Altair's Student Guides - Instructor's Manual - CAE and Multi Body Dynamics

Student Project Summaries CAE and Multi Body Dynamics
Contents
Introduction.............................................................................................2
Installation Instructions: .......................................................................2
Dynamic Stresses in a Gear Assembly........................................................3
Description of the Problem ....................................................................3
Planning the Approach ..........................................................................4
Setting up the FE Model ........................................................................4
The MBD Model and Results ..................................................................5
Further Work ........................................................................................6
Summary .............................................................................................6
Design of a Torque Limiter .......................................................................7
Description of the Problem ....................................................................7
Planning the Approach ..........................................................................8
Setting up the FE Model ........................................................................8
The MBD Model and Results ..................................................................9
Further Work ........................................................................................9
Summary ........................................................................................... 10
Analysis and Design of a Valve Train ....................................................... 11
Description of the Problem .................................................................. 11
Planning the Approach ........................................................................ 12
Setting up the FE Model ...................................................................... 13
The MBD Model and Results ................................................................ 13
Further Work ...................................................................................... 14
Summary ........................................................................................... 14
Design of a Wiper Subsystem ................................................................. 15
Description of the Problem .................................................................. 15
Planning the Approach ........................................................................ 15
Setting up the FE Model ...................................................................... 16
The MBD Model and Results ................................................................ 17
Further Work ...................................................................................... 18
Summary ........................................................................................... 18
1
Introduction
This material is best used after reading the book CAE and Multi Body
Dynamics.
Access to HyperWorks software is not essential for you, the instructor. Of

course, if you choose to solve the problems yourself before working with
your students, you will need HyperMesh, MotionView, MotionSolve,
HyperView, HyperGraph and OptiStruct.
This book describes 4 assignment problems that highlight different

applications of HyperWorks. Each problem is independent, and is complete
in itself. Students may choose to do more than one, depending on their
interest.
To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player program
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a
server and accessed by clients.
You can customize the HTML files to suit your

requirements. After opening the file, double-
click on any text to edit it. Use the save
changes link on the left of your Browser window
when you are finished.
Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
edu.support@altair.india.com
2
Dynamic Stresses in a Gear Assembly

Areas covered:
• Use of an FE mesh to calculate mass and inertial
properties
• Creation of Hexahedral and Shell meshes
• Transfer between FE models and MDL models
• The use of contact in transient analyses
• Flexible Body Analysis – mixing the rigid-body and
flexible-body approaches in a single model
Software used:
• HyperMesh
• MotionView
• MotionSolve
• OptiStruct
• HyperView
• HyperGraph
Description of the Problem

An actuator is being designed for use in a
position controller. The design is at the concept
stage, and various alternatives are being worked
out. The design specification of the actuator
assembly calls for the design of gears, given the
center-to-center distance is 106 mm and the
velocity ratio is 1.28.
The current proposal calls for the use of steel

gears, but these may later be replaced with
plastic. Obviously various options exist, but the
easiest is to check if involute profile spur gears
can do the job.
Hand-design for gears is well-established, but

FEA can provide higher precision calculations,
thereby allowing the designers to use a lower
factor of safety. Conventional FEA’s
disadvantages are twofold. First, the problem
setup can be fairly demanding since the loads
vary with time. Second, integrating the finite
element model into the assembly-design
simulation is not very easy.
3
Traditional rigid-body mechanics is limited by the

assumption that the bodies are rigid, but the
option to use flexible models in a Multi-Body-
Dynamics (MBD) solver opens up new
possibilities.
Planning the Approach

The starting point for our design is a CAD model
of the two gears. The analysis involves contact
between the teeth - as the gears rotate, teeth
engage and disengage. We use shell elements
on the faces of the teeth to setup contact
between the two gears, since this is much more
efficient (computationally) than using the
hexahedral-element model.
Further, to conduct a flexible body analysis, we

perform a Component Mode Synthesis, for which
we need an acceptable model of the gear and
pinion. Since the proposal contains spur gears,
we use hexahedral elements for their greater
accuracy. For further proposals, as the geometry
gets more complicated, we can use a larger
number of tetrahedral elements if we are willing
to increase solver time in return for reduced
modeling time.
Once the finite element models are set up we

transfer the data to the MBD modeler. Here we
define joints, apply the motion, define the
contact, and solve. We choose to use contact
instead of defining a "gear" joint, since our
interest is in the calculation of tooth stresses.
Setting up the FE Model

