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Fig.1
Analysis
The software used to perform the analysis is SolidWorks. The first step is to build the model according
to the specified design and dimensions. After the design is complete and the dimensions are fully
defined, a tetrahedral mesh is created. The shape of a tetrahedron was chosen as it is the most
accurate and is a default setting by this software.
The second step is the material selection. SolidWorks software has its own materials library. The
chosen material is Aluminium Alloy 5052-H38, which has very close properties to the ones found in the
Coursework Brief, as presented in Tab.1.
In order to make sure that the study runs properly it is necessary to make sure that the point A of the
structure is fixed and that no external force is acting on the body. SolidWorks calculates the mass of
the structure as being m=1.43kg. To check this result we use the formula =m/V , where is
the density of the material and V is the total volume of the structure. The results are the same.
Aluminium Alloy 5052-H38
Elastic Modulus
70 GPa
Poisson's Ratio
0,33
Shear Modulus
25.9 GPa
Mass Density
2680 kg/m3
Tensile Strength
290 Mpa
Yield Strength
255 Mpa
Tab.1
After applying the specified constrains, a Frequency Study is ran in order to find the first 3 natural
frequencies of the system, presented in Tab.2.
Fig.2
Fig.3
Fig.4
Frequency
(Hertz)
Frequency
(Rad/sec)
19,399
23,851
63,182
121,89
149,86
396,98
X
direction
(mm)
0,051548
0,59474
0,041928
4,00 x10-7
0,015827
0,12514
Tab.2
Period
(Seconds)
Y
direction
(mm)
3,34 x10-7
0,61984
9,20 x10-7
Z
direction
(mm)
0,023581
3,92 x10-9
0,15399
Magnitude
0,78633
0,7873
0,52834
M = x 2+ y 2 + z 2
Fig.3
Fig.4
In order to find the maximum displacement of point C relative to the horizontal plane passing through
point A and also the locations of the greatest vonMises stress we need to run a Static Study. A new
constrain is added, a mass of m=0.5kg being placed on point C. Also, the structure has to be under
the action of the gravitational force, where a=9.81m/s2 .
The most accurate maximum displacement of the structure is -1.444mm at point C, as in Fig.5.
However, in point B the displacement is approximately -0.7221mm and it decreases uniformly towards
Fig.5
Fig.6
Modeling idealisations
The welding between the two beams represents the first and most important factor on this analysis.
However, studying this factor is not part of the actual project. For this reason, the structure was
designed as a unit-body and the studies were completed assuming a constant material density
throughout the structure.
Another factor which needs to be taken into consideration is the definition of a point mass. Because
a point mass is physically impossible, an evenly distributed load on a very small area was created. At
point C of the structure, a small cylinder with a radius of 3mm and a height of 1mm was designed in
order to perform the analysis successfully. Because of its very small dimensions, the cylinder will not
visibly affect the results.
Accuracy
In order to check if the results are reasonable and accurate, the same study, on the exact same
model, can be performed in different software. In this case CATIA V5 was used. Because the
percentages of error are less than 5%, it is considered that the difference is due to the mesh
difference and the slight difference of 1.1% in the mass density.
Error %
3.3%
3.9%
3.7%
3.6%
3.9%
1.1%
1.96%
The difference in mesh size is a factor which plays a crucial role in getting accurate results. As
illustrated in the graph below, the accuracy increases proportional with the number of nodes in the
mesh. There is a difference of 5.75% between the displacement obtained by using the smallest and
the biggest mesh. Throughout both studies performed in SolidWorks, the most accurate mesh was
applied, in this case having more than 60000 nodes.
61476
33002
Accuracy
16403
5051
7450
-1.35 -1.36 -1.37 -1.38 -1.39 -1.4 -1.41 -1.42 -1.43 -1.44 -1.45
Conclusion
The objective of the project was successfully met, the studies on the structure were performed using
Solidworks and the results obtained were collected and analysed. Furthermore, the cause of errors
and the idealizations that helped achieving the data were explained.
The structure can successfully support a mass of 0.5kg without deforming plastically. The design of
the I-beam is more efficient at serving this purpose than the box-beam, due to its shape.
References
Finite Element Analaysis Software | Autodesk available from
http://www.autodesk.com/solutions/finite-element-analysis
[7.12.2015]
Coursework Brief , School of Mechanical, Aeronautical and Automotive Engineering
available on Moodle
[7.12.2015]
3D CAD Design Software SolidWorks Education Edition Software
[30.11.2015]
CATIA V5 Student Edition
[3.12.2015]