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In the present study, KED analysis of four bar planar mechanism using
MATLAB program and ANSYS software has been carried out. The analysis has also
been carried out by considering rigid links in the same mechanism. In the analysis of
rigid links all pin joint forces, angular velocities and angular accelerations of links has
been computed. The coupled solution of governing equations of motion has been
obtained using MATLAB. In this MATLAB analysis each link has been considered as
an element. The simulated results have been validated with the experimental results
available in literature [13]. The modeling and simulations of four bar planar
mechanism has been executed in ANSYS by considering rigid link and flexible links
with more elements. The effect of moment of inertia of coupler and its length, flexibly
of crank and rocker, and rocker length on the strain developed in coupler has been
studied. After the dynamic analysis of four bar planar mechanism this methodology is
extended to six bar mechanism.
Multibody simulation deals with deals with study and analysis of dynamic
behavior of system of flexible and/or rigid interconnected bodies. These bodies are
subjected to constrain with respect to one another through a kinematic constraints
modeled as joints. These systems can represent a space structure with antenna
deployment capabilities, an automobile, a robot with manipulator arms, an aircraft as
an assemblage of rigid and flexible parts, and so on. The components may be
subjected to large displacement, large rotation, and also effects of finite strain.
5.1
computational resources and modeling time compared to standard analysis; it has the
following advantages [75]:
The finite element mesh automatically represents the geometry while the large
deformation/rotation effects are built into the finite element formulation.
Inertial effects are greatly simplified by the consistent mass formulation or
even point mass representations.
Interconnection of parts via joints is greatly simplified by considering the
finite motions at the two nodes forming the joint element.
(i) Build the model: A flexible mechanism usually comprises of flexible and/or rigid
body parts connected via joint elements. The modeling the flexible parts with any
of the 3-D solid, shell, or beam elements. The flexible and/or rigid parts are
connected using joint elements. In one scenario, two parts may be simply
connected to ensure that the displacements at the joints are identical. In other
scenario, the two connected parts may involve joint such as the universal jointor a
planar joint. While modeling these joints, a suitable kinematic constraint is
implemented on the relative motion (displacement and rotation) between the two
nodes that form the joint.
(ii) Define element types: Simulation of a flexible multibody involving flexible and
rigid components joined together subjected to some form of kinematic
constraints, using appropriate joint and contact element types.
(iii) Define materials: Defining the linear and non-linear material properties for each
components of multibody system.
(iv) Mesh the model: Mesh the all flexible components of multibody system. Two
nodes define joint elements and no special meshing is required to define them.
(v) Solve the model: Multibody analyses generally involve large rotations in static or
transient dynamics analysis, so non-linear geometric effects must be accounted
for.
5.2
(vi) Review the results of model: Results from a flexible multibody analysis consist
mainly of displacements, velocities, accelerations, stresses, strains, and reaction
forces in structural components. Constraint forces, current relative positions,
relative velocities, and relative accelerations in joint elements are also available.
In its most basic use, the ANSYS Workbench process is straight forward to
select the type of analysis that is to be performed from the analysis systems group of
the Toolbox and add that system to the project schematic. When the system is in
place, than work through the cells in the system, generally from top-to-bottom, until
completed all the required steps for analysis are completed. In most cases, data flows
from top to bottom through the system as well. For example, in a mechanical system,
the geometry must be defined before one defines the model; the model cell uses the
geometry defined in the geometry cell as its input.
5.3
Fig. 5.1 Step for renaming the system
5.4
schematic. The analyst can select edit from the engineering data cell's menu, or opt to
double-click the cell. Subsequently, the engineering data workspace appears. From
here, the user can navigate through the database required for analysis system, access
external data sources, create new data, as well as store data for subsequent use.
To import the geometry following step can be performed. From the analysis
system subroutine, select the geometry cell. Browse to the CAD file from the
following access points: Right-click on the geometry cell in the project schematic and
choose import geometry. The model cell in the project schematic can be selected via
5.5
double click. Subsequently the mechanical application displays the geometry. The
dialogue box related to geometry import as shown in Fig. 5.3.
5.6
function of temperature, it is evaluated at the reference temperature. For contact
conditions, specify Youngs modulus. Flexible is the default stiffness behavior. To
change, simply select rigid from the stiffness behavior drop-down menu.
