BMEE306P - Computer Aided Design and Finite Element Analysis Lab

SHAURYA GUPTA

22BMA0026

ASSESSMENT - 6 [Total: 10 marks]

Exercise No. 6a:

Stress analysis of a rectangular plate with a circular hole [5 marks]

Exercise No. 6b:

Modal analysis and the Campbell diagram for a rotor model [5 marks]

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Exercise No. 6a – Stress analysis of a rectangular plate with a circular hole

[5 marks]
Determine the stress concentration factor and the maximum stress around the hole for the
given plate.

Geometric Model:

f 40mm

100mm 20N

200mm

Thickness of the Plate=20mm

Data: E=20X103 N/mm2 and Poission’s Ratio = 0.3

GUI (Graphical User Interface) Procedure:

1) File – Clear & Start New – Do not read File – Ok.

2) File-Save as - Select suitable Drive - enter file name as ‘Plate1.db’- ok.
3) ANSYS Main Menu - Preferences – Structural – ok.
(Used to specify type of analysis)
Preprocessing Steps:
4) ANSYS Main Menu - Preprocessor – Element type – Add/Edit/Delete – Add –
Solid – Quad 4 Node 42 – Ok – Options – Change the Element Behavior K3 – Select
Plane Stress with Thickness – Ok – Close.
(Used to select type of finite element)
5) Preprocessor – Real Constants - Add/Edit/Delete – Add – ok –
I – 20
J- 20
K- 20
L - 20 -Ok- Close

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

6) Preprocessor – Material Props – Material Models – Structural (double click) –

Linear – Elastic – Isotropic
EX – 20e3 (in exponential form)
PRXY – 0.3 - ok – Material – Exit.
(Used to enter Young’s Modulus and Poisson’s ratio of the given material)
7) Preprocessor – Modeling – Create – Areas– Rectangle – 2 corners –

WP X 0
WP Y 0
Width 200
---Ok
Height 100

8) Preprocessor – Modeling – Create –area – circle – Solid circle –

WP X 100
WP Y 50
Radius 20

9) Preprocessor – Modeling – Operate –Booleans – Subtract –Areas – Pick the base

areas from which area to be subtracted (select the rectangle) – ok- Pick the
area to be subtracted (select circle) –ok.
10) Preprocessor – Meshing – Mesh tool – Smart size – mesh – select full area – ok.
Preprocessor – Loads – Define loads – Apply – Structural – Displacement – On nodes
– [Select box – Select left side of rectangle] – ok – (Select) All DOF– ok.
11) Preprocessor – Loads – Define loads – Apply – Structural – Force/Moment – on
Nodes –– [Select box – Select right side of rectangle] – ok – (enter the force
value as FX = 20 N/total number of nodes selected) – ok
Processing:
12) Solution – Solve – Current LS –ok – Solution is done – Close.
(Used to solve the problem)

Post processing Steps:

13) General Postproc – Plot Results – Contour Plot –nodal solutions–stress – X-
component of stress – (or von-Mises Stress)ok.
14) PlotCtrls – Animate – Deformed Shape – Ok.

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

(Animates the given model according to applied boundary conditions)

15) PlotCtrls – Symbols – All BC’s.
(Displays the all applied boundary conditions)
16) File – Save as – Select the Directory – Plate1.db – Ok.

RESULT: Calculate the stress concentration values and compare with theoretical value:

Analytical approach:
Calculation:

ANSYS approach:

ANSYS Theoretical
Deformation 37067 1486.66
Stress 0.722 2.23

Contour plots:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

School of Mechanical Engineering, VIT Vellore.

 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Inference:

The ANSYS experiment aimed to analyze stress distribution and concentration in a plate
under specific loading. Results showed a max stress of 37067 N/mm² (FEM) vs. 1486.66
N/mm² (Theoretical). Stress concentration factor (Kt) was 0.722 (FEM) vs. 2.23
(Theoretical), indicating discrepancies between FEM and theoretical values.Thus in
conclusion we can observe in the stress around the hole is higher than others parts.