We use HyperMesh to create the Finite Element
Models. As described earlier, there are two sets
of Finite Elements we need to create: one for
the flexible body analysis, the other for contact.
4
The process involves
• import of CAD data from an IGES file

• creation of material collectors so that
mass properties can be calculated
• generation of hexahedral elements by
“dragging” shell elements
• creation of nodes at locations where the
MDL model will place joints
• translation of the FE data into an MDL
Model
• generation of shell elements for contact-
surface definitions
Several files are generated by this stage – the

MDL statements themselves, the H3D file for the
graphics images and the mass and inertial
properties of the model.
The MBD Model and Results

Once the FE model is ready, the MBD setup is
relatively easy.
We follow the incremental approach in model-

building. This involves checking that the model is
behaving as expected at each step, before
adding the next level of abstraction or
complexity.
The MDL file created from the HyperMesh model

– this contains the “links” (or “bodies”), with the
associated graphics and mass-properties. We
add revolute joints for the gear-rotation and
setup contact using the surfaces defined by the
shell meshes. Since the bodies already have H3D
graphics associated with them, we create
dummy bodies, locate these in the correct place,
and assign the surface definitions to these.
For Component mode synthesis we use rigid

elements to connect the joint-center to the finite
element mesh and export this FE model using
5
the utility FlexPrep that interfaces with

OptiStruct to generate the flexible body data.
After the analysis we use HyperView and

HyperGraph to view the results of interest -
forces at various locations, animation of the
motion, stresses, etc.
Further Work
There are several aspects that can make the
project more complete. You may choose to
assign these to your students based on their
level of proficiency on programming, the time
available, etc.
Some of the areas for further work include
• tracking the variation of tooth-forces

with contact parameters
• running the analysis for plastic gears
• plotting the change in peak-stress with
the change in rotation-speed of the
gears
Summary
By the end of this assignment, the student will
know how to
• create MDL models from CAD data

• create hexahedral and shell elements
• create revolute joints
• assign graphics to various bodies
• define contact and assign friction
parameters
• setup Component Mode Synthesis
• assign prescribed motion
• assign solver parameters
• animate the assembly’s motion
• plot parameters of interest
6
Design of a Torque Limiter

Areas covered:
properties
• Creation of tetrahedral meshes
• The use of contact to investigate friction
• Preloading springs to generate contact forces
Software used:
• HyperMesh
• MotionView
• MotionSolve
• HyperView
• HyperGraph

A torque limiter is similar to a friction clutch,
except that it works "backwards". Where a
clutch transmits motion, the job of the torque
limiter is to permit free relative motion once the
design torque has been exceeded.
The case at hand is at the concept-design stage.

The designers are trying to achieve the specified
functionality within the given package space,
which is tightly limited.
The shaft, supported by bearings at both ends,

has a nut which carries an axial load. The gear,
mounted on the shaft, receives the drive. If the
axial load exceeds the design value (90 dN) the
gear must slip - that is, the shaft should not
rotate. As long as the axial load is less than the
design load, the shaft must rotate with the gear.
To achieve this, the designers have chosen to

rely on friction. They want to use springs to
exert a frictional-force between the gear and the
shaft. Using power-screw calculations, the gear-
torque can be related to the axial load on the
nut. If the spring-preload is set correctly, drive
will be transmitted as long as the friction-load is
7
more than the gear torque. When the gear

torque exceeds the friction-forces, the gear will
slip.
The design requirement is to establish the

required spring-load to ensure that slip occurs at
the design load.

