and select the only available coordinate system. Click OK > Confirm to finish. The model is defined as a plane stress model successfully. Task 2. model. Define shell properties to assign material and thickness to the
1. Click Idealization > Shells > New . The SHELL DEFINITION dialog box appears.
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NOTES
For University Use Only - Commercial Use Prohibited 2. Define the shell: Accept the default name. Click [Select]. Select the same surface that is used to define the plane stress model by using Query Sel , followed by Done Sel . Accept the default type Simple . Enter a thickness of [3]. Assign the material properties to the model. Click More next to the MATERIAL drop down list. Click AL6061 from the list. Add it to the model. Click OK to finish material definition. Click OK to finish shell definition. 3. Click Done/Return twice to return to the top-level menu. 4. Switch to the standard application. 5. Save and erase the model.
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NOTES
MODULE SUMMARY
You have learned: How to simplify a model for analysis by suppressing features and using symmetry. How to shell models using a midsurface. How to create regions for loads and constraints. How to prepare an assembly for a shell model and for a solid model. How to define a model to be used in a 2-D analysis using Integrated mode.
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Module
Assigning Material Properties

In this module, you learn how to assign material properties to a part and how to define a library of material properties.
Objectives
After completing this module, you will be able to: Assign structural and thermal properties to parts. Define linear and nonlinear properties. Create materials libraries. Define temperature-dependent material properties. Edit and delete material properties.
Page 4-1
NOTES
BASIC MECHANICS OF MATERIALS

You must have a thorough understanding of relevant engineering units when running analyses Pro/MECHANICA. What is the value of density? What are its units? What is the value of Young's Modulus? What are its units? What is Poisson's Ratio, and what are its units? What are the units of Coefficient of Thermal Expansion?
Yield Stress
Ultimate Stress Stress Youngs Modulus is the Slope off the linear portion of Stress/Strain Curve.
Strain
Figure 1: Strain-Stress Curve
Young's Modulus
The previous graph shows a sketch of a general stress-strain curve. These curves are created by applying an increasing axial load to a test specimen and by measuring the load and deformation simultaneously. From this data, the stress (the vertical axis) can be plotted against the strain or percent elongation (the horizontal axis). As the axial load is increased, the strain increases in a linear fashion. The slope of this line is called Young's Modulus. The units are stress (load/area) over strain (change in length/original length).
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NOTES
Poisson's Ratio
Poisson's Ratio is the ratio of lateral strain to longitudinal strain. Its value is between 0.25 and 0.33 for most metals. For example, if you had a round bar of steel that was 250 mm long and 25 mm diameter, with a Poisson's Ratio of 0.3, and if you pulled on it so that it deformed 25 mm axially from 250 mm to 275 mm, the resulting change in diameter would be:
= Poissons Ratio =
lat 25 = 0 .1 where axial = 250 axial

d , d and d are initial diameter d
so lat = = 0.3 0.1 = 0.03 where lat = and the change of diameter respectively. then
d = lat d = 0.03 25 = 0.75mm . The new diameter would be: d new = d d = 25 0.75 = 24.25mm Most materials (when unrestrained) expand when heated and contract when cooled. The strain due to a 1 degree temperature change is known as the coefficient of thermal expansion, which is the change in length over original length over temperature. The units are strain units over in m temperature: , in F m C Failure begins whenever the part's actual stress exceeds its Yield Strength. Pro/MECHANICA always assumes that the Young's modulus has a constant slope. Analyses that only consider the straight-line portion of the stress-strain curve (constant Young's Modulus) are considered linear. If the maximum stress in your model exceeds the material's Yield Stress, then the reported values are not accurate.
Ass igning Mat e ria l Propert ies
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NOTES
For University Use Only - Commercial Use Prohibited Pro Mechanica is a linear Code.
Ultimate Stress
Stress
Yield Stress
Youngs Modulus is the Slope of the linear portion of Stress/Strain Curve.
Strain
.
Figure 2 Linear elastic model.
Systems of Units
When changing the units system for a model, you have the option to convert existing numbers or interpret existing numbers. If you build a part in IPS (Inch-Pound-Second; Pound in this system assumes Pound Weight) that is 10 inches long, and then switch to mmNS using the Convert Existing Numbers option (same size), then Pro/ENGINEER would re-dimension your model to be 254mm long. If you choose the Interpret Existing Numbers option (same dimensions), then your part would become 10mm long. IPS and I-lbm-S (Inch-Pound Mass-Second) are different unit systems. The unit for mass in IPS is lbf-sec^2/in, whereas the unit for mass in Ilbm-S is lbm. These two systems differ as to whether your model is mass driven or force driven. If your model is force driven, then your units of mass are considered to be in Weight density which differs from Mass density by the gravitational constant, gc= 386.4.
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NOTES
Goal
To create a library of material properties and assign the properties to a model.
Method
In Exercise 1, you assign structural and thermal material properties to a part. In Exercise 2, you review some basic mechanics of materials. In Exercise 3, you add your own material to the library. In Exercise 4, you edit a material properties file and define temperature dependent material properties.
EXERCISE 1: Assign Structural and Thermal Material Properties

Task 1. Define a system of units for your model in Pro/ENGINEER. By default, Pro/ENGINEER assumes all models are in units of inches-pounds mass-seconds-Fahrenheit. 1. Set your working directory to the folder that corresponds to the name of the current module. Open the T_BRACKET.PRT. 2. Change this setting, click Setup > Units . 3. The dialog box displays the available systems of units. Change to millimeter Newton Second (mmNs) as necessary. 4. Enter Pro/MECHANICA, click Applications > Mechanica. (Note the units.) 5. Assign the material properties of steel to this part. Click Structure > Model > Materials . 6. The material window appears. Add STEEL to the MATERIAL IN THE MODEL.
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For University Use Only - Commercial Use Prohibited 7. Click Assign> Part, select the part. Click Done Sel . Task 2. Review the properties.
1. Select STEEL from the Material in model column and click Edit . 2. The MATERIAL DEFINITION dialog box for Steel appears and gives you the opportunity to review the values for: Density Cost Per Unit Mass Young's Modulus Coefficient of Thermal Expansion Poisson's Ratio
3. Select the Failure Criterion tab in the Material Properties dialog box. Select the Distortion Energy (vonMises) option from the drop-down list. 4. Enter [231] for the TENSILE YIELD STRESS. 5. Accept the default N / mm^2 unit from the drop-down list. 6. Click OK when finish.
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EXERCISE 2: Adding New Materials to the Library

Task 1. Create a new material that is not in the Pro/MECHANICA Material library. Assign this new material to the T-Bracket. Save this new material to your own custom material library. 1. Click New , to open the MATERIAL DEFINITION dialog box. 2. Select the units you want and enter the properties listed below. You could flip from unit to unit by selecting it, MECHANICA will do the conversion accordingly.
Material Name Description Mass Density Young's Modulus Poisson's Ratio Coeff of Thermal Expansion NICKEL Nickel Material Properties 8802 kg/m3 or 17.08 slug/ft3 206843 N/ mm^2 or 30E06 psi 0.31 1.296E-05 /C or 7.2E-06 /F
3. Click OK . 4. Add the new material to the library. In the MATERIAL dialog box, click on the arrow pointing toward MATERIAL IN LIBRARY. Click Yes to add the property to library. 5. Assign the new material to the part Select the new material. Click Assign > Part . Click the part. Click DoneSel > Yes .
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EXERCISE 3: Edit and Delete Materials

Task 1. Edit all the AL6061 in the Material Library and make Poissons Ratio temperature dependent. 1. Select AL6061 from the Library column and click on the arrow to place it in the model column. 2. Select it and click Edit . 3. In the Material Properties data form for POISSON'S RATIO type, click the function button, f(x) . 4. In the function definition form, enter the name [Poisson_Function], and the description [Temperature Dependent Poissons Ratio]. 5. Select Table from TYPE drop-down list. Select the temperature drop-down list, and notice that temperature is the only option available. Material properties can only be dependent upon temperature. 6. Click Add Row . In the Enter Rows dialog box, click OK to accept the default values. 7. Enter table values as shown below in the following figure.
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Figure 3 Enter the table values. 8. Click OK . Note the value of Poissons Ratio is now the Poisson_Function you defined. 9. Click OK to accept. 10. Click on the left arrow to place it back in the library. 11. Click Yes > Yes to overwrite existing library. 12. Close the dialog box. Save the model. 13. Return to Pro/ENGINEER and erase the model.
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MODULE SUMMARY
You have learned: How to assign structural and thermal properties to a part. How to create a materials library. How to edit material property files. How to define temperature dependent material properties.
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Module
Applying Constraints
In this module, you learn how to apply different types of constraints to your model.
Objectives
After completing this module, you will be able to: Create different types of constraints. Constrain models in Pro/MECHANICA. Set the active coordinate system.
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INTRODUCTION
Constraints and loads are Pro/MECHANICA features that simulate the realworld environment that you expect your model to encounter. Pro/MECHANICA uses this information to calculate the behavior of your model during analyses and sensitivity studies. Your model's optimal shape and mass will depend on the constraints and loads you define. A Constraint is an external limit on the movement of a structure or portion of a structure. A load is a force, pressure, acceleration, velocity or moment you apply to a structure or portion of a structure. The way you constrain your model differs depending on whether you are working in Structure or Thermal. For Pro/MECHANICA to perform most types of analyses, you must apply at least one constraint to your model. When you apply constraints in Integrated Mode, Pro/MECHANICA associates the constraints with the part's geometry rather than the elements it will create during the analysis phase. Before you add constraints to your model, be sure you have all the necessary geometry and references you need in place. Pay particular attention to the following items:
Coordinate Systems If you plan to make a constraint relative to
any coordinate system other than the World Coordinate System (WCS), then that coordinate system needs to be in place and active. You can specify constraints relative to a user-defined coordinate system of the following types:
Cartesian
Cylindrical Spherical Datum Points If you plan to constrain a specific point on an exterior curve or surface, your part needs to include a datum point at that location. As we will discuss later in this class, this method is generally not recommended because it causes singularities (infinite stress) to occur in your model. However, under rare circumstances, you may choose to use this option. Regions If you plan to constrain a specific surface region, your model needs to include the datum curve contours defining that region.
In defining constraints for a Structure model, your goal is to fix portions of the part's geometry so the part cannot move or can only move in a specific
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For University Use Only - Commercial Use Prohibited way. Pro/MECHANICA assumes any unconstrained portion of your part is free to move in all directions available for that model type. Fixing your part in space provides Pro/MECHANICA with a basis for understanding how to treat your part. For most Pro/MECHANICA analyses, the software evaluates the behavior of your part and the stresses it experiences in terms of the constraints you apply. Constraints can also be used to reduce model size by allowing you to take advantage of symmetry.
Edge Constraints
Before you can run an analysis, you need to constrain your model. The first step in applying constraints to your model is to select the type of entity you want to constrain. The next step is to fill out the dialog box that will determine how these entities will, or will not be allowed to move during the analysis. After the form is filled out, a constraint icon that graphically represents the allowable movements will be attached to the entity and, at a glance, you can visually determine how your part is constrained.
Constraint Icons
The constraint icon is comprised of 2 rows and 3 columns: the top row represents translational DOFs, and the bottom row represents Rotational DOFs. The 3 columns are X,Y, and Z (or R, , Z for cylindrical coordinate systems). Each square represents one of the six DOFs. If one of the squares in the icon is filled, that indicates that a particular DOF as been fixed or assigned a fixed displacement value. If the square is not filled, then the entity is free to move in that DOF. Notice how the information from the data form was transferred to the icon.
Appl ying Con st raint s
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X Translate Row Rotate Row Free Trans X Fixed Rot X
Y Free Trans Y Fixed Rot Y
Z Fixed Trans Z Free Rot Z
Figure 1 The constraint icon. Solid models have only three DOFs that can be constrained (all translation). Shell models have six DOFs that can be constrained. If you constrain a surface, then you only need to constrain the translational degrees of freedom. With edges, you need to constrain the translational and rotational degrees of freedom.
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For University Use Only - Commercial Use Prohibited This constraint restrains the translations of this surface in the X, Y and Z direction, and the model is fully constrained.
This constraint restrains the translation of this edge in the X, Y and Z direction, but the model is free to rotate around the X-axis.
This constraint restrains the translations of this edge in the X, Y and Z direction, as well as the rotation around X, and the model is fully constrained.
Figure 2 Constraining the model. Symmetry
Symmetry is a special application of constraints. A part is symmetrical if, when cut into a section, every point reflected from the mirror plane is the same. Every load, constraint, all the geometry, and the material properties must be symmetrical in order to perform a valid symmetrical analysis. Using symmetry reduces meshing and analysis time, as well as required disk space.
Cyclic Symmetry
A cyclic symmetry constraint allows you to analyze a section of a cyclically symmetric model that simulates the behavior of the whole part or assembly. This relational constraint reduces meshing and analysis time. The original model (part or assembly) that you take a section of must exhibit cyclic symmetry. That is, copying the cut section about a common axis a specified number of times reproduces the whole model. (The
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For University Use Only - Commercial Use Prohibited number of times must be an integer.) The model must exhibit cyclic symmetry in all of the following: Geometry Loads Other constraints Material type and orientation
In Pro/MECHANICA, a cyclic symmetry constraint prescribes rotation and displacement on two boundaries to be the same. In Thermal, a cyclic symmetry constraint prescribes the temperature distribution on two boundaries to be the same.
Singularities
Constraints and loads should usually be applied to an entity with area. If you constrain or load an entity with no area, then stress in your model can theoretically go to infinity. Recall that the basic equation for stress is: Stress = Load/Area. For solid models, surfaces, or regions of surfaces constitute area. For shell models, surfaces, regions, and edges constitute area. Why do edges have area in a shell model? For shell compressed models, edges are at the midsurface of the shell that have a defined thickness. Therefore the area of an edge is the length of the edge times its thickness. For both solid and shell compressed models it is not recommended that you constrain points; because in both cases the points have no area. The following table lists entities that should and should not be constrained or loaded.
Table 1 Constraining various entities. Shell Point Edge Surface NO OK OK Solid NO NO OK
As the area approaches zero, the smallest of loads will cause unrealistically high stress in your model. However, this may not be of concern if your interest is only in deflections.
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For University Use Only - Commercial Use Prohibited If you apply constraints to datum points or curves, be aware of the following: Point constraints can introduce high stresses and poor stress accuracy in both solid and shell models. Curve constraints can introduce high stresses and poor stress accuracy in solid models.
If you cannot avoid a point or curve constraint, and this situation concerns you, you can work with your model in Linked Mode. Linked Mode enables you to exclude a small set of elements around the constrained geometry, thus preventing the stress concentrations from affecting the analysis. To avoid stress concentrations in Integrated Mode, you can define a small region and apply the constraint or load to that region.
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Goal
To create model constraints.
Method
In Exercise 1, you fix the edge of a plate by applying an edge constraint to the specified edge. In Exercise 2, you apply point constraints to remove all six DOFs from the model. In Exercise 3, you apply constraints to a surface of the plate. In Exercise 4, you create a cyclic symmetry constraint. In Exercise 5, you learn how to correctly apply constraints to shell models. In Exercise 6, you learn how to create User Defined Coordinate Systems and to apply constraints with respect to the new coordinate system.
EXERCISE 1: Using Fixed Edge Constraints

Task 1. Fix the edge of a plate from translating in the Z-direction and rotating with respect to the X and Y axes. All other Degrees Of Freedom (DOFs) will be free. 1. Set your working directory to the folder that corresponds to the name of the current module, and open the PLATE.PRT. 2. Enter Pro/MECHANICA. Click Applications > MECHANICA. Click Continue in the UNIT INFO window. 3. Apply a constraint. Click Structure > Model > Constraints > New > Edge/Curve . 4. The constraints dialog box appears. Enter [edge_constraint ] for Constraint name, and leave ConstraintSet1 as a Set name. 5. Click the curve arrow to select the edge. Select the edge of the plate as shown in the following figure, followed by Done Sel .
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NOTES
Figure 3 Select the edge.
6. Keep WCS as the coordinate system. 7. Free Trans. X, Trans. Y, and RotZ. Fix all other Trans. and Rot. The dialog box should look like the following figure.
Figure 4 The finished constraint dialog-box.
8. Click OK to complete the constraint.
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EXERCISE 2: Using Point Constraints

Task 1. Delete the edge constraint.
1. Delete the constraint you just created. From the constraint menu click Delete and select the constraint icon. 2. Click Done/Return . Task 2. Create datum points at the locations to constrain.
1. Click Model > Features > Datum Point > Create > On Vertex . 2. Select the three vertices shown in the following figure, followed by Done Sel > Done > Done Return .
DTM Point 1 DTM Point 3
DTM Point 2
Figure 5 Constrain the vertices of the model.
Task 3.
Constrain the first point.
1. Click Constraints > New > Point from the STRC MODEL menu. 2. The CONSTRAINT dialog box appears. Enter [Constraint_1] for the constraint name.
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NOTES
For University Use Only - Commercial Use Prohibited 3. Leave the default name for the constraint set name, ConstraintSet1. 4. Click on the arrow for points. Pick the top left point, PNT0 , and click Done Sel . 5. Keep WCS as the coordinate system. 6. Fix all the translational DOFs and free all the rotational DOFs, as shown in the following figure. This constraint removes all translational DOFs, but the part is still free to rotate around the X, Y, and Z axes.
Figure 6 Constrain the first point.
7. Click OK to close the dialog-box. Task 4. Constrain the second point.
1. Click New > Point . 2. Enter [Constraint_2] for the constraint name. 3. Leave the default name for the constraint set name, ConstraintSet1.
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NOTES
For University Use Only - Commercial Use Prohibited 4. Click on the arrow for points. Pick the bottom left point, PNT1 , and click Done Sel . 5. Keep WCS as the coordinate system. 6. Fix only the X and Z translations. 7. Leave the Y Translation and all three rotational DOFs free as shown in the following figure.
Figure 7 Constrain the second point.
8. Click OK . Task 1. Create a point constraint for the third point.
1. Repeat the above steps to constrain the lower right point. 2. Fix point PNT2 only in the Z translation as shown in the following figure. (Even though this constraint scheme does not explicitly remove a rotational DOF, the two bottom points cannot translate in the Z direction, which removes rotation around the Y-Axis.)
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Figure 8 Constrain the third point.
Note:
The three translational constraints have removed all six DOFs, including rotations, even though a rotational box was never explicitly fixed in any of the CONSTRAINT dialog boxes. It is not necessary to explicitly fix each DOF in a CONSTRAINT dialog box in order to remove all six DOFs from a model.
1st Constraint removes all translations.
2nd Constraint removes X and Z rotations
3rd Constraint removes Y rotation
Figure 9 The constrained model.
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NOTES
EXERCISE 3: Using Surface Constraints

Task 1. Delete the three point constraints.
1. Click Constraints > Delete and click each Constraint icon. 2. Repaint the screen. Click View > Repaint . Task 2. Create a surface constraint.
1. Click New > Surface . 2. The CONSTRAINT dialog box appears. Leave Constraint1 as the default constraint name. 3. Leave the default name for the constraint set name, ConstraintSet1. 4. Click on the arrow for surface. Select the vertical sides of the plate and then click Done Sel . 5. Keep WCS as the coordinate system. 6. Fix all the translational DOFs. 7. Leave the rotational DOFs free. 8. Click OK . 9. Click Applications > Standard . Click File > Save and Window > Close .
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NOTES
EXERCISE 4: Constraining Shell Models

Task 1. Apply constraints to shell models using the T-Bracket in order to hold the two ends of the T-Bracket fixed in all DOF for the model. 1. Open the T_BRACKET.PRT and verify that the units are mmNs . 2. Enter MECHANICA Structure. 3. Click Structure > Model > Idealizations . 1. Define the surface pairs and test the midplane compression. Click
Shells > Midsurfaces > AutoDetect > Compress > Shells only > ShowCompress . The model should appear as in the following
figure. 2. Click Done > Done Return > Done Return .
Figure 10 The compressed bracket.
Note:
The first step to constraining a part is to think about how this part will actually be held in place. Then, apply the appropriate constraints to the model. In this example, the part is welded on the right and left edges of the base into a larger assembly.
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For University Use Only - Commercial Use Prohibited Task 2. Fully constrain the two vertical surfaces of the t_bracket.
1. Click Constraints > New > Surface . 2. Enter [Constraint_1] for the constraint name. 3. Leave the default name for the constraint set name, ConstraintSet1. 4. Click on the arrow for surface. Pick the right and left vertical surfaces as shown in the following figure. Click Done Sel .
Figure 11 Surface Constraints 5. Keep WCS as the coordinate system. 6. Fix all DOFs in the dialog box and accept the form. 7. Click OK . 8. Switch to the standard application. 9. Save and erase the model.
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NOTES
EXERCISE 5: Using Coordinate System Constraints

Task 1. Create a cylindrical coordinate system aligned with the hole to define a constraint with respect to. 1. Retrieve the T_BRACKET_HOLE.PRT. 2. Click Applications > MECHANICA > Continue > Structure . 3. Click Model > Features > Coord System > Create > 2 Axes > Cylindrical > Done . 4. When prompted for the first axis, pick the axis of the first hole. This reference partially defines the orientation and location of the coordinate system. 5. When prompted for the second axis, pick the top edge of the plate as shown in the following figure. With the second reference, the location of the coordinate system is fully defined.
Figure 12 Select the edge to define the coordinate system.
6. A red arrow pointing downward will appear. Select Z-Axis to define Z direction. 7. Another arrow is highlighted in red. Select the default Theta=0 to define the starting point of the Theta direction. The cylindrical coordinate system is fully defined. 8. Repeat for the other hole to create CS1. Reverse the direction of the Z-axis arrow as necessary, so that it has the same direction as CS0.
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NOTES
For University Use Only - Commercial Use Prohibited 9. Click Done/Return . Task 2. Simulate bolted bracket by constraining the edges of the holes. A bolt in a threaded hole allows the hole to displace radially, but not translate along or rotate around the bolt. 1. Click Constraints > New > Edge/Curve . 2. In the CONSTRAINT dialog box, enter [bolt1 ] as the name. 3. Click on the [select] under the CURVES. Select the two top edges that define the top of the right hole and click Done Sel . 4. Click on the [select] under the COORDINATE SYSTEM. Select corresponding cylindrical coordinate system, followed by Done Sel . Note:
Constraints and Loads are always applied with respect to a current coordinate system. The Mechanica World Coordinate System (WCS) is the default. In this case, local coordinate systems are referenced when constraining the model.
5. Free R and fix other Degrees of Freedom. 6. Click OK to finish. 7. Constrain the second hole on the left hole using the same procedure and name it [bolt2 ]. 8. Switch to standard application. 9. Save and erase the model.
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NOTES
EXERCISE 6: Using Cyclic Symmetry Constraints

