CAD/CAM-LABORATORY

(M E 357)
2009-2010

Prepared by

Asst. Prof. S.V.Satish

Department of Mechanical Engineering P E S Institute of technology Bangalore

Introduction to Finite Element Analysis

A Brief History

Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz method of numerical analysis and minimization of variational calculus to obtain approximate solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R. W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis. The paper centered on the "stiffness and deflection of complex structures". By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries. Since the rapid decline in the cost of computers and the phenomenal increase in computing power, FEA has been developed to an incredible precision. Present day supercomputers are now able to produce accurate results for all kinds of parameters.
What is Finite Element Analysis?

FEA consists of a computer model of a material or design that is stressed and analyzed for specific results. It is used in new product design, and existing product refinement. A company is able to verify a proposed design will be able to perform to the client's specifications prior to manufacturing or construction. Modifying an existing product or structure is utilized to qualify the product or structure for a new service condition. In case of structural failure, FEA may be used to help determine the design modifications to meet the new condition. There are generally two types of analysis that are used in industry: 2-D modeling, and 3-D modeling. While 2-D modeling conserves simplicity and allows the analysis to be run on a relatively normal computer, it tends to yield less accurate results. 3-D modeling, however, produces more accurate results while sacrificing the ability to run on all but the fastest computers effectively. Within each of these modeling schemes, the programmer can insert numerous algorithms (functions) which may make the system behave linearly or non-linearly. Linear systems are far less complex and generally do not take into account plastic deformation. Non-linear systems do account for plastic deformation, and many also are capable of testing a material all the way to fracture.

How Does Finite Element Analysis Work?

FEA uses a complex system of points called nodes which make a grid called a mesh (Figure 2). This mesh is programmed to contain the material and structural properties which define how the structure will react to certain loading conditions. Nodes are assigned at a certain density throughout the material depending on the anticipated stress levels of a particular area. Regions which will receive large amounts of stress usually have a higher node density than those which experience little or no stress. Points of interest may consist of: fracture point of previously tested material, fillets, corners, complex detail, and high stress areas. The mesh acts like a spider web in that from each node, there extends a mesh element to each of the adjacent nodes. This web of vectors is what carries the material properties to the object, creating many elements. A wide range of objective functions (variables within the system) are available for minimization or maximization:

Mass, volume, temperature Strain energy, stress strain Force, displacement, velocity, acceleration Synthetic (User defined)

There are multiple loading conditions which may be applied to a system. Next to Figure 3, some examples are shown:

Point, pressure (Figure 3), thermal, gravity, and centrifugal static loads Thermal loads from solution of heat transfer analysis Enforced displacements Heat flux and convection Point, pressure and gravity dynamic loads

Each FEA program may come with an element library, or one is constructed over time. Some sample elements are:

Rod elements Beam elements Plate/Shell/Composite elements Shear panel Solid elements Spring elements Mass elements Rigid elements Viscous damping elements

Many FEA programs also are equipped with the capability to use multiple materials within the structure such as:

Isotropic, identical throughout Orthotropic, identical at 90 degrees General anisotropic, different throughout

Types of Engineering Analysis Structural analysis consists of linear and non-linear models. Linear models use simple parameters and assume that the material is not plastically deformed. Non-linear models consist of stressing the material past its elastic capabilities. The stresses in the material then vary with the amount of deformation as in Fig 4. Vibrational analysis is used to test a material against random vibrations, shock, and impact. Each of these incidences may act on the natural vibrational frequency of the material which, in turn, may cause resonance and subsequent failure. Fatigue analysis helps designers to predict the life of a material or structure by showing the effects of cyclic loading on the specimen. Such analysis can show the areas where crack propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance of the material (Figure 5). Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or structure (Figure 1). This may consist of a steady-state or transient transfer. Steady-state transfer refers to constant thermo properties in the material that yield linear heat diffusion.

