DesignandSensitivityStudies UnderstandingLocalSensitivityDesignStudiesLecture UnderstandingLocalSensitivityDesignStudies.

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Understanding Local Sensitivity Design Studies

Local Sensitivity Studies enable you to calculate how sensitive your models quantities of interest are to slight changes in the design variables.

Local Sensitivity Design Study

1% perturbation Helps determine most influential design variables

Design Variable edge_rad vs. Maximum von

Local Sensitivity Design Study Local Sensitivity Studies enable you to calculate how sensitive your models quantities of interest are to slight changes in the design variables. In a Local Sensitivity Study, Mechanica perturbs a dimension parameter by 1% to estimate the sensitivity of your quantity of interest with respect to the design variable. Thus, for a given location in design variable space, a Local Sensitivity Design Study takes a snapshot of the sensitivity of your model subjected to all design variables. Using these sensitivities, you can determine design variables that have the most influence on the design. The figures on the slide show three different design variables on which a Local Sensitivity Study was performed. You can see from the graphs that the starting values are perturbed plus 1% and minus 1% and that an analysis was run at each value. In this case, the Local Sensitivity Study gives you an idea of how much impact a small change in each of the studied design variables will have upon the maximum von Mises stress in the model. UnderstandingLocalSensitivityDesignStudiesDemonstration UnderstandingLocalSensitivityDesignStudies_demo.mp4 UnderstandingLocalSensitivityDesignStudiesProcedure

Procedure: Understanding Local Sensitivity Design Studies

Scenario
In this procedure, you will set up an analysis that can be used to investigate the effects of changing different design variables (2 dimensions) has upon the Von Mises stress and max displacement measures. Based on this investigation, you can make informed decisions about which design variables you might select for future Global Sensitivity Studies. Local_Sens_DS local_bracket_orig.prt

Task 1. Open the Mechanica application and define a Local Sensitivity Design Study.
1. Click Applications > Mechanica. The simulation features (material, load, constraints, parameters, static analysis) are already defined in this model.

2. Click Mechanica Analyses/Studies

from the main toolbar.

3. Click File > New Sensitivity Design Study.... 4. In the Name field, type LOCAL_SENS_STUDY. 5. Select Local Sensitivity from the Type drop-down menu. 6. In the Analyses section of the dialog box, select the BRACKET_STATIC (Static) analysis.

7. Click Select Dimension in the Sensitivity Study Definition dialog box (loads and constraints removed from image for clarity). 8. Select the round feature under the mouse cursor in the figure. Select the R1.00 dimension. 9. Select d4 in the Variables area of the dialog box and type INNER_FILLET.

10. Click Select Dimension in the Sensitivity Study Definition dialog box (loads and constraints removed from image for clarity). 11. Select the Extrude feature as shown in the figure. Select the 7.00 dimension. 12. Select d1 in the Variables area of the dialog box and type FLANGE_LENGTH.

Note: Mechanica will automatically change these dimensions +/- 1% and run analysis BRACKET_STATIC at each value to determine the local sensitivity for each design variable.

13. Click OK to close the Sensitivity Study Definition dialog box and return to the Standard Pro/ENGINEER mode by clicking Applications > Standard. 14. Click Save from the main toolbar and click OK to save the model. 15. Click File > Erase > Current > Yes to erase the model from memory. This completes the procedure. UnderstandingLocalSensitivityDesignStudiesExercise

Exercise: Understanding Local Sensitivity Design Studies

Objectives
After successfully completing this exercise, you will be able to:

Prepare a Pro/ENGINEER model for Local Sensitivity Design Studies.

Use judgment when approaching Local Sensitivity Design Studies. Interpret the results of a Local Sensitivity Design Study. Generate conclusions based on Mechanica findings.

Scenario
In this exercise, you examine the structural stresses on the components of a jack that lifts a car with a certain applied torque. When lifting a car, the brackets of the jack are subjected to loads that transfer from one to another at the joints. The loads developed in the model are mainly bearing loads and can be easily evaluated using the Mechanism Design module within Pro/ENGINEER. Because the model is symmetrical (all the loads, constraints, and materials are as well) you can reproduce the structural behavior of the entire model by simply examining one bracket part of the jack. Also, it's important to investigate how sensitive the stresses are that developed in the model due to certain design changes. In addition, you will examine the effects these design changes have on the bracket's mass. The conclusions from this investigation will provide important information for a Global Sensitivity and/or Optimization Study.

JackSens

up_link.prt

Task 1. Open the Mechanica Structure Mode and Investigate the UP_LINK.PRT part.
1. Click Applications > Mechanica. 2. Investigate the model and note the existing material definition, bearing load, and constraints. Additionally, there are midsurface shell idealizations because the model is very thin and of uniform thickness.

Task 2. Compress and mesh the model using shell idealizations.