Task 1. Create the cyclic symmetry constraint.
1. Retrieve the WHEEL.PRT. 2. Investigate the last cut by redefining it. 3. Quit redefining without changing anything. Note:
The wheel part is cyclically symmetric. The last cut is created to remove geometry, as shown in the following figure. The geometry you are going to perform analysis on is the one slice of the entire model.
Figure 13 The cyclic symmetric wheel.
Task 2.
Create the cyclic symmetry constraint.
1. Click Application > Mechanica . Click Continue in the UNIT INFO dialog box. 2. Click Structure from the MECHANICA menu. 3. Click Model > Constraints > New > Cyclic Symm . 4. Click the [Select] icon right next to the FIRST SIDE. Select the one pie cut surface as the FIRST SIDE as shown in the following figure. Click Done Sel to finish.
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NOTES
For University Use Only - Commercial Use Prohibited 5. Using the same procedure to select the other pie cut surface as the SECOND SIDE, as shown in the following figure.
First Side Second Side
Figure 14 Select the indicated surface to create the cyclic constraint.
6. Click OK to finish. 7. Switch to the standard application. 8. Save and erase the model.
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MODULE SUMMARY
You have learned: How to define different types of constraints. How to create user defined coordinate systems.
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Module
Simulating Applied Loads

In this lesson, you learn how to apply the different types of loads available in Pro/MECHANICA.
Objectives
After completing this module, you will be able to: Create different load types. Describe the difference between point, edge, and surface loads Describe when to use each load type.
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NOTES
INTRODUCTION
For Pro/MECHANICA to perform most types of analyses, you must load at least one area of your model. Pro/MECHANICA provides a wide variety of load types. Below is a list of the types of loads that Pro/MECHANICA STRUCTURE supports: Point Bearing Pressure Edge/Curve Centrifugal Temperature Face/Surface Gravity
Pro/MECHANICA THERMAL supports: Heat Loads
You can define as many loads for your model as you like. When you apply loads in Integrated Mode, Pro/MECHANICA associates the loads with part geometry, rather than the elements it will create during the analysis phase. Before you add loads to your model, be sure you have the geometry and references you need already in place. Pay particular attention to the following items:
Coordinate Systems If you plan to make a Structure load relative
to any coordinate system other than the World Coordinate System (WCS), then you must have that coordinate system in place and active.
Datum Points If you plan to load a specific point on an exterior
curve or surface, then your part must include a datum point at that location. Be aware that point loads can introduce high stress concentrations or theoretically infinite thermal fluxes in your model.
Regions If you plan to load a specific surface region, your model
needs to include the datum curve contours that define the region.
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Goal
To create different types of loads on a model.
Method
In Exercise 1, you apply Point, Edge, and Surface Loads. You also review and verify the created loads. In Exercise 2, you investigate some of the spatial variations that you can assign to loads using linear, quadratic, and cubic interpolation options. In Exercise 3, you explore how to apply a load using Direction and Magnitude. In Exercise 4, you apply a pressure load that varies as a function of a coordinate system. You also apply a gravity load. In Exercise 5, you will create a load distribution using the Total Load at Point Option.
Simu lat ing Appl ied Lo ads
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EXERCISE1: Applying General Loads

Task 1. Create datum points on the T-Bracket to prepare for loads creation. 1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open T_BRACKET_HOLE.PRT. 3. Enter Pro/MECHANICA. Click Applications > MECHANICA > Continue> Structure . 4. Turn off the display of the constraint symbols. Click View > Simulation Display > Visibilities . Unselect the constraint sets from the LOAD/CONSTRAINT SETS list and click OK to finish. 5. Click Model > Features > Datum Point > Create > On Vertex and add four datum points to the vertices shown in the following figure.
Figure 1 Points Created For Applying the Load 6. Click Done Sel > Done > Done/Return . Assume for now that you will model this part as a solid.
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For University Use Only - Commercial Use Prohibited Task 2. Create a point load.
1. Click Loads > New > Point . 2. A FORCE/MOMENT dialog box appears. Click New to create a new load set. A LOAD SET dialog box appears. 3. Enter [point_load] as the load set name and click OK . 4. Enter [point0] for the load name. 5. Click Sel . [Select] under the POINTS and select PNT0 . Click Done
6. Keep the default coordinate system WCS. 7. Enter [10] for the Y component. Click OK to finish. Note the Load icon at point PNT0 .
Note:
If it is necessary to apply point or curve loads on a solid model, and the potential effects of this concern you, you can work with your model in Independent Mode instead. This mode enables you to exclude elements around the loaded geometry, thus preventing infinite stress concentrations from affecting the analysis. Point loads can introduce theoretically infinite stresses and distort your results for both solid and shell models. Curve loads can introduce theoretically infinite stresses and distort your results for solid models. To avoid stress concentrations in Integrated Mode, you can define regions and apply the load to the region instead of the point or curve.
Task 3.
Review the load you applied to the model.
1. Click Rev Tot Load . 2. When the system prompt for the point, select the datum point PNT0 , where you just applied the load.
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For University Use Only - Commercial Use Prohibited 3. When prompted for a load to review, click the load symbol for the point load you just created, followed by Done Sel . 4. The LOAD RESULTANT dialog-box appears. It shows the summary of the resultant load on the point due to the point load. Review the dialog-box. Notice that the moments are zero, due to the zero moment arm. 5. Repeat reviewing the resultant load at PNT1 , PNT2 , and PNT3 due to the point load PNT0 . 6. Notice that FY is -10 for all the points. The values of the moments change due to the change of the moment arm. Task 4. Apply an edge load.
1. Click New > Edge/Curve . 2. A FORCE/MOMENT dialog box appears. Click New to create a new load set. A LOAD SET dialog box appears. 3. Enter [edge_load] as the load set name and click OK . 4. In the FORCE/MOMENT dialog box, enter [edge_load1] for the load name. 5. Click [Select] under the CURVES and select edge, shown in the following figure. Click Done Sel . 6. Keep the default coordinate system WCS.
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Figure 2 Apply load at the indicated edge.
7. Enter [1] for the X component. The total load of 1 N is uniformly distributed over the entire edge, producing a unit load of 0.004 N/mm . (The edge length is 250 mm.) 8. Preview the load. Click OK to finish.
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EXERCISE 2: Applying Spatial Load Variations

Task 1. Edit the edge load to linearly interpolate over the edge length.
1. Click the edge load icon, it should turn red. 2. Right-click the edge load icon and choose Edit . Pro/MECHANICA highlights the referenced coordinate system and edge. The FORCE/MOMENT dialog box appears. 3. Change the distribution. Click the second DISTRIBUTION dropdown list and change from Uniform to Interpolated Over Entity . 4. Click Define , the INTERPOLATION OVER ENTITY dialog-box appears. 5. Enter [0] for point 1 and [1] for point 2 . Click Preview , the load appears as shown in the following figure. 6. Click OK from the interpolation dialog-box and click OK from the FORCE/MOMENT dialog box. Note: the load icon still remains even though you selected Interpolated over Entity.
Figure 3 Interpolate over two points.
Task 2.
Review the resultant load at the 4 datum points.
1. Click Model > Loads > Rev Tot Load .
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For University Use Only - Commercial Use Prohibited 2. Select any one of the four datum points when prompted for point. 3. Click the edge load icon from the model, followed by Done Sel . 4. The Load Resultant dialog-box should report FX = -1 . Try reviewing the load at the other datum points. FX should remain a constant -1 , but the moments will vary. 5. Check the load's value at Point 2 . 6. Click Done Sel > Done Return > Done Return .
Task 3. Create three additional datum points on the edge to use as interpolation points. 1. Click [Insert datum point].
2. Click On Curve > Length Ratio . 3. Click the edge you just applied the load to and click Done Sel . 4. Enter [0.25] for the curve length ratio. 5. Repeat to add points at [0.5] ratio and [0.75] ratio along the curve. 6. Click Done to finish. The bracket should look like in the following figure.
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NOTES
For University Use Only - Commercial Use Prohibited Figure 4 Create three interpolation points.
Task 4. Edit the edge_load to change its interpolation scheme to quadratic. 1. Click the edge load icon, it should turn red. 2. Right-click the edge load icon and choose Edit . The FORCE/MOMENT dialog box appears. 3. Define the distribution. Click Define . 4. In the INTERPOLATION OVER ENTITY dialog-box, click ADD . 5. When prompted for an interpolation point, click the datum point in the center of the curve, PNT5 , and click Done Sel > Done/Return . 6. Enter [0], [0], [1] for the interpolation point values. 7. Click Preview and note the parabolic distribution of the load along the edge shown in the following figure.
Figure 5 Parabolic distribution.
Task 5. To develop a cubic interpolation, add additional datum points to the edge. 1. Click ADD , in the INTERPOLATION OVER ENTITY dialog-box. 2. Click the datum point at 0.25 ratio (PNT4 ) to the interpolation. 3. Click ADD to add the datum point at 0.75 ratio (PNT6 ) to the interpolation. Read the error message.
NOTES

When you try to add the 5th interpolation point, you get an error message. Only 4 points are allowed for interpolated loads.
4. Click OK to acknowledge the error message. 5. Now set the values for the four remaining points as shown in the following figure.
Figure 6 fill in the dialog-box. 6. Click Preview and note the cubic distribution as in the following figure.
Figure 7 Define a cubic interpolation. 7. Click OK from the interpolation dialog-box to complete the review. Note that the total load is still 1.
Simu lat ing Appl ied Lo ads Pag e 6- 11
NOTES

For the Interpolated option of Spatial Variation, specifying two points results in a linear interpolation, three points in a quadratic interpolation, and four points in a cubic interpolation.
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NOTES
EXERCISE 3: Varying Load Direction and Magnitude

Task 1. Enter the edge_load directions and then input a magnitude in the Load dialog-box. 1. In the FORCE drop-down list, change from Components to Dir Vector & Mag . 2. Enter [-1] for FX, [1] for FY and [10] for the Mag. 3. Click Preview to review the resulting load distribution, and note how it is now at a 45 angle to the XZ plane as shown in the following figure. Click OK to accept the Load.
Figure 8 Preview the Load Distribution
Note:
If Components is used to define the same load, the values of the components are Fx = Fy =
(10 )2
2
= 7.071
4. Verify the components of the direction and magnitude load you just applied Click Model > Load > Rev Tot Load . Select any datum point.
Pag e 6- 13
NOTES
For University Use Only - Commercial Use Prohibited Select the edge load. Click Done Sel . The Load Resultant dialog-box should report Fx = -7.071 and Fy = 7.071 N . Click OK to finish.
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NOTES
EXERCISE 4: Using Pressure and Gravity Loads

Task 1. Apply a pressure load on the right side of the vertical plate. This load will vary with the square of the distance along the Y-axis . 1. Click [Create a pressure load].
2. A PRESSURE dialog box appears. Click New to create a new load set. 3. Enter [surface_load] for the load set name. Click OK . 4. Enter [surface_load1] for the load name. 5. Click [Select] and select the surface on the right side of the bracket and click Done Sel .
Figure 9 The Finished Pressure Load Dialog Box 6. From the DISTRIBUTION drop-down list, select Function of Coordinates . 7. Define the magnitude. Enter [1] for the P. 8. Click f(x) to define the distribution. The FUNCTIONS dialog box appears. 9. Click on New . The FUNCTION DEFINITION dialog box appears.
Simu lat ing Appl ied Lo ads Pag e 6- 15
NOTES
For University Use Only - Commercial Use Prohibited 10. Enter [y_squared] for name. 11. Select Symbolic from TYPE drop-down list. Enter [y^2] as the function as shown in the following figure.
Figure 10 Define a load function. Task 2. Review the function.
1. Click Review , followed by Graph . 2. Enter [12.5] as the lower limit (the bottom of the vertical surface) and enter [250 ] for the upper limit (the top of the vertical surface). 3. Display the distribution. Click Graph . 4. Zoom in and expand a portion of the graph. Click Utilities > Seg Graph and select any two points on the graph. 5. Display the full graph. Click Utilities > Full Graph . 6. Display the exact value at a specific point. Click Utilities > Point Query and select any point. Click OK to confirm. 7. Click File > Exit Graphing when finish. 8. Click Done > OK > OK . 9. Click Preview to view the load distribution. The model should look like the following figure.
Pag e 6- 16
NOTES
For University Use Only - Commercial Use Prohibited 10. Click OK to finish.
Figure 11 Preview the pressure load.
Task 3.
Apply a gravity load to your part.
Note:
In a lot of cases, the gravity load is negligible in magnitude relative to the applied loads; however, vibration analyses, in particular, often rely on heightened gravity loads to simulate drop or shock conditions.
1. Click
[Create gravity load].
2. The system reminds you that the gravity load is always applied using the WCS. Click OK . 3. Create a new load set. In the GRAVITY dialog-box, click New . 4. Enter [gravity] as the Load Set name. Click OK to finish. 5. Enter [gravity1] as load name. 6. Enter [-0.00981] for Y.
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NOTES
For University Use Only - Commercial Use Prohibited 7. Click OK to accept the dialog-box. .Notice the addition of the G icon at the default coordinate system origin. 8. Switch to the standard application. Save and erase the model.
Pag e 6- 18
NOTES
EXERCISE 5: Creating Load Distributions

Task 1. Retrieve CRANK.PRT and create datum points on the crank to prepare for load creation. 1. Retrieve the CRANK.PRT. 2. Click Application > Mechanica > Continue > Structure . 3. Click [Insert datum point].
4. Select the At Center from the DATUM POINT menu. 5. Click the edge as shown in the following figure.
Figure 12 Create a datum point at the center of the indicated edge. 6. Click Done Sel > Done to finish. 7. Create another point offset from the point you just created. Click [Insert datum point].
Select the Offset Point from the DATUM POINT menu, followed by Plane Norm . Click the surface as the offset plane reference, as shown in the following figure. Click Done Sel to finish.
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NOTES
Figure 13 Select the indicated surface as the offset reference.
Click the point you just created as the point reference. Click Done Sel to finish. Enter [3] as the offset value. 8. Click Done to finish. Task 2. Create a surface load with the Total Load at Point
DISTRIBUTION option.
1. Click Model > Loads from the STUC MODEL menu. 2. Click New > Surface . 3. Click the [Select] icon under SURFACE(S) and select the hole surfaces as shown in the following figure.
Figure 14 Select the load surface.
4. Accept the default world coordinate system WCS. 5. Select Total Load at Point from the DISTRIBUTION drop down list.
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NOTES
For University Use Only - Commercial Use Prohibited 6. Select the second point you created as shown in the following figure.
Figure 15 Select the point for load distribution.
7. Enter [350] for the F Z. The dialog box should look like the following figure.
Figure 16 FORCE/MOMENT dialog box.
8. Preview the load and close the dialog box. 9. Save and erase the model.
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NOTES
MODULE SUMMARY
You have learned: How to create different types of loads. How to create Interpolated and Function of Coordinates spatially varying loads. How to create a load distribution using Total Load at Point option.
Pag e 6- 22
Module
Running and Evaluating Analyses

In this module, you define and run an analysis, and evaluate your results. You learn the differences between Single-Pass Adaptive and Multi-Pass Adaptive analyses. You also learn how to define run settings and RAM allocations.
Objectives
After completing this module, you will be able to: Set up models for analysis. Combine structural and thermal analyses. Describe the difference between Single-Pass Adaptive and MultiPass Adaptive analyses.
Page 7-1
NOTES
INTRODUCTION
For this exercise, assume that you are working for a toilet manufacturer who is developing a new portable toilet unit. You are assigned the task of developing inexpensive seat for the unit. You want to use readily available materials capable of surviving a harsh outdoor environment; additionally, the seat must support a 1570 N (160 kg) load without excessive deformation or stress.
Analysis Options
An analysis is the calculation of your model's response to its boundary conditions. Pro/MECHANICA STRUCTURE/THERMAL provides 12 types of analyses that span a wide range of actual experimental conditions. The following table lists the analysis types.
Analysis Type Static Modal Pre-stress Static Pre-stress Modal Buckling Contact Dynamic Time Response Dynamic Frequency Response Random Vibration Shock Response Steady-State Thermal Transient Thermal Product Structure Structure Structure Structure Structure Structure Vibration Vibration Vibration Vibration Thermal Thermal Use it to find Stress/displacements of the structure Natural frequencies and mode shapes of the structure (eigenvalues and eigenvectors) Stress/displacements of the pre-stressed structure Natural frequencies and mode shapes of the prestressed structure The multiplication factor for the load that will make the structure buckle, and buckle shape. Possible contact area and pressure. Stresses and displacement as a function of loading. Response versus time of the structure given any general time or varying load. Response versus frequency of the structure given any periodic (frequency varying) load. Response versus frequency of the structure given any Power Spectrum Density input. (PSD) Response versus time of the structure given any general shock loading condition. Temperature throughout the structure given heat loads, and convection conditions Temperature throughout the structure given time-varying heat and/or convection conditions.
Anal ysi s a nd Resu lts
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NOTES
Goal
To define an analysis, run the analysis, and review the results.
Method
In Exercise 1, you are concerned with the comfort of the seat design. Therefore, you perform and determine the resulting temperatures, thermal deformations, and stresses. In Exercise 2, you define a thermal analysis on the seat. A steady-state thermal analysis calculates thermal response to specified heat load, subject to specified prescribed temperatures and/or convection condition. Since all Pro/MECHANICA modules (Structure, Thermal, and Motion) share a common database, you do not have to reassign the material properties. You only need to set up the thermal boundary conditions and define the thermal analysis. In Exercise 3, you set up a combined thermal and structural static analysis. Assuming you already have a defined thermal analysis, this is a four steps process that requires a special load type called a MEC/T load. In Exercise 4, you develop three Load Sets: the mechanical load, the temperature load, and the combined temperature/mechanical load. This ensures convergence on the combined loading, but also allows you the flexibility of superimposing and scaling the results from each load set in the post-processor. In Exercise 5, you learn about the difference between Single Pass Adaptive and Multi Pass Adaptive convergence algorithms methods through the seat example. You create a Multi-Pass static analysis and compare the resulting answers with those of a Single-Pass.
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NOTES
EXERCISE 1: Running a Structural Analysis
Figure 1 A symmetric toilet seat is cut in half.
Task 1. Retrieve the seat model. Create datum curves for region creation. 1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open SEAT.PRT. Tip & Technique:
The model in the preceding figure is symmetric about DTM1 in terms of geometry, properties, constraints, and loads; therefore using symmetry is recommended. Symmetry takes advantage of the fact that important model features and boundary conditions are symmetric about a plane.
3. Insert a datum curve by clicking
[Insert a sketched curve].
4. Select the top surface of the seat and click Okay. 5. Select BOTTOM and pick DTM3 datum plane.
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NOTES
Figure 2 Sketch the section with two dimensions.
6. Click
[Done] to finish, then click OK .
Task 2. Create a datum plane referencing DTM3. This datum plane will be used in the region creation. 1. Click [Insert a datum plane].
2. Click Through , set the filter to AxisEdgeCurv . 3. Display axis as necessary. Click the A_1. 4. Click Angle , select DTM3, and click Done . 5. Click Enter Value and enter [-55]. Task 3. To create the first support's datum curve. [Insert a sketched curve].
1. Insert a datum curve by clicking
2. Select the bottom surface of the seat. 3. Remove the default references and specify DTM4 and A-1 as the references. 4. Sketch a circle with the center aligned to the DTM4.
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NOTES
For University Use Only - Commercial Use Prohibited 5. Create the dimension scheme referencing the datum axis, as shown in the following figure. 6. Click [Done] to finish.
Align the sketched circle to DTM4
Dimension to the Datum Axis
Figure 3 Dimension the circle.
7. Repeat the procedures to create a second datum plane and curve 45 degrees from DTM3, the sketch should look like the following figure.
Figure 4 Create the second datum curve. 8. Save the model.
Pag e 7- 6
NOTES
For University Use Only - Commercial Use Prohibited Task 4. Enter MECHANICA and create the regions.
1. Enter MECHANICA. Click Applications > Mechanica > Continue > Structure . 2. Add the regions to the model, before defining the surface pairs. 3. Click Features > Surf Region > Create > Select > Done . Tips & Techniques
You can also sketch a Region directly in Pro/MECHANICA using Features , Surf Region from the STRC MODEL menu then using Sketch instead of Select option.
4. Select one of the two circles representing the seat's support. 5. Select the bottom surface as the surface to split. Click Done Sel > Done > OK . 6. Repeat the procedures to define the region on the bottom surface with the other circle. 7. Repeat the procedures to define the region on the top surface. 8. Click Done/Return to finish. 9. Visualize the surface regions. From the VIEW pull-down menu, click Model Setup > Mesh Surface . Click inside the circles. The model should appear as shown in the following figure. Select Close to complete.
Figure 5 Visualize the regions.
Pag e 7- 7
NOTES
For University Use Only - Commercial Use Prohibited Task 5. Compress the midsurfaces
1. Click Done/Return . 2. Click Model > Idealization > Shells > Midsurfaces > New . 3. Select all five surfaces to be projected onto the compressed midsurface. Select the three new regions Then select the two larger remaining surface areas on the top and bottom of the seat, followed by Done Sel . 4. Click Compress > Shells only > Show Compress . The model should appear as shown in the following figure. 5. Click Done > Done/Return > Done/Return .
Figure 6 The compressed midsurface with regions.
Task 6.
Assign the material properties.
1. Click Model > Materials , the MATERIAL dialog box appears. 2. Select PVC from the Materials in Library column and click on the right arrows to place it in MATERIALS IN MODEL column. 3. Click Assign > Part and click the model, followed by Done Sel . 4. Click on Edit while PVC in highlighted in MATERIALS IN MODEL column. 5. Click Thermal tab. For the thermal conductivity value, type [0.667527]. 6. Click OK > Close .
Pag e 7- 8
NOTES
For University Use Only - Commercial Use Prohibited 7. Save the model. Task 7. Apply the support constraint.
1. Apply the support constraints that restrain the seat from moving up and down. Click Constraints > New > Surface . The CONSTRAINT dialog-box appears. [Select] the two small circular surfaces on the bottom of 2. Click the seat representing the supports using Query Sel , followed by Done Sel . 3. Fix the Y translation only, leaving all other DOFs free, followed by OK . Task 8. Apply the hinge constraint.
1. Click New > Edge/Curve . [Select]. Select the edge as shown in the following 2. Click figure, followed by Done Sel .
Figure 7 Constrain the back edge to simulate the hinge.
3. Free the TransX and RotX and fix all other DOFs, followed by OK . Task 9. plane. Apply the symmetric constraint to the edge/curve on the cutting
1. Click New > Edge/Curve . 2. Click [Select]. Select the two top edges on the cutting plane, followed by Done Sel . 3. Fix X translation, Y and Z rotations. Leave others free.
Pag e 7- 9
NOTES