Results of Finite Element Analysis FEA has become a solution to the task of predicting failure due to unknown stresses by showing problem areas in a material and allowing designers to see all of the theoretical stresses within. This method of product design and testing is far superior to the manufacturing costs which would accrue if each sample was actually built and tested. Introduction to ANSYS The ANSYS program is a computer program for finite element analysis and design. The program is used to find out how a given design (e.g., a machine component) works under operating conditions. The ANSYS program can also be used to calculate the optimal design for given operating conditions using the design optimization feature. The ANSYS program is a multi-purpose program, meaning that you can use it for almost any type of finite element analysis in virtually any industry - automobiles, aerospace, railways, machinery, electronics, sporting goods, power generation, power transmission, and biomechanics, to mention just a few. "Multi-purpose" also refers to the fact that the program can be used in all disciplines of engineering - structural, mechanical, electrical, electromagnetic, electronic, thermal, fluid, and biomedical. The ANSYS program is also used as an educational tool in universities and other academic institutions. ANSYS software is available on many types of computers - PCs (personal computers), workstations, minicomputers, superminis, mainframes, super mainframes, etc. Several operating systems are supported, as are a multitude of graphics devices. Reference Books 1. Finite Element Analysis Theory and Programming By C.S.Krishnamurthy, Tata Mc Graw Hill Publishing Company 2. Finite element analysis: theory and application with ANSYS By Saeed Moaveni, Pearson Prentice Hall, 2008 3. Finite Element Analysis from concepts to applications By David S.Burnett, Addison-Wesley Publishing .Co. 1987

1 D Problems TRUSS PROBLEMS

Problem # 1

Step 1 Step 2 Step 3 Step 4

Preferences - Structural Element type Link 2D Spar Real Constants Area Enter the value Material Properties Ex Youngs Modulus Pxy Poissons ratio

Step 5

Create Nodes in active Co ordinate System Node 1(x,y) Node 2 (x,y) Node 3 (x,y)

Step 6

Element Connectivity Select Node 1 and connect to Node 3 Similarly, Select Node 2 and connect to Node 3

Step 7 Step 8

Apply Boundary Conditions Select Nodes and apply constraints. i.e Ux, Uy, and Uz Apply Force on Node

Step 9 Step 10

Solve Run Static Analysis Go to Post Processor Plot Results Deformed Shape Nodal Solution O K

Step 11

Create Element Table LS,1 to obtain stress plot LEPEL, 1 to obtain strain plot SMISC,1 to obtain force plot

Step 12

Results Comparison FEM (ANSYS) Displacement Stress 0.188 x 10 m 10 x 106 N/m2

-3

Theoretical 0.182 x 10-3 m 10.08 x 106 N/m2

Problem # 2 (Practice problem)

BEAM PROBLEMS
Problem # 1

Step 1 Step 2 Step 3

Preferences - Structural Element type Beam 2D elastic Real Constants Area Enter the value Moment of Inertia Enter the value Total Beam Height Enter the value

Step 4

Material Properties Ex Youngs Modulus Pxy Poissons ratio

Step 5

Create Nodes in active Co ordinate System Node 1(x,y) Node 2 (x,y) Node 3 (x,y) etc.,,

Step 6

Element Connectivity Select Node 1 and connect to Node 2, Node 2 to Node 3,,, etc.

Step 7 Step 8

Apply Boundary Conditions Select Nodes and apply constraints. i.e Ux, Uy, and Uz Apply Force on Node

Step 9 Step 10

Solve Run Static Analysis Go to Post Processor Plot Results Deformed Shape Nodal Solution O K

Step 11

Create Element Table SMISC,6 & SMISC,12 to obtain bending moment plot SMISC,2 & SMISC, 8 to obtain shear force plot NMISC, 1 - to obtain bending stress

Step 12

Results Comparison FEM (ANSYS) Displacement Stress 14.642 mm 98.765 N/mm

2

Theoretical 14.63 mm 98.765 N/mm2

Problem # 2 (Practice Problems)

BAR PROBLEMS

Step 1 Step 2 Step 3 Step 4

Preferences - Structural Element type Link 2D Spar Real Constants Area Enter the value Material Properties Ex Youngs Modulus Pxy Poissons Ratio

Step 5

Create Nodes in active Co ordinate System Node 1(x,y) Node 2 (x,y)

