Exp.

No: Date:

MODELING
SOLID MODELING

CRANK SHAFT part using Solid modeling

Getting Started

Before getting into the detailed instructions for using Pro-Engineer wildfire 5.0 part modeling,
the following crank shaft part aims at giving you a feel about what you can do with the product.
It provides a step-by-step procedure showing you how to use key functionalities. The main tasks
described in this section are:

 Entering into the interface

 Creating part modeling
 Creating 2d drawing by using pre-defind profiles such as
line,rectangle,arc,circle,polygons etc….
 Extrude ( to add (or) remove the material along normal to the sketching
plane)
 Revolve (to add (or) remove the material around the axis)

Pro-Engineer wildfire 5.0 GUI (Graphic user interface)

Menu bar planes

Model tree Title bar

1|Page
The final part will look like these

2|Page
Step 1 :

Use sketch entities to develop the shape of the lobe

Step 2:

Constrain and dimension the lobe sketch and extrude geometry from the sketch

Select the Complete Sketch icon in the sketcher toolbar to exit the sketch.

3|Page
Step 3:

1. Click the Extrude icon with the sketch selected.

2. Select Both Sides from the pull down in the dashboard as the depth direction, and
enter 1.125 as the depth.

Select the Complete Feature icon in the dashboard.

Step 4:

Click the revolve icon with the sketch selected

Select the axis, to enter the angle 3600

4|Page
Dimension sketch of shaft and revolve geometry from the sketch

5|Page
Step 5:

Trace an existing sketch to cut-away geometry on the lobe

6|Page
Step 6:

1. Click the Sketch Tool icon on the right toolbar to create a sketch.
2. Select the surface shown as the Sketch Plane, then click the Sketch button in the Sketch
dialog.

7|Page
`

8|Page
Exp. No: Date:

SURFACE MODELING
Hand part using surface modeling

Getting Started

Before getting into the detailed instructions for using Pro-Engineer wildfire 5.0 Surface
modeling, the following Hand part aims at giving you a feel about what you can do with the
product. It provides a step-by-step procedure showing you how to use key functionalities. The
main tasks described in this section are:

 Entering into the interface

 Creating surface modeling
 Creating geometry points
 Creating Lines by joining points
 Creating splines by using points
 Creating Fill surfaces

 Creating blend surface

9|Page
Pro-Engineer wildfire 5.0 GUI (Graphic user interface)

The final part will look like these

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Step 1:

We are taking geometry points by using dimensions with reference to co-ordinate system.

Geometry points Co-ordinate system

 By using co-ordinate system we are taking points by giving X,Y,Z values.

Step 2

By using geometry points, to join through points and we create splines and lines.

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Splines Lines

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Step 3

We are taking the closed boundary, to fill the boundary by the form of surface using Fill
command.

Boundary 1

boundary (fill)

Boundary 2

boundary(fill)

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Step 4

We are using blend command, to join splines to get the required hand shape.

Fig 1.

Blend surface

Fig2.

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Fig3.

Fig4.

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Final part of the hand

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Exp. No: Date:

ASSEMBLY
Draw individual parts in part modelling &save parts.

File>select new>select assembly module>ok

Assembly window

Select assemble icon >select part>open.

Select default>then component (crank shaft) will be fully constrained.

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Select assemble icon >select part (connecting rod)>open.

Select align & mate constrains select connecting rod planes and crankshaft planes up to fully
constrained to object.

Select assemble icon >select part (connecting rod)>open.

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Select align & mate constrains select piston pin planes and crankshaft planes up to fully
constrained to object.

Select assemble icon >select part (connecting rod)>open.

Select align & mate constrains select piston planes or surfaces and crankshaft planes up to fully
constrained to object.

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Finally this is assembly part of opposed piston

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Exp. No: Date:

DRAWING
Getting Started

Before getting into the detailed instructions for using Pro-Engineer wildfire 5.0 drawing module

We are done piston part using drawing module

After completing this module, you will be able to:

 Describe the Pro/ENGINEER drawing development process.