(ii) Coordinate systems: The coordinate systems object and its child object, global
coordinate system is automatically placed in the tree with a default location of 0,
0, 0, when a model is imported. For solid parts and bodies by default, a part and
any associated bodies, use the global coordinate system. If desired, it is also
possible to apply a local coordinate system to the part or body. When a local
coordinate system is assigned to a part, by default, the bodies also assume this
coordinate system but one may modify the system on the bodies individually as
desired. For surface bodies, solid shell bodies, and line bodies by default, these
types of geometries generate coordinates systems on a per element type basis. It is
necessary for the user to create a local coordinate system and associated it with the
5.7
parts and/or bodies using the coordinate system setting in the details view for the
part/body if one wishes to orient those elements in a specific direction.
(iii) Reference temperature: The default reference temperature is taken from the
environment (by environment), which occurs when solving. This necessarily
means that the reference temperature can change for different solutions. The
reference temperature can also be specified for a body and will be constant for
each solution (by body). Selecting by body will cause the reference temperature
value field to specify the reference temperature for the body. It is important to
recognize that any value set by body will only set the reference temperature of the
body and not actually causes the body to exist at that temperature.
(iv) Material property assignment: Once the geometry has been attached, the next step
is to choose a material for the simulation. Upon selecting a part in the tree outline,
the assignment entry under Material in the details view lists a default material for
the part. This can be edited using material properties in the engineering data
workspace.
(v) Non-linear material effects: It is possible to ignore any nonlinear effects from the
material properties. As default setting, all pertinent material properties are used,
including non-linear properties such as stress-strain curve data. Setting non-linear
effects to no will ignore any non-linear properties only for that part. This option
will allow the analyst to assign same material to two different parts and also treat
one of the parts as linear.
(vi) Thermal strain effects: For structural analyses, it is possible to have workbench to
calculate a thermal strain result by setting thermal strain effects to yes. Choosing
this option enables the coefficient of thermal expansion to be sent to the solver.
5.8
across the contact boundaries and structural loads and connects the various bodies.
The analysis can be linear or nonlinear, depending on the type of contact.
The model is automatically meshed for further process. The element size by
default is determined based on various factors including body curvature, the overall
model size, the complexity of the feature and the proximity of other topologies. When
required, the mesh size is adjusted up to four times (eight times for an assembly) till a
5.9
successful mesh is achieved. The dialogue box for meshing the model is shown in Fig.
5.6.
If desired, it is possible to preview the mesh before solving. Mesh controls are
available to assist you in fine tuning the mesh.
There are some options available to modify the mesh: (i) default group, (ii)
sizing group, (iv) inflation group, (v) advanced group, (vi) pinch group and (vii)
statistics group.
Slender structures typically require large deflection. The user can use large
deflection in case a slender structure has transverse displacements that are more than
10% of the thickness. Small strain and small deflection analysis assume that
5.10
displacements are small enough so that the resulting stiffness changes are
insignificant. Switching ON large deflection will account for stiffness changes
resulting from change in orientation and element shape due to large deflection, large
strain, and large rotation. This ensures that the results will be more accurate. But this
effect demands an iterative solution. In addition it may also need the load to be
applied in small increments. Hence the solution may take longer time. Use of hyper
elastic materials also requires large deflection to be turned on as shown in Fig. 5.7.
Step controls permits to control the time step size in a transient analysis. In
addition this control also makes it possible to create multiple steps. In case new loads
are to be introduced or removed at different times in the load history, or if the analyst
wants to change the analysis settings such as the time step size at some points in the
time history, multiple steps are to be used. In case nonlinearities are present or if the
applied load has high frequency content, one might be required to use a small time
5.11
step size (that is, small load increments) and compute solutions at these intermediate
time steps to subsequently arrive at more accurate results. This group can be modified
on a per step basis.
Output controls option is useful to specify the time points at which results
should be available for post processing. In a transient nonlinear analysis it may be
necessary to perform many solutions at intermediate time values. However, (i) one
may not be interested in all the intermediate results, and (ii) writing all the results can
make the results file size unwieldy. This group can be modified on a per step basis
except for calculating stress and strain.
Non-linear controls feature allow the user to modify convergence criteria and
other specialized solution controls. Typically one will not need to change the default
values for this control. This group can be modified on a per step basis.