Since the cutting plane is in the Y-Z direction, the direction normal the TransX must be fixed. However, an object is free to move horizontally and/or vertically meaning TransY and TransZ must be free. Rotation is more difficult to imagine. Of course, RotX is allowed because you are free to spin an object as long as its spin axis is normal to the mirror. However, if you try to spin that object in RotY or RotZ, the object will try to pass through the symmetry plane, which is not allowed. Therefore, RotX is free while RotY and RotZ are fixed.
4. Click OK > Done/Return when finished. The model should appear as shown in the following figure.
Figure 8 The fully constrained seat.
Task 10. Load the seat, designing it to support a 160 kg user. Apply a 80 kg which corresponds to 785 N load to the cheek region. 1. Click Loads > New > Surface . 2. The FORCE/MOMENT form appears, for the load name enter [one_cheek]. 3. Create a new load set. Click New and enter [one_cheek], followed by OK . You have created a load one_cheek and a load set one_cheek. 4. Click [Select]. Select the cheek region, followed by Done Sel .
Pag e 7- 10
NOTES
For University Use Only - Commercial Use Prohibited 5. Apply a total load of 785 N , uniformly distributed over the region in the negative Y direction. Enter [-785] for Y FORCE component, followed by OK > Done/Return . Task 11. Set up a static analysis with the previous created loads and constraints. Tips & Techniques:
A static analysis calculates deformations, stresses, and strains in your model in response to specified constraints and loads. A static analysis tells you if your model will withstand stress or break, where the part will break, and how much the part will move.
1. Click Analyses from the MEC STRUCT menu. 2. The ANALYSIS dialog box appears, select Static and click New . 3. The STATIC ANALYSIS DEFINITION form appears, for the name Enter [static_seat]. 4. For description, enter [Static analysis of the seat with a 160 Kg person on it]. 5. Verify that the Constraintset1 , one_cheek , are highlighted. Unhighlight LOADSET1 as necessary. 6. Click on Convergence Tab and select Single-Pass Adaptive . 7. Click on Output Tab and set the Plotting Grids to 7 . 8. Click OK > Close to finish. Task 12. Create a standard design study by running multiple analyses on a single part. Tips and Techniques:
You can group analyses together under one standard design study, and just run the study. If you are running multiple analyses on a model, this may make file management easier. The results from all the analyses will be contained within a single design study result directory.
Pag e 7- 11
NOTES
For University Use Only - Commercial Use Prohibited 1. Click DesignStudies from the MEC STRUCT menu. The DESIGN STUDY DEFINITION dialog box displays. 2. For the Study Name, enter [standard_seat]. 3. For the description, enter [Design Study to run a static analysis of the seat]. 4. For the Analyses, select static_seat . 5. Click Accept followed by Done . Task 13. Run your study. 1. Click Run from the MEC STRUCT menu. 2. Accept the default Standard_seat(Standard) design study. 3. Click Settings . 4. Change the RAM allocation. Click Settings and select Ram Allocation . Change it to half the RAM on your machine. (Consult the instructor as necessary.) Click Accept . Task 14. Start the analysis run and check the Run Status. 1. Click Start . 2. Click Yes when prompted for error checking. 3. Click Summary to monitor the progress of your design study. 4. Click Close > Done when the run is finished. Task 15. Review the results by creating a fringe plot of stresses. 1. Create a RESULT window. Click Results from the MEC STRUCT menu. 2. Click No when prompted whether you want to save the model. The result interface is displayed. 3. Create a window to display the stress.
Pag e 7- 12
NOTES
For University Use Only - Commercial Use Prohibited Click [Insert result window].
Enter [vm_static] as the name, followed by Accept . The DESIGN STUDY dialog box appears Click the Standard_Seat\ in the CURRENT DIRECTORY. Click Accept to finish. 4. Define the result window contents. In the DEFINE CONTENTS FOR RESULT WINDOW MAX_PRINCIPAL dialog box, For the Title, enter [Static Analysis Von Mises Stress on Seat]. For Quantity, select Stress > Total > von Mises . For LOCATION, select All > Maximum > of shell top/bottom . For DISPLAY, select Fringe and clear the Continuous Tone and Average . Accept the Deformed scale 10%. Select Animate . Change the number of frames to 16. Note:
More frames will result in smoother animation and take longer to generate.
Select Auto Start and Reverse . Click Accept and Show . 5. Use following icons to play and control the result animation: [Stop]; Back]. [Play]; [Single Step]; [Single Step
Stop the animation when finish.
Task 16. Create an animation of the seat displacement. The quickest way to create a result window that is referencing the same study or analysis as a result window that has already been defined, is to copy the predefined results window and then edit its contents. 1. Click [Copy window].
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NOTES
For University Use Only - Commercial Use Prohibited 2. Enter [disp_animate] as the name, followed by Accept . 3. Fill out the dialog-box as shown in the following figure.
Figure 9 Define a displacement result window.
4. Click Accept . Task 17. Generate a third result window to display the displacements along the outer edge of the seat. 1. Stop the current animation if necessary. Click [Copy window].
2. Enter [edge_disp] as the name, followed by Accept . 3. Fill in the dialog-box as shown in the following figure.
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NOTES
Figure 10 Define another result window.
4. Click Select to define the LOCATION. 5. Reorient the model in 3D using the <Ctrl> key and the mouse buttons. 6. Click the outer edge as shown in the following figure.
Select this edge.
Figure 11 Generate the displacement graph of the select the edge.
7. Click the middle mouse button to finish. Click OK when prompted.
Pag e 7- 15
NOTES
For University Use Only - Commercial Use Prohibited 8. Click Accept . Task 18. Display multiple windows. 1. Click [Display Result Windows].
2. In the display result window dialog box, click [Select all], followed by OK . The system starts to animate all animated windows. Note:
To control multiple animated windows simultaneously, select the windows using <Shift> first.
3. In the selected window, switch the model to the isometric view. Click View > Spin/Pan/Zoom > Isometric > OK . Task 19. Edit the legend of the stress result window. Assume the maximum allowable stress is 35 Mpa. Display higher stress in red. 1. Select the stress result window. Click inside the stress result window. The system highlights its boarder in yellow. 2. Click Edit > Legend Value . 3. Click the second value from the top in the legend. 4. Enter [35], followed by OK . 5. Click Yes when prompted for linear redistribution. Task 20. Examine the displacements of the outer edge of the seat. 1. Select EDGE_DISP window. 2. Zoom in on a specific range of the plot. Click Utilities > Segment Graph . Pick any two points on the graph. 3. Display the entire graph, click Utilities > Full Graph . 4. Change the format of the table.
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NOTES
For University Use Only - Commercial Use Prohibited Click Format > Result Window . Clear the Labels and Titles check boxes followed by OK . Observe the changes in the window. 5. Write the graph data to a file on disk. Click File > Export > Graph Report . Save in the current directory. Enter [my_data] for the file name. Click Accept . Click No when prompted for saving the legend information. Note:
Pro/MECHANICA will write the data to disk in an ASCII file with a .GRT extension.
6. Click File > Exit Results . Answer No when prompted to save the window. 7. Click Done/Return to return to the top-level menu.
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NOTES
EXERCISE 2: Defining Thermal Analyses

Task 1. Enter Pro/MECHANICA Thermal. Apply a heat load.
1. Click Thermal . 2. Click [Define a heat load on surface]. The HEAT LOAD dialogbox appears. 3. Enter [thermal_load] for the name. 4. Create a new load set. Click New for load set. Enter [therm_load] as the load set name. Click OK . [Select]. Select the two circular regions on the bottom of 5. Click the seat representing the supports using Query Sel . Click Done Sel when finished. 6. Enter [-50] for Q. 7. Click OK to finish the load definition. Note the addition of the heat load icons to the display. Task 2. Apply the fixed temperature of 37 C to the cheek region. [Prescribed temperature on surface].
1. Click
2. Enter [body_temp] for the name. 3. Create a new constraint set. Click New . Enter [thermal_const] for the set name. Click OK . 4. Click [Select]. Select the cheek region on the top surface of the seat. Click Done Sel when finished. 5. Enter [37]. Click OK to finish. Notice the addition of the fixed temperature T icon.
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NOTES
For University Use Only - Commercial Use Prohibited Task 3.

Apply the convection conditions.
1. Click
[Surface convection condition]. The CONVECTION
CONDITION dialog box appears.
2. Enter [side_conv] for the name. 3. Accept the default therm_const constraint set. 4. Click [Select]. Select the larger region on the bottom of the seat followed by Done Sel . Do not select the small regions that already have heat loads applied to them. 5. Enter [0.2] for the CONVECTION COEFFICIENT. 6. Enter [25] for the BULK TEMPERATURE to simulate 25 C air. 7. Click OK to finish. Notice the addition of the convection icon.
Figure 12 Thermal boundary conditions.
Task 4.
Define a thermal analysis.
1. Click Analyses . Accept the default Steady State type. 2. Click New . The STEADY THERMAL ANALYSIS dialog box appears.
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NOTES
Figure 13 Define a thermal analysis. 3. Click OK > Close > Done/Return .
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NOTES
EXERCISE 3: Running Combined Analyses

Task 1. Create a MEC/T load for a static analysis. The temperature distribution of the MEC/T load is the result of the previously defined thermal analysis. 1. Click Structure > Model > Loads > New > Temperature > MEC/T Temp . 2. Enter [temps1] as the name. 3. Create a new load set. Click New . Enter [temps] as the name. Click OK . 4. Uncheck the Use previous design study if necessary. 5. Enter [25] for the Reference Temperature. 6. Click OK and note the addition of the MECT icon. Task 2. Create a load set that contains both thermal and structural load. First, create the thermal load in the set. 1. The thermal load in the combined load set is identical to the load created in the previous task. Click New > Temperature > MEC/T Temp . 2. Enter [temps2] as the name. 3. Create a new load set. Click New . Enter [mech_and_therm] as the name. Click OK . 4. Uncheck the Use previous design study if necessary. 5. Enter [25] for the Reference Temperature. 6. Click OK and note the addition of the MECT icon.
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NOTES
For University Use Only - Commercial Use Prohibited Task 3. Create the structural load in the thermal/structural load set.
1. Click [Create a surface load]. The FORCE/MOMENT dialogbox appears. 2. Enter [one_side] as the load name. 3. Assign the load to the MECH_AND_THERM load set created in the previous task. Select mech_and_therm from the load set dropdown list as necessary. 4. Click [Select]. Select the cheek region, followed by Done Sel .
5. Enter [-785] for Y FORCE component. 6. Click OK . Note the addition of a new load icon in the cheek region. The model should appear as shown in the following figure. Note:
It may appear that the loads are doubled on the model. But as you will soon see, you are not.
Figure 14 Apply a thermal/structural combined load set.
Task 4. Create a static analysis that calculates the thermal stresses as well as the combined thermal/mechanical stresses. 1. Click Analyses .
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NOTES
For University Use Only - Commercial Use Prohibited 2. Select Static > New . 3. Fill in the dialog box as shown in the following figure. 4. Click OK > Close .
Figure 15 Define analyses.
Task 5.
Run the static analyses.
1. Click Run . 2. Select the analysis, THERMAL_MECH(STANDARD/STATIC). 3. Click Start . 4. Click Yes to when prompted for error detection. 5. Click Summary to monitor the progress of your runs. 6. When the analysis is finished running, scroll up through the summary file and review the information for all four runs. Review the Summary file carefully.
Anal ysi s a nd Resu lts Pag e 7- 23
NOTES
For University Use Only - Commercial Use Prohibited How much disk space did it take? How long did it take? What is the maximum temperature in the seat? What is the maximum stress for each case? What are the error estimates? How many elements did AutoGEM create? What are the resultant loads? 7. Click Close > Done when finish. Note
You have created a single analysis, thermal_mech, and you selected three Load Sets. Two of these Load Sets need temperatures from the thermal analysis, thermal_seat, you defined earlier. Consequently Pro/MECHANICA runs thermal_seat first and then runs three static analyses, one for each Load Set. One of these loads, temps, is the stresses due only to the non-uniform temperature distribution in the seat, while mech_and_therm is stress due to both the non-uniform temperature distribution and the 250 lb. person sitting on the seat. One_side is the stress due to just the person, exactly as on your first run with the one_cheek load.
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NOTES
EXERCISE 4: Combining Loads in Results

Note
When you run an analysis, you may toggle on more than one load in the Load Sets column. Pro/MECHANICA will analyze and converge the model on one load set at a time. You can ask for combined loading in the results section; and the software superimposes the results from each load case. It is important to note, if you want to converge on combined loading, you should have both loads defined under one Load Set name.
Task 1. Examine the temperature distribution due to the heat loads from the sun and the user. 1. Click Results . Click No when prompted to save current model. 2. Create a window to display the temperature distribution. Click [Insert result window].
Enter [temperature] as the name, followed by Accept . Click the thermal_mech\ in the CURRENT DIRECTORY. Click Accept to finish.
thermal_seat ,
In the SELECT ANALYSIS dialog-box, click the followed by Accept .
3. Define the result window content Select Temperature from the QUANTITY drop down list. Select All from the LOCATION drop-down list. Select Fringe from the DISPLAY drop down list. Clear Animate if necessary. Accept other defaults. Click Accept and Show . Task 2. Define and view the convergence graph of the MPA thermal analysis. 1. Click [Copy window].
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NOTES
For University Use Only - Commercial Use Prohibited 2. Enter [flux_gradient] as the name, followed by Accept . 3. Define the result window content. Select Measure from the QUANTITY drop down list to plot a measure. Click Select . Select energy_norm and click Accept . Accept other defaults. Click Accept and Show . 4. Hide the convergence graph window. Click the FLUX_GRADIENT window. Click [Hide result window].
5. Hide the temperature result window using the same procedures. Task 3. Investigate the stresses due to the thermal expansion.
1. Create a result window to display the thermal stress. Click [Insert result window].
Enter [therm_stress] as the name, followed by Accept . Click the thermal_mech\ in the CURRENT DIRECTORY. Click Accept to finish. In the SELECT ANALYSIS dialog-box, click the thermal_ mech , followed by Accept . 2. Select the load set. In the LOAD SET COMBINATION dialog box, Clear the Combine Load Sets if necessary. Select temps , followed by Accept . 3. Define the result window content. Enter [Seat Thermal Stresses] for the name. Display Total von Mises Stress . Display the Fringe plot. Select Deformed > Animate and accept other defaults. Click Accept and Show . 4. Play the animation and pay attention to the maximum stress and the location of the stress concentration.
NOTES
For University Use Only - Commercial Use Prohibited 5. Stop the animation when finished. Task 4. Create a fringe plot of the combined thermal/mechanical stress.
1. Create a new result window. Click [Insert result window].
Enter [combined_loads] as the name, followed by Accept . Click the thermal_mech\ in the CURRENT DIRECTORY. Click Accept to finish.
mech ,
In the SELECT ANALYSIS dialog-box, click the thermal_ followed by Accept .
2. Select the load set. In the LOAD SET COMBINATION dialog box, Clear the Combine Load Sets if necessary. Select mech_and_therm , followed by Accept . 3. Define the result window content. Enter [Therm/Mech Stress from Combined Loads] as the title. Display Total von Mises Stress . Display the Fringe plot. Select Deformed > Animate and accept other defaults. Click Accept and Show . 4. Play the animation and pay attention to the maximum stress and the location of the stress concentration. 5. Stop the animation when finished. Task 5. Create a von Mises stress fringe plot for the combined thermal/mechanical loads, but the loads will be combined in the result section. 1. Create a new result window. Click
Accept .
[Insert result window].
Enter [combined_results] as the name, followed by Click the thermal_mech\ in the CURRENT DIRECTORY.
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NOTES
For University Use Only - Commercial Use Prohibited Click Accept to finish. In the SELECT ANALYSIS dialog-box, click the thermal_ mech , followed by Accept . 2. Select the load set. In the LOAD SET COMBINATION dialog box, Select the Combine Load Sets if necessary. Select one_cheek and temps . Keep the default factors. Note:
The scale factors can be used to magnify/shrink the effects of the load sets.
Clear the mech_and_therm . Click Accept . 3. Define the result window content. Enter [Therm/Mech Stresses from Combined Results] as the title. Display Total von Mises Stress . Display the Fringe plot. Select Deformed > Animate and accept other defaults. Click Accept and Show . 4. Reorient the view in multiple windows. Select multiple windows using the <Shift>. Click View > Spin/Pan/Zoom > Isometric > OK . 5. By comparing the combined result and combined load windows, we conclude that the maximum stresses and stress distributions in the two plots are almost identical. 6. Exit the result interface. Click File > Exit Results . 7. Save the result window when prompted for saving the result windows. Choose Yes . Enter [SPA], followed by Accept .
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NOTES
EXERCISE 5: Comparing MPA to SPA

Task 1. Define and run the Multi-Pass analysis.
1. Click Analyses from the MEC STRUCT menu. 2. Make sure Static is selected. Click New . 3. Define the analysis: Enter [seat_mpa] as the name. Verify that the Constraint Set ConstraintSet1 is selected. Select the Load Set one_cheek . Select Multi-Pass Adaptive from METHOD drop-down list. Set the Polynomial Order minimum to 1 and the maximum to
9.
Enter [2] in the PERCENTAGE CONVERGENCE field. Select Local Displacement, Local Strain Energy and Global RMS Stress for the convergence criteria. Click Output tab and change the Plotting Grid to 7 . Click OK > Close . 4. Run the analysis. Click Run . Select the seat_mpa(Standard/Static) if necessary. Click Start to begin the analysis. 5. Monitor the analysis. Click Summary . Notice the following changes as the analysis run progress. Multiple passes are made. Each time, the polynomial orders of the equations used in the solution are increased. Each pass reports fewer elements not converged and more equations than the pass before. Eventually, all elements will converge to the specified percentage and the run will be complete. Note:
If the analysis does not converge to the specified accuracy, Pro/MECHANICA will report that, and allow you to look at
NOTES
For University Use Only - Commercial Use Prohibited the non-converged results. In either case, the overall solution quality of every run is known and can be controlled by changing the convergence percentage on the analysis form. Review the Summary file carefully.
6. Click Close > Done when finish. Task 2. Define a result window to display a convergence plot and a fringe plot for the Multi-Pass run. 1. Click Results . Choose No when prompted to save the model. 2. Create a new result window. Click [Insert result window].
Enter [conv_stress] as the name, followed by Accept . Click the seat_mpa\ the CURRENT DIRECTORY. Click Accept to finish. 3. Define the result window content. Enter [Von Mises Stress vs. P-Pass] as the title. Select Measure from the QUANTITY drop-down list. Click Select and select max_stress_vm from the list. Click Accept . Accept other defaults. 4. Click Accept and Show . Task 3. Create a fringe plot of von Mises stress for the Multi-Pass run. [Copy window].
1. Click
2. Enter [vm_stress_mpa] as the name, followed by Accept . 3. Define the result window content. Enter [Von Mises Stress Multi-Pass] as the title. For Quantity, select Stress > Total Von Mises . Display von Mises Stress . Display the Fringe plot.
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NOTES
For University Use Only - Commercial Use Prohibited Select Deformed > Animate and accept other defaults. Click Accept and Show . 4. Retrieve the previously saved single pass adaptive result windows for comparison. You will lose the two previously created results, and you may need to recreate the MPA result. Click [Open file].
Select SPA, followed by Accept . Click [Display result windows].
Select the COMBINED_RESULTS window, followed by OK . 5. A close examination of the result windows shows: The Multi-Pass Adaptive analysis converges very well. The fringe plots of the Single-Pass Adaptive analysis and Multi-Pass Adaptive analysis are very close. 6. Exit the result interface. Switch to the standard application. Save and erase the model.
Note:
The answers with the Multi-Pass Adaptive (MPA) and SinglePass Adaptive algorithm (SPA) are within 10% of each other. For larger models SPA can be up to ten times faster and use up to two-thirds less disk space than MPA. As a default, you should use SPA as a solution method. MPA is good for cases where you would like to specify the convergence, and you want to manually control the convergence percentage.
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NOTES
MODULE SUMMARY
You have learned: How to define an analysis. How to define a combined analysis. How to review the results.
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Module
Analysis and Results: Examples

In this module, you will apply Pro/MECHANICA modeling techniques to real-world examples.
Objectives
After completing this module, you will be able to: Describe how to build a Pro/MECHANICA model. Analyze models for stress and heat distribution. Design models around frequency (repetitions per unit time) requirements.
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NOTES
INTRODUCTION
When you begin applying Pro/MECHANICA, you may select large, complex models to analyze. However, it is recommended that you initially attempt to apply Pro/MECHANICA to simple, basic models in order to learn the process of building and analyzing Pro/MECHANICA models.
Analyzing Models
You must apply the following steps when running Pro/MECHANICA analyses: 1. Create or import geometry 2. Assign material properties 3. Define loads 4. Apply constraints 5. Create elements 6. Define the analysis 7. Run the analysis 8. Review the results 9. Assign design parameters 10. Run a sensitivity study 11. Run an optimization study 12. Update the part geometry
Steps 1 through 8 define an engineering analysis in order to understand how a model behaves under certain boundary conditions. Steps 9 through 12 enable you to improve a design.
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F u n d am en t al o f P ro /M E CH A N I C A
NOTES
Goal
Review the basic steps of building a Pro/MECHANICA model. Analyze a roller mill bearing. Analyze a pan assembly under heat load and gravity. Perform a modal analysis and determine the natural frequency of a tuning fork for the musical note "G".
Method
In Exercise 1, you will de-feature a model and then set up and run an analysis. Understanding the Pro/MECHANICA Structure process will enable you to expand your skills into more advanced techniques such as optimization. In Exercise 2, you will analyze the thermal and structural response of a Pro/ENGINEER assembly. In Exercise 3, you will design a tuning fork, run a modal analysis, and then optimize the model.
Anal ysi s a nd Resu lts: E xamp les
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NOTES
EXERCISE 1: Analyzing Roller Mill Bearing Mechanical Properties