 Describe the elements of completed drawings.
 Create drawings by manually adding drawing views and detail items.
 Create drawings using drawing templates.
 Describe the drawing ribbon user interface.
 Use the drawing ribbon user interface to complete detailing tasks.

Drawing Development Process

The drawing development process can be divided into three broad phases.

 Drawing Standards Configuration

 Drawing Initiation
 Drawing Creation

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Understanding the Drawing Ribbon User Interface

The Drawing mode was reorganized with a ribbon-style user interface.

The ribbon organizes and configures user-interface.

 Tabs based on the current task.

 Sets up selection scope.
 Appropriate right-click options.

Ribbon structure

 Tabs contain groups of commands.

 Can be customized.

RIBBON TAB CONTAINS GROUP OF COMMANDS

 Layout: Drawing Models, Sheets, Views

 Table: Create and Modify Tables, Repeat Regions, BOM Balloons
 Annotate: Show, Erase, Cleanup, and Delete Detail Items
 Sketch: 2-D Sketching Tools
 Review: Model CHECK, Updating, Comparison, Information Tools
 Publish: Preview, Print, or Plot Drawings

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SPECIFYING THE SHEET SIZE

Drawing format

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CREATE MODEL VIEWS IN DRAWINGS

Adding General Views

General views are the first view you can place in a drawing. You can then derive other views
from general views

View Orientation

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Adding Projection Views
A projection view is an orthographic projection of another view’s geometry along a horizontal or
vertical direction.

Views Projected from Front View

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Adding Detailed Views

A detailed view is a small portion of a drawing view shown enlarged in another view

Detailed Views

Adding 2-D Cross-Section Views

You can configure 2-D cross-section views when placing a view in a drawing.

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Understanding Annotations in Drawings
Model annotations such as 3–D model dimensions and model axes, can be shown on drawing
views.
Model Annotations in Drawings Theory:
 Model Annotations
 Dimensions, model axes, geometric tolerances, set datum planes.
 Show in drawing views
 Associative with the model.
 Erase or delete annotations in a drawing.
 Erase — temporarily remove from display.
 Delete — remove from display. Not deleted from model.
 Show model dimensions only once.
 Move to different views
 Create additional (driven) dimensions in the drawing.

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Show model annotations

Understanding Dimensional Tolerances

Dimensional tolerances enable you to specify allowable variations in model dimensions.

Dimensional Tolerances
 General
 Individual
Tolerance Standards
 ANSI
 ISO
Tolerance Display Formats
 Nominal
 Limits
 Plus-Minus
 Symmetric
ISO Tolerance Tables
 General
 Broken edge
 Holes and shafts
 Tolerance class

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ANALYSIS

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Exp. No: Date:

STATIC ANALYSIS

POINT LOADING OF A 1D CANTILEVER BEAM

Problem Description

Nomenclature:

L =110m Length of beam

b =10m Cross Section Base

h =1 m Cross Section Height

P=1000N Point Load

E= 70GPa Young’s Modulus of Aluminum at Room Temperature

Poisson’s Ratio of Aluminum = 0.33

In this module, we will be modeling an Aluminum cantilever beam with a point load at the end
with one dimensional elements in ANSYS Mechanical APDL.

Preferences

1. Go to Main Menu -> Preferences

2. Check the box that says Structural
3. Click OK

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Key points
Since we will be using 1D Elements, our goal is to model the length of the beam.
Go to Main Menu -> Preprocessor -> Modeling -> Create ->Keypoints ->
On Working Plane
1. Click Global Cartesian

2. In the box underneath, write 0,0,0 creating a keypoint at the origin .

3. Click Apply

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4. Repeat Steps 3 and 4 for the point 110,0,0

5. Click OK

Line

Go to Main Menu -> Preprocessor -> Modeling -> Create ->Lines -> Lines -> Straight Line
Select Pick