Damping controls are used to specify damping for the structure in a transient
analysis. The following forms of damping are available for a transient analysis: beta
damping and numerical damping. In addition, element based damping from spring
elements as well as material based damping factors are also available for the transient
structural (ANSYS) analysis.
A transient analysis involves loads that are functions of time. The first step in
applying transient loads is to establish initial conditions (that is, the condition at initial
time = 0).
5.12
The default initial condition for a transient structural (ANSYS) analysis is that
the structure is at rest, that is, both initial displacement and initial velocity are zero.
A transient structural (ANSYS) analysis is at rest, by default. The initial conditions
object allows to specified velocity.
In many analyses one or more parts will have an initial known velocity such as
in a drop test, metal forming analysis or kinematic analysis. A constant velocity initial
condition can be specified if required. The constant velocity could be aimed at one or
more parts of the structure. The remaining parts of the structure which are not part of
the horizon will be subjected to the at rest initial condition.
Initial condition can also be specified using step controls, that is, by specifying
multiple steps in a transient analysis and controlling the time integration effects along
with activation/deactivation of loads. This is extremely useful when there are different
parts of a model that have different initial velocities or more complex initial
conditions. Some commonly encountered initial condition is tackled as explained
below:
Initial displacement = 0, Initial velocity 0 for some parts: The non zero
velocity is established by applying small displacements over a small time interval on
the part of the structure where velocity is to be specified.
Specify second steps in the analysis. The first step is used to establish initial
velocity on one or more parts. A small end time (compared to the total span of the
transient analysis) is choosen for the first step. The second step will cover the total
time span.
Specify displacement(s) on one or more faces of the part(s) that will give the
required initial velocity. This requires that one does not have any other boundary
condition on the part that will interfere with rigid body motion of that part. Make sure
that these displacements are ramped from a value of zero.
Deactivate or release the specified displacement load in the second step so that
the part is free to move with the specified initial velocity.
5.13
Initial displacement 0, Initial velocity 0: This is similar to previous case
except that the imposed displacements are the actual values instead of small values.
Specify second steps in the analysis. The first step is used to establish initial
displacement and velocity on one or more parts. A small end time (compared to the
total span of the transient analysis) is choosen for the first step. The second step will
cover the total time span.
Specify second steps in the analysis. The first step will be used to establish
initial displacement on one or more parts. An end time for the first step is choosen
that together with the initial displacement values will create the necessary initial
velocity.
Deactivate or release the specified displacement load in the second step so that
the part is free to move with the initial displacement values.
5.14
5.1.10 Apply loads and supports
A positive joint load will tend to cause the mobile body to move in the
positive DOF direction with respect to the reference body, assuming the mobile body
is free to move. If the mobile body is not free to move then the reference body will
tend to move in the negative DOF direction for the joint load. One way to learn how
the mechanism will behave is to use the configure feature. For the joint with the
applied joint load, dragging the mouse will indicate the nature of the reference/mobile
definition in terms of positive and negative motion.
To apply a joint load: Highlight the transient environment object and insert a
joint load from the right mouse button context menu or from the loads drop down
menu in the environment tool bar as shown Fig. 5.8.
From the joint drop down list in the details view of the joint load, select the
particular joint object that has to be applied to the joint load. Apply a joint load to the
mobile bodies of the joint. It is therefore important to carefully select the reference
and mobile bodies while defining the joint.
5.15
Fig. 5.8 Step for applying the load
The unconstrained DOF has to be selected for applying the joint load, based
on the type of joint. This selection can be made from the DOF drop down list. For
joint types that allow multiple unconstrained DOF, a separate joint load is necessary
to drive each one. Joint load objects that include velocity, acceleration, rotational
velocity or rotational acceleration are not applicable to static structural analyses.
Type of joint load has to be selected from the type drop down list. The list is
filtered with choices of displacement, velocity, acceleration, and force if case of
selection of a translational DOF in step 3. The choices are rotation, rotational velocity,
rotational acceleration, and moment if you selected a rotational DOF.
5.16
5.1.11 Description of solve tool
Solution output continuously updates any listing output from the solver and
also specifies useful information related to behavior of the structure during the
analysis.
Fig. 5.9 Step for setting solve method and result tracker
5.17
large number of contact surfaces. When the solution diverges, identifying regions of
high Newton-Raphson residual forces can provide insight into possible problems.