Exercise No. 6b - Modal analysis and Campbell diagram for a rotor model

[5 marks]
Perform a modal analysis and draw the Campbell Diagram for a given free-free boundary
condition rotor model using ANSYS workbench

Theory: Rotor Dynamics is a specialized branch of applied mechanics concerned with the
behavior and diagnosis of rotating structures. It is commonly used to analyze the behavior of
structures ranging from jet engines and steam turbines to auto engines and computer disk
storage. At its most basic level, rotor dynamics is concerned with one or more mechanical
structures (rotors) supported by bearings and influenced by internal phenomena that rotate
around a single axis. The supporting structure is called a stator. As the speed of rotation
increases the amplitude of vibration often passes through a maximum that is called a critical
speed. This amplitude is commonly excited by imbalance of the rotating structure.

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Schematic diagram of the shaft-disk system showing the system components

Dimensions of CAD Model in mm:

CAD Model:

Reference Video for Exercise: https://www.youtube.com/watch?v=fNtcKxHjIKs

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Point Mass 1 40 kg
Point Mass 2 40 kg
Free Face Mesh Type QUAD element
Point Mass 3 40 kg
Rotational velocity 10000RPM
Maximum modes to excite 10

GUI (Graphical User Interface) Procedure:

1. File – Save – Enter Suitable File Name – Choose appropriate file location – Save

2. Toolbox – Modal – Click and drag mouse to project schematic section to create Modal menu

3. Modal – Right click Geometry – select Import Geometry – select Browse – Select
required model file from saved location – click open

4. Modal – Right click Model – select Update

5. Modal – Double click Setup to open Ansys Mechanical

6. Outline – Project – Model – Select Mesh

7. Details of Mesh – Sizing – Select “on curvature” in Use Advanced Size Function –
Set Relevance Center as fine – Set Smoothing as high – Set Transition as slow – Set
Span Angle Center as fine

8. Outline – Project – Model – Right click Mesh – Select Insert – Select Method

9. Set Select type as Box Select – Draw box around entire model to select all parts

10. Details of Automatic Method – Scope – Select no selection in Geometry – Select

Apply to set it to all parts of the model

11. Details of Automatic Method – Definition – Set method as Sweep – Set Free Face
Mesh Type as all quad

12. Outline – Project – Model – Right click Mesh – Select Generate Mesh to form mesh
structure

13. Set Select type as Single Select

14. Outline – Project – Model – Right click Geometry – Select Insert – Select Point-Mass

15. Repeat previous step two more times to create a total of 3 point-masses.

16. Outline – Project – Model – Geometry – Point Mass 1

17. Outline – Project – Model – Connections – Contacts – Select Contact face between
first two larger tubes

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

18. Details of Point Mass 1 – Scope – Geometry – Select Apply to place the point mass at
the select face from the previous step

19. Details of Point Mass 1 – Definition – Set mass as 40 kg – Set Mass Moment of
Inertia Z as 0.32 kg.mm2 – Set Behaviour as rigid

20. Outline – Project – Model – Geometry – Point Mass 2

21. Outline – Project – Model – Connections – Contacts – Select Contact face between
second and third larger tubes

22. Details of Point Mass 2 – Scope – Geometry – Select Apply to place the point mass at
the select face from the previous step

23. Details of Point Mass 2 – Definition – Set mass as 40 kg – Set Mass Moment of
Inertia Z as 0.32 kg.mm2 – Set Behavior as rigid

24. Outline – Project – Model – Geometry – Point Mass 3

25. Outline – Project – Model – Connections – Contacts – Select Contact face between
third and final larger tubes

26. Details of Point Mass 3 – Scope – Geometry – Select Apply to place the point mass at
the select face from the previous step