Step 6

Element Connectivity Select Node 1 and connect to Node 2

Step 7

Apply Boundary Conditions Select Node and apply constraints i.e Ux, Uy, and Uz

Step 8 Step 9 Step 10

Apply Force on Node Solve Run Static Analysis Go to Post Processor Plot Results Deformed Shape Nodal Solution O K

Step 11

Create Element Table LS,1 to obtain stress plot LEPEL, 1 to obtain strain plot SMISC,1 to obtain force plot

Step 12

Results Comparison FEM (ANSYS) Displacement Stress Reaction 0.01 mm 2 N/mm2 -1000 N Theoretical 0.01 mm 2 N/mm2 -1000 N

Problem 2 Stepped Bar (Practice Problem)

A1 = 875 mm2; A2 = 625 mm2; E1 = 210GPa; E2 = 74 GPa

2 D Problems PLATE PROBLEMS

Step 1 Step 2

Preferences - Structural Element type Solid Quad 4 Node Type Plane 42

Go to options Element type options select k3 plane stress w/thk option ok Step 3 Step 4 Real Constants Enter the value of thickness Material Properties Ex Youngs Modulus Pxy Poissons Ratio Step 5 Create keypoints in active Co ordinate System Key point 1(x,y) Key point 2(x,y) etc. Totally create 6 keypoints Step 6 Create areas thru lines Go to areas arbitrary thru keypoints. Connect key point 1-2-3-4-5-6-1 Select Node 1 and connect to Node 2 Step 7 Step 8 Create Solid Circle Select center of the area enter co-ordinates as WP x 250; WP y 0; Radius 25 press OK Go to Boolean operations select subtract areas first select rectangle and click OK then select circle - press OK

Step 9

Go to Mesh Tool select free mesh select area and click OK Go to Refine Mesh at elements select 2 or 3 press OK

Step 10 Step 11 Step 12 Step 13

Apply Constraints Select displacement Select nodes for constraints - select corner nodes Select Uy - press OK Define Loads Select keypoints where load is to be applied Select Fy enter the value with ve sign. Solve Run solution - Current LS Go to Post Processor Select Plot results Deformed Nodal solution Go to Nodal Solution select stress x component stress etc Von mises stress etc and plot the stress contours.

Step 14

Finally go to Reaction Solution select all items Record the results.

Problem 2 (Practice Problem)

Problem 3 (Corner Bracket Analysis) http://www.csa.ru/CSA/CADS/docs/ansys/tut2/ansys.html http://www.asiri.net/courses/meng412/Lab/2DAnalysis.pdf

Steps
1. Set preferences 2. Define element types and options 3. Define real constants 4. Define material properties 5. Define the model starting with two rectangles 6. Change plot controls and replot 7. Change working plane (WP) to polar and create first circle 8. Move the WP and create second circle 9. Add areas (rectangles and circles) 10. Create line fillet 11. Create area fillet 12. Add remaining areas together 13. Create first bolt hole 14. Move WP and create second bolt hole 15. Subtract the holes from the bracket 16. Mesh the area

Solution
17. Apply displacement constraint 18. Apply pressure load 19. Solve 20. Results

Postprocessing steps
21. Enter the general postprocessor 22. Plot deformed shape 23. Plot the von Mises equivalent stress 24. List reactions at constrained nodes 25. Exit the ANSYS program

CNC PROGRAMMING
PROGRAMMING STRUCTURE
Main Programs are written using I.S.O. address codes listed below: Addresses A FANUC compatible program number line is written in the following format: O Where, O is the Address Code. is the four digit program number N G refers to the block number. refers to the G code (Preparatory function).

X refers to the absolute/incremental distance travelled by the slide tool in the X axis direction. Y refers to the absolute/incremental distance travelled by the slide tool in the Y axis direction. Z refers to the absolute/incremental distance travelled by the slide tool in the Z axis direction. F M S T refers to the feed rate. refers to the M code (Miscellaneous function). refers to the spindle speed. refers to the tooling management.