We start with the IGES geometry of the sub-
assembly. We could build an MBD model directly
from this geometric data, with links and joints
only. However, 3D graphics can dramatically
improve visualization and results-interpretation.
Accordingly, we use the FE pre-processor to

address two tasks: calculation of mass properties
of the components, and generation of 3D
graphics images for subsequent use.
After that, it's plain sailing: once the joints have

been defined and motion assigned, we run the
analyses for a series of different frictional-loads
on the bearing-surfaces.

We start with the IGES geometry of the
assembly, and delete components that are not
essential for the analysis. The design uses
Belleville springs, which we can dispense with in
the MBD model, for example.
The first step is to assign material data so that

the mass and inertial properties are calculated
correctly.
The FE model is only for the calculation of mass

properties and for 3D graphics. There is no
stress analysis involved, so we do not need to
use hexahedral elements – they are more
accurate for stress analysis but harder to
generate. Instead, we use the easily generated
tetrahedral meshes and translate this to the
8
MBD model using a TCL program to do this

automatically.
We also use shell meshes to define the contact-

surface. Since contact-calculations are critical,
the mesh is chosen to closely follow the contours
of the bearing-surfaces.

relatively easy.

complexity.
We start with the MDL file created from the

HyperMesh model – this contains the “links”
(called “bodies”), with the associated graphics
and link-properties (center of gravity, moments
of inertia, coordinate systems, and mass). We
then add revolute joints for the gear and shaft
rotation, and create springs at the bearing-
surfaces.
Next, we setup contact using the surfaces

defined by the shell meshes.
Finally, we assign the uniform angular velocity to

the gear and run the analysis for the period of
interest, after which we use HyperView and
HyperGraph to view the results of interest –
force-vs.-time plots, animation of the motion,
etc.
Further Work
level of proficiency, the time available, etc.
9
• creating a screw joint between the nut

and the shaft and applying the axial load
• generating graphs showing the variation
of slip-load vs. spring-preload for
different surface finishes of the bearing
surfaces
• using flexible body analysis to check the
strength of the shaft
• a study of the effect of friction at the
shaft-nut interface
• check the affect of uneven spring-loads
Summary
know how to

• create tetrahedral and shell elements
parameters
• use springs and assign spring
parameters
• use screw-joints
10
Analysis and Design of a Valve Train

Areas covered:
properties
• The use of joints to mimic the effects of contact
• Application of simple-harmonic motion
• Generation of the profile of the cam
Software used:
• HyperMesh
• MotionView
• MotionSolve
• HyperView
• HyperGraph

There are several different valve-train designs
that are tried-and-tested in IC engines. The
problem at hand, related to the design of
components of the valve-train, addresses two
different aspects.
First, the engine designers have started working

with a particular configuration that has to be
detailed. The design is currently undergoing
stress analysis, and the cam-profile has to be
generated for the specified valve-movement.
Second, a proposal has been received for an

alternate valve-design. The details are sketchy,
but the designers have been asked to verify
whether the proposed design functions as
claimed.
We start with the finite element models of the

current configuration, and calculate the required
profile of the cam. Once this has been done, we
analyse the alternative mechanism to check
whether it performs as specified. Note that the
two models are totally unrelated: our task is to
provide a comparative analysis of the results for
both designs.
11
Details on the alternative design can be found in

a patent-document. Variable timing valves, of
course, are one way to enhance engine
performance, but not the only way. As the
Further Work section describes, there are a
number of options that can be worked on
towards design improvement.

We start with the Finite Element model of the
current configuration, and use this to build our
MBD model - the elements help us calculate the
mass properties and to define graphic images,
should we choose to use them.
Our design problem is: given the time-

displacement profile of the valve (a simple-
harmonic function has been specified) we need
to derive the cam profile.
To do this, we take the reverse approach: we

apply the given motion to the valve and track
the displacement of the point-of-contact
between the cam and the rocker arm. If we plot
this displacement, as measured from the center
of the cam, we have the profile.
The second part of the assignment is similar,

except that we start with the IGES geometry.
Further, our interest here is not to calculate the
cam profile, but to calculate how the valve
moves when the cam is actuated.
In both cases, we can work with "traditional"