Enter 1,2 for keypoints

Click OK

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Pre-processor

Element Type 1. Go to Main Menu -> Preprocessor ->

Element Type -> Add/Edit/Delete
2. Click Add

3. Click beam -> 3D Elastic 4

4. Click OK

5. Click Close

BEAM4
IT is a one dimensional linear element with 6 degrees of freedom
(UX,UY,UZ,ROTX,ROTY,ROTZ). It has tension, compression, bending, and torsional
capabilities.
Material Properties

1. Go to Main Menu -> Material Props -> Material Models

2. Go to Material Model Number 1 -> Structural -> Linear -> Elastic -> Isotropic

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Meshing

1. Go to Main Menu -> Preprocessor ->Meshing -> Mesh Tool

2. Go to Size Controls: -> Global -> Set

3. Under SIZE Element edge length put 55.

4. Click OK

5. Click Mesh

6. Click Pick All

7. Click Close

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Displacements
1. Go to Utility Menu -> Plot -> Nodes

2. Go to Utility Menu -> Plot Controls -> Numbering…

3. Check NODE, Node Numbers to ON

4. Click OK
5. Go to Main Menu -> Preprocessor -> Loads -> Define Loads ->
Apply -> Structural -> Displacement -> On Nodes
6. Click Pick -> Single and with your cursor, click on first node

7. Click OK

8. Click All DOF to secure all degrees of freedom

9. Under Value Displacement value put 0.

10. Click OK

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The fixed end will look as shown below:

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POINT LOAD

1. Go to Main Menu -> Preprocessor -> Loads -> Define Loads ->
Apply -> Structural ->Force/Moment -> On Nodes
2. Under List of Items enter 2 for node 2 and press OK
3. Under Lab Direction of Force/mom select FY

4. Under Value Force/moment value type -1000

5. Press OK

The load at the end face should look as below:

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Solution

1. Go to Main Menu -> Solution ->Solve -> Current LS (solve). LS stands for Load Step. This
step may take some time depending on mesh size and the speed of your computer (generally a
minute or less). Ignore any warnings that may appear on your screen, as they are irrelevant to the
problem at hand.
General Postprocessor
We will now extract the Preliminary Displacement and Von-Mises Stress within our model.
Displacement
1. Go to Main Menu -> General Postprocessor -> Plot Results -> Contour Plot -> Nodal
Solution
2. Go to DOF Solution -> Y-Component of displacement
3. Click OK
4. To give the graph a title, go to
Utility Menu -> Command Prompt and type /title, Deflection of a Cantilever Beam with a
Point Load.
5. Press enter and write /replot to refresh the window.

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Equivalent (Von-Mises) Stress
Unfortunately, we cannot create a contour plot of Von-Mises stress for 1D elements. We can,
however, look up the moment reactions at each element. If we plug this value into equation we
can readily calculate the bending stress in our model and by extension, the equivalent stress.
1. Go to Utility Menu -> List -> Results -> Element Solution …

2. Go to Element Solution -> All Available force items

3. Click OK

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Exp. No: Date:

2D ELEMENT TRUSS

Problem Description
Determine the nodal deflections, reaction forces, and stress for the truss system shown below (E
= 200GPa, A =(3250mm2).

In the Utility menu bar select File > Change Title:

Enter the title and click 'OK'. This title will appear in the bottom left corner of the 'Graphics'
Window once you begin.

Enter Key points

The overall geometry is defined in ANSYS using keypoints which specify various principal
coordinates to define the body. For this example, these keypoints are the ends of each truss.

We are going to define 7 keypoints for the simplified structure as given in the following table

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42 | P a g e
Element Material Properties

You then need to specify material properties:

In the 'Preprocessor' menu select Material Props > Material Models

Double click on Structural > Linear > Elastic > Isotropic

We are going to give the properties of Steel.