1. Click AutoGEM > Review Geometry... from the main menu. Click Apply from the Simulation Geometry dialog box. 2. After you have examined the Shell surfaces, click Close in the Simulation Geometry dialog box. 3. Click Create from the main menu. Click Create from the AutoGEM dialog box. 4. Examine the resulting mesh and note the generation of about 80 shell elements. 5. Click Close from the AutoGEM Summary dialog box and Close to close the AutoGEM dialog box. Click No to close the AutoGEM information window.

Task 3. Examine the maximum von Mises stress developed in the model due to the loads and constraints.
1. Click Mechanica Analyses/Studies from the main toolbar. Select Static_Analysis_3D_SHELL from the list in the Analyses and Design Studies dialog box. This analysis has been previously defined. It evaluates the structural response to the bearing loads while fully constrained at the opposite end. Also, the analysis evaluates the max von Mises stress using a multi-pass adaptive convergence algorithm.

2. Click Start Run

> Yes to start the analysis.

3. Click Display Study Status once the analysis is started. When the analysis completes, note the maximum Von Mises stress measure from the Run Status. The max Von Mises value is listed as a default measure at the end of the summary report. The max_stress_vm value is currently 472 MPa and exceeds the allowable stress, 240 MPa. We can confidently say that the bracket will fail due to structural stresses and we will look for model changes in order to avoid this failure. These design changes will be covered in the upcoming tasks.

4. Click Close from the Diagnostics and Run Status windows.

Task 4. Examine the buckling effects in the model due to the loads and constraints.
1. From the Analyses and Design Studies dialog box, select Buckling_Analysis_3D_SHELL from the list of Analyses and Design Studies.

The analysis has been previously defined. It evaluates the Buckling Load Factor (BLF) from the bearing loads while fully constrained at the opposite end.

2. Click Start Run

> Yes to start the analysis.

3. Click Display Study Status once the analysis is started. When the analysis completes, note the BLF factor from the Run Status. The BLF value is roughly 3. This means that you can apply about three times the existing load without any buckling failures. From this, you can conclude that you should concentrate on the maximum von Mises stress in the model and limit it to 240 MPa or less.

4. Click Close from the Diagnostics and Run Status windows.

Task 5. Consider different design change scenarios and their anticipated effects on the von Mises stress, and total mass measures.

1. Our current task is centered on finding valid design changes in the model. This translates to finding design variables (in this case, dimensions) that you can change to limit the von Mises stress to 240 MPa or less. There are more than 15 dimensions to select from the model, but you have to use your best judgment when determining which are important:

You cannot shorten the length of the bracket because the jack wont lift to the appropriate height. Also, increasing the jack height would increase the likelihood that the jack brackets could buckle. You cannot modify the holes because they are designed for standard pins that fit through them in the assembly. Thus, the model dimensions you can modify are the thickness of the bracket (adding more will reduce the stress) and the radial offset. Additionally, you can add the curved edge radius (shaving off material will decrease the total mass of the bracket).

2. Next, you investigate the effects of the mentioned design variables upon the max Von Mises stress and total mass measures using a Local Sensitivity Design Study. Based on this study you can establish which one of these design variables contribute dramatically to the measures of interest and which will be eliminated from further investigation.

Task 6. Define a Local Sensitivity Study and Design Variables.

1. Click File > New Sensitivity Design Study... from the Analyses and Design Studies dialog box. Type LINK_LSDS in the Name field. 2. From the Type drop-down menu, select Local Sensitivity. 3. Select STATIC_ANALYSIS_3D_SHELL from the Analyses list.

4. Click Select Dimension

from the Variables area of the dialog box.

5. Select Shell id 528 from the model tree. 6. Select the resulting 3.81 dimension from the display area. 7. Click Select Dimension from the Variables area of the dialog box.

8. Select Cut id 91 from the model tree. 9. Select the resulting 12.7 dimension from the display area. 10. Click Select Dimension from the Variables area of the dialog box.

11. Select Cut id 91 from the model tree. 12. Select the resulting 16.662 dimension from the display area. 13. The values in the Variables area of the dialog box should appear as shown in the figure below. Click OK to complete the Sensitivity Study Definition and close the dialog box.

Task 7. Run the Local Sensitivity Study.

1. Verify that LINK_LSDS is selected in the list of Analyses and Design Studies and click Start Run > Yes to start the design study. once the analysis is started. 2. Click Display Study Status

The design study should complete in a few minutes. Once the analysis is completed, you will create graphs for the measures of interest versus the design variables.