; is the End Of Block (EOB) signal. Each block, or program line, contains addresses which appear in this order: N,G,X,Y,Z,F,M,S,T; This order should be maintained throughout every block in the program, although individual blocks may not necessarily contain all these addresses. The organization of blocks of data within the program follows a layout. Again, it is recommended that the programmer keeps to this program layout.

Differences between a sub and main program: 1) A sub program does not have a billet size definition at the top of the program listing. 2) A sub program is ended by the M99 code. 3) Sub programs can also call other sub programs into operation.

Sub Program: To call a sub program the M98 code is used followed by P (the number of the sub program required). For example, M98 P2 This command is read call program number 2. A sub program call command (M98 P) can be specified along with a move command in the same block. For example, G1 X42.5 M98 P1; At the end of a sub program, the M99 code is entered. This returns control to the main program. The M99 code will return control to the next block after the M98 sub program call block in the main program. If the code M99 P is entered, control will pass to the main program at a block with the N number equal to that of the P number stated after the M99 code. For example, M99 P16; This command is read return to the main program at block number N16. A call command can be set to call a sub program repeatedly. This call can specify upto 999 repetitions of a sub program. A sub program repeat command is written in the following format: M98 P where, M98 is the call command. P is the number of times the sub program is to be repeated. is the sub program number. For example, M98 P11; This command is read call the sub program number 1 ten times. When the repetition is omitted, the sub program will be called once only.

G Code Group
G 1 G1 1 G2 1 G3 1 G4 G2 6 G21 G28 6

Function

Positioning (Rapid Traverse) Linear Interpolation (Cutting Feed) Circular Interpolation CW Circular Interpolation CCW Dwell, Exact Stop Imperial Data Input (Inches) Metric Data Input (Millimeters) Reference Point Return Cutter Compensation Cancel Cutter Compensation Left Cutter Compensation Right Call Radius Offset High Speed Peck Drilling Cycle Counter Tapping Cycle Canned Cycle Cancel Drilling Cycle, Spot Boring Drilling Cycle, Counter Boring Deep Hole Peck Drilling Cycle Tapping Cycle Boring Cycle Boring Cycle Back Boring Cycle (not recommended on Denford Machines) Boring Cycle Absolute Zero Command Incremental Command Feed per Minute Feed per Revolution Return to Initial Level in Canned Cycle Return to R Point Level in Canned Cycle Circular Pocket Canned Cycle Circular Pocket Canned Cycle Rectangular Pocket Canned Cycle Rectangular Pocket Canned Cycle

G4 7 G41 G42 G43 G73 G74 7 7 7 9 9

G8* 9 G81 G82 G83 G84 G85 G86 G87 G89 9 9 9 9 9 9 9 9

G9* 3 G91 3

G94* 5 G95 5

G98* 1 G99 1

G17 G171 G172 G173

M code

Function

M* Program Stop M1* Optional Stop M2* Program Reset M3 Spindle Forward (clockwise) M4 Spindle Reverse (counter clockwise) M5* Spindle Stop M6 Automatic Tool Change M8 Coolant On M9* Coolant Off M1 Vice/Work Clamp Open M11 M13 M14 M19 Vice/Work Clamp Close Spindle Forward and Coolant On Spindle Reverse and Coolant On Spindle Orientation

M2 ATC Arm In M21 M22 ATC Arm Out ATC Arm Down

M23 ATC Arm Up M24 M25 M27 ATC Drawbar Unclamp ATC Drawbar Clamp Reset Carousel to Pocket One

M3* Program Reset and Rewind M32 M33 M38 M39 M62 M63 M64 M65 Carousel CW Carousel CCW Door Open Door Close Auxiliary Output 1 On Auxiliary Output 2 On Auxiliary Output 1 Off Auxiliary Output 2 Off

M66* Wait for Auxiliary Output 1 On M67* Wait for Auxiliary Output 2 On

M7 Mirror in X On M71 M76 Mirror in Y On Wait for Auxiliary Output 1 Off

M77 Wait for Auxiliary Output 2 Off M8 Mirror in X Off M81 M98 M99 Mirror in Y Off Sub Program Call Sub Program End and Return