Mesh Size
The last step before meshing is to tell ANSYS what size the elements should be. There are a
variety of
ways to do this but we will just deal with one method for now.
In the Preprocessor menu select Meshing > Size Cntrls > ManualSize > Lines > All Lines

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Assigning Loads and Solving

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Results

Displacement

Stress

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Exp. No: Date:

3D-ELEMENT OF CONNECTING ROD

Open ansys14.5 mechanical APDL 14.5

File>import>open file

Imported model from PRO-E in the format of IGES

Imported model

Preferences>structural>ok

Pre-processor>element type>add/edit/delete>add>solid>20node186>ok

Material properties>material models

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Aluminum alloy 6061

Young modulus – 68000 MPa

Poisson’s ratio- 0.33

Density-0.0000027 kg/mm3

Meshing>mesh tool>smart sizes (ON)>pick all>ok

Meshed model

Loads>define loads>apply>structural>displacement>on areas>select fixed area>ok

Pressure>on areas>select pressure areas>ok

Pressure =30.83N/mm2

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Solution>solve>current Ls>ok

General post processor>plot results>contour plot>nodal solution>DOF solution>displacement

vector sum>ok

Displacement

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Nodal solution>stress>von misses stress>ok

Stress

Strain

Nodal solution>total mechanical strain>von misses total mechanical strain>ok

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Exp. No: Date:

MODAL ANALYSIS OF TRAIN BRAKE

Main menu>Preprocessor>Loads>Analysis Type>

New Analysis> Select Modal>

Click> OK

Main menu>Preprocessor>Loads>Analysis Type>

Analysis Options>

No. Of Modes to Extract: 5

Click> OK

Main menu>Solution>Solve>Current Ls>Ok

Results

Main menu>General Postproc>Read Results> First Set

Plot result>Deformed Shape> Def+ Undeform > Click> OK

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Main menu>General Postproc>Read Results> Next Set

Plot result>Deformed Shape> Def+ Undeform > Click> OK

Main menu>General Postproc>Read Results> Next Set

Plot result>Deformed Shape> Def+ Undeform > Click> OK

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Main menu>General Postproc>Read Results> Next Set

Plot result>Deformed Shape> Def+ Undeform > Click> OK

Main menu>General Postproc>Read Results> Next Set

Plot result>Deformed Shape> Def+ Undeform > Click> OK

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Exp. No: Date:

BUCKLING ANALYSIS OF BEAM

Open ansys14.5 mechanical APDL 14.5

File>import>open file

Imported model from PRO-E in the format of IGES

Preferences>structural>ok

Pre-processor>element type>add/edit/delete>add>solid>20node186>ok

Material properties>material models

Aluminium material properties

Young’s modulus=68000MPa

Poisson’s ratio=0.3

Density=0.00000269kg/mm3

Meshing>mesh tool>smart sizes (ON)>pick all>ok

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 MESHED MODEL

Loads>define loads>apply>structural>displacement>on areas>select fixed area>ok

Pressure>on areas>select pressure areas>ok

Pressure =0.0769N/mm2

Click the unbridged menu that it will change abridge menu, then it will come to “Analysis
Options”

Click “Analysis option” to changes the memory save click : ON

Reduced I/O : click no options, OK

Solutions:

>solve>current ls>ok>close>OK

To type main menu “Finish” write.

Solution

>Analysis type >New analysis >Click Eigen Buckling>OK

Analysis Options

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 >No of modes to extract “3”>Ok

Solution

>Solve>Current LS > ok > close >ok

Write finish options write

Solution

>Analysis type>Expansion pass(click)>Expansion pass on>ok

Solution

>load step options>Expansion plan>single expand>Expand modes

>No of modes to expand 5>ok

>solve>current LS>ok>close>close

General post processor

>list results>Detail summary

>Read results >by pick > last set

>Plot Results

>Deformed shape>Deformed shape only>ok

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BUCKLING FACTOR 1

BUCKLING FACTOR 2

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BUCKLING FACTOR 3

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Exp. No: Date:

HARMONIC ANALYSIS OF SPINDLE

Imported model :-

Enter units in command prompt: /units, si, mm, kg, sec, k

Preferences: structural

Preprocessor:

Main Menu> Preprocessor> Element Type> Add/Edit/ Delete

Structural Properties for Steel

Element Type: solid 20 nodes 186

Material Properties: Density – 0.00000785Kg/mm3

Young’s Modulus – 205000Mpa

Poisson’s ratio - 0.29

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Generate Mesh

Meshing is done by using size controls command of lines, the line of specimen is divided to get a
good mesh. After that mesh area is selected as shown in Fig

[Mesh] < [Pick All] < [Close] Warning.

