1 Lab session 1

1.1 Objective:
Introduction to ANSYS Software
1.2 Introduction to ANSYS Software

ANSYS is a comprehensive engineering simulation software that helps engineers and designers
perform finite element analysis (FEA), computational fluid dynamics (CFD), electromagnetic
field simulations, and more. Developed by ANSYS Inc., the software suite is widely used in
industries such as aerospace, automotive, civil engineering, electronics, and energy to design and
optimize products.

1.2.1 Background
ANSYS is a finite element analysis software suite developed by ANSYS, Inc. The
software provides engineers and designers with a comprehensive set of tools for
simulating and analyzing the physical behavior of structures, components, and systems.
Originally developed in the 1970s, ANSYS has evolved over the years to become an
industry-standard software solution.

Figure 1-1 Fluent simulation

1.3 Overview of ANSYS

Purpose: ANSYS is designed to solve complex structural, thermal, fluid, and electromagnetic
problems through simulation, reducing the need for physical prototypes.
Applications: It is applied across a range of fields, including:
 Structural analysis: Simulating stress, strain, and deformation in mechanical
components.
  Thermal analysis: Assessing heat distribution and transfer.
 Fluid dynamics: Modeling fluid flow, turbulence, and interactions.
 Electromagnetic simulations: Analyzing electric, magnetic, and electromagnetic fields.
User Interface: ANSYS offers a graphical user interface (GUI) and scripting options for
advanced users, making it suitable for both beginners and experts.

1.4 Finite Element Analysis (FEA)

1.4.1 What is FEA?

Finite Element Analysis is a numerical method for solving complex engineering problems. It
involves breaking down a large, complex system into smaller, manageable pieces (finite
elements) to analyze their behavior under various conditions.

Figure 1-2 Gear Simulation

1.4.2 Key Concepts of FEA

1. Meshing: Dividing the model into small, finite elements.

2. Boundary Conditions: Applying constraints and external forces.
3. Solver: Calculating the system's response using mathematical equations.
4. Post-processing: Interpreting the results through graphs, animations, and contour plots.

1.4.3 FEA in ANSYS

ANSYS automates much of the FEA process while allowing users to customize settings for
specific needs. Its solvers handle linear and nonlinear problems, static and dynamic analysis, and
other scenarios.
1.5 Workflow of FEA in ANSYS

Pre-Processing

o Model Creation: Import or create a geometry in ANSYS.

o Material Properties: Define properties like density, elasticity, thermal
conductivity, etc.
o Meshing: Generate a finite element mesh for the model.
o Boundary Conditions: Specify supports, loads, pressures, temperatures, or any
external conditions.
o

Solution

o Select the type of analysis (e.g., static, dynamic, thermal).

o Run the simulation using the ANSYS solver.
o Monitor the convergence of the solution to ensure accuracy.

Post-Processing

o Visualize results through stress-strain plots, thermal maps, or flow patterns.

o Interpret data for decision-making or further optimization.

Figure 1-3 Dynamic FEA analysis

1.6 Advantages of FEA and ANSYS

1. Cost-Effective

 Reduces the need for expensive physical prototypes.

 Optimizes material usage by identifying areas of overdesign.
 2. Time-Efficient

 Accelerates the design cycle by simulating and analyzing multiple scenarios

quickly.

3. Accuracy

 Provides detailed insights into complex problems that are difficult to solve
analytically.

4. Versatility

 Capable of handling a wide range of engineering applications.

5. Risk Mitigation

 Identifies potential failures or inefficiencies before production.

6. Integration

 ANSYS integrates well with CAD software and supports multiphysics

simulations for coupled problems.

1.7 Objectives of Lab Session 1

The primary objectives of the first lab session are as follows:

i. Introduction to ANSYS Interface: Familiarize participants with the ANSYS Workbench
environment, including the layout, menu options, and toolbars.
ii. Basic Finite Element Analysis Concepts: Provide an overview of fundamental FEA
concepts, such as nodes, elements, and boundary conditions.
iii. Creating a Simple Model: Guide participants through the process of creating a basic
model using ANSYS, including geometry input, meshing, and material assignment.
iv. Applying Loads and Constraints: Instruct participants on how to apply loads and
constraints to the model, simulating real-world conditions.
v. Running a Simulation: Demonstrate the steps involved in running a finite element
simulation within ANSYS.
1.8 Other Details
1.8.1 Key Modules in ANSYS
i. ANSYS Mechanical: Structural analysis.
ii. ANSYS Fluent: Computational fluid dynamics (CFD).
iii. ANSYS HFSS: High-frequency electromagnetic simulations.
iv. ANSYS Maxwell: Low-frequency electromagnetic analysis.
v. ANSYS Workbench: A unified environment for integrating all simulation tasks.
1.8.2 Industries and Applications

 Aerospace: Aircraft design, structural integrity, and heat dissipation.