Result tracker is also a useful tool that permits monitoring of displacement and
energy results as the solution moves ahead. This is typically useful when structures
that go through convergence difficulties owing to buckling instability.
The analysis type determines the results available for user to examine after
solution. For example, in a structural analysis, one may be interested in maximum
shear results or equivalent stress results, while in a thermal analysis, the user may be
interested in total heat flux or temperature. The result in the mechanical application
section lists various results available for post processing.
After the solution has been obtained, it is possible to review and interpret the
output as explained below:
5.18
Animation - Animates the change of results over geometry along with
deformation of structure.
Stress Tool - to access a design using different failure theories.
Fatigue Tool - to carry out advanced life prediction calculations.
Contact Tool - to review contact zone behavior in complex assemblies.
Beam Tool - to study stresses in line body representations.
The kinematic and dynamic analysis using MATLAB and ANSYS software
have been carried with different considerations and also tabulated in Table 5.1.
5.19
Table: 5.1 Detail of cases simulated in present study
Two type of analysis have been carried out in ANSYS software, (i) Rigid
analysis and (ii) Flexible analysis. The links are connected to each other through
revolute joints. The effect of gravity is taken into consideration. The crank, follower
and coupler are modeled using beam elements. A constant time step was chosen for
the simulation. The strain of coupler at various time intervals is calculated.
5.20
model of four bar planar mechanism has been presented in Fig. 5. 11. Detail related to
modeling and parameters to be selected for analysis have been mention in Table 5.3.
Parameters Fixed link (1) Crank (2) Coupler (3) Follower (4)
Length (mm) 250 110 280 260
C/S Area (mm2) - 108 40 40
Area moment of
- 160 9 9
Inertia (mm4)
Modulus of Elasticity, E = 7.10 104 MPa
Density = 2770 kg/m3 Crank speed = 32.3 rad/sec
5.21
Table 5.3 Detail of finite element model of four bar planar mechanism
Modeling of four bar mechanism has been done for varying different
parameter i.e. cross section and orientation of cross section of coupler, length of the
rocker and coupler, and flexibility of other links to study the effect on the strain
produce in flexible coupler. Therefore, different models have been prepared in Pro-E
5.22
and exported ANSYS for analysis as presented in Figs 5.12-5.18 and detail of model
i.e. number of nodes and element are presented in Tables 5.4-5.8.
Fig. 5.12 Coupler link having rectangular cross section with orientation 1
Fig. 5.13 Coupler link having rectangular cross section with orientation 2
5.23
Figures 5.15 to 5.18 show the rectangular, circular and elliptical cross section
with different orientation of coupler link with cross section area of 40 mm2. Due to
the change in orientation of coupler has changed its moment of inertia from Ixx to Iyy
(rectangular cross section). It is worth to mention here, that in case of Ixx, the width of
coupler is parallel axis of rotation while, it is perpendicular to axis of rotation in case
of Iyy.
5.24
Table 5.4 Detail of FE model for different cross section and orientation of coupler
Coupler length
260 270 280 290 300
(mm)
Statistics
Nodes 883 883 924 921 921
Elements 96 96 102 100 100
5.25
Fig. 5.16 Meshed model of mechanism with flexible coupler and rocker
Table 5.6 Detail of finite element model with flexible coupler and rocker
5.26
Fig. 5.17 Meshed model of mechanism with flexible crank and coupler
Table 5.7 Detail of finite element model with flexible crank and coupler
5.27
Fig. 5.18 Meshed model of mechanism with flexible crank, coupler and rocker
Table 5.8 Detail of finite element model with flexible crank, coupler and rocker
5.28
5.3 Modeling of Watts mechanism
The strain developed in links of Watts mechanism (six bar planar mechanism)
has been investigated using the ANYSYS. In this analysis two links are to be
considered as flexible with numbers of beam elements.
Specifications of six bar mechanism for analysis are mentioned in Table 5.9
and mesh model of six bar mechanism is shown in Fig. 5.19.
Area moment of
- 160 9 9 10 9
Inertia (mm4)
Modulus of Elasticity, E = 7.1 104 MPa
5.29
Table 5.10 Detail of finite model of six bar mechanism
5.30
Object Name LINK 1 LINK2 LINK3 LINK4 LINK5 LINK6
Statistics
Nodes 1 152 1 240 1
Elements 1 42 1 88 1
Mesh Metric None
5.31