The model you will be analyzing in this exercise is a mill bearing part. First, notice that the model contains a large number of features, specifically, many holes that will increase the size of the Pro/MECHANICA model. Remember that suppressing features that are inconsequential to the analysis is recommended practice. Also note that the model is symmetric and that the boundary conditions are symmetric as well. Consequently, you will perform two tasks before entering Pro/MECHANICA: Remove features from the part. Cut the model in half.
Figure 1: Mill Bearing
Task 1.
In Pro/ENGINEER, open the model.
1. Set the working directory to the folder that corresponds to the name of the current module. 2. Open the MILL_BEARING.PRT. 3. Check that units are mm , Newtons and Seconds .
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NOTES
For University Use Only - Commercial Use Prohibited Task 2. De-feature the production model to create a simulation model. The production model is carefully constructed. All the features after Cut id 2826 can be suppressed. Note:
There are many pin-holes in your model that will not transmit any load but will increase the number of elements in the Pro/MECHANICA model significantly.
Note:
The model is symmetric. It can be cut in half to reduce the element count. The model is actually constructed in half, and merged to create the whole model.
1. Display the MODEL TREE if necessary. Click tree display] to display the MODEL TREE. 2. Click Feature > Suppress > Clip . 3. Click the first Pattern(Hole) . 4. Click Done .
[Toggle model
Task 3. Enter Pro/MECHANICA Structure and apply material properties. 1. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Structure . 2. Apply steel material properties to the part. Click Model > Materials . The MATERIALS dialog box appears. Select STEEL from MATERIALS IN LIBRARY and add to MATERIALS IN MODEL. Click Assign > Part , then click the part. Click Done Sel > Close .
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NOTES
For University Use Only - Commercial Use Prohibited Task 4. Create two loads that belong to the same load set.
1. Create a bearing load of 1,000,000 Newtons applied to the large inner cylindrical surface in the positive Y-direction. Click Click [Create a bearing load]. [Select] under the HOLE(S).
Click the surface as shown in the following figure, then click Done/Sel .
Figure 2: Bearing Load Surface
Enter [1000000] fort the Y component Click Preview. The message displayed is a warning that Pro/MECHANICA was expecting an entire cylindrical surface for the bearing load. Click OK since this model has been cut at the plane of symmetry. Click OK > OK . 2. Create a surface load of 500,000 Newtons in the positive Zdirection applied to the lip of the inner protrusion Click Click [Create a surface load]. [Select] under the SURFACE(S).
Use Query Sel to select the surface as shown in the following figure.
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NOTES
Figure 3: Surface Load in the Z-direction Click Done Sel . Enter [500000] for the Z-direction. Click Preview > OK . The model should appear as shown in the following figure.
Figure 4: Finished Loads
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NOTES
For University Use Only - Commercial Use Prohibited Task 5. Create three constraints that belong to the same constraint set.
1. Create a sliding constraint on the pin hole surfaces. Note:

A sliding constraint allows a constrained surface to slide in its own plane but not perpendicular to it. Therefore, the translation normal to the plane is fixed.
Click Click
[Create a surface constraint]. [Select] under the SURFACE(S).
Select the bottom flat surface of all three pin holes, followed by
Done/Sel .
Fix the Y-direction translation and free the other DOFs. Click OK when finished. 2. Create another sliding constraint. Click Click [Create a surface constraint]. [Select] under the SURFACE(S).
Select the flat surface as shown in the following figure.
Figure 5: Second Sliding Constraint
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NOTES
For University Use Only - Commercial Use Prohibited Fix the Z-direction translation and free the other DOFs. Click OK when finished. 3. Create a symmetric constraint. Click Click [Create a surface constraint]. [Select] under the SURFACE(S).
Select the plane of symmetry. Fix the X-direction translation and the Y and Z-direction rotation. Free the other DOFs. Click OK when finish. Task 6. Define and run the analysis.
1. Create a static SPA analysis named mill_static. Accept the other default options when defining the analysis. 2. Run the analysis and monitor the process. 3. Review the summary file. Note the following information. Total Elapsed Time ________________ Total CPU Time _______________ Solution "efficiency", CPU Time divided by Total Elapsed Time ______________%. Working Directory Disk Usage _________________ Mb. Result Directory Size ___________________ Mb. Maximum Memory Usage ___________________ Mb. How many elements are in the model? __________________ What is the error of the solution? ______________ %. Measure: max_disp_mag __________________ Measure: max_stress_vm __________________ 4. Click Close > Done when finish. Task 7. View and interpret the results.
1. Create two result windows: Repeated displacement animation (for the display, select animation instead of fringe).
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NOTES
For University Use Only - Commercial Use Prohibited Repeated von Mises stress animation fringe plot over the entire model. 2. The result windows should appear as shown in the following figure. 3. Switch to the appropriate orientations to visually verify the effects of the boundary conditions.
Figure 6: Displacement and Stress Results
4. In the stress results window, notice the "hot" spots (in red) near the symmetric boundary. 5. Also notice the few "green" spots near the sliding constraints. Constraints can often introduce artificially high stresses at the constraint boundary. These high stresses can typically be disregarded. Task 8. MPa). Focus on the "hot" spots(von Mises stress higher than 100
1. In the stress window, change the fringe legend so that any stress above 100 MPa (N/mm2) is indicated in red. Click Edit > Legend Value . Note:
If the yield stress of steel is 200 MPa and you want to maintain a safety factor of 2, no stress in the model should exceed 100 MPa.
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NOTES
For University Use Only - Commercial Use Prohibited Click the first value beneath the Maximum stress. Enter [100], followed by OK . 2. Exit the result interface. Switch to the standard application. Save and erase the model.
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NOTES
EXERCISE 2: Analyzing Frying Pan Thermal Properties

In this exercise, you will use Pro/MECHANICA to ensure that a frying pan distributes heat evenly and is structurally strong. The model consists of two simple partsthe pan itself and the handle. The bolts have been removed to simplify the assembly.
Figure 7: Frying Pan
You will perform two types of analysis: A thermal analysis will simulate the pan sitting on a hot stove. A static analysis will determine if the handle is strong enough to withstand the weight of the pan.
Task 1. Retrieve the pan. Create the datum curves for region creation. The region is used to represent the ring of heat from a gas stove. 1. Open PAN.PRT. Make sure that unit system is millimeter Newton Seconds(mmNs) . 2. Create circular datum curves on the bottom of the pan. Click [Insert a sketched curve].
Select the bottom surface of the pan. Sketch a 177.8 mm diameter circle concentric to the pan. Click [Done] to finish.
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NOTES
For University Use Only - Commercial Use Prohibited 3. Create another circular datum curve with a 127 mm diameter using the same procedures. The model should appear as shown in the following figure.
Figure 8: Bottom of The Pan With Two Datum Curves
Note:
The datum curves will be used for regions and must be applied to the part, not to the assembly. In addition, the curves must be created as separate features or the region creation will fail.
Task 2.
Create two surface regions in Pro/MECHANICA.
1. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Structure . 2. Split the bottom surface into two surface regions. Click Model > Features > Surf Region > Create > Select > Done . Select the outer datum curve, when prompted. Select the bottom surface of the pan, when prompted. Click Done Sel > Done > OK . The bottom surface is split into two surfaces. 3. Split the surface again using the other curve. Click Create > Select > Done . Select the inner curve. Select the bottom, inner surface of the pan.
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NOTES
For University Use Only - Commercial Use Prohibited Click Done Sel > Done > OK . The bottom, inner surface is split into two surfaces (for a total of 3 surfaces on the bottom of the pan). 4. Click Done/Return twice. 5. Switch to the standard application. Save and close the window. Task 3. Retrieve the handle. Create the datum curves for region creation. The region will represent the area held by hand. 1. Open PAN_HANDLE.PRT. Make sure that unit system is millimeter Newton Seconds(mmNs) . 2. Create a datum plane offset from the end of the handle 116 mm towards the pan. Click [Create a datum plane].
Select Offset . Select the end surface of the handle. Select Enter Value . Enter [-116], followed by Done . 3. Create datum curves. Click [Create datum curve].
Select Intr.Surfs > Done > Whole . Select the top surface of handle. Select Single and select DTM4 that was just created. 4. The model should appear as shown in the following figure.
Figure 9: Datum Curve Created On The Handle
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NOTES
For University Use Only - Commercial Use Prohibited Task 4. Enter Pro/MECHANICA and create a region on each of the four sides of the handle. 1. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Structure . 2. Split the top handle surface into two surface regions. Click Model > Features > Surf Region > Create > Select > Done . Select the datum curve, when prompted. Select the top, bottom, and side surfaces of the handle, when prompted. Click Done Sel > Done > OK . The four surfaces are each split into two surfaces, for a total of eight surfaces. 3. Verify that four regions have been created. Click Show All . Do not worry about which surfaces highlight. What is important is that there are now separate surfaces on which loads or constraints may be applied. 4. Click Done/Return . 5. Switch to the standard application. Save and close the window. Task 5. Open the frying pan assembly model. Create a datum curve on the pan where it intersects with the handle. The datum curve will be used for surface region creation. 1. Open the FRYING_PAN.ASM. Make sure that unit system is millimeter Newton Seconds (mmNs) . 2. Click [Select primary item].
3. Right-click the pan from the Model Tree and choose Insert Feature . 4. Click [Create datum curve].
5. Select Composite > Done > Exact > Done . 6. Click the four edges of the handle part that are in contact with the pan. 7. Click Done > OK to finish.
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NOTES
For University Use Only - Commercial Use Prohibited Task 6. Create a surface region where the handle intersects the pan.
1. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Thermal . 2. Click Model > Features > Surf Region > Create. 3. Select the pan, when prompted for component. 4. Choose Select > Done . 5. Select the rectangular datum curve, when prompted for curves. 6. Select the outer surface of the pan that intersects the handle, when prompted. 7. Click Done Sel > Done > OK > Done/Return . Task 7. Assign the material properties.
1. Apply material properties. Click Model > Materials . Assign the pan AL6061 Assign the handle STEEL . Note:
Aluminum has more than 4 times the thermal conductivity of steel, making a good material for cooking. On the other hand, steel has lower thermal conductivity, making it a good candidate for the handle because of the high thermal resistance.
Task 8. Simulate the cooking heat with the appropriate boundary conditions. 1. Simulate the cooking heat from the gas stove (12,500 BTU/hr) with a heat load. Click Model > Heat Loads > New > Surface . Enter [cooking_heat] as the name. Click [Select] and select the ring shape surface region. Click Done Sel . Select Total Load from the DISTRIBUTION drop-down list.
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NOTES
For University Use Only - Commercial Use Prohibited Enter [3661000]. Note:
The value is calculated by converting 12,500 BTU/hr into N mm/sec. N mm/sec is the unit for heat flux in the mmNsec unit system.
Click OK > Done/Return to finish. 2. Simulate the heat loss due to ambience air with a convection boundary condition. Click Model > Bndry Conds > New > Conv Cond > Surface . Enter [cool_air] as the name. Click [Select] and select the following surfaces: The narrow top surface. Note:
When selecting the external side surfaces. The rectangular region where the pan intersects the handle is excluded.
Internal and external surfaces of the round. Internal and external surfaces of side.
Click Done Sel . Enter [0.4] for CONVECTION COEFFICIENT. Enter [25] for BULK TEMPERATURE. Click OK to finish. 3. Simulate the heat loss due on the cooking surface with a convection boundary condition. Click New > Conv Cond > Surface . Enter [cooked_food] as the name. Click [Select] and select the interior bottom surface where the food is cooked. Click Done Sel . Enter [0.5] for CONVECTION COEFFICIENT. Enter [100] for BULK TEMPERATURE.
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NOTES
For University Use Only - Commercial Use Prohibited Click OK to finish. 4. Simulate the heat loss through the handle surfaces not held by the cook's hand with a convection boundary condition. Click New > Conv Cond > Surface . Enter [handle_heat_loss] as the name. Click [Select] and select the handle surfaces that are not touched by hand. Click Done Sel . Enter [0.35] for CONVECTION COEFFICIENT. Enter [25] for BULK TEMPERATURE. Click OK > Done/Return to finish. Task 9. Create a steady-state thermal analysis.
1. Click Analyses . Accept the default Steady Thermal analysis type. 2. Click New . Enter [pan_therm] as the name. 3. Make sure you select the correct constraint and load sets and accept all other default options. 4. Click OK > Close > Done/Return when finish. Task 10. Simulate the structural aspect of the pan model. The materials have already been defined in the previous tasks. Define the constraint (where the cook is holding the handle) and the load (gravity). 1. Enter Pro/MECHANICA Structure. Click Structure . 2. Define a surface constraint that simulates the holding hand. Click Click [Create a surface constraint]. [Select] under the SURFACE(S).
Select the four surface regions held by hand. Fix X, Y and Z-direction translations and free the other DOFs. Click OK when finish. 3. Define a gravity load. Click [Insert a gravity load].
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NOTES
For University Use Only - Commercial Use Prohibited Enter [-9810] for Z. Preview and click OK to finish. Task 11. Create a static structural analysis. 1. Click Analyses . Accept the default Static analysis type. 2. Click New . Enter [pan_static] as the name. 3. Make sure you select the correct constraint and load sets and accept all other default options. 4. Click OK > Close when finish. Task 12. Create a design study that includes the structural and thermal analyses. 1. Click DesignStudies . 2. Enter [pan_study] as the name. 3. Select both the pan_therm and the pan_static. 4. Click Accept > Done to finish. Task 13. Run the analysis and monitor the process using the summary file. Note the following information when the analysis is finished. 1. Total Elapsed Time ________________ 2. Total CPU Time _______________ 3. Working Directory Disk Usage ___________________ Mb 4. Result Directory Size ___________________ Mb 5. Maximum Memory Usage ___________________ Mb 6. How many elements are in the model? __________________ 7. What is the error of the solution? ______________ % 8. What is the maximum displacement magnitude? __________mm 9. What is the maximum Von Mises stress? ____________ N/mm 2
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NOTES
For University Use Only - Commercial Use Prohibited 10. What is the maximum temperature? ____________ o C Task 14. Create result windows to display the results. 1. Create an animated result window to view the displacement. Use "animation" as the display instead of fringe. 2. Create an animated fringe plot to display von Mises stress. As expected, high stresses occur at the junction between the handle and the mounting plate. However, since these stress values are much lower than the material's yield strength, these stresses are not a big concern. 3. Create a result window to display temperature distribution. Notice that the temperature is evenly distributed around the thick aluminum bottom. 4. Exit the Results window. Save and erase the model.
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NOTES
EXERCISE 3: Analyzing a Tuning Fork

Tuning forks produce a sound by vibrating at specific resonant frequencies. If the resonant frequency is within the audible range of 20 Hz to 20,000 Hz , then the frequency can be classified as a musical note. For example, the note, middle-C, a vibrates at 256 Hz , whereas the note, E, vibrates at a frequency of 320 Hz . Piano tuners and guitar players use tuning forks to tune their instruments to certain musical notes. In this exercise, you tune a fork to the musical note "G", which vibrates at
384 Hz .
Task 1.
Build the simulation model.
1. Open the part FORK.PRT. Make sure the units are in mm , Newtons , and seconds . 2. Enter Pro/MECHANICA Structure and apply steel material properties to the tuning fork part. 3. Fully constrain the handle surface of the fork (the cylindrical protrusion). Task 2. Run the modal analysis.
1. Click Analyses > Modal (from the drop down list) > New . 2. Enter [fork_mode] for the analysis name. Change the number of modes to [1], because we are interested in the lowest, or primary mode. 3. Accept all other defaults. 4. Run the analysis. Task 3. Verify the accuracy of the model and note the following:
1. Total Elapsed Time ________________ 2. Total CPU Time _______________ 3. Working Directory Disk Usage ________________ Mb
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NOTES
For University Use Only - Commercial Use Prohibited 4. Result Directory Size ___________________ Mb 5. Maximum Memory Usage ___________________ Mb 6. How many elements are in the model? __________________ 7. What is the error of your solution? ______________ % Task 4. Now that you understand the resources the analysis required and the error it produced, you are ready to start reviewing the results. In the summary file, you may find the calculated modal frequency. 1. What is the modal frequency? _________________ Hz . You have determined that this frequency is approximately G# (G-sharp) which is close, but half a note from your desired frequency of G. 2. Create a displacement animation result window. Task 5. Define a design parameter. The length of the tuning fork will dictate its resonant frequency. . 1. Assign a design parameter to the length of the fork. Click Model > Dsgn Controls > Design Params . 2. Click Create > Dimension > Select . Pick the fork feature. Pick the 91.24mm dimension as shown in the following figure. Enter [Fork_length] as the new name for design parameter.
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NOTES
For University Use Only - Commercial Use Prohibited Figure 10: Design Parameter On The Tuning Fork Length
3. Define the range from a minimum of 90 to a maximum of 110. 4. Click Accept > Done . Task 6. Optimize the model. To achieve the desired note of G, the resonant frequency must be 384 Hz. This will be accomplished by varying the length of the fork. 1. In Pro/MECHANICA Structure, define an optimization. Click DesignStudies . 2. For the optimization name, enter [fork_opt]. 3. Select Optimization from the TYPE drop-down list. 4. Clear the Goal check box. 5. Define the Limits on Measures . Click Create Select modal frequency from the pre-defined measure list Click Accept . Set modal_frequency equal to [384]. 6. Select the Fork_length parameter in the parameters section. 7. Accept all other defaults. 8. Run the optimization. Task 7. Verify the results of the optimization.
1. Enter the total Elapsed time. ____________________ sec 2. What is the final value of design parameter? ____________ mm 3. What is the optimized modal frequency? _______________ Hz 4. Is this within the 1% specified in the optimization convergence? ________________
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NOTES
For University Use Only - Commercial Use Prohibited Task 8. Update the model using the optimized design parameter.
1. Click Model > Dsgn Controls > Optimize Hist > Enter Study. Enter [fork_opt] when prompted and answer Y to all questions. 2. When you have completed this process, the fork will be tuned to G. 3. Create a plot of the modal frequency vs. optimization pass. It should look like the following figure.
Figure 11: Modal Frequency vs. Optimization Pass
4. Exit the result interface. Switch to the standard application. Save and erase the model.
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NOTES
MODULE SUMMARY
You have learned how to: Set up and run a Pro/MECHANICA structural analysis. Set up and run a thermal analysis and a structural analysis, simultaneously. Set up and run a modal analysis and an optimization design study.
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Module
Running Sensitivity and Optimization Studies

So far, you have learned how to model and analyze a part in Pro/MECHANICA. In this lesson, you will learn the tools that enable you to determine how sensitive measures such as stress, displacement, and mass are to changes in model parameters. You will also learn how to optimize your model by setting goals and limits on measures, while varying model parameters.
Objectives
After completing this module, you will be able to: Set up and run design and optimization studies. Describe the purpose of design parameters.
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INTRODUCTION
Sensitivity studies enable you to more fully understand the effects of varying the design parameters on your model. You can use these studies to determine how sensitive a particular quantity, such as von Mises stress, is to variations of a particular dimension parameter. Pro/MECHANICA provides the following sensitivity capabilities:
Running Global Sensitivity Studies

Global sensitivity studies are used to generate a picture of how measures respond to changing a design parameter over a specified range (usually a large range, hence the name global). Global sensitivity studies provide the big picture and will be most useful in understanding the overall effect of a given parameter. Running a global sensitivity study helps you understand in detail how changes are affecting your part. You will then use this information to set up the optimization study. Normally you would run global sensitivity studies on all the parameters that survived the local sensitivity study, but in the interest of time, you will run global sensitivity studies for limited parameters. In the exercise, you will run a global sensitivity on the slot length parameter to get a better understanding of its impact on your model. However, by doing so, you can only determine the optimal value for a given parameter if it were varied alone. But would this optimal parameter value be the same if other design parameters were changed simultaneously? The answer is most likely no. This is why you need the optimizer. However, this does give you a good starting position for the optimizer.
Running Local Sensitivity Studies

Local Sensitivity Studies are used to calculate the sensitivity of your model's measures to perturbations (very slight changes) in parameters. Pro/MECHANICA uses local sensitivity to perturb a dimension parameter by 1% to estimate the derivative of your measure with respect to the parameter. Thus, for a given location in parameter space, you may take a "snapshot" of the sensitivity of your model subject to all parameters. If
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NOTES
For University Use Only - Commercial Use Prohibited parameter A induces a slope of your measure of 100, while parameter B induces a slope of your measure of 0.01, then you may postulate that changing the parameter A will have a bigger effect than working with parameter B. Therefore, you use local sensitivity to narrow your selection of dimension parameters to the most important ones.
Running Optimizations
An optimization study adjusts one or more parameters to best achieve a specified goal or to test feasibility of a design, while respecting specified limits. To create an optimization study, you define the following components:
Goal You select a measure to minimize or maximize as the study's goal. Limits You define limits on one or more measures that
Pro/MECHANICA cannot violate during the optimization.