CNC MILLING
PROGRAM 1
(This program demonstrates Linear Interpolation, Circular Interpolation and Automatic Tool Change)

BILLET SIZE 100X100X10 mm

O1234 (Program Name) G21 (Metric Data Input); G94 (Feed Per minute); G90 (Absolute Command); G28 X0 Y0 Z0 (Reference Point Return); M06 T01 (Automatic Tool Change END MILL of Diameter 5); M03 S1200 (Spindle Forward); M08 (Coolant On); G00 X30 Y0 Z0 F50 (Rapid Positioning); G01 Z-12 F5 (Linear Interpolation); G01 X30 Y30; G01 X-30 Y30; G01 X-30 Y-30; G01 X30 Y-30; G01 X30 Y0;

G01 Z0; G00 X0 Y0 Z0 F50; M05 (Spindle Stop); M06 T02 (Automatic Tool Change END MILL of Diameter 5); M03 S1300 (Spindle Forward); G01 X20 F5; G01 Z-12; G03 X20 Y0 R20 (Circular Interpolation); G01 Z0; G28 X0 Y0 Z0; M09 (Coolant Off); M05 (Spindle Stop); M30 (Program Reset and Rewind);

PROGRAM 2
(This Program demonstrates Mirroring and Sub programming)

BILLET SIZE 100X100X10 mm

O1234 (Program Name) G21 (Metric Data Input); G94 (Feed Per minute);

G90 (Absolute Command); G28 X0 Y0 Z0 (Reference Point Return); M06 T01 (Automatic Tool Change END MILL of Diameter 5); M03 S1200 (Spindle Forward); M08 (Coolant On); G00 X10 Y10 F50; M98 P6666 (Sub Program Call); G01 Z0; G00 X0 Y0; M70 (Mirror in X on); G00 X10 Y10; G01 Z0; M98 P6666 (Sub Program Call); G01 Z0; G00 X0 Y0; M71 (Mirror in Y on); G00 X10 Y10; G01 Z0; M98 P6666 (Sub Program Call); G00 G90 Z0; G00 X0 Y0; M80 (Mirror in X off); M81 (Mirror in Y off); M71 (Mirror in Y on); G00 X10 Y10; G01 Z0; M98 P6666 (Sub Program Call); G00 G90 Z5; G00 X0 Y0; M81 (Mirror in Y off); G28 X0 Y0 Z0; M09 (Coolant Off); M05 (Spindle Stop); M30 (Program Reset and Rewind);

O6666 G91 (Incremental Command); G01 Z-12 F5; G01 X25 Y0; G01 X-25 Y25; G01 X0 Y-25; G01 Z12; G90 (Absolute Command); M99 (Sub Program call and Return);

PROGRAM 3
(This program demonstrates Linear Interpolation, Circular Interpolation, Automatic Tool Change, Drilling Canned Cycle and Cutter Compensation)

BILLET SIZE 200X200X10 mm

O1234 (Program Name) G21 (Metric Data Input) G94 (Feed Per minute) G90 (Absolute Command) G28 X0 Y0 Z0 (Reference Point Return) M06 T01 (Automatic Tool Change END MILL of Diameter 5) M03 S1200 (Spindle Forward) M08 (Coolant On) G00 X50 Y50 Z0 (Rapid Positioning) G01 Z-12 F5 G01 X-50 G01 Y-50 G01 X50 G01 Y50 G01 Z5 G01 X20 Y0 G01 Z-12 G03 X20 R20

G41 (Cutter Compensation Left) G03 X20 R20 G42 (Cutter Compensation Right) G03 X20 R20 G01 Z5 G40 (Cutter Compensation Cancel) G28 X0 Y0 Z0 M06 T02 (Automatic Tool Change-STDRILL of Diameter 20) M03 S1200 G00 X75 Y75 Z0 G01 Z-12 F5 G01 Z5 G01 X-75 Y75 G01 Z-12 G01 Z5 G01 X-75 Y-75 G01 Z-12 G01 Z5 G01 X75 Y-75 G01 Z-12 G01 Z5 M06 T03 (Automatic Tool Change-STDRILL of Diameter 10) M03 S1000 G00 X75 Y0 Z0 G83 X75 Y0 Z-14 Q0 R0 F5 (Deep Hole Peck Drilling Canned Cycle) X-75 X0 Y75 Y-75 G80 (Canned Cycle Cancel) G28 X0 Y0 Z0 M09 (Coolant Off) M05 (Spindle Stop) M30 (Program Reset and Rewind)

