ANSYS v17

Update Seminar

Presented by:
CAE Associates
 Multiphysics
Analysis using
ANSYS v17
Demonstration of ANSYS/Multiphysics

 Scenario: Your company designs and manufactures gear boxes. You

recently switched your gears supplier and are now experiencing an
increase in field failures. The gear supplier is claiming that the failures are
not their fault. You are tasked with determining the root cause of the and
the modifications required to correct the problem.
 The issues you need to contend with are as follows:
— You do not have a CAD file of the gear.
— You use induction heating to assemble the gear and shaft.
— You need to determine if the resulting assembly loads are contributing to the
field failures.

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Demonstration of ANSYS/Multiphysics

 The approach will be as follows:

1. Scan the actual gear and use
reverse engineering to generate
CAD geometry using
SpaceClaim.
2. Calculate the ohmic losses of the
induction heating process of the
gear using Maxwell.
3. Calculate the resulting
temperature distribution in the
gear using Fluent.
4. Assemble the gear/shaft and
calculate the residual stress
using Mechanical.
5. Add the operational load and
estimate the life of the gear using
the Fatigue Tool.

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Demonstration of ANSYS/Multiphysics

 Extra credit: You have observed surface cracking on some of the gears.
Determine if the cracks will propagate under load.

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ANSYS SpaceClaim
Direct Modeler

Eric Stamper
ANSYS SpaceClaim Direct Modeler

 SpaceClaim brings 3D modeling to the desktops of engineers and analysts

who work with but don’t want to become experts in traditional feature-
based CAD systems.
 ANSYS SpaceClaim Direct Modeler (ANSYS SCDM) software is a new
way to manipulate CAD models and is integrated into Workbench.
 The model becomes completely dynamic, allowing the user to move,
stretch, add and remove features with ease.
 All changes to the CAD model occur in real time on the screen, providing
instant feedback on a design.
 ANSYS SCDM addresses the specific needs of the finite element analyst,
including simplifying existing CAD geometry, creating detailed and
complex geometry, and allowing parametric modeling.

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 SpaceClaim v17.0
Reverse Engineering

Gear Demo
Overview of Reverse Engineering

 What is Reverse Engineering?

— The process by which a physical component is converted into a 3D CAD
model.
— A faceted geometry file can be created by scanning a physical part and
connecting all the point cloud measurements into triangular surfaces. The
result is a faceted surface representation that can be saved in a .STL file
format.
— The faceted geometric representation is then converted back into an analytical
and manufacturable representation.

 ANSYS’ Reverse Engineering Solution:

— The “Faceted Toolkit” within ANSYS’ SpaceClaim Direct Modeler can be used
to manipulate the surface facets and provide the user with a “geometric guide”
from which a new CAD model can be recreated.

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Overview of Demo

 Reverse Engineering Strategy:

— Use the faceted surfaces as a guide to rebuild a new CAD model.
— Solid geometry can be created directly from the faceted surfaces; however the
resulting CAD model will typically be poorly represented.
• Cleaning up all the poorly represented surfaces of the CAD model is generally more
difficult than dealing with the surface facets directly.

Reversed Engineered Direct STL to CAD

STL

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Reverse Engineering Gear Demo

 Open: Gear_Coarse.stl
 Right click on the “Facet Mesh” object in the tree > Convert to solid >
Merge Faces.
— The faceted surface model is now converted into a solid, however it’s very
faceted and poorly represents the physical part. Manual clean up will be
needed to improve the geometry.
— The Faceted toolkit tab is designed to work with these types of surfaces before
a 3D solid is created.
 Undo this operation!

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Reverse Engineering Gear Demo

 Click on the World Origin in the modeling window

 Click the plane icon to create the 3 orthogonal global planes.

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Reverse Engineering Gear Demo

 Click the vertical plane in this view

 Select Move Tool
— Check box “Create patterns”
 Drag green angle on triad over to
create 1 plane as shown

 Click on “Pattern” in the tree

— Change the properties as shown

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Reverse Engineering Gear Demo

 Click the vertical plane in this view

 Select Move Tool
— Check box “Create patterns”
 Drag green angle on triad over to
create 1 plane as shown

 Click on “Pattern” in the tree

— Change the properties as shown

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Reverse Engineering Gear Demo

 Facets Tab > Split

 Use planes to split .stl

 Delete unneeded features:

— Select anything on the “yellow” body
and the two planes that sliced it
— Ctrl+H to hide them
— Ctrl+A to select all
— Delete key to delete everything shown
— RMB click, show all

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Reverse Engineering Gear Demo

 Insert Tab > Extact Curves

 Orient normal and zoom in

— “V” then “Z”
— Click Checkmark
Use front plane

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Reverse Engineering Gear Demo

 View in 3d
— “D”
— Hide all but the lines to show that the x-section was extracted
— Orient view normal to plane
• Click plane, then “V”

 Repair Tab > Fit Curves

— Check Correct Tangency
— Box select curves shown
— Use slider to show how the curves are fixed.
• Go with Max. dist = 0.2mm
— Click green check to complete
Box Select

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Reverse Engineering Gear Demo

 Repair Tab > Fit Curves

— Repeat box selections to fix other locations

Box Select

Box Select

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Reverse Engineering Gear Demo

 Turn on Facet Mesh to see the lines against the edges

 Zoom to bottom
— Select edge and fill “f” to replace curve with line
— Fill twice to remove chamfer to corner

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Reverse Engineering Gear Demo

 Show just curves

— Fill edges shown

 Box select these 4

edges and fill once
more to replace with
single edge

 Select all edges and

Fill to convert to
surface

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Reverse Engineering Gear Demo

 Show just the facets

 Facets Tab > Smooth
— Double click faces to select all facets in hole, top and bottom surfaces, then
smooth twice

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Reverse Engineering Gear Demo

 Double click facet in hole to select all facets

in hole
— Then: Insert Tab > Cylinder.