Solution – Analysis type-new analysis-select harmonic-ok

Load step options>time/frequency>frequence&substeps>enter harmonic frequency range 0 to

1000>ok write ls load step file number 1>ok

Read ls>load step file number n>1>ok

Solution>solve>current ls>ok

Time hist postprocessor>add data >select nodal solution>displacement>select Z-component of

displacement>select node on pressure area>ok

Select Graph data>ok

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Graphs

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 Exp. No: Date:

STEADY-STATE THERMAL ANALYSIS OF GAS TURBINE BLADE

 FILE -> Import -> IGES -> Ok -> Browse -> select File -> Open
 PREFERANCES -> Thermal -> Ok

PREPROCESSER -> Element Type -> Add/Edit/Delete -> Add -> Solid -> 20 node 279 -
> Ok

 Material properties -> Material Modals -> Thermal ->Thermal Conductivity -> Isotropic -
> enter Thermal conductivity(KX), Specific Heat(C), Density for required material ->Ok

Close

Meshing -> Mesh Tool -> Smart size ON -> select FINE MESH(1-6) -> Mesh -> Pick
All
Loads -> Define Loads -> Apply -> Thermal -> Temperature ->On Area -> select
Temperature Area on the component -> enter Temperature value -> Ok
Convection -> On Areas ->Pick All
Delete -> Thermal -> Convection -> select given temperature area -> Ok

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 SOLUTION -> Solve -> Current LS(Load Step)file ->Ok ->Solution is done -> Ok ->
Close
 GENERALPOSTPROS -> Plot Results -> Contour Plot -> Nodal Solution ->DOF
solution -> Nodal Temperature -> select True Scale ->Ok

Thermal Gradient -> Thermal Gradient Vector Sum -> Ok

 Thermal Flux -> Thermal Flux Vector Sum -> Ok

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Exp. No: Date:

TRANSIENT THERMAL ANALYSIS OF PISTON

 FILE -> Import -> IGES -> Ok -> Browse -> select File -> Open
 PREFERANCES -> Thermal -> Ok

 PREPROCESSER -> Element Type -> Add/Edit/Delete -> Add -> Solid -> 20 node 279 -
> Ok
 Material properties -> Material Modals -> Thermal ->Thermal Conductivity -> Isotropic -
> enter Thermal conductivity(KX), Specific Heat(C), Density for required material ->Ok
-> Close
 Meshing -> Mesh Tool -> Smart size ON -> select FINE MESH(1-6) -> Mesh -> Pick

All
 SOLUTION -> Analysis Type -> New Analysis -> TRANSIENT -> Ok ->Ok

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 Analysis Type ->

Solution Contrls -> Time at end of load step -> No. of sub steps -> enter Max. no. of sub
steps -> enter Min. no .of sub steps -> Ok

 Loads -> Define Loads -> Apply -> Thermal -> Temperature ->On Area -> select
Temperature Area on the component -> enter Temperature value -> Ok
 Convection -> On Areas ->Pick All
 Delete -> Thermal -> Convection -> select given temperature area -> Ok
 Load Step Options ->Write LS file ->enter load step file no 1 -> Ok -> Define loads ->
Delete -> Thermal -> Temperature -> On Areas -> Pick All

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 Go to Analysis Type -> Solution Contrls -> enter time at end of load step ->Ok

 Loads -> Define Loads -> Apply -> Thermal -> Temperature ->On Area -> select
Temperature Area on the component -> enter Temperature value -> Ok
 Load Step Options ->Write LS file ->enter load step file no 2 -> Ok -> Define loads ->
Delete -> Thermal -> Temperature -> On Areas -> Pick All -> As per same up to Last

step
 SOLUTION -> Solve -> From LS file -> enter the starting and ending file no’s ->Ok ->
Solution is Done -> Ok -> Close

