Workbench - Simulation Basics

1
Workbench - Simulation Basics

• Workshop 2

2
Notes on Workshop 2

• The first workshop is extensively documented. As
  this course progresses, students will become more
  familiar with basic Workbench Simulation
  functionality (menu locations etc.), thus
  subsequent workshops will contain less details.
• Throughout these workshops menu paths are
  documented as First pick gt Second pick gt etc..
• Workshops begin with a goals section followed by
  an assumptions section.

3
Workshop 2 - Goals

• Using the Stress Wizard, set up and solve a
  structural model for stress, deflection and
  safety factor.
• Problem statement
• The model consists of a Parasolid file
  representing a control box cover (see figure).
  The cover is intended to be used in an external
  pressure application (1 Mpa/145 psi).
• The cover is to be made from aluminum alloy.
• Our goal is to verify that the part will function
  in its intended environment.

4
Workshop 2 - Assumptions

• We will represent the constrains on the counter
  bores, bottom contact area and inner sides using
  frictionless supports.
• Frictionless supports place a normal constraint
  on an entire surface. Translational displacement
  is allowed in all directions except into and out
  of the supported plane. Since we would expect
  frictional forces to at contact areas this is a
  conservative approach.

5
Workshop 2 - Start Page

• From the launcher start Simulation.
• Choose Geometry gt From File . . . and browse
  to the file Cap_fillets.x_t.
• When Workbench - Simulation starts choose
  Structural Branch under Outline Branch Macros,
  Ductile Materials under New Structural
  Simulation and click Run.

6
Workshop 2 - Environment

• Loads the load consists of a 1 MPa pressure
  applied to the 17 exterior surfaces of the cover.

7
. . . Workshop 2 - Environment

• Supports As described earlier frictionless
  supports are applied on 3 different regions of
  the model.
• Note the use of all frictionless surfaces will
  trigger the message shown here
• Workbench Simulation automatically places weak
  springs on structural models where the potential
  of rigid body motion exists. An inspection of
  the boundary conditions on this model should
  confirm that rigid body motion is prevented. In
  this case the weak springs have no effect on the
  results.
• This is an informational warning that the model
  should be inspected. It does NOT indicate the
  solution is invalid.
• The weak spring feature can be configured on/off
  by the user.

8
Workshop 2 - Preprocessing

• Setup working unit system
• From the main menu go to Units gt Metric (mm, Kg,
  N, C, s).

9
. . . Workshop 2 - Preprocessing

1. From the Simulation Wizard choose Verify
   Material. Locate the Material detail field
   and choose to Import gt Aluminum Alloy.

• Notice that verifying and changing material
  automatically highlighted the part branch in the
  tree.

10
. . . Workshop 2 - Preprocessing

• Loads Select the 17 exterior surfaces of the
  cover. To simplify selection
• Select 1 surface (choice is arbitrary).
• Click Extend to Limits to select the remaining
  16 surfaces.

4
3
11
. . . Workshop 2 - Preprocessing

• Loads Continued
• Choose Insert Loads from the SimWiz.
• Structural gt Pressure.
• Enter a Magnitude of 1 Mpa in the Details window.

12
. . . Workshop 2 - Preprocessing

• Supports (counter bores)
• Select the 4 counter bore surfaces (figure below
  shows 1).
• Choose Insert Supports from the SimWiz.
• Structural gt Frictionless Support

10
9
8
13
. . . Workshop 2 - Preprocessing

• Supports (inner sides)
• Select one of the inside surfaces of the bottom
  recess. Click the Extend to Limits button to
  add the remaining 7 surfaces to the selection set
  (8 total).
• Choose Insert Supports from the SimWiz.
• Structural gt Frictionless Support

11
13
12
14
. . . Workshop 2 - Preprocessing

• Supports (bottom)
• Select the surface at the bottom of the recess.
• Choose Insert Supports from the SimWiz.
• Structural gt Frictionless Support

15
Workshop 2 - Solution

• From the SimWiz choose Solve.
• The callout will direct you to the solve icon at
  the top of the GUI. Alternately you could right
  click on any branch in the tree and choose
  solve.

17
16
Workshop 2 - Results

1. From the SimWiz choose View Results. The call
   out will direct you to the Solution branch.
   Selecting various results branches will cause
   that result to be plotted (see next page).

18
17
. . . Workshop 2 - Results

• Plotting a models deformation often provides a
  reality check in structural analysis.
  Verifying the general nature (direction and
  amount) of deflection can help avoid obvious
  mistakes in model setup. Animations are often
  used as well.

18
. . . Workshop 2 - Results

• After reviewing stress results expand the safety
  tools and plot safety factors and margins.
  Notice both failure theories predict a minimum
  safety factor of lt 1.

19
Workshop 2 - Report

• To create an html report first click the Report
  Preview tab. The customization page allows you
  to set up the report.
• At this point simply choose Generate Report to
  review the default setup.

20
. . . Workshop 2 - Report

• When the report generation is complete scroll
  through the report and review its contents.
• Notice at this point there are no graphic images.
  Return to the Geometry tab to insert figures.

21
. . . Workshop 2 - Report

• Choose the graphical items you wish to include in
  your report by first highlighting the branch and
  orienting the plot.
• Next right click and insert a figure.
• The next time the report is generated the figures
  will be included.

22
. . . Workshop 2 - Report

• Notes on Figures
• Figures are not limited to results items. Adding
  a plot of the environment branch, for example,
  will include an image of model boundary
  conditions in the Report.
• Figures are independent. You may set up
  individual figures and have their orientation,
  zoom level, etc. retained regardless of the
  active model orientation or other figures.
• Individual branches can have multiple figures
  associated with them.