Parameters You select one or more design parameters you want
Pro/MECHANICA to adjust to achieve the goal. You will also define a range and initial value for each parameter. The goal and limits are each optional, but you must have at least one goal or one limit. Pro/MECHANICA adjusts the model's parameters in a series of iterations through which it tries to move closer to the goal while satisfying any limits. If you have no goal, Pro/MECHANICA simply tries to satisfy your limits. An optimization with no goal is sometimes called a feasibility study. If you do not define a goal, you must define limits. Without a goal, Pro/MECHANICA searches for the first feasible design that satisfies the limits you define. When defining a goal and limits, you can select measures associated with different analysis types. You can set up an optimization that would perform any of Pro/MECHANICA's analysis types except motion and contact. For example, you could optimize the clip for stress, displacement, natural frequencies (modes), and temperature simultaneously.
Running Sens iti vity and O p ti miz ation Studie s
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Goal
To use sensitivity and optimization design studies to view the effects of design variables and find an optimized model.
Method
In the first exercise you will create a Pro/MECHANICA model and define design parameters. In the second exercise, you will run a sensitivity study to view the effects of varying the design parameters on specific aspects of your model. In the third exercise, you will run an optimization study to find an optimized set of dimensions for your model. The goal is to reduce the stress in this model while increasing the maximum deflection to a value greater than 7 mm, but less than 9 mm. You will also attempt to reduce the weight of the current design.
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EXERCISE 1: Optimizing a Belt Clip

The belt clip model you will be optimizing, as shown in the following figure, fits onto a portable electronic device. The part is inserted and released from its latch by applying a 2.5 N force downward on the tab. The catch that protrudes down from the curved tip moves up and must clear a latch that is 7 mm high, but the maximum deflection cannot exceed 9 mm. In addition, the stresses must be kept to a minimum without increasing the weight of the part.
Press down the tab with 2.5 N
Constrain the Flange
Clip Body Catch 7 mm <displacement < 9 mm
Curved Tip
Figure 1 The Clip Part
Task 1. Build the simulation model by cutting away half of the symmetric model. 1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open the part CLIP.PRT. Check that units are mm , Newtons and Seconds . 3. Cut away half of the part. Click Insert > Cut > Extrude . Click Both Sides > Done .
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For University Use Only - Commercial Use Prohibited 4. Select DTM2 as the Sketching Plane and click Default as orientation reference. Create a sketch to remove the left half of the clip and complete the feature. When finished the clip should look like the following figure.
Figure 2 The Symmetric Clip Cut in Half
Task 2. Create a datum point for the measure. One of your big concerns is, for the given load, will the catch displace enough to clear the latch on the mating part? You will now add a measure to track the displacement of a point on the tip of the catch, but first you need to create the datum point at the point of interest. 1. Create a datum point as shown in the following figure. Click [Insert a datum point].
Select On Vertex . Click the vertex of the catch to create the point, as shown in the following figure. Click Done Sel > Done when finish.
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Figure 3 Create a datum point at the tip of the catch.
Task 3. Create a Region in Pro/MECHANICA to apply the load. The load on the tab will be applied by a finger pressing on a localized area represented by a region. 1. Enter MECHANICA. Click Applications > Mechanica > Continue > Structure . 2. Create surface region for load. Click Model > Features > Surf Region > Create > Sketch > Done . 3. Sketch the section of the region. Select the top surface of the tab as the sketching plane. Select Bottom and select DTM3 as the reference plane. Specify the appropriate sketching references and draw a horizontal line across the tab as shown in the following figure. Dimension the curve 6.35 from the edge of the tab. Click [Done] to finish.
4. Select the top surface of the clip, where the sketch resides on, to split. Click Done Sel > Done > OK . 5. Verify the created region. Click View > Model Setup > Mesh Surface .
Run n ing Sen s i t i vi ty and O p ti miz ation Studie s
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For University Use Only - Commercial Use Prohibited Click the region. The region should appear as shown in the following figure.
Figure 4 Create the Region
Task 4.
Create the midsurfaces.
1. Click Done/Return . 2. To create the surface pairs, click Idealizations > Shells > Midsurfaces > Auto Detect . 3. Test the compression to verify a successful pairing. Click Compress > Shells only > ShowCompress . The midsurfaces model should look like the following figure.
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For University Use Only - Commercial Use Prohibited Figure 5 The Midsurface Clip
Task 5.
Set the material properties.
1. Assign NYLON material properties to the clip. 2. Edit the NYLON properties to assign values for failure criteria. Click the Failure Criterion tab in the MATERIAL DEFINITION dialog box. Select the Distortion Energy (von Mises) option from the drop-down list. Enter [85] for the TENSILE YIELD STRESS. Note:
The tensile yield strength entered does not affect the calculations that Mechanica makes during the analysis. The purpose of this value is to provide a more convenient option for plotting stress results.
Select [N/mm^2] for the units of the tensile yield strength. Task 6. Define the constraints.
1. Apply a symmetry constraint to the model. Select the 5 edges shown in the following figure. Constraint the X translational dof, Y and Z rotational dof on the plane of symmetry. Free other dofs. 2. Create a second constraint. The clip is glued to the appliance at the flange location. Fix all dofs of the bottom surface of the flange, shown in the following figure.
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For University Use Only - Commercial Use Prohibited Constraint these edges
Constraint this surface
Figure 6 Constrain the clip.
Task 7.
Define a surface load to simulate a finger pushing on the tab.
1. Apply a 1.25 N surface load (half of the total load, due to the symmetry), in the negative Y-direction on the created region. After the load is applied, the model should appear as shown in the following figure.
Figure 7 Apply a surface load.
Task 8. Define the measures. Because the tip of the catch must clear a 7 mm latch, you will want to track the displacement at the bottom of the catch with a measure. 1. Define the measures. Click Model > Measures . 2. Pro/MECHANICA informs you of the coordinate system that the measure will reference. Click OK .
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For University Use Only - Commercial Use Prohibited 3. Enter [Y_disp_clip_tip] for the measure name. 4. Select Displacement for QUANTITY. 5. Click Select/Review and select PNT0 . 6. Accept other defaults and close the dialog boxes. Task 9. Create and run a static analysis.
1. Create a static analysis called CLIP_STATIC. Click Analyses from the STRC MODEL menu. Leave Static as the TYPE and click New . Enter [clip_static] as the name. Accept all the defaults and click OK> Close . 2. Click Done/Return > Settings and verify that Use Pairs is selected. 3. Run the structure analysis. Task 10. Checking the results. 1. Examine the summary file and the key statistics regarding the model, such as the number of elements, the elapsed time, and required disk resources. 2. Look for maximum von Mises and principal stresses, maximum displacement, resultant loads, and error estimates. Did the run complete without any errors? ________ What is the value for Y_disp_clip_tip? ___________mm Task 11. Display and interpret the results. 1. Create an animated result window to display the displacement fringe plot. 2. Create an animated result window to display the von Mises Stress fringe plot. Notice that the high stress area is near the inner tab fillet area.
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For University Use Only - Commercial Use Prohibited Task 12. Create a Failure Criteria results window. 1. Create a failure index result window by copying the stress window. Enter [failure_index] as the name. Select Failure Index as the QUANTITY. Unselect Animate . Accept other defaults. 2. The results indicate that the failure index is below 1.0 for the entire model. This means there are no areas in the model where the stresses will surpass yield stress of the material. 3. (Optional) Set the color legend to display the area that is above 1 in red. The model should have no red spot. 4. Exit the result window interface. Task 13. Define design parameters. Design Parameters change the shape of the model within a specified range during a sensitivity or optimization design study. 1. Create the Design Parameters. Click Model > Dsgn Controls > Design Params > Create . The DESIGN PARAMETER DEFINITION dialog box appears. 2. Select the design parameter. Leave the TYPE as Dimension and click Select . Select the slot feature. Use Query Sel if necessary. The dimensions associated with the slot feature will then appear. Select the R0.89 dimension. This dimension controls the width of the slot. 3. Change the name to [slot_radius]. 4. Enter [0.8] for the minimum and [1.5] for the maximum. Click Accept to complete the design parameter definition. 5. Repeat this process to create the design parameters shown in the following table.
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For University Use Only - Commercial Use Prohibited Table 1: Design Parameters Dimension slot_length, d32 (orig=31.75) slot_width, d50 (orig=7.62) body_width, d51 (orig=20.32) Minimum 19.05 2.54 17.78 Maximum 44.45 7.62 25.4
Task 14. Shape Animate the clip. Note:

Use Shape Animate to vary the parameters across different ranges and in different combinations, to anticipate problems that might arise during the optimization process, and to make sure the parameter ranges are causing the part to change as intended. Also, use Shape Review to review the model at specific settings for each parameter and to identify conflicting design changes within dimension ranges.
1. Click Shape Animate . 2. Select on all four of the design parameters, and set the NUMBER OF INTERVALS to 2. Click Animate . When prompted, press <Return> to continue. 3. The clip is regenerated at the initial and final configuration shown in the following figure.
Figure 8 Shape Animation
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For University Use Only - Commercial Use Prohibited 4. When prompted to restore the model to its original shape, click Yes . Task 15. Shape Review the clip. Shape Review modifies the current value of any or all of the design variables. 1. Click Shape Review . 2. Select all of the design parameters and click Review . 3. When prompted to restore the model to its original shape, click Yes .
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EXERCISE 2: Running Sensitivity Studies

Task 1. Create a local sensitivity.
1. Click DesignStudies from the MEC STRUCT menu. 2. In the DESIGN STUDY DEFINITION dialog-box, enter [clip_ls] for the study name. 3. Select Local Sensitivity from the TYPE drop down list. 4. Verify that clip_static is selected. 5. Click Set Parameters and select all parameters by checking all the check boxes next to the parameters. 6. Set the parameter values as shown in the following figure.
Figure 9 Define a Local Sensitivity Design Study.
7. Accept all the defaults. Click Accept > Done to finish.
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For University Use Only - Commercial Use Prohibited Task 2. Run the design study.
1. Click Run . Click Settings in the RUN dialog box. 2. Reuse elements from an existing study. Select Use elements from an existing study and click Select . Select clip_static , followed by Accept > Accept . 3. Click Start . Use the summary file to monitor the process. 4. Pay attention to the run times, convergence behavior, and information dealing specifically with local sensitivity. Task 3. Review local sensitivity results. Create four result windows to compare how much of an effect each of the four parameters is having on maximum von Mises Stress. 1. Click Results from the MEC STRUCT menu. 2. In the result interface, click [Insert a result window].
3. Name the window [slot_rad_stress]. 4. Select the clip_ls results directory, and click Accept . 5. For the MEASURE select max_stress_vm , followed by Accept . 6. For the DESIGN VAR, select slot_radius , followed by Accept . 7. Clip Accept and Show the result window definition. 8. Copy the result window to create and display three more windows. The names are [slot_wide_stress], [slot_len_stress] and [body_wide_stress]. Keep the max_stress_vm as the MEASURE. Select slot_width , slot_length , and body_width as the
DESIGN VAR respectively. Display all four windows.
9. By default, the four windows will all have different Y-axis scales. To compare the four parameters, you will tie the graphs together.
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NOTES
For University Use Only - Commercial Use Prohibited Click the SLOT_LEN_STRESS window that has the largest Yaxis scale. Click Utilities > Tie > Graphic Quantity and select another window. Repeat for the other two windows. When finished, all graphs should have the same Y-axis range. Note:
The von Mises stress should always be non-negative. The local sensitivity plot extrapolates the von Mises stress over a parameter range, using the sensitivity at a specific parameter value. Therefore, the graphs may indicate negative von Mises stress.
Task 4. Create four windows to see the effect of the parameters on the displacement measure Y_DISP_CLIP_TIP. 1. Copy the body_wide_stress window to [body_wide_y_disp]. 2. Change the MEASURE from max_stress_vm to Y_disp_clip_tip . 3. Blank all the von Mises stress windows. 4. Create and show other three windows by copying the body_wide_y_disp window. Use the following result window names, measures and design parameters:
slot_wide_y_disp: Y_disp_clip_tip slot_len_y_disp: slot_rad_y_disp: Y_disp_clip_tip Y_disp_clip_tip
vs. slot_width vs. slot_length vs. slot_radius
5. Tie all the Y-axes together. 6. Review the plots and determine the following information. Which parameter has the greatest effect on the tip's displacement? _______________________ Which parameter has the least, or perhaps no effect? ______________________
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NOTES
For University Use Only - Commercial Use Prohibited 7. The following observations can be made: The tip displacement is most sensitive to slot length and slot width. Slot radius appears to have less effect. Body width has no effect at all. 8. The following conclusions are made: The slot length and slot width have a big impact on the maximum von Mises stress and clip tip displacement. Slot radius has less effect. Body width has no effect on the maximum von Mises stress and clip tip displacement. Since body width has no effect on any quantity of interest, it will be excluded from future studies. Note:
The calculated slopes are strictly relevant to the single geometry state called for in the Local Sensitivity Study definition form. The slopes will be different for different current values of your parameters.
9. Exit result interface when finished. Task 5. Define and run a global sensitivity design study called CLIP_GS to study the effect of slot_length over its range. 1. Click DesignStudies > Create . 2. Enter [clip_gs] for the design study name. Select Global Sensitivity for the TYPE. 3. Verify that clip_static is selected. 4. Select slot_length and unselect all other parameters. 5. Change the NUMBER OF INTERVALS to 4 . 6. Verify that Repeat P-Loop Convergence is selected. The dialog box should appear as shown in the following figure.
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NOTES
For University Use Only - Commercial Use Prohibited 7. Click Accept > Done to finish.
Figure 10 Define a global sensitivity.
8. Run the global sensitivity study clip_gs . Monitor the process using the SUMMARY file. Task 6. Review the global sensitivity results. Look at sensitivity plots of mass, von Mises Stress, and tip displacement versus the slot length parameter. 1. Create a results window: Name the window [slot_len_mass], referencing the clip_gs design study. Select clip_static analysis. Select total_mass for the MEASURE and slot_length for the DESIGN VAR. 2. Create and show three more windows by copying the slot_len_mass window. Use the same DESIGN VAR slot_length . Name: slot_len_vm; MEASURE: max_stress_vm Name: slot_len_disp; MEASURE: Y_disp_clip_tip
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NOTES
For University Use Only - Commercial Use Prohibited Name: slot_len_maxd; MEASURE: max_disp_mag 3. The following observations can be made from the result windows: Increasing the slot length decreases mass. Increasing the slot length also increases maximum displacement and the clip tip deflection Increasing the slot length increases the maximum stress. 4. The observations above will help us prepare the optimization, where our goal is to find the value for the slot_length that decreases stress, and mass, and results in a clip tip deflection between 7 mm and 9 mm. 5. Exit result interface when finished.
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NOTES
EXERCISE 3: Optimizing the Clip

Task 1. Define an optimization.
1. Click DesignStudies from the MEC STRUCT menu. 2. Click Create and enter [clip_opt] as the name. 3. Select Optimimization for the TYPE. 4. Define the GOAL: Minimize max_stress_vm . 5. Define the LIMITS: Y_disp_clip_tip > 7 , Y_disp_clip_tip < 9 , and total_mass < 2.2e-6 . Note:
When the unit system is mmNsec, the mass unit is a metric tonne.
6. Define the parameters that will be used in the optimization. Check the check boxes next to the slot_radius , slot_length and slot_width parameters. 7. Since the parameter body_width does not impact stress or displacement as seen in the local sensitivity analysis, make sure the check box is CLEARED. You may have to scroll through the parameter list. 8. Define the parameter initial values. Set all parameters (except body_width) to the middle numeric value. 9. Converge to 2% with a max number of iterations of 20 . Verify that Repeat P-Loop Convergence is selected. 10. The dialog box should look like the following figure. Click Accept > Done when finish.
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NOTES
Figure 11 Optimization Study Definition
Task 2.
(Optional)Run the optimization.
1. Run the optimization. Monitor the process using the summary file. 2. Alternatively, you can retrieve the provided result to save time. Task 3. Create four result windows showing the optimization history of displacement, tip displacement, von Mises stress and mass. 1. If you have run the optimization, use those results to create result windows. Otherwise, use the results provided to create result windows. Consult the instructor for the stored results location, if necessary. 2. Create the following result windows to display the measure variation vs. Iteration during the optimization.
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NOTES
For University Use Only - Commercial Use Prohibited NAME [vm_opt_pass]; MEASURE: max_stress_vm NAME [disp_opt_pass]; MEASURE: Y_disp_clip_tip NAME [mass_opt_pass]; MEASURE: total_mass NAME [maxd_opt_pass]; MEASURE: max_disp_mag
3. Examine the windows. The results show the measure variation during the optimization. Notice the maximum von Mises stress changes from 66 M Pa to approximately 50 M Pa. The optimized model satisfies all constraints. As Pro/MECHANICA approaches the optimal shape, the values for stress, displacement, and mass stop fluctuating; and, as soon as all of the values are within 2% of the goal and limits, the optimization is complete. Task 4. Create result windows for von Mises and displacement stress fringe animations. 1. Create von Mises stress fringes without animation. 2. Click Info > Model Max to display the maximum von Mises stress on the model. 3. Create an animated displacement result window. Review the results window carefully. 4. Exit the result interface when finished. Task 5. Update the current part design dimensions to those of the optimized design. 1. Click Model > Dsgn Controls > Optimize Hist > Search Study. 2. Select clip_opt from the list. Pro/MECHANICA begins an animation of the shape changes. 3. Click <Return> when prompted to review the next shape. 4. Click <Return> to confirm when prompted to leave the model at the optimized shape.
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For University Use Only - Commercial Use Prohibited 5. Compare the original design to the new one. In the original design, the catch displacement was not sufficient to clear the latch, the stresses were higher, and it was heavier. The new design has sufficient displacement, less stress, and is lighter. 6. Switch to the standard application. Save and erase the model.
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MODULE SUMMARY
You have learned: How to run local sensitivity and global sensitivity studies to understand the effects of shape change on the model. How to run an Optimization Study and replace the Pro/ENGINEER part with the optimized shape that Pro/MECHANICA developed.
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Module
Running Analyses
In this module, you will apply all you have learned to analyze and optimize a plate-with-a-hole part.
Objectives
After completing this module, you should know how to: Define and run static analyses. Create design parameters. Define and run global sensitivity studies. Define and run optimization studies.
Page 10-1
NOTES
Model Description
The part is a 10 x 10 x 0.125 steel plate, with a 2 diameter hole through its center. The hole can move along a 45 line from the upper left hand corner, 2 from each edge, to the lower right hand corner, 2 from each edge. The plate is subjected to a tensile load of 10,000 lbf on its vertical sides. The model is shown in the following figure.
Figure 1: A Plate with A Hole
Task 1.
Perform a static analysis on the design.
1. Perform a static analysis on the design as it exists. Your instructor will review your results and modeling technique with you. Task 2. Create a design parameter.
1. Create a design parameter to move the hole along the 45 line. Task 3. Run a global sensitivity study.
1. Run a global sensitivity study to learn how von Mises stress is affected by the holes location. 2. Record the hole location for minimum stress. Show your instructor the results. Hole Location for Minimum Stress _______________
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Fundam ent al s of M E C HAN I C A ST RU CT UR E/ TH ERMA L
NOTES
For University Use Only - Commercial Use Prohibited Task 4. Define and run an optimization study.
1. Define and run an optimization study to find the hole location that minimizes von Mises stress. Test the optimizer by starting the optimization far from the minimum value determined in the global sensitivity study. Start the optimization with the holes design parameter value at minimum of its range. Record the hole location for minimum stress. Show your instructor the results. Hole Location for Minimum Stress ________________
Running A nal yse s
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Module
Advanced Exercises
In this lesson, you will work with additional exercises to help further your development in Pro/MECHANICA.
Objectives
After completing this module, you will be able to: Describe the purpose of spot-welding. Desiree the purpose of contact analysis. Desiree the purpose of transient thermal analysis. Desiree the purpose of large deformation analysis.
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INTEGRATED MODE CONTACT FUNCTIONALITY

You can use contact analysis to solve design problems where parts come into contact, but the exact regions that touch are unknown. Examples of these parts are rollers pressing against each other, press fits, rotating gears or shaft assemblies. Contact analysis is applicable whenever the model stiffness or load path changes as a function of the applied load. Before running a contact analysis, you first must define contact regions. Contact regions indicate which curves or surfaces may touch during a contact analysis. Pro/MECHANICA ignores contact regions for analysis types other than contact. Additionally, contact regions are frictionless and will only transfer normal forces. When running a contact analysis, Pro/MECHANICA calculates the detailed stress gradients and deformations found in contact regions that in some cases may cause the part failure. Determining stresses and deformations in a contact analysis is a non-linear problem requiring an iterative solution scheme. The non-linearity is due to the contact area varying non-linearly with the applied load. Pro/MECHANICA uses advanced P-element technology and geometric elements with a penalty solution method for achieving a converged contact solution. This procedure is fully adaptive and automated and requires no artificial constraints such as the gap elements used in conventional finite element codes.
Running Contact Analyses

Contact analysis in Pro/MECHANICA is considered frictionless; the interface in contact is assumed to be perfectly lubricated. When using contact analysis on your own models, you should be aware of the following limitations: You cannot use enforced displacements on contact regions. You can only run standard or global sensitivity design studies and optimization with a contact analysis; local sensitivity design studies can not be run. You can not use the iterative solver. You cannot combine results from two load sets.
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F u n d a m e n t a ls o f P ro / M EC H A N IC A
NOTES
For University Use Only - Commercial Use Prohibited The contact solution is computed for solid elements only. Pro/MECHANICA will not create contact regions on surfaces with shell or beam elements.
Pro/MECHANICA Structure handles moderate displacements and rotations. These displacements and rotations are small enough so that the Small Displacement Theory is adequate for element calculations, but large enough that significant rotation of element normals or significant relative tangential motion of the two surfaces of contact occurs. For 3D models, the allowable inter-penetration tolerance is one-half the minimum length of the two surfaces defining a contact region, where length represents the square root of the surface area.
Defining Contact Regions

You can define the contact regions manually or automatically. However, if you use the automatic option, and the assembly is complex (many possible contact surfaces), some contact regions that are not needed may be defined. To prevent longer run times, you should delete the excess contact icons. For a complex model, this can be cumbersome, thus, use this option with care.
Defining Contact Analysis Measures

There are two default global measures that are calculated for every contact analysis:
contact_area: Sums the total area of all the contact regions in the
model.
contact_max_pres: Tracks the maximum pressure in any of the
defined contact regions. You can also set up user-defined measures to track five attributes of a single contact region. These are very helpful when your assembly contains multiple contact regions: Contact area Average contact pressure Force Maximum contact pressure Contact load
Adva nced Exe rc ise s
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NOTES
Setting Contact Analysis Options

The following options are available when defining contact analyses.
Specifying Load Increments

For contact analyses, you can enter a value for the Number of Load Increments which specifies the steps at which Pro/MECHANICA calculates results. This enables you to see how measures vary with the load. This is similar to performing a global sensitivity with a design parameter on the load (if that were possible in Structure). You will use the default of 1 for number of load increments. This option tells Pro/MECHANICA how to apply the loads or enforced displacements to the model incrementally. You can set the number of load increments to more than 1 if you want to view any contact measures as a function of the applied load. For example, use a value larger than 1 if you need a plot of contact area vs. applied load. In conventional FEA (h-codes), the contact solution accuracy is dependent on the load increment. Pro/MECHANICA, on the other hand, gives you solution accuracy regardless of what load increment you specify.
Refining the Localized Mesh

Localized Mesh Refinement is available for achieving accurate contact pressures in the model. If Localized Mesh Refinement (often called h/p adaptive refinement) is selected, the mesh will automatically be refined near the contact region to improve the pressure accuracy. However, Localized Mesh Refinement does increase analysis run time. Contact analyses are run for a variety of reasons. One reason to define a contact analysis is to calculate stresses at an interface of two parts that are contacting each other. Another reason to run a contact analysis is to accurately simulate the load transfer between parts, where the maximum stress in the model is not at the contact zone. For this type of analysis, localized mesh refinement is not needed, and should be turned off to save run time.
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NOTES
TRANSIENT THERMAL ANALYSIS

For engineering processes that involves heating and cooling, the transitional period of time is of great interest. The analysis must be modified to take into account the change in internal energy of the body with time. In Pro/MECHANICA, this type of data is obtained through a Transient Thermal analysis.
Fundamentals
When evaluating a design, you may need to investigate what will take place between material bodies as a result of a temperature difference. This energy transfer between two bodies (commonly referred to as heat) may be considered in steady-state or in a transient state. Thermodynamics deals with systems in equilibrium - it may not be used to predict how fast a change will take place. Systems in equilibrium are considered to be in steady-state. Heat transfer is used to predict the rate at which this exchange will take place under specified conditions. Bodies not in equilibrium are considered to be in a transient phase.
Transient Heat Transfer