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 GENERAL POST PROS -> Read Results -> select 1st set -> Plot results -> Contour Plot -
> Nodal Solution -> DOF solution -> select NODAL TEMPERATURE -> Ok -> save a

picture -> select

THREMAL GRADIENT -> select Thermal Gradient Vector Sum -> Ok -> save a picture
-> select THERMAL FLUX -> select Thermal Flux Vector Sum -> Ok -> save a picture

 Read Results -> select NEXT set

 -> Plot results -> Contour Plot -> Nodal Solution -> DOF solution -> select NODAL
TEMPERATURE -> Ok -> save a picture -> select THREMAL GRADIENT -> select
Thermal Gradient Vector Sum -> Ok -> save a picture -> select THERMAL FLUX ->
select Thermal Flux Vector Sum -> Ok -> save a picture

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 Exp. No: Date:

TRANSIENT STRUCTURAL ANALYSIS OF CONNECTING ROD

 GO to File -> Import -> IGES -> Ok ->Browse -> select IGES file -> Open -> Ok
 PREFERANCES -> select Structural -> Ok
 PREPROCESSER -> Element type -> Add/Edit/Delete -> Add -> Solid -> 20 node 186 -
> Ok
 Material properties -> Material models -> Structural -> Linear -> Elastic -> Isotropic ->
enter the YOUNGS MODULUS(EX), POSSIONS RATIO(PRXY), DENSITY values for
required materials -> Close

• Meshing -> Mesh Tool -> Smart Size ON -> select FINE MESH(1-6) -> Mesh -> Pick All

 Go to SOLUTIONS -> Analysis Type -> New Analysis -> TRANSIENT -> Ok -> Ok

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 Analysis Type ->SoluContls -> Time at End of Load steps -> No of sub steps -> Max no.
of sub steps -> enter no. of Min. sub steps(1) -> Ok

 Loads -> Define Loads -> Apply -> Structural ->Displacement-> On Areas -> select
required area on the component -> select ALL DOF -> Ok
 Pressure -> On areas-> select required area on the component -> Ok -> enter Pressure
value -> Ok

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 Load Step Options -> Write LS file -> enter load step 1 -> Ok -> define Loads ->

 DELETE -> Structural -> Pressure -> On Areas -> Pic All
 Go to Analysis Type -> Solution Contrls -> enter Time at end of load step -> Ok ->again
LOADS -> Apply -> Pressure -> On Areas -> enter pressure value -> Ok -> Load Step
Options -> Write LS file -> enter load step 2 -> Ok -> define Loads -> DELETE ->
Structural -> Pressure -> On Areas -> Pic All -> up to Last material
 SOLUTION -> Solve -> From LS file -> enter starting LS file 1 to ending file no(3) ->
Ok -> solution is done -> Ok -> close

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  GENERAL POST PROS -> Read Results -> select 1st set -> Plot results -> Contour Plot -
> Nodal Solution ->DOF solution -> displacement vector sum -> select TRUE SCALE -

> Ok

Save a Picture

 Stress -> select VON MISS STRESS -> Ok

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Exp. No: Date:

SHELL ELEMENT

MATERIAL – CARBON FIBER

Element Type: Shell 8 node281

Material Properties

Ex =126900 N/mm2

Ey =11000 N/mm2

Ez =126900 N/mm2

Poisson's ratio = 0.2

Gxy = 6600 N/mm2

Gyz = 4230 N/mm2

Gxz = 4880 N/mm2

Thickness material ID orientation

5.08 1 -90

5.08 1 0

5.08 1 90

Ok-plot section-range of layer 1 to 3 ok

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Meshed model

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 Displacement Vector Sum

The maximum displacement value was found out to be 0.0000298 mm.

Von Mises Stress

Maximum Stress value was found out to be 0.002434N/mm2

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Strain

The maximum strain value was found out to be 0.0000000224

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