MBD data - links, properties of bodies and joints.
However the availability of 3D graphics has a
dramatic impact on our ability to appreciate the
results of the analyses, so we prefer to use the
"solid" (shaded images) bodies in our models.
12

Since we have the FE model already, our work is
relatively easy: all we need to do is calculate the
mass properties of the various bodies and
transfer these to the MBD model.
We review the FE data to ensure that material

data has been specified correctly (both values
and units), and create nodes at locations where
we want to create joints in the MBD model.
We then use a TCL program to do this

automatically, as shown in the 6 minute video.

relatively easy.

complexity.

of inertia, coordinate systems, and mass).
We then add a revolute joint for the rotation of

the camshaft, and a translational joint for the
reciprocating movement of the valve. Since we
want to track the locus of the cam-rocker
contact point, we define a dummy body here.
We then use in-plane joints to ensure that the
bodies move as designed. Note that this
approach assumes that the components are
always in contact – it does not provide, for
example, for valve-float. Also, we do not need to
model the spring.
13
Finally, we assign the simple-harmonic motion to

the valve and run the analysis for the period of
interest, after which we use HyperView and
HyperGraph to view the results of interest –
displacement-vs.-time plot, animation of the
motion, etc.
The locus of the cam-tip gives us the cam-

profile, which can be exported as a text file for
use in a CAD program to create the 3D model of
the cam.
Further Work
• using the flexible-body analysis

capabilities of MotionSolve and
OptiStruct to calculate stresses
• use a contact model to simulate motion
• include a valve-spring in the model and
check for valve-float as the rpm changes
Summary
know how to

• create in-plane joints
• create translational joints
• assign prescribed motion using the
function-generator
14
Design of a Wiper Subsystem

Areas covered:
properties
• Creation of tetrahedral meshes
• The use of contact to transmit motion
Software used:
• HyperMesh
• MotionView
• MotionSolve
• HyperView
• HyperGraph

Windscreen wipers for vehicles represent an
interesting problem: there are several statutory
aspects that must be complied with, such as the
time of operation, coverage of the windscreen
etc. In addition, the power-consumption of the
assembly must lie within the specifications laid
out by the OEM.
The wiper itself must, obviously, follow the

shape of the windshield itself. This is usually
done by spring-loading the wiper blade. But if
the frictional force is too high, the motor
required to drive the wiper blade must generate
more power.
Our problem concerns a design that is to being

used as the basis for an initial quotation. In
order to verify that the motor power
consumption is adequate, the designers want to
carry out an MBD analysis - they wish to
generate a graph showing the change in motor-
power rating vs. the frictional force on the wiper
blade.

We start with the IGES geometry of the sub-
15
assembly. We could build an MBD model directly

from this geometric data, with links and joints
only. However, 3D graphics can dramatically
improve visualization and results-interpretation.
Accordingly, we use the FE pre-processor to

address two tasks: calculation of mass properties
of the components, and generation of 3D
graphics images for subsequent use.
After that, it's plain sailing: once the joints have

been defined and motion assigned, we run the
analyses for a series of different frictional-loads
on the blade.
The sub-assembly uses a worm-drive, but we

can ignore it in our model - assuming no losses
between the gear and the worm, it is enough to
track the forces at the gear as a function of
time.
Further, we choose to use a contact model

instead of a gear-joint. for improved
visualization. Since the assembly is small, there
is little computational penalty.

The FE model is only for the calculation of mass
properties and for 3D graphics. There is no
stress analysis involved, so we do not need to
use hexahedral elements – they are more
accurate for stress analysis but harder to
generate. Instead, we use the easily generated
tetrahedral meshes.
Starting with the IGES model of the assembly,

we assign material properties – the density is
critical, since we want to calculate the mass
properties from the elements. We also create
nodes at points where the MBD model will need
to locate joints, then translate this FE model to
the MBD model using a TCL program to do this
automatically.
16
We also use shell meshes to define the contact-

surface, to transfer motion between the sector-
gear and the link.

relatively easy.

complexity.