When bodies are suddenly subjected to a change in environment, some time may elapse before an equilibrium temperature condition will exist in the body. Until then, the body is in an unsteady state. Many engineering problems are concerned only with the steady-state heat transfer of a part or assembly. This type of information can be obtained by running a Steady-State Thermal analysis in Pro/MECHANICA. However, for engineering processes that involve heating and cooling, this transitional period of time is of great interest as well. The analysis must be modified to take into account the change in internal energy of the body with time. In Pro/MECHANICA, this type of data is obtained through a Transient Thermal analysis. Whenever there exists a temperature difference in a medium or between media, heat transfer must occur. This exercise deals with two modes of heat transfer: conduction and convection.
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NOTES
Thermal Conduction
Conduction is the heat transfer mode that occurs when a temperature gradient exists in a stationary solid or fluid. Conduction is the transfer of heat through materials without net mass motion of the material. The general equation for heat transfer by conduction is: q =-kA dT/dx where:
q is the rate of heat flow in x-direction k is the thermal conductivity A is the area normal to x-direction through which heat flows dT/dx is the temperature gradient in the x-direction dT is the temperature change in the x-direction and dx is increment in length in x-direction
Thermal Convection
Convection is the heat transfer mode that occurs between a surface and moving fluid when they are at different temperatures. It is the process in which thermal energy is transferred between a solid and a fluid flowing past it. The general equation for heat transfer by convection is: q = hA T where: q is the rate of heat flow via convection h is the heat-transfer coefficient (also known as the film coefficient) A is the surface area through which heat flows (convection area) T = Tw -T, (temperature potential for heat flow away from surface) Tw is the wall (surface) temperature and T is the bulk temperature (average fluid temperature far away from wall)
Pag e 1 1 - 6 F u n d a m e n t a ls o f P ro / M EC H A N IC A
NOTES
Defining the Measures

The Transient Thermal analysis has three default measures that are evaluated over the model at each time step. They are: min_dyn_temperature max_dyn_ temperature max_ flux_ mag
Any information that you want graphed against time, other than these measures, has to be specified as a user-defined measure before an analysis is run. The options for Quantity are: Temperature Heat Flux Temperature Gradient Driven Pro Parameter Time
The options for Spatial Variation are: At Point Max Over Model Range Over Model Min Over Model Max Abs Over Model
The options for Time Evaluation are: At Each Time Step Maximum Minimum Maximum Absolute At Time
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NOTES
Goal
To gain more experience with idealizations and analyses.
Method
In the first exercise, you will create and analyze the spot welded subassembly. The overall stress in the sub-assembly can be determined, as well as any excessive stress concentrations at the location of the spot welds In the second exercise, you will use Pro/MECHANICA to determine:1) The stress on the mounting surface of the pin. 2) The values for the contact area and contact pressure. 3) Any unreasonable hot spots in the latch mechanism. In the third exercise you will set up and run a transient thermal analysis. In the fourth exercise, you will set up and run a large deformation analysis.
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NOTES
EXERCISE 1: Creating and Analyzing Spot Welded Sub-Assemblies Overview

A spot weld consists of a beam that is fused to a surface over an area defined by the diameter of the weld. You can use spot welds to model welded structures and bolted connections. When you use spots welds, you must specify both the diameter of the weld and the material. The length of the weld is determined by the location of the fusion points on each surface. Spot welds can be used in both part mode and assembly mode, but patterns and zero-length spot welds are not supported. In this lesson, imagine the following scenario. You are the lead engineer for a company that makes motor-controlled robots for picking up heavy objects. Due to marketing demands, engineering has decided to use a heavier, more powerful motor. The current motor rests in a u-channel that is spot welded to an electronics barrier shelf. This shelf then slides into the framework of a larger assembly. The team you are working with is worried that the added weight of the new motor will cause excessive deflection in the u-channel (the new motor weighs 1000 N). A deflection of more than 2.54 mm would cause the motor to come in contact with the lower level of the assembly. For this reason, they want to move to a continuous seam weld instead of spot welds. From a labor point of view, that option is very expensive and your boss wants you to make sure it is absolutely necessary. The motor has a 152 mm x 406.4 mm base attached to the bottom of the U-Channel. The four spot welds are placed at 152.4 mm intervals between them. Because the parts are thin, you will define the assembly as a shell model. The spot welds are 25.4 mm diameter and 6.35 mm long.
Task 1. Define the surface pairs in part mode to model the assembly as a shell model. 1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open the SPOT_WELD.ASM. The units are mmNs . Notice the there is a 6.35 mm gap between the parts.
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For University Use Only - Commercial Use Prohibited 3. Enter Pro/MECHANICA Structure to test the sheet metal compression. Notice no midsurfaces have been defined. Note:
Recall that when simulating an assembly as a shell model, the midsurfaces have to be defined at the part level.
4. Open the part U_CHANNEL.PRT. Enter Pro/MECHANICA Structure. Auto-detect and compress the surface pairs. Save the part and close the window. 5. Repeat the procedure to compress the SHELF.PRT. Task 2. Idealize the assembly as a shell model. Assign material properties. 1. Switch to the assembly window. 2. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Structure . 3. Compress the surface pairs. Click Model > Idealizations > Shells > Midsurfaces > Compress > Shells only > ShowCompress . 4. Return to the STRC MODEL menu when finished. 5. Assign STEEL as the material for both parts. Task 3. Create the spot welds.
1. Click Idealization > Spot Welds > Create . 2. Define the references. For the first surface, select the bottom surface of the shelf to be welded. For the second surface, select the top right flange surfaces of the U channel. For the points, select the 4 datum points on the right side of the shelf and the 4 datum points on the right side of the U channel. Click Done Sel to finish. 3. Define the weld diameter. Enter [25.4].
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For University Use Only - Commercial Use Prohibited 4. Assign STEEL as the material for the spot welds when prompted. The system displays the spot weld icons. 5. Repeat the steps above to create spot welds on the left-hand side. Task 4. Define the boundary conditions. The surface regions for the boundary conditions have already been defined for your convenience. 1. Create a surface constraint to represent the slot that clamps the edges of the shelf. Click [Create a surface constraint].
Enter [slot] as the name. Select the two surface regions that represent the clamp area on the shelf part, as shown in the following figure. Fix all 6 DOFs. 2. Create a load to simulate the motor. Click [Create a surface load].
Enter [motor] as the load name. Select the rectangular surface region on the bottom of the U channel. Enter [-1000] as the FORCE component in the Y direction.
Figure 1: Assembly With All The Boundary Conditions And Spot Welds Defined
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For University Use Only - Commercial Use Prohibited Task 5. Create and run a static analysis.
1. Define a static analysis named [spot_weld]. Accept all the defaults. 2. Run the spot_weld analysis. 3. A confirmation window warns that there are originally 2 disjoint bodies in the model. They should be properly connected by spot welds. Click Confirm to proceed. Task 6. Display and interpret the results.
1. Create and show a displacement result window. Note the maximum displacement in the model.
Figure 2: Displacement Fringe Plot
2. Create and show a von Mises stress result window. Note the maximum stress in the model.
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Figure 3: Von Mises Fringe Plot
3. Do the spot welds create any excessive stress concentrations on the shelf?
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EXERCISE 2: Contact Problems Overview

The following figure shows a latch mechanism used to secure a small electronic box on an airplane. When the front compartment door to this box is closed, the latch is subjected to a horizontal force of 400 N. Further movement is prevented when it comes into contact with a pin that is completely fixed to the interior skin of the aircraft. As an engineer, you are concerned about stresses on the mounting surface of the pin due to this contact. In addition, you want to check for any unreasonable stresses in the latch or pin due to the contact pressure. Finally, some of your team thinks the mechanism is over designed and that mass should be taken out of the latch.
Figure 4: Latch Mechanism
Task 1.
Retrieve the latch model and enter MECHANICA.
1. Open LATCH.ASM. Verify that the units are mmNs . 2. Enter Pro/MECHANICA. Click Applications > Mechanica > Continue > Structure . Task 2. Assign STEEL as material for both parts.
1. Click Materials . Add STEEL to the model.
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For University Use Only - Commercial Use Prohibited 2. Click Assign > Part . Select both parts, followed by Done Sel . 3. Click Close when finish. Task 3. Constrain the latch assembly.
1. Constraint the bottom of the latch so that the latch can only move freely in the x-direction. Click [Create a surface constraint].
Select the bottom surface of the latch as shown in the following figure. Free translation in x-direction. Fix all other DOFs. Click OK to finish.
Figure 5: Latch Surface Constraint
2. Constrain the back of the pin. Click [Create a surface constraint].
Select the back surface of the pin as shown in the following figure. Fix all 6 DOFs. Click OK to finish.
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Figure 6: Pin Surface Constraint
Task 4.
Apply the load.
1. Apply a load of 400 N in the x direction as shown in the following figure.
Figure 7: Surface Load
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For University Use Only - Commercial Use Prohibited Task 5. Define the contact regions.
1. To define a contact region, click Model > Contacts > Create > Face/Surface . 2. Select the surfaces that may be in contact (meshed in the following figure). 3. Click Done Sel . Note that the contact icon appears. 4. Review the contact region. Click Review . Click the contact icon. The system highlight surfaces in red.
Figure 8: Contact Region Surfaces
Task 6.
Define the measures.
1. Set up any relevant measures you need for this analysis. Two contact measures are automatically defined for the contact analysis pressure area. Task 7. Define the contact analysis.
1. Click Analyses > Static > New . 2. Enter [contact_spa] as the name.
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For University Use Only - Commercial Use Prohibited 3. Click the Convergence tab. Make sure the Convergence Method is Single-Pass Adaptive . Select Localized Mesh Refinement . Click OK > Close . 4. Run the CONTACT_SPA analysis. 5. Confirm when prompted for error checking. 6. Click Confirm when system warns that there 2 disjoint bodies in the model. Since there is a contact region defined between the 2 bodies, the model is sufficiently constrained. 7. Monitor the process using the summary file. Notice that the Pro/MECHANICA recognizes the contact area is small and automatically refines the mesh in that area. Task 8. View and interpret the results.
1. Create and display an animated displacement fringe plot. Verify that the loading is causing the latch to come into contact with the pin. Note that the latch may appear to pass through the pin. This happens because the magnitude of the displacement is magnified (scale factor).
Figure 9: Displacement Result Window
8. Create and display a non-animated von Mises stress fringe plot. Edit legend scale for clearer display as necessary.
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Figure 10: Von Mises Stress Fringe Plot
9. Notice that the contact area is very small. Is this an effective latch mechanism? From the stress level, you can conclude that the latch mechanism is over designed. Task 9. The values at the mounting surface are reasonable. However, if the team makes design changes to reduce mass in the mechanism, these stress concentrations could pose problems. Take a closer look at the contact area and pressure on the latch. 1. Create a cutting surface to look at the inside of the model. Click Insert > CuttingSurfs . Accept the default WCS as well as the XY plane. Enter [30%] for the cutting depth. Click Accept to finish. 10. Dynamically modify the cutting plane. Click Edit > Cutting Plane . Click the Dynamic option. Drag left mouse button to move the cutting plane. Click the middle mouse button to finish. Click Accept to finish.
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Figure 11: Stress Inside Of The Model Using The Cutting Plane
11. Exit the results interface. 12. Switch to the standard application. Save and erase the model.
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EXERCISE 3: Running Transient Thermal Analyses Overview

The following figure shows a rocket-engine nozzle for a prototype shuttle between Earth and the new Space Station. At the time of ignition, this nozzle will be subjected to hot gases at 1648.8 C. The gases combine and reach their maximum temperature over time. The part is coated with a ceramic material having the following properties: Thermal Conductivity k=10,781 W/m oC Specific Heat Density c=1.624 kJ/kgoC
=4.52 103 kg/m3
The convective heat-transfer (film) coefficient between the nozzle and the gases is 4 103 kW/ m2 oC . The nozzle is initially at 17.7 oC.
Figure 12 A Rocket-Engine Nozzle Prototype
Your job as engineer is to determine if the rocket's engine is on too long before launch, thus, over-heating the nozzle. The engine is on for 100 seconds before lift off. There is an electronic warning switch located on the inner surface of the nozzle that will alert launch control if the nozzle temperatures are higher than 1371C. In addition, you need to ensure that the temperature gradients in the coating are not too large during the initial
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For University Use Only - Commercial Use Prohibited start-up. There can be no more than a 400C difference between the inner and outer surfaces of the nozzle. Finally, the thermal protection engineers would like to correlate data with your analysis and have asked you to provide complete temperature profiles for two points during the countdown; one half-way through ignition (50 seconds), and one right before lift-off (100 seconds). You will use Pro/MECHANICA to determine: How long after start up will it take for the temperature on the ceramic coating's surface to reach 1371C. If there are any large thermal gradients during ignition that might cause the ceramic coating to crack. What the temperature profile looks like half-way through ignition and right before lift-off.
Considerations for Transient Thermal Analyses

Some issues to consider when using Transient Thermal Analysis in Pro/MECHANICA are as follows: The model cannot contain multi-point constraints. It is available for 3D models with isotropic elements only (no shells/beams). It is available for standard analyses only (no sensitivity or optimization).
The time dependence is a multiplier function, so the user can only enter loads that also have a spatial variation as the product of two functions. For example: f(x,y,z) * f(time) NOT f(x,y,z,time)
Task 1.
Retrieve the model and assign the material properties.
1. Open NOZZLE.PRT. Note that the unit system is mmNs . 2. Enter the Pro/MECHANICA Thermal module. 3. The material properties of the ceramic file and the convection coefficient are as follows: Thermal Conductivity k=10,781 W/m oC
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For University Use Only - Commercial Use Prohibited Specific Heat Density Youngs Modulus Convection Coefficient c=1.624 kJ/kgoC E = 400,000 N/mm^2 h = 4 (103) kW/ m2 oC
=4.52 (103) kg/m3
Using the units found in the strategy guide, the above information can be converted as follow: Specific Heat Capacity Thermal Conductivity Density Convection coefficient Young's Modulus c = 1624 m^2/sec^2C k =10781 N/secC h = 4000 mW/mm^2C E = 400,000 N/mm^2
== 4520 kg/m^3
4. Create a new material named CERAMIC and assign the material properties to the part using the information shown above. Task 2. Apply the convection boundary conditions with a variable bulk temperature. The gasses flow in at a rate such that temperature values per unit of time are defined in a text file.. 1. Click [Surface convection condition]. The CONVECTION CONDITION dialog box appears.
2. Enter [flame] for the name. 3. Accept the default constraint set. 4. Click
Done Sel .
[Select]. Select the inside nozzle surface, followed by
5. Enter [4000] for the CONVECTION COEFFICIENT. 6. Enter [1] for the BULK TEMPERATURE. 7. Select the Time Dependant option. Note:
In this case, the Bulk Temperature is only a factor. The actual time dependent temperature is defined in the next step.
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For University Use Only - Commercial Use Prohibited 8. Select Time Dependent > f(x) . 9. Select Table from the TYPE drop-down list. 10. Click Import and retrieve the CONVECTION.TXT located in the current directory. 11. Review the graph. 12. Finish the definition. Task 3. Define and run a Transient Thermal analysis.
13. Click Analyses . 14. Choose Transient Thermal from the NEW ANALYSIS drop-down list and name the analysis NOZZLE_THERM. 15. Name the analysis [nozzle_transient ]. 16. Select the constraint set. 17. On the Temperature tab, enter [-17.7] as the initial temperature. 18. On the Output tab, Select calculate Heat Flux . Choose User-defined Output Intervals . Set the number of Master Intervals to 3. Select the User-defined Steps button. For Interval 0, enter 0 seconds; for interval 1, enter 50 seconds; for interval 2, enter 100 seconds; for interval 3, enter 120 seconds. Check the Full Results box next to each interval. 19. Click OK > Close to finish. 20. Run the analysis. Monitor the process using the summary file. Task 4. Review the results.
1. Create a graph for max_dyn_temp measure vs. time. The result window should appear as shown in the following figure.
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For University Use Only - Commercial Use Prohibited 2. Using the following graph, determine at what time the nozzle reaches a temperature of 1371 C: ____________ . Is it prior to lift-off (100 seconds)? _______________ 3. Create a temperature gradient fringe plot at 50 and 100 seconds. Does the temperature gradient exceed 400 degrees C anywhere in the model? 4. Create a temperature distribution fringe plot at 50 and 100 seconds. This fringe plot could be used to correlate to experimental data. 5. Exit the results interface. 6. Switch to the standard application. Save and erase the model.
Figure 13: Maximum Dynamic Temperature vs. Time
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EXERCISE 4: Analyzing Large Deformation Overview