27. Details of Point Mass 3 – Definition – Set mass as 40 kg – Set Mass Moment of
Inertia Z as 0.32 kg.mm2 – Set Behavior as rigid

28. Outline – Project – Model – Geometry – Select all 3 point-masses – Right click
selection – Select promote to remote point

29. Outline – Project – Model – Select Remote Points

30. Details of Remote Points – Set Show Connection Lines as yes

31. Activate Wireframe View to view connection lines, disable to continue setup

32. Outline – Project – Model – Modal – Analysis Settings

33. Details of Analysis Settings – Options – Set Max Modes to Find as 10

34. Details of Analysis Settings – Solver Controls – Set Damped as yes – Set Solver Type
as Program Controlled

35. Details of Analysis Settings – Rotordynamics Controls – Set Coriolis Effect as on –

Set Campbell Diagram as on

36. Outline – Project – Model – Right click Modal – Insert – Select Rotational Velocity

37. Outline – Project – Model – Modal – Rotational Velocity

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38. Details of Rotational Velocity – Select Axis – Set it to act on Z axis of the left most
circular face in the direction towards the model – Select apply

39. Tabular Data – Set rotational velocity at point 2 as 10000 rpm

40. Outline – Project – Model – Modal – Right click Solution – Select solve

41. Required values can be viewed from Tabular Data

42. Tabular Data – Select required damped frequency values – Right click selection –
Select Create Mode Shape Results

43. Outline – Project – Model – Modal – Solution – Right click Total Deformation 1 –
Select Evaluate all Results

44. Graph – Select Play button to view analysis animation of each deformation type

45. Outline – Project – Model – Modal – Right click Solution – Insert – Select Campbell
Diagram

46. Outline – Project – Model – Modal – Solution – Right click Campbell Diagam –
Select Evaluate all Results

47. Outline – Project – Model – Modal – Solution – Campbell Diagram – Diagram and its
details can be viewed from worksheet

48. File – Save

49. Modal Analysis of given Model has been completed.

Tabulate the Total Deformation and Campbell Diagram:

a). Tabulate the natural frequencies

S.No Frequency in Hz
Natural Frequency 1 512.31
Natural Frequency 2 887.67
Natural Frequency 3 2049.7
Natural Frequency 4 3004.8
Natural Frequency 5 3.4433
Natural Frequency 6 1.5735E-002

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

b). Campbell Diagram from ANSYS & tabulate the first 3 critical speeds

Campbell Diagram:

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 BMEE306P - Computer Aided Design and Finite Element Analysis Lab

Critical speeds:

S.No In Hz
Critical Speed - 1 0
Critical Speed -2 500
Critical Speed -3 1000

Inference:

In rotor dynamics, ANSYS software is frequently employed to perform modal analysis and
generate Campbell diagrams, which are crucial for understanding and predicting the
vibrational behavior of rotating machinery. Modal analysis within ANSYS identifies the
natural frequencies and mode shapes of the rotor, revealing its inherent vibrational
tendencies. Subsequently, the Campbell diagram plots these natural frequencies against the
rotor's rotational speed, highlighting critical speeds where resonance may occur. These
critical speeds, where the operating speed coincides with a natural frequency, pose a risk of
excessive vibrations and potential failure. By utilizing ANSYS to conduct these analyses,
engineers can effectively design and optimize rotors to avoid resonance and ensure safe
operating conditions.

Conclusions:

In conclusion, the modal analysis conducted in ANSYS provided crucial insights into the
rotor's natural frequencies and mode shapes, revealing potential resonance vulnerabilities.
Subsequently, the Campbell diagram, generated by varying the rotor's rotational speed,
effectively illustrated the critical speeds where these natural frequencies intersected with
excitation frequencies. This analysis is vital for predicting and mitigating the risk of
resonance-induced failures, ultimately ensuring the rotor's operational stability and longevity.

School of Mechanical Engineering, VIT Vellore.