of inertia, coordinate systems, and mass).
We then add revolute, cylindrical and ball joints,

as dictated by the designer. It’s important to
remember that the different joints impose
different constraints on the motion. The ball-
joint and cylindrical joint, for instance, are
essential for the design to function as required –
other joints may over or under-constrain the
assembly.
Rather than use gear joints, we use contact to

ensure that the sector gear drives the link. The
geometry that defines the pinion-surfaces is
attached to the link, so that motion is
transmitted as desired.
We also apply an “action-reaction” force a the

wiper-blade to mimic the affect of friction. The
value of the force can be linked to the rpm of
the drive gear if we assume that the frictional
force between the blade and the windshield can
be taken as a “constant” value.
Finally, we apply a uniform angular velocity to

the drive gear and run the analysis for the
17
period of interest, after which we use HyperView

and HyperGraph to view the results of interest –
force-vs.-time plot, animation of the motion, etc.
Further Work
• use of a contact model to simulate

friction between the blade and the
windhsield
• use of gear-joints to capture the motion
of the pinion
• inclusion of the worm in the model, with
an assigned friction-loss characteristic
• application of a non-uniform rotation
speed to the drive to calculate power-
requirements
• investigation of the impact of different
stiction / transition velocities on the
startup torque of the motor
Summary
know how to

• create tetrahedral and shell elements
• create ball joints
• create cylindrical joints
parameters
• use action-reaction forces
• animate the mechanism’s motion
18

Altair&#39;s Student Guides - Instructor&#39;s Manual - CAE and Multi Body Dynamics

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Altair&#39;s Student Guides - Instructor&#39;s Manual - CAE and Multi Body Dynamics

Uploaded by

Copyright:

Available Formats

Student Project Summaries CAE and Multi Body Dynamics

Access to HyperWorks software is not essential for you, the instructor. Of

This book describes 4 assignment problems that highlight different

You can customize the HTML files to suit your

Dynamic Stresses in a Gear Assembly

Description of the Problem

The current proposal calls for the use of steel

Hand-design for gears is well-established, but

Traditional rigid-body mechanics is limited by the

Planning the Approach

Further, to conduct a flexible body analysis, we

Once the finite element models are set up we

Setting up the FE Model

The process involves

• import of CAD data from an IGES file

Several files are generated by this stage – the

The MBD Model and Results

We follow the incremental approach in model-

The MDL file created from the HyperMesh model

For Component mode synthesis we use rigid

the utility FlexPrep that interfaces with

After the analysis we use HyperView and

Some of the areas for further work include

• tracking the variation of tooth-forces

• create MDL models from CAD data

Design of a Torque Limiter

Description of the Problem

The case at hand is at the concept-design stage.

The shaft, supported by bearings at both ends,

To achieve this, the designers have chosen to

more than the gear torque. When the gear

The design requirement is to establish the

Planning the Approach

Accordingly, we use the FE pre-processor to

After that, it's plain sailing: once the joints have

Setting up the FE Model

The first step is to assign material data so that

The FE model is only for the calculation of mass

MBD model using a TCL program to do this

We also use shell meshes to define the contact-

The MBD Model and Results

We follow the incremental approach in model-

We start with the MDL file created from the

Next, we setup contact using the surfaces

Finally, we assign the uniform angular velocity to

Some of the areas for further work include

• creating a screw joint between the nut

• create MDL models from CAD data

Analysis and Design of a Valve Train

Description of the Problem

First, the engine designers have started working

Second, a proposal has been received for an

We start with the finite element models of the

Details on the alternative design can be found in

Planning the Approach

Our design problem is: given the time-

To do this, we take the reverse approach: we

The second part of the assignment is similar,

In both cases, we can work with "traditional"

Setting up the FE Model

We review the FE data to ensure that material

We then use a TCL program to do this

The MBD Model and Results

We follow the incremental approach in model-

Altair's Student Guides - Instructor's Manual - CAE and Multi Body Dynamics

Altair's Student Guides - Instructor's Manual - CAE and Multi Body Dynamics