CNC TURNING

PROGRAM 1
(This program demonstrates Straight Turning, External Thread Cutting and Drilling)

O1234 (Program Name); G21 (Metric Data Input); G95 (Feed per Revolution); G90 (Absolute Zero Command); G28 X50 Z50 (Reference Point Return); M06 T01 (Automatic Tool Change Left Hand Tool); M03 S1200 (Spindle Forward); M08 (Coolant On); G00 X75 Z0; G01 Z-2; G01 X0 ; Z2 ; X70; Z-70 F0.5; X75; Z2 F5; X65; Z-50 F0.5; X75; Z2 F5; X60; Z-30 F0.5; X75; Z2 F5;

M06 T02 (Automatic Tool Change External Thread); S1200 M03; X60 Z0 F0.2; G92 X60 Z-30 F2 (Thread Cutting Cycle); X59.5; X59; X58.5; X58; X57.5; X57; X56.5; X56; X55.5; X55; X54.5; X54; X53.5; X53; X52.5; X52; X51.5; X51; X50.5; X50; X49.8; X75; Z10 F5; G28 X0 Z50; M06 T03 (Automatic Tool Change Centre Drill); G01 X0 Z0; G01 Z-2; G28 X0 Z50; M06 T04 (Drill - DIA 20); M03 S1200; G01 X0 Z-26 F5; Z10 F5; G28 X50 Z50 (Reference Point Return); M06 T01 (Automatic Tool Change Left Hand Tool); M09 (Coolant Off); M05 (Spindle Stop); M30 (Program Reset and Rewind);

PROGRAM 2

(This program demonstrates the use of Contour Tool and Groove Tool)

O1234 (Program Name) G21 (Metric Data Input) G95 (Feed per Revolution) G90 (Absolute Zero Command) G28 X50 Z50 (Reference Point Return) M06 T01 (Automatic Tool Change Left Hand Tool) M03 S1200 (Spindle Forward) M08 (Coolant On) G00 X61 Z5 G01 Z0 F5 Z-80 F0.1 X65 Z5 F5 X60.5 Z-80 F0.1 X70 Z5 F5 X40 Z-10 F0.1 X60 Z-20 F0.1 X70 Z5 F5 M06 T0202 (Automatic Tool Change Groove Tool) S1200 M03 G01 X65 Z-70 X57 F0.1 G04 X5 (Dwell)

G01 X65 Z5 F5 M06 T0303 (Automatic Tool Change Contour Tool) M03 S1200 G01 X62 Z-35 G02 X60 Z-55 R10 F0.1 X70 G28 X50 Z50 M06 T01 (Automatic Tool Change Left Hand Tool) M09 (Coolant Off) M05 (Spindle Stop) M30 (Program Reset and Rewind)

PROGRAM 3
(This program demonstrates the use of Stock Removal Canned Cycle G71)

O1234 (Program Name) G21 (Metric Data Input)

G95 (Feed per Revolution) G90 (Absolute Zero Command) G28 X50 Z50 (Reference Point Return) M06 T01 (Automatic Tool Change) M03 S1200 (Spindle Forward) G71 U1 R1 (Stock Removal in X Axis) G71 P100 Q200 U0 W0 F0.1 N100 Z0 F0.1 G03 X28 Z-2 I0 K-50 F0.1 G01 Z-17 G02 X40 Z-22 R6 G01 Z-17 G02 X40 Z22 R6 G01 Z-32 G03 X50 Z-37 R5 G01 Z-52 X60 Z-62 N200 X62 Z5 F5 M06 T01 (Automatic Tool Change Left Hand Tool) M09 (Coolant Off) M05 (Spindle Stop) M30 (Program Reset and Rewind)