The following figure shows an implant for an eye. As an engineer, you are concerned about stresses and displacement around the tips of the implant.
Task 1.
Investigate the symmetric model.
1. Retrieve the EYE_IMPLANT.PRT located in the current working directory. 2. The model is cut in half to take advantage of its symmetry. Investigate the last cut by redefining it.
Figure 14: Symmetric model of Implant
3. Quit redefining without changing anything. Task 2. Assign the material properties.
1. Click Application > Mechanica . Click Continue in the UNIT INFO dialog box. 2. Click Structure from the MECHANICA menu. 3. Click Model > Materials . 4. Select Nylon from the MATERIALS IN LIBRARY. 5. Add the Nylon to the model. 6. Click Assign > Part .
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For University Use Only - Commercial Use Prohibited 7. Select the eye implant part, followed by Done Sel . 8. Close the MATERIALS dialog box. Task 3. Create a constraint for symmetry
1. Click Constraints > New from the CONSTRNTS menu followed by Surface . 2. Enter [symmetry] as the constraint name. 3. Click the [Select] icon under SURFACE(S) and select the cut surface as shown in the following figure.
Figure 15: Surface for Symmetry Constraint
4.
Click Done Sel to finish.
5. Click the [Select] icon under COORDINATE SYSTEM and select the locate coordinate system CS1 previous created, as shown in the following figure.
Figure 16: Coordinate System for the Symmetry Constraint
6. Fix Z Translation and choose Free for all the DOF's. The data form should look like the following figure.
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Figure 17: Symmetry Constraint Data Form
7. Click OK to finish. Task 4. Create a constraint on bottom of the implant.
1. Click New from the CONSTRNTS menu followed by Surface . 2. Enter [eyeball] as the constraint name. 3. Click the [Select] icon under SURFACE(S) and select the bottom surface as shown in the following figure.
Figure 18: Eyeball Surface Constraint
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For University Use Only - Commercial Use Prohibited 4. Click Done Sel to finish.
5. Change the coordinate system to the World Coordinate System by selecting WCS from the SIM CSYS SEL menu.
Figure 19: WCS for the Eyeball Constraint
6. Fix X, Y, Z Translation and choose Free for all the DOF's. The data form should look like the following figure.
Figure 20: Eyeball Constraint Data Form
7. Click OK to finish. Task 5. Create a load at the end of the long segment
1. Click Loads from the STUC MODEL menu. Click New > Surface .
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For University Use Only - Commercial Use Prohibited 2. Click the [Select] icon under SURFACE(S) and select the surface region as shown in the following figure.
Figure 21: Tip Load Surface
3. Select the world coordinate system WCS from the SIM CSYS SEL menu. 4. Select Total Load > Interpolated Over Entity from the distribution drop down list. 5. Click Define to specify the interpolation points. Turn on the datum point display as necessary. Click Add in the INTERPOLATED OVER ENTITY dialog box. Select PNT0, PNT1, PNT2, as shown in the following figure.
Figure 22: Interpolation Points
Click Done Sel > Done/Return when finish. Enter [1] for the second point and preview the load. The load should look like the following figure. Click OK to finish. 6. In the FORCE/MOMENT data form, enter [-0.0008] as the Y force component. The FORCE/MOMENT data form should look like the following figure.
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Figure 23: Interpolation Points for the Tip Load
Figure 24: Tip Load Data orm
7. Click OK to finish. Task 6. Define a large deformation analysis.
1. Click Analyses . Accept the default Static from the NEW ANALYSIS drop down list. 2. Click New to define a new static analysis. In the STATIC ANALYSIS DEFINITION dialog box, accomplish the following steps: Enter [large_def] as the analysis name. Accept the default constraint set.
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For University Use Only - Commercial Use Prohibited Accept the default load set. Check the Calculate Large Deformations check box under the NONLINEAR OPTIONS. Accept the default Single-Pass Adaptive from the METHODS drop down list on the CONVERGENCE tab. Click the LOAD INTERVALS tab, and examine the options. You can use the Number of Intervals to run the analysis at certain load intervals. To save time, accept the default interval 1. Click OK to close the STATIC ANALYSIS DEFINITION dialog box. 3. Click Close to close the ANALYSES dialog boxes. Task 7. Run the analysis.
1. Click Run from the MEC STRUCT menu. 2. Click Start in the RUN dialog box. 3. Click Yes , when prompted whether you want error detection. 4. Click Summary in the RUN dialog box and monitor the analysis process. 5. When the analysis run is finished, close the summary window and click Done to close the Run window. Task 8. Create the result windows.
1. Click Results from the MEC STRUCT menu. 2. Click No when prompted whether you want to save the model. The result interface is displayed. 3. Create a window to display the displacement. Click Insert > Result Window . Name the result window DISPLACEMENT. Click the large_def\ in the CURRENT DIRECTORY. Click Accept . Fill out the data form as shown in the following figure. Click Accept to finish.
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NOTES
Figure 25: Definition for the Displacement Result window
4. Create a result window to display the stress using the same procedure. Fill out the data form as shown in the following figure. Click Accept to finish.
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Figure 26: Definition for the Stress Result Window.
Task 9.
Display the result window and examine the results.
1. Click View > Display from the UNTITLED window. 2. Select both windows and click OK . 3. Select both windows. Press <Shift> key and click both windows. The borders of both windows should be highlighted in yellow. 4. Play the animate. Stop when finished. 5. Notice there are only two frames for each result window. Had you specified more intervals when you defined the analysis, there would have been more frames generated for the result window. 6. Click File > Exit Results . 7. Choose No when prompted.
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NOTES
For University Use Only - Commercial Use Prohibited 8. Save and erase the model.
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MODULE SUMMARY
You have learned: How to define spot weld idealizations. How to include contact regions in an analysis. How to define a transient thermal analysis. How to define a large deformation analysis.
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Module
Fatigue Advisor
This module presents the fundamentals of Fatigue Advisor, as well as a tutorial demonstrating how to conduct a fatigue analysis.
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OVERVIEW
Pro/MECHANICA offers a tool called Fatigue Advisor, which can be used to evaluate the potential of a model to fail due to fatigue damage. The solving engine behind Fatigue Advisor is a product of nCode International , a world leader in fatigue analysis. Through a partnership between nCode and PTC , Fatigue Advisor is now accessible from within the Pro/MECHANICA interface. In general, fatigue may be defined as: Failure under a repeated or otherwise varying load, which never reaches a level sufficient to cause failure in a single application. The initiation and growth of a crack or growth from pre-existing defect until it reaches a critical size.
As this definition suggests, to address the entire phenomenon of fatigue, we must consider both the initiation and growth of a crack. The focus of Fatigue Advisor is to predict the initiation of cracks. It uses a strain based analysis (EN analysis) to predict this initiation. It does not address the Linear Elastic Fracture Mechanics (LEFM) associated with crack growth. The goal of Fatigue Advisor is to accomplish one of the following: Ensure an engineer that a particular model will not fail due to fatigue damage throughout its desired life. Allow the engineer to optimize the model to eliminate fatigue problems. Alert the engineer that, if the problems can not be eliminated through optimization, the model should be given to a fatigue expert for additional attention.
To perform and analysis in Fatigue Advisor the following input is required: Material properties (additional) Ultimate Tensile Strength (UTS) A previously defined Pro/MECHANICA static analysis Load history information characteristics of the loading Desired Life of the component Correction factors for surface treatment (optional)
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For University Use Only - Commercial Use Prohibited The results available from Fatigue Advisor are: Log life Log damage Confidence of life Factor of safety
Fatigue Ad vis or
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EXERCISE 1: Piston Fatigue
Figure 1: A Petrol Engine Piston
You are designing a petrol engine for a new range of small cars. It is a 4cylinder unit of 1100cc capacity with 90 ft.lb. torque. One of the components that need analyzing is the new piston. Pistons have never been known to fail through fatigue in the past but you are now required to prove this before the component progresses to the next stage in the design. Your colleague has provided you with Pro/ENGINEER geometry of of the piston. The chief engine designer has estimated that each piston has a force of 900 lbf. applied to the crown (i.e. 225 lbf. total on piston model.) The material chosen is an aluminum alloy (details given in the following table). The new engine has a target life of approximately 200,000 miles or 600 million cycles under a peak-to-zero loading.
Method
Determine whether the piston is likely to suffer a premature fatigue failure. Find the location that any cracks will start to form so the test engineer knows where to inspect after the tests are completed.
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For University Use Only - Commercial Use Prohibited Determine the permitted factor of safety on load to determine how sensitive the piston is to overstress.
Table 1 Fatigue Parameters Material Units Name Material Type Surface finish Cut-off UTS E Kf lbf, in AL2014 Aluminum Alloys Polished 2e+016 70051 1.06e+007 0.33 1 Loading Desired Endurance Load type Amplitude Type Distribution Force component 6e+008 Constant Amplitude Peak-zero Total load Y = -225
Goal
This is a typical example of an analysis where fatigue failure is not expected but verification is still required. The piston will have to endure a very high number of cycles; most fatigue analysis is only strictly valid for less than 1E8 cycles. You will learn the following procedures: How to apply material fatigue properties to a Pro/MECHANICA solid model. How to apply fatigue load cases to the model. How to set up a static stress and fatigue analysis run. How to enable the Factor-of-Safety calculation using the Edit Session option. Set the fatigue material properties.
Task 1.
1. Set your working directory to the folder that corresponds to the name of the current module. 2. Open PISTON.PRT and familiarize yourself with the model. 3. Enter MECHANICA. Click Applications > Mechanica > Continue > Structure . Notice that the model is properly constrained for your convenience. 4. Assign material properties to the piston.
Fatigue Ad vis or
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For University Use Only - Commercial Use Prohibited Click Model > Materials . Add AL2014 to the MATERIALS IN MODEL. Click Assign > Part . Select the piston part, followed by Done Sel . 5. Define the fatigue properties. Click Edit , and click the Fatigue tab. Enter the properties given in the previous table. The dialog box should appear as shown in the following figure. Click OK > Close to finish.
Figure 2: Fatigue Definition Form
Task 2. Define a surface load. The load simulates repetitive combustion that causes fatigue. 1. Click [Create a surface load].
2. Enter [Combustion] as the name. 3. Click [Select] under the SURFACE(S).
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For University Use Only - Commercial Use Prohibited 4. Click the surfaces (meshed in the following figure) that make up the piston crown. 5. Click Done Sel to finish.
Figure 3: Combustion Load Surfaces on Piston (shown meshed).
6. Enter [225] as the Y force components. 7. Click OK to finish. Task 3. Setup a static analysis.
1. Click Analyses > Static > New . 2. Enter [piston_static]. 3. Accept the defaults. Click OK > Close to finish. Task 4. Run the static analysis and display the result.
1. Run the analysis. Monitor the process using the summary file. 2. Create a result window to display the von Mises stress fringe plot. 3. Exit the result interface when finished.
F atig ue Ad v i s o r
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For University Use Only - Commercial Use Prohibited Task 5. Create a fatigue analysis.
1. Click Analyses and select Fatigue from the NEW ANALYSIS drop-down list 2. Click New . Enter [piston_fatigue] as the name. 3. Click the Load History tab. Enter the following information. Enter [6e8] for the DESIRED ENDURANCE. Select Constant Amplitude for the LOADING TYPE. Select Zero-Peak for the AMPLITUDE TYPE. 4. Click the Previous Analysis tab. Enter the following information. Check the Use static analysis results from previous design study check box. Accept the default piston-static for both the DESIGN STUDY and the STATIC ANALYSIS. Set the load to loadset1 . 5. Set the PLOTTING Grid to 4 . Click OK to finish. Task 6. Run the analysis.
1. Run the piston_fatigue analysis. Monitor the process using the summary file as it proceeds. Task 7. View and interpret the results.
1. Create a result window for the piston_fatigue analysis to display the Log Life plots. 2. Notice where the fatigue cracks is likely to form. The minimum life is 1013.544 or 3.5E13, do you think this safety factor is OK? 3. Create a result window for the piston_fatigue analysis to display the Confidence of Life plots. 4. Notice how the Confidence of Life is all green.
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For University Use Only - Commercial Use Prohibited 5. Create a result window for the piston_static analysis to display the animated von Mises stress plots. 6. Exit the result interface when finish.
Figure 4: Stress and Log Life Plots
Task 8. Enable the FACTOR OF SAFETY option and rerun the analysis. The Factor of Safety option is switched off by default because it requires longer run time. Had you created a Factor of Safety result window, the value would be zero. 1. Turn on the Factor of Safety option using the session configuration file. Return to the top-level menu. Click Configuration > Edit Session . Add the keyword Fatigue_FOS_Calculation . Use <F4> as necessary. Set the value to ON . Use <F4> to view options, as necessary. Click Exit when finish. Click Save Session As . Accept the default name.
Fatigue Ad vis or
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For University Use Only - Commercial Use Prohibited Click Load File and load the saved file. 2. (Optional) Re-run the Fatigue Analysis. It could take long time depending on the hardware. Alternatively use the results found in the same directory generating the result windows. 3. Create and display a Factor of Safety result window. 4. View the Factor of Safety results. The minimum Factor of Safety suggests a permissible overload of 2.8 times before the fatigue life is jeopardized. 5. Change the legend for easier interpretation as necessary. Click Edit > Legend Value , and select the appropriate value to edit. Use the FOS minimum (2.8 in this example) as the legend minimum. Use around 10 times the minimum as the legend maximum. 6. Exit the result interface. 7. Switch to the standard application. Save and erase the model.
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NOTES
MODULE SUMMARY
In this module, you learned how Pro/Pro/MECHANICA can be used to calculate the fatigue life of a typical component. If this safety critical component were designed for a life of 10000 cycles, would you pass this onto a fatigue expert or would you trust this analysis? If you only required 5000 cycles what would you do? What is the value of Fatigue Advisor in this instance?
Fatigue Ad vis or
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Module
Student Projects
In this module you measure your basic Pro/MECHANICA Structure/Thermal knowledge.
Objectives
After completing this module, you will be able to: Assign properties. Apply constraints. Define loads. Run static, thermal, and modal analyses. Modify the shape your part with design parameters. Use measures. Run sensitivity and optimization studies Evaluate your results.
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STUDENT PROJECTS
Each of the following design projects is outlined in detail. They vary in degree of difficulty. Choose a project that most closely reflects you area of interest. Flagpole Wing spar Heat Sink Beverage Can Driveshaft Valve Housing Buckling Ring
Hints on how to design the projects are provided in the second half of the module.
Designing a Flagpole
Design a horizontal flagpole, minimizing mass while keeping maximum stress safely below yield. The flag pole must be 4 meters long and extend in the z-direction. It must be fully constrained at one end to represent the connection to the side of a building. The other end must have a 100N downward load in the ydirection representing the weight of the attached flag, and a 15N lateral load in the x-direction representing wind loading on the flag (we can ignore wind loading on the pole). Earthquake codes require that the pole be able to carry 2G's worth of downward seismic loading in addition to the regular 1G weight of the pole, for a total gravity load of 3G. Build your model out of the "Steel" found in the Pro/MECHANICA material library, which is a general HS low-alloy steel. Shigley & Mischke list the yield stress of 1212 Hot-Rolled steel to be 193 MPa. We need a safety factor of 4 on this project. Choose a convergence value for your static analyses of 10%, and an optimization convergence of 1%. Do not build the model with beam elements, since we want very specific stress information across the entire cross-section of the flagpole. After validating that you've built a good model, incorporate design variables on geometry and/or material properties to add design flexibility. Optimize for minimum mass, while maintaining the other design criteria. Any design with a total mass below 20 kg is acceptable, although there are some designs with significantly less mass.
Pag e 1 3- 2
NOTES
For University Use Only - Commercial Use Prohibited No picture is shown because there could be many solutions to this exercise. Your job is to find the one you think is the best and willing to put into production.
Designing a Driveshaft
Design the lightest truck drive shaft that meets static and modal design requirements. You must design a 4 meter long driveshaft that is constrained at one end, and has a 25,000 Nm axial torque at the other end. Although the loaded end of the shaft is free to twist about its axis, for the purposes of looking at realistic mode shapes, it should not be able to move radially or axially since it represents the end of the shaft connected to the truck's transmission. Due to packaging constraints, the shaft can have a radius no greater than1 meter at any point. The first mode of the shaft needs be greater than 60 Hz, so that engine and ground terrain loading do not create destructive resonance in the shaft that would shorten the shaft life. Build your model out of the "Steel" found in the Pro/MECHANICA material library, which is a general HS low-alloy steel. Shigley & Mischke list the yield stress of 1212 Hot-Rolled steel to be 193 MPa. We need a safety factor of 4 on this project. Use sensitivity and optimization studies to find the design with the lowest mass that meets these criteria. Choose a convergence value for your static analyses of 10%, and an optimization convergence of 1%. Feel free to use the single-pass adaptive algorithm where appropriate. After you find the best design, run a pre-stress modal analysis to see if the stress stiffness (and subsequent frequency of the first mode) is affected by the torsion load. No picture is shown because there could be many solutions to this exercise. Your job is to find the one you think is the best and willing to put into production.
Designing a Wing Spar

A Wing Support needs to be designed for low weight and displacement resilience. The loads have been derived from wind tunnel experiments and
St u d e n t P ro j e c t s
Pag e 1 3- 3
NOTES
For University Use Only - Commercial Use Prohibited have been given to the engineer as a boundary condition for the problem. Stresses for fatigue failure are also a concern in the design. Create the part as a shell model, using surfaces to represent the mid-plane geometry. The part dimensions, in inches, are shown below. Each surface should have a .2" thickness. The holes' axes must intersect the line that connects the midpoints of one end of the beam web to the other. The holes are equally spaced along this line. Define loads and boundary conditions. The left (or larger) end of the spar should be immovable. The part is loaded on the top surface(s) with a total load of (100, -200, 0) in x, y, and z directions, respectively. Run a static analysis, using convergence of .05%. Place design parameters on the three holes, allowing them to vary in radius from .25 to .4. Using the existing static analysis, run sensitivity studies and/or an optimization to minimize mass while keeping the maximum Von Mises stress below 1900 psi and the maximum displacement magnitude below .0025 inches.
Figure 1: Wing Spar
Pag e 1 3 - 4
NOTES
Designing a Valve Housing

ABC Valve Company has an existing line of valves that have been in production for over 35 years. They have an excellent safety record with these valves. Lately, ABC Valve Co. has been losing some existing accounts due to cost. ABC refuses to skimp on quality and safety, but must find a way to reduce cost. ABC makes over one million valves a year, and the ability to reduce material costs was judged to be imperative. As a new engineer with the company, you were sent to Pro/MECHANICA training. You were asked to evaluate the existing line of valves. After evaluating each valve you were asked to propose improvements that would reduce cost, increase valve life, and maintain the current safety record. The first part you are to evaluate is a small brass valve that is shown in the following figure. This valve must be manufactured out of brass, due to the environment to which it is exposed. Naval Brass Material Properties: Specific Weight = 0.304 lb/in3 Modulus of Elasticity = 15,000 ksi Poisson's Ratio = 0.35 Yield Stress = 60 ksi Ultimate Stress = 85 ksi
This design meets all OSHA's safety requirements. OSHA allows for pressure valves to yield at 1.5 times their designed operating pressure. This little valve is designed to a maximum operating pressure of 600 psi. Under pressure testing the valve began to yield between 900 - 1,000 psi, thus meeting the limits. Your assignment is to: Build this valve and confirm these test results. Propose changes that would reduce material costs while keeping the failure pressure the same or higher.
There are certain design constraints that your final design must not violate. You may not reduce the volume that is free inside the valve. For example, the inside height must remain 0.875 inches, and the ID must remain 1.812 inches. The inside corner radii's can be as large as 0.075 inches. The 0.275 inch base must remain this thick, and top thread length must not change. The overall height can not change either, due to current design constraints.
Pag e 1 3- 5
NOTES
For University Use Only - Commercial Use Prohibited The top outside thread is capped with a plastic cap to allow the housing to hold pressure. This adds essentially no structural strength, so it need not be modeled. The bottom inside thread is where the pressure feed is attached, and should be fixed from translating in all three directions. A uniform pressure should be applied to all inside areas. Use Failure due to yielding as your failure criteria on this valve. This is Max. Distortion Energy Theory (or Von Mises - Henckly Theory). Max distortion energy theory has been found to agree best with available test data for ductile materials.
Figure 2: Valve Housing
Pag e 1 3 - 6
NOTES
Designing a Heat Sink

You must attach a heat sink to a 20W CPU that has been running too hot in past designs. This CPU will be mounted to a circuit card assembly for a flight control computer box in an aircraft. An engineer looks in a vendor catalog to find a simple heat sink that will fit the profile of the CPU. He discovers that there are 40 different types to choose from that also vary in price and availability. There is no forced air moving over this heat sink. The challenge is to select the best heat sink for the job. The engineer must use Pro/MECHANICA to validate a base line heat sink, then use sensitivities and optimization to decrease the mass of the part while maintaining a maximum temperature of 135 degrees F. These studies will assist the engineer in selecting the proper heat sink for the application at hand. The initial model will have a 20W heat source placed on the bottom surface, and a convection of 0.01 placed on the long vertical faces of the fins. hstart = 0.01 (lbf /in degree F sec) => free convection or no forced air. Q = 20 (Watts) = 14.75 (lbf in/sec).
Figure 3: Heat Sink Drawing
Pag e 1 3- 7
NOTES
Analyzing a Buckling Ring

Determine the best way to simplify the buckling analysis of a disk under radial compression. You are designing components for a jet engine. One of your components is a complex ring that undergoes a radial (inward) load. You wish to see if that load is at or above the critical load that will induce linear buckling. The complex model would take a long time to run, so you would like to simplify the model, using shells, symmetry, and/or axisymmetric modeling. Not knowing your buckling mode shapes ahead of time, however, you're not sure what kinds of simplifications are appropriate. So you should build a full 3D solid test model with the approximate shape of your ring, look at the mode shapes, estimate what types of simplification that you can put on the model, build a simplified test model, and then run that simplified model to confirm validity. If the simplified test model gives the same answers as the full test model, then you can be reasonably confident that the complex model can be simplified in the same way. The test model with the same approximate shape as your real-world part would be an annulus with an outer diameter of 2 meters, an inner diameter of .2 meters, and a thickness of .02 meters, as shown in the following figure. The material is Steel. Remember to add your constraints and loads in the current working coordinate system. Build your model with solid elements. Since buckling analyses take more time to run than regular static analyses, make sure to use whatever element creation method necessary such that there are fewer than 100 solid elements, or you will spend too much time waiting for the analysis to solve. Constrain the inner radius of the annulus in all 6 DOF. Load the outer radius with an inward radial load. Run a buckling analysis for the first 5 buckling load factors (BLF), with all convergences set to 10% Look at animations of the buckling shapes that correspond to each of the BLF. Are all five half symmetric? If so, you could cut the model in half, add appropriate symmetric boundary conditions, and run it that way. Are all five quarter symmetric? If so, you could cut the model in quarters, again adding appropriate symmetric boundary conditions. Are all 5 axisymmetric? If so, you could rebuild this model as axisymmetric.
Pag e 1 3 - 8
NOTES
For University Use Only - Commercial Use Prohibited Decide how you wish to simplify the model (half symmetric, quarter symmetric, or axisymmetric). Then rebuild the test model with shell elements. Run the simplified test model. Notice that the shell model runs much, much faster than the solid model. Compare the BLF and buckling shapes in the simplified shell test model to those from the solid test model. Are they essentially the same? Does your simplified model capture a wide enough numerical range of BLF that you are confident that you've captured the major BLF of concern? If the answer to both of these questions is yes, then your simplification of the solid model is valid in an engineering sense, and you can expect that a similar simplification of your real world part would be similarly valid. Based on either of your models, would the part be able to sustain a 500,000 N load without undergoing linear static buckling?
Figure 4: Ring
Analyzing a Beverage Can

You will create a shell model of a beverage can and determine how much stiffer the can is with positive pressure inside (before being opened) vs. with atmospheric pressure inside (after being opened). If you are starting in Pro/ENGINEER, create the can_body and can_lid parts. Make sure to start each part with a default coordinate system and default datum planes. Use an aluminum material for the body and a steel material for the lid. Auto-pair each part and check the results using the Shell Compress command. Assemble the parts together, making sure you use offsets (mate or align) appropriate to allow the shell compressions of the parts to meet up edge to edge. Check the shell compression of the assembly for connectivity before preceding.
Pag e 1 3- 9
NOTES
For University Use Only - Commercial Use Prohibited If you are starting in Pro/MECHANICA Structure, define the midplane surfaces for the body and the lid in one part, making sure that associativity exists around the upper edge. Apply a breathing constraint on the bottom surface of the can using a cylindrical coordinate system (i.e. constrain theta and z translations). There will be two load sets, a pressure load set and a step' load set (simulating standing on the can): Apply a 30 psi pressure load to all the internal surfaces of the can (don't pressurize the rim on top) in a load set called press_load. Display the load to verify that the pressure is directed outward. Apply a -165 lb load in the negative z-direction along a single edge on the rim of the can (the top surface will be compressed so a load on the surface will cause an error). Use the load set name step_load. Display the load to verify its distribution.
Next you will define three analyses. For each analysis, converge to 10% on Local Displacement, Local Strain Energy and Global RMS Stress. Allow a maximum p-order of 9 and increase the plotting grid to 7 or more. The analysis types and load sets are as follows: A Static analysis called press_ld_only' will have only the pressure load set applied. Another Static analysis will have only the step load applied. A Pre-stress Static analysis called pre_sts_step' will have only the step load applied. Click the Page Down button and verify that the specified Static Analysis (providing the pre-stress condition) is the press_ld_only' analysis already defined.
Run the analyses one at a time or together in a design study called something like can_study'. Compute the stiffness for the pressurized can and compare to the stiffness of the open' (de-pressurized) can. Stiffness units are force per length and the stiffness values can be calculated by dividing the applied load (165 lbs) by the displacement of the top of the can. If you have extra time you can create a Buckling analysis using the step_load load set. Find the first two or three Buckling Modes with 10% convergence on the Buckling Load Factor & Local Displacement & Local Strain Energy & RMS Stress. Use a maximum p-order of 9 and a plotting grid of 7 or more.
Pag e 1 3 - 1 0
NOTES
Figure 5: Beverage Can Body
Figure 6: Beverage Can Lid
Pag e 1 3-11
NOTES
STUDENT PROJECT HINTS