Task 8. Examine the design study results for von Mises stress.
1. Verify that LINK_LSDS is still selected in the Analyses and Design Studies dialog box and click Results to start Results mode. 2. Type EDGE_RAD in the Name field and von Mises vs. Edge Radius in the Title field. 3. Verify that the drop-down menu in the Display type area of the dialog box is set to Graph and that the Graph Ordinate (vertical) Axis field is set to Measure. 4. Click Define Measure to open the Measures dialog box. 5. Select max_stress_vm from the list of Measures and click OK to close the Measures dialog box. 6. From the second drop-down menu in the Graph Location area of the dialog box, select edge_rad:UP_LINK, if required. 7. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

8. Click Copy

from the main toolbar in the Results window.

9. Type RAD_OFFSET in the Name field and von Mises vs. Radial Offset in the Title field. 10. From the second drop-down menu in the Graph Location area of the dialog box, select radial_offset:UP_LINK. 11. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

12. Click Copy

from the main toolbar in the Results window.

13. Type THICK in the Name field and von Mises vs. Thickness in the Title field. 14. From the second drop-down menu in the Graph Location area of the dialog box, select thick:UP_LINK. 15. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

16. Examine the resulting graphs.

The software varies each of the design variables, one at a time, 1% of the current settings to estimate the derivative of the max_stress_vm measure. Thus, for a given location in design variable space, the design study takes a

snapshot of the sensitivity of the max_stress_vm measure to changes in each design variable. You now need to quantify this in the graph format: a sharper slope indicates that the design variable dramatically affects the defined measure whereas a flat slope does not. For the purposes of comparison, you should set the Yaxis for all of the design measures to the same scale. You will not modify the X-axis range. The minimum of all the Y-axes is 462 and maximum is 481 (MPa), so you will adjust all the graphs to these new Y-axis values in order easily compare the slopes of each graph.

17. Select the von Mises vs. Radial Offset graph. Click Utilities > Tie > Graph Quantity from the main menu and select the von Mises vs. Thickness graph. Note how the Y axis values in the von Mises vs. Thickness is now tied to the same values that are in the von Mises vs. Radial Offset graph.

You could also get the same effect by selecting a graph, clicking Format > Graph and manually setting the Maximum and Minimum values.

18. Select the von Mises vs. Thickness graph. Click Utilities > Tie > Graph Quantity from the main menu and select the von Mises vs. Edge Radus graph. With all of the Y-axes set to the same scale, it is much easier to compare the slopes of each parameter. From these three graphs you can conclude that the Von Mises stress is sensitive to changes in the radial_offset design variable, less sensitive to changes in the thick design variable, and relatively insensitive to changes in the edge_rad design variables. Based on this information, you should consider the radial_offset and thick design variables in future Global Sensitivity and Optimization Studies.

Task 9. Examine the design study results for total mass.

1. Click Show Definitions from the main toolbar.

2. De-select all of the items in the list except EDGE_RAD and click OK. 3. Click Edit Selected Definition 5. Click Define Measure from the main toolbar.

4. Type Mass vs. Edge Radius in the Title field. to open the Measures dialog box. 6. Select total_mass from the list of Measures and click OK to close the Measures dialog box. 7. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

8. Click Copy

from the main toolbar in the Results window.

9. Type THICK_MASS in the Name field and Mass vs. Thickness in the Title field. 10. From the second drop-down menu in the Graph Location area of the dialog box, select thick:UP_LINK. 11. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

12. Click Copy

from the main toolbar in the Results Window.

13. Type RAD_OFF in the Name field and Mass vs. Radial Offset in the Title field. 14. From the second drop-down menu in the Graph Location area of the dialog box, select radial_offset:UP_LINK. 15. The dialog box should now appear as shown in the figure. Click OK and Show to complete the Result Window Definition and show the resulting graph.

The minimum in all the Y-axes is 171 and maximum is 175 (grams). As before, you will adjust all the graphs to the new Y-axis values in order to more easily compare the slopes.

16. Select the Mass vs. Thickness graph. Click Utilities > Tie > Graph Quantity from the main menu and select the Mass vs. Radial Offset graph. 17. Select the Mass vs. Radial Offset graph. Click Utilities > Tie > Graph Quantity from the main menu and select the Mass vs. Edge Radius graph.

18. Examine the resulting graphs and make conclusions about the design variable effects on the total_mass measure. From these three graphs you can conclude that the mass of the bracket is sensitive to all of the design variables changes, especially the thick design variable. This is a rather obvious engineering observation (increasing or decreasing the thickness changes the mass of the bracket). The edge_rad and radial_offset design variables sensitivities are similar. As such, you should consider all these design variables for future Global Sensitivity and Optimization Studies where you are concerned about affecting the total mass measure.

19. Click File > Exit Results > No to exit the Result Window without saving any results. 20. If necessary, return to the Standard Pro/ENGINEER mode by clicking Applications > Standard. 21. Click Save from the main toolbar and click OK to save the model. 22. Click File > Erase > Current > Yes to erase the model from memory. This completes the exercise.