 Automotive: Crash simulation, aerodynamics, and NVH (noise, vibration, and
harshness).
 Electronics: PCB cooling, electromagnetic interference.
 Civil Engineering: Building and bridge design.

1.8.3 Challenges

 Learning Curve: It requires some technical knowledge to fully utilize its capabilities.
 Computational Requirements: High-fidelity simulations demand powerful hardware.

By leveraging the tools and methodologies provided by ANSYS, engineers can significantly
enhance the efficiency and reliability of their designs, ultimately leading to better product
performance and faster market entry.

2
 2 Lab Session No. 2
2.1 Objective
The static structural analysis using ANSYS, with a specific focus on understanding the influence
of different materials on the mechanical behavior of a cap part.
2.2 Software:
 ANSYS
2.3 Static Structure Analysis

Static structural analysis in ANSYS is a powerful simulation tool used to evaluate the behavior
of structures under steady-state loading conditions. It determines key parameters like
deformation, stress, strain, and reaction forces in components or assemblies subjected to static
forces that remain constant over time. Widely applied across industries, it helps analyze
mechanical parts such as beams and gears, civil structures like bridges and buildings, and even
automotive and aerospace components under static loads. The process begins with pre-
processing steps, including geometry creation, defining material properties, meshing, and
applying boundary conditions such as supports and static loads. During the solution phase,
ANSYS solves the equilibrium equations to calculate displacements, stresses, and strains,
ensuring convergence for accurate results. In the post-processing stage, engineers can visualize
deformation, stress distribution, and safety factors to assess structural performance. ANSYS
supports advanced features like contact detection, nonlinear analysis for complex behaviors, and
integration with other simulation domains. Its precise results reduce the need for physical
prototypes, identify potential failure points early, and provide a cost-effective way to optimize
designs for safety and performance. For example, analyzing a cantilever beam under a
concentrated load in ANSYS can reveal deformation patterns and stress concentrations, guiding
design improvements. This versatility makes static structural analysis in ANSYS an
indispensable tool for modern engineering.

Figure 2-4 Static structure analysis

2.4 Procedure:

1. The CAD model of the designated mechanical part was imported into ANSYS, with
careful attention to verifying geometry integrity and making necessary adjustments as
required.

Figure 2-5 Import CAD model

Figure 2-6 Cap port

2. Material properties were then assigned to the original part, and alternative materials
were selected for subsequent analyses to explore their impact on structural behavior.

Figure 2-7 Material assignment

3. To ensure accurate results, we generated a finite element mesh for the part,
considering the significance of mesh density and quality.

Figure 2-8 Meshing or port cap

 4. Realistic loads, such as forces and pressures, were applied to simulate authentic
operating conditions. Additionally, boundary conditions were defined to represent
how the part interacts with its surroundings.

Figure 2-9 Elastic strain

5. Solver settings were configured, specifying static structural analysis, solution methods,
and convergence criteria.
6. The static structural analysis was executed, and the solution's convergence was monitored
to ensure a successful run without errors.
7. Post-processing of results involved examining stress distribution and deformation.
Comparisons were made between results obtained with different materials to understand
their distinct impacts on structural performance.
2.5 Material data
Steel
2.5.1 units
TABLE 1
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

2.5.2 Model
TABLE 2
Model > Geometry Imports
Object Name Geometry Imports
State Solved
TABLE 3
Model > Geometry Imports > Geometry Import
 TABLE 5
Model > Geometry > Parts
Object Name Part 1
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Reference Frame Lagrangian
Material
Assignment Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 80. mm
Length Y 50. mm
Length Z 20. mm
Properties
Volume 19819 mm³