Flagpole
1. Build a shell model. Flag poles are generally thin walled, so a solid model would contain too many elements. 2. Use extruded or lofted surfaces. 3. Apply all loads, constraints, and properties to geometry (curves and surfaces) not elements, so that if Pro/MECHANICA must remesh as a result of design variable changes, it can. 4. Put the end load and the gravity load in the same load set, for easier display of results. 5. Use Total Load Applied at Point to apply the load at the end of the pole. 6. Use Load > Gravity to apply the 3G load, which has a magnitude of -29.4 m/s^2 (in MNS units) and -29400 mm/s^2 (in mmNS units). 7. Converge on the quantity of interest, the maximum von Mises stress measure. 8. The maximum von Mises stress in the model must be below (193e6/4=) 4.5e7 Pa (in MNS units) or 45 Mpa (in mmNS units.)
Driveshaft
1. Since drive shafts are generally thick walled structures, you should use solid elements in your model. 2. Shell mesh a surface and then extrude it. If you AutoGEM the surface, consider the number of elements created, and whether you can more efficiently hand-mesh the same surface. 3. Note the aspect ratios of the solids you create. This model has a very simple and smooth load path, so there's no reason not to use aspect ratios of 20 or 30 to 1. At the same time, though, design your mesh so that you can change the geometry of the model with a minimum of automatic smoothening and regeneration by the engine.
Pag e 1 3 - 1 2
NOTES
For University Use Only - Commercial Use Prohibited 4. You must have some sort of constraint at the loaded end of the shaft. Consider defining a User Coordinate System before defining the constraint, so that it's in a system other than the World Coordinate System. 5. Use Total Load Applied at Point to apply the load at the end of the pole. 6. After running your first static analysis, look at fringe plots of maximum Von Mises stress and maximum principal stress. Which one do you consider to be a better failure criteria? 7. The stress in the model (whichever stress criteria you choose to use) must be below (193e6/4=) 4.5e7 Pa (in MNS units) or 45 Mpa (in mmNS units.) 8. The default number of requested modes, 4, will be enough to confirm that the frequency of the first mode is significantly below the frequency of the next lowest mode. 1.
Wing Spar
All users:
1. The dimensions shown in the diagram refer to the ideal part. Since a shell model uses midsurfaces, you will need to figure out your dimensions with reference to the midsurfaces. 2. The performance criteria are maximum Von Mises stress and maximum displacement magnitude. Specify that the static analyses converge on these quantities. 3. To be able to specify your convergence percentage, you must run the Multipass Adaptive Convergence Algorithm. 4. If your top surface is actually two separate surfaces, you will need to place two loads of (50, -200, 0) on each of those surfaces. 5. Make your optimization convergence 1%, and limit your maximum number of iterations to 20.
If using Pro/MECHANICA in Integrated Mode:
1. The part geometry and material must be in inches.
Pag e 1 3-13
NOTES
For University Use Only - Commercial Use Prohibited 2. Careful attention must be paid to the thickness of the beam. These surfaces will be paired at a later time, so this step is very critical. We want to have a .2 surface thickness property after compression. 3. Place an immovable displacement constraint on the left hand or thicker end of the part. The constraints must be on the inside edges of the surface for them to properly pair during the compression. The constraints must be for all translations but no rotations.
Valve Housing
1. Use symmetric boundary constraints to reduce the size of the model. A 30, 45, or 90 degree section would run much more quickly, and with less disk, than the full 360 degree model. 2. The last paragraph in the instructions that refers to Max. Distortion Energy Theory (or von Mises - Henckly Theory) means that you should use Maximum Von Mises stress as your failure criteria. It should never exceed 60 ksi (60e3 psi), and it should be the quantity upon which your static analysis converges.
If using Pro/MECHANICA in Integrated Mode:
1. Start your model by creating a DATUM COORD SYS, and DEFAULT DATUM PLANES. 2. Build your profile on the DTM3, the XY plane of the coordinate system. 3. When defining your revolved protrusion select Variable as the REV TO option. Enter a value of about 15 to 20 degrees. Use this parts symmetry to reduce the GEA model size. 4. When defining the fillets and rounds use the SURF-SURF option. If you use the default EDGE option, the regeneration will fail if you Redefine the protrusion to 360 degrees. If you use SURFSURF then there is no problem with Redefining the protrusion. 5. As the drawing states all of the unmarked radii are 0.032 inches. These do not have to remain all the same value. Make them separate rounds, and do not define relationships between them. 6. To make your design parameters easy to remember, you may want to modify the dimension cosmetics of the dimension symbols, to more logical names. For example: Rename a radius dimension from Rd15 to Rtop_rad.
Pag e 1 3 - 1 4
NOTES
For University Use Only - Commercial Use Prohibited If using Pro/MECHANICA in Independent Mode:
1. Build your geometry on the default XY plane, with the Y-axis as the valves centerline. 2. For the Model Type use 2D Axisymmetric. 3. As the drawing states all of the unmarked radii are 0.032 inches. These do not have to remain all the same value. Have them defined by separate Parameters.
Heat Sink
1. Starting in Pro/MECHANICA Structure, create the surface of extrusion according to the dimensions given above, and AutoGEM and extrude this surface 1. 2. Use AL2014_IPS is the material. 3. Place a Total heat load of 14.75 on the base surface. 4. Place a convection coefficient of 0.01 lbf /in deg F sec and Bulk temperature of 90 deg. F, on the long vertical faces of the fins. There should be a total of 12 surfaces selected.
Validation Analysis:
1. Convergence Method: Multipass Adaptive. 2. Convergence: Measures: Local Temps & Local & Global Energy Norms 1%.
Design Variables and Sensitivity Studies:
1. For the fin height, translate the top fin surface. Original height = 0.7. Final height = .2 2. For the base thickness, translate the base surface. Original thickness = .3. Final thickness =.15 3. All convection Film Coefficients should range from 0.01 to 1. The quantity 1 is derived from 2 cfm of airflow that could be potentially rerouted through the enclosure to the CPU. The question should be asked What does a varying convection coefficient relate to physically. You should be comparing this variable to mass flow rate. 4. Plot max_temperature vs. design variable.
St u d e n t P ro j e c t s Pag e 1 3-15
NOTES
For University Use Only - Commercial Use Prohibited 5. Run sensitivities on all the above, referencing the same validation analysis mentioned before.
Optimization
1. Goal: minimize total_mass. 2. Limits: max_temperature < 135 degree F. 3. Optimization Convergence should be 1%, Maximum # Iterations = 20. 4. Deselect Smooth, Regenerate, & repeat
Extra Credit:
1. Run a sensitivity on the Convection Bulk Temperature from 70 to 130 Deg. F. The question should be asked, What does a varying convection bulk temperature relate to physically. Students should relate this to the ambient operating temperature of the flight control computer box in the air craft.
Buckling Ring
1. Since the output of a buckling analysis is a buckling load factor that represents the critical buckling load over the current load, enter a magnitude of 1 for the solid model radial load. That way, the buckling load factor will be equal to the critical buckling load. If you build quarter or half symmetric models later, make sure to scale the load so that you are comparing apples to apples when comparing the buckling load factors. If you build an axisymmetric model, use a value of 1 since axisymmetric loads are input with the magnitude that they would have on an entire model. 2. Some of your buckling shapes (and BLF) will essentially be duplicates of each other. This is normal- Mechanica is finding two different poles of the same buckling shape. 3. One criteria for deciding if you've looked at enough BLF might be the following: if the highest BLF is at least twice the lowest BLF, then your BLF are not just clustered around one particular value, and it would be very unlikely that a small design change would make a previously unseen buckling shape (with a higher BLF value) drop it's BLF in half to become the new, lowest (and hence most critical) buckling shape.
Pag e 1 3 - 1 6
NOTES
Beverage Can
1. Below are two more efficient ways to analyze the stiffness of the can (using less elements; therefore, solving more quickly); however, these simplified models will not be suitable for a buckling analysis. 2. To save analysis time, you can cut the Pro/ENGINEER assembly to a smaller section (a 30 degree pie section for instance) and apply symmetry constraints at the boundaries. A 30 degree section should require about 1/12 the degrees of freedom to solve than a 360 degree section. Remember to reduce the load appropriately if using a partial model! 3. Since the model and loads are axisymmetric you could run the model in independent mode using an axisymmetric model type and 2D-shell elements along the boundary. To do this cut the model to a section with one side of the cut on the xy plane. Transfer the model to Independent MEC, verifying that the setting to Use Pairs is checked. Once in Mechanica do a top view and delete all geometry except the curves on the xy plane. Make sure all geometry is in the positive xy plane and use the Axisymmetric model type. AutoGEM the curves and apply the loads and constraints.
Note:
If you attempt this Exercise in Independent Mode, use only the outer surfaces of the can -- not the midsurfaces.
Pag e 1 3-17
Appendix
Using PTC Help

In this module you learn how to use PTC Help to search for Pro/ENGINEER information. PTC Help provides quick references and detailed information on selected topics.
Objectives
After completing this module, you will be able to: Start PTC Help. Search for specific information about Pro/ENGINEER. Obtain context-sensitive help while performing a task.
Page A-1
NOTES
DEFINING THE PTC HELP FEATURES

The PTC Help system is integrated into Pro/ENGINEER. It offers: A table of contents, an index, and searching capability. Context-sensitive help access. Online tutorials focussed on teaching different aspects of the software. Expanded help topics available as special dialog boxes.
Database
For addition help, the PTC Technical Support online Knowledge features thousands of suggested techniques. Detailed information on the Knowledge Database is referenced in the Technical Support Appendix.
USING THE Pro/ENGINEER ONLINE HELP

The Pro/ENGINEER Online Help can be accessed:
Using the Main Menu .
1. Click Help > Contents and Index from the Pro/ENGINEER Main Menu, as shown in the following figure.
Figure 1: Accessing Help from the Main Menu
Pag e A- 2
Append ix
NOTES
For University Use Only - Commercial Use Prohibited The Pro/ENGINEER Online Help homepage displays in your web browser window. A list of topics displays in the left frame of the window.
Figure 2: Online Help Homepage
Using Context-Sensitive Help .
1. Click the
icon in the Pro/ENGINEER Main Menu toolbar.
2. Click any icon or any part of the Pro/ENGINEER Main Menu for detailed information on a particular item. A browser window displays with a description of the item.
Usin g PT C Help
Pag e A- 3
NOTES
For University Use Only - Commercial Use Prohibited In the following example, clicking the Model Tree icon in the Main Menu toolbar displays a browser window explaining the Model Tree icon functionality.
Figure 3: Model Tree Icon
Figure 4: The Help Browser Window for the Model Tree Icon
3. The lower left corner of the browser window displays a See Also link, as shown in the previous figure
Pag e A- 4
Append ix
NOTES
For University Use Only - Commercial Use Prohibited 4. The See Also link provides a list of related topics, as shown in the following figure.
Figure 5: The See Also List of Topics
Usin g PT C Help
Pag e A- 5
NOTES
For University Use Only - Commercial Use Prohibited

Using the Pro/ENGINEER Menu Manager .
1. Click the
icon in the Pro/ENGINEER Main Menu toolbar.
2. Select any menu command from the Menu Manager. 3. A TOPIC ROUTER browser window opens with a list of topic links that explain the menu command. 4. Select a topic link. The X-Section menu command in the Menu Manager displays the TOPIC ROUTER browser window with a list of two related topics, as shown in the following figure.
Figure 6: Using the Menu Manager
Pag e A- 6
Append ix
NOTES
For University Use Only - Commercial Use Prohibited Using Vertical Menu Commands .
1. Right-click and hold on a menu command until the GETHELP window displays.
Figure 7: Right-Clicking in Menu Manager
Usin g PT C Help
Pag e A- 7
NOTES
Defining the PTC Help Table of Contents

There are four branches in the PTC Help Table of Contents:
Figure 8: Four Main Branches in Help System
Figure 9: Foundation and Additional Modules in Help
Pag e A-8
Append ix
Appendix
Technical Support
In this module you learn about the telephone hotline and the online services that provide 24 hour / 7 day Technical Support.
Objectives
After completing this module you will be able to: Open a Technical Support telephone call. Register for online Technical Support. Navigate the PTC Products Knowledge Base. Locate telephone numbers for technical support and services.
Page B-1
NOTES
Locating the Technical Support Web Page

Select SUPPORT from the PTC HOME PAGE, www.ptc.com, or go directly to www.ptc.com/support/support.htm.
Opening Technical Support Calls via E-Mail

Send email to cs_ptc@ptc.com. Use copen as the e-mail subject. Use the following format (or download the template from www.ptc.com/cs/doc/copen.htm):
FNAME LNAME CALLCENTER TELEPHONE CONFIG_ID PRODUCT MODULE PRIORITY DESC_BEGIN
First Name Last Name U.S., Germany, France, U.K., Singapore,Tokyo NNN NNN-NNNN x-NNNN NNNNNN
description starts description continues description ends
DESC_END
Pag e B- 2
Append ix B
NOTES
Opening Technical Support Calls via Telephone

For your local Technical Support Center, refer to the Contact Information telephone list referenced at the end of this module. When logging a call, you must provide the following information to the Technical Support Engineer: Your PTC software Configuration ID. Your name and telephone number. The PTC product name. Priority of the issue.
Opening Technical Support Calls via the Web

To open Technical Support calls 24 / 7, select PRO/CALL LOGGERY in the PTC web site, www.ptc.com/support.
Sending Data Files to PTC Technical Support

To send data files to PTC Technical Support, follow the instructions at: www.ptc.com/support/cs_guide/additional.htm.
Note:
When a call is resolved, your data is deleted by a Technical Support Engineer. Your data confidential and will not be shared with any third party vendors, under any circumstances. You may request a Non-Disclosure Agreement from the Technical Support En gineer.
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Pag e B- 3
NOTES
Routing Your Technical Support Calls
Call
Customer question
Telephone Call
Web Call
Tech SupportEngineer creates a call in the database
Call is automatically created in the database
Investigation
Call Back and Investigation
Support Engineer solves issue or reports it to Development (SPR)
SPR
Software Performance Report SPR fixed from Development
Software Performance Report (SPR) SPR Verification through Tech. Support Engineer
Update CD to customer
Pag e B- 4
Append ix B
NOTES
Technical Support Call Priorities

Extremely Critical Critical Urgent
Work stopped
Work severely impacted Work impacted
Non Critical General Information
Software Performance Report Priorities

Top Priority
Highly critical software issue that is causing a work
stoppage. Critical software issue that affects immediate work and a practical alternative technique is not available.
High Medium
Software issue that does not affect immediate work or a practical alternative technique is available.
Registering for On-Line Support

To open a registration form, go to www.ptc.com/support, click Sign-up Online, then enter your CONFIGURATION ID. To find your CONFIGURATION ID, click Help > About Pro/ENGINEER . Complete the information needed to identify yourself as a user. Note your username and password for future reference.
Pag e B- 5
NOTES
Using the Online Services

After you have registered, you will have full access to the online tools.
Pag e B- 6
Append ix B
NOTES
Finding Answers in the Knowledge Base

The Technical Support KNOWLEDGE BASE contains over 18,000 documents. Technical Application Notes (TANs), Technical Point of Interest (TPIs), Frequently Asked Questions (FAQs), and Suggested Techniques offer up-todate information about all relevant software areas.
Pag e B- 7
NOTES
Terminology Used by Technical Support

TAN
A Technical Application Note provides information about SPRs that may affect more than just the customer originally reporting an issue. TANs also may provide alternative techniques to allow a user to continue working. A Technical Point of Interest provides additional technical information about a software product. TPIs are created by Technical Support to document the resolution of common issues reported in actual customer calls. TPIs are similar to TANs, but do not reference an SPR. Provides step-by-step instructions including screen snapshots, on how to use PTC software to complete common tasks.
TPI
Suggested Techniques
FAQ
Frequently Asked Questions provides answers to many of the most commonly asked questions compiled from the PTC Technical Support database. FAQs and Suggested Techniques are available in English, French, and German.
Getting Up-To-Date Information

To subscribe to our KNOWLEDGE BASE MONITOR e-mail service, go to www.ptc.com/support, and click Technical Support > Online Support Applications > Knowledge Base Monitor . You will receive daily e-mail with the latest information on your product.
Figure 1: Knowledge Base Monitor Sign Up
Pag e B- 8
Append ix B
NOTES
CONTACT INFORMATION
Technical Support Worldwide Electronic Services
The following services are available 24 / 7:
Web
www.ptc.com/support/index.htm (Support) www.ptc.com/company/contacts/edserv.htm (Education)

E-mail
cs_ptc@ptc.com (for opening calls and sending data) cs-webmaster@ptc.com (for suggestions about the Customer Service web site)
FTP
ftp.ptc.com (for transferring files to PTC Technical Support)
Technical Support Customer Feedback Line

The Customer Feedback Line is intended for general customer service concerns that are not technical product issues.
E-mail
cs-feedback@ptc.com
Telephone
www.ptc.com/cs/doc/feedback_nums.htm
Pag e B- 9
NOTES
TELEPHONE AND FAX INFORMATION

For assistance with technical issues, contact the Electronic Services noted in the previous section, or the Technical Support line as listed in the Telephone and Fax Information sections below. PTC has nine integrated Technical Support Call Centers in North America, Europe, and Asia. Our worldwide coverage ensures telephone access to Technical Support for customers in all time zones and in local languages.
North America Telephone Information

Customer Services (including Technical Support, License Management, and Documentation Requests): Within the United States and Canada 800-477-6435 Outside the United States and Canada: 781-370-5332 781-370-5513 Maintenance 888-782-3774 Education 888-782-3773
Pag e B- 10
Append ix B
NOTES
Europe Telephone Information

Technical Support Telephone Numbers
Austria 0800 29 7542 Belgium 0800-15-241 (French) 0800-72567 (Dutch) Denmark 08001-5593 Finland 0800-117092 France 0800-14-19-52 Germany 0180-2245132 49-89-32106-111 (for Pro/MECHANICA outside of Germany) Ireland 1-800-409-1622 Israel 1-800-945-42-95 (All languages including Hebrew) 77-150-21-34 (English only) Italy 0800-79-05-33 Luxembourg 0800-23-50
Cu s to m e r Su p p o rt I n f o rm a t io n
Pag e B-1 1
NOTES
For University Use Only - Commercial Use Prohibited Netherlands 0800022-4519 Norway 8001-1872 Portugal 05-05-33-73-69 South Africa 0800-991068 Spain 900-95-33-39 Sweden 020-791484 Switzerland 0800-55-38-33 (French) 0800-83-75-58 (Italian) 0800-552428 (German) United Kingdom 0800-318677
License Management Telephone Numbers

Belgium 0800-75376 Denmark 8001-5593 Finland 0800-117-092 Eastern Europe 44 1252 817 078 France 0800-14-19-52 Germany 49 (0) 89-32106-0
Pag e B- 12
Append ix B
NOTES
For University Use Only - Commercial Use Prohibited Ireland 1-800-409-1622 Italy 39 (0) 39-65651 Netherlands 0800-022-0543 Norway 8001-1872 Portugal 05-05-33-73-69 Russia 44 1252 817 078 Spain 900-95-33-39 Sweden 020-791484 Switzerland 41 (0) 1-8-24-34-44 United Kingdom 0800-31-8677
Pag e B-1 3
NOTES
Education Services Telephone Numbers

Benelux 31-73-644-2705 France 33-1-69-33-65-50 Germany 49 (0) 89-32106-325 Italy 39-039-65-65-652 39-039-6565-1 Spain/Portugal 34-91-452-01-00 Sweden 46-8-590-956-00 (Malmo) 46-8-590-956-46 (Upplands Vasby) Switzerland 41 (0) 1-820-00-80 United Kingdom 44-0800-212-565 (toll free within UK) 44-1252-817-140
Pag e B- 14
Append ix B
NOTES
Asia and Pacific Rim Telephone Information

Technical Support Telephone Numbers
Australia 1800-553-565 China* 10800-650-8185 (international toll free) 108-657 (manual toll free) Hong Kong 800-933309 India* 000-6517 Indonesia 001-803-65-7250 7-2-48-55-00-35 Japan 120-20-9023 Malaysia 1-800-80-1026 New Zealand 0800-44-4376 Philippines 1800-1-651-0176 Singapore 65-830-9899
South Korea 00798-65-1-7078 (international toll free) 080-3469-001 (domestic toll free)
Pag e B-1 5
NOTES
For University Use Only - Commercial Use Prohibited Taiwan 0080-65-1256 (international toll free) 080-013069 (domestic toll free) Thailand 001-800-65-6213 Callers dialing from India or China must provide the operator with the respective string: China MTF8309729 India
MTF8309752 The operator will then connect you to the Singapore Technical Support Center.
License Management Telephone Numbers

Japan 81 (0) 3-3346-8280 Hong Kong (852) 2802-8982
Education Services Telephone Numbers

Australia 61 2 9955 2833 (Sydney) 61 3 9561 4111 (Melbourne)
China 86-20-87554426 (GuangZhou) 86-21-62785080 (Shanghai) 86-10-65908699 (Beijing) Hong Kong 852-28028982 India
Pag e B- 16
Append ix B
NOTES
For University Use Only - Commercial Use Prohibited 91-80-2267272 Ext.#306 (Bangalore) 91-11-6474701 (New Delhi) 91-226513152 (Mumbai) Japan 81-3-3346-8268 Malaysia 03-754 8198
Pag e B-1 7
NOTES
For University Use Only - Commercial Use Prohibited Singapore 65-8309866 South Korea 82-2-3469-1080 Taiwan 886-2-758-8600 (Taipei) 886-4-3103311 (Taichung) 886-7-3323211 (Kaohsiung)
ELECTRONIC SERVICES
Up-to-Date + Information Worldwide ISO 9000 Certification Quality Control System
= Maximum Productivity with PTC Products
Pag e B- 18
Append ix B

Pro Engineer 2001 Mechanica Structure Thermal

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Pro Engineer 2001 Mechanica Structure Thermal

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PTC Global Services

Fundamentals of Pro/MECHANICA Structure/Thermal

For University Use Only - Commercial Use Prohibited -

For University Use Only - Commercial Use Prohibited -

PRINTING HISTORY Document No. Date T741-320-01 11/10/01

Description Initial Printing of Fundamentals of Pro/MECHANICA Structure/Thermal for Release 2001

Order Number DT-741-320-EN Printed in U.S.A

For University Use Only - Commercial Use Prohibited -

PTC Telephone and Fax Numbers

Technical Support (Monday - Friday)

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RUNNING ANALYSES.................................................................................................... 1-4

USER INTERFACE: INTEGRATED MODE I .............................................................. 1-12

MODULE SUMMARY ................................................................................................... 1-53

SIMPLIFYING MODELS WITH IDEALIZATIONS

IDEALIZATIONS ............................................................................................................. 2-2

LABORATORY PRACTICAL ..........................................................................................2-6

OPTIMIZING MODELS FOR ANALYSIS

INTEGRATED MODE MODELING ................................................................................3-2

LABORATORY PRACTICAL ........................................................................................3-10

ASSIGNING MATERIAL PROPERTIES

BASIC MECHANICS OF MATERIALS ..........................................................................4-2

Systems of Units .................................................................................................................4-4 LABORATORY PRACTICAL ..........................................................................................4-5

MODULE SUMMARY ................................................................................................... 5-21

SIMULATING APPLIED LOADS

INTRODUCTION.............................................................................................................. 6-2 LABORATORY PRACTICAL ......................................................................................... 6-3

MODULE SUMMARY ................................................................................................... 6-22

RUNNING AND EVALUATING ANALYSES

LABORATORY PRACTICAL ......................................................................................... 7-3

MODULE SUMMARY ................................................................................................... 7-32

ANALYSIS AND RESULTS: EXAMPLES

LABORATORY PRACTICAL ......................................................................................... 8-3

MODULE SUMMARY ................................................................................................... 8-25

LABORATORY PRACTICAL ..........................................................................................9-4

Model Description ............................................................................................................10-2

INTEGRATED MODE CONTACT FUNCTIONALITY ...............................................11-2

TRANSIENT THERMAL ANALYSIS ...........................................................................11-5

LABORATORY PRACTICAL ........................................................................................11-8

OVERVIEW .....................................................................................................................12-2 LABORATORY PRACTICAL ........................................................................................12-4

STUDENT PROJECTS ....................................................................................................13-2

STUDENT PROJECT HINTS ....................................................................................... 13-12

USING PTC HELP

CONTACT INFORMATION ........................................................................................... B-9

TELEPHONE AND FAX INFORMATION .................................................................. B-10

ELECTRONIC SERVICES ............................................................................................ B-18

For University Use Only - Commercial Use Prohibited -

For University Use Only - Commercial Use Prohibited -

For University Use Only - Commercial Use Prohibited -

For University Use Only - Commercial Use Prohibited -

For University Use Only - Commercial Use Prohibited -

Analysis Design Scenario

Figure 1 Designing a shelving bracket

Identifying the Design Requirements

Creating the Bracket Design

Figure 2 Bracket design parameters.

For University Use Only - Commercial Use Prohibited Note:

Figure 3: The bracket dimensioning scheme.

Idealizing the Bracket as a Shell

Figure 4 Mid-surface compression.

Defining Material Properties

For University Use Only - Commercial Use Prohibited -