 Pull faces just to make it a little longer and

not co-planar with the facet surface

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Reverse Engineering Gear Demo

 Show just the mesh and zoom in as shown

 Double click the facets to select shown as show. Use
Ctrl+Double click as need to add the right facets, then
— Insert > Fit Spline (REPEAT)

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Reverse Engineering Gear Demo

 The surfaces will eventually be used to cut away the teeth

 First trim surfaces with planes
— Make sure the planes are slightly off the surfaces of the mesh. Use orange
facets to initially place plane
— Design Tab > Plane

— Click newly created plane and Move “M”

— Drag up slightly with z direction

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Reverse Engineering Gear Demo

 Whilst in the move tool, hold Ctrl, and drag

down a copy of the plane just off the surface
of the lower gear face

 Show just the surfaces and planes

 Use Design > Combine with box select and
trim away extra surfaces.
3. Click 4. Box Select

2. Box
select

1.

Repeat

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Reverse Engineering Gear Demo

 Imprint all surfaces

— Prepare Tab > Imprint

 Select unused surfaces and delete

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Reverse Engineering Gear Demo

 Create a solid from the surfaces.

— Select the two edges shown, Design Tab > Blend

 Box select edges

— Use fill to create solid

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Reverse Engineering Gear Demo

 Pull edges to 0.75mm

 Save this value as a parameter by clicking the “P”, now making the blends
parametric. Go to “Groups” Tab to see it.

 Show all, put axis on global z

— Design Tab > Axis

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Reverse Engineering Gear Demo

 Only show surface

 Pull “Revolve” surface 360° around axis 2. Click

1. Click

3. Click

 Subtract hole solids

— Show hole body
— With “combine”. 1st click gear, 2nd click
box select hole body, 3rd click box select
hole bodies.
— Click hole body in tree, delete

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Reverse Engineering Gear Demo

 Pattern the holes with Move:

1.
4. Use or drag
3. Click
yellow triad to global axis
surface

2.

6. Click
7.
5. Use blue
angle arrow to
create pattern

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Reverse Engineering Gear Demo

 Options to create the teeth:

1. Move body to create a pattern of the teeth solids and then subtract
2. Subtract 1 tooth and move faces to a pattern
3. Subtract 1 tooth and pattern faces Show

OR

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Reverse Engineering Gear Demo

 Create chamfer
— Select 1 edge
— Go to “Selection” and use search to find all edges on face

— Use Pull, and select Chamfer

Pull to 2.5mm

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Reverse Engineering Gear Demo

 Create chamfer
— Manually, just select a couple edges to show additional pull.

— Pull with “Pivot Edge” Matched

2. Up to

1. Direction

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Summary: Reverse Engineering Gear Demo

 The faceted surface representation (STL file) of the gear was converted
into 3D CAD model and is ready to be used in an analysis.
 The STL file served a guide from which surfaces and curves were
extracted and used to build new features.
 The main tools used to reverse engineer the gear were:
— Pull, Move, Fill and Combine

STL
Reversed Engineered

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 Highlighted
Features in SCDM
V17

For detailed release

information visit:
http://www.spaceclaim.com/2016
New Skin Surface Feature

 Interactively generate surfaces over faceted models

 Skin Surface supports:
— 4-sided, 3-sided, domed, and periodic patches
— Tightness control
— Direct editing of patch boundaries
— Connecting of neighboring patches
— Automated smoothing
— Auto-skin from planes

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New Scripting (Beta Release)

 Automate geometry creation and cleanup

 IronPython based
 Editor in SC for script creation and execution
 Access to math and any Python library

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v17 Update Agenda
8:30 Welcome 1:00 Customer Q&A
— Introduction 1:30 CFD Update
— Pass out the question cards 2:30 New Mechanical tools
— What’s new, website additions, etc. — Simulation for Electronic Products
8:45 New Product Packaging — Model Assembly
— Mechanical Features
9:15 Coupled Field Demo:
— Adaptive meshing
— Reverse Engineering Geometry
3:15 Break
— Induction Heating with Maxwell
10:15 Break 3:30 Product update details
— ACT
10:30 Coupled Field Demo continued:
• Topological optimization Example
— Conjugate Heat Transfer using Fluent
— APDL
— Structural Analysis using Mechanical
• XFEM
• Assembly and operational loading
— ACP
• Estimating life with the Fatigue
Module
• Fracture Analysis
— HPC
12:00 Lunch

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 ANSYS
Electromagnetic
Simulation
Jim Kosloski
Why Do Electromagnetic Analysis?

 Gain a better and more detailed understanding of the

response and behavior of an electromagnetic device.

 Virtual prototyping = Time and cost savings

— Safe virtual testing of dangerous operating

environments.

 Design sensitivity studies allow efficient assessment

of changes in electric loading and environmental
conditions.

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Example Electromagnetic Problems

 Capacitor – Compute the electric field between and

around the conducting plates. Calculate capacitance.
— Brakes in electric cars store energy in capacitor

 Motor/Generator – Analyze the magnetic field in a motor

due to coil windings or permanent magnets. Study
fringing and field results across the air gap. Calculate
flux linkage, inductance, reactance, force and torque.

 Solenoid – Analyze the magnetic field and force

generated.

 Induction heater – Determine the electric and magnetic

fields in a part induced by an alternating current in an
adjacent coil. Determine the losses (heat generations) in
the part due to the induced currents

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Example Coupled Field Problems

 Electromagnetic calculations are often used

in conjunction with other field solutions: Electromagnetic CFD Mechanical

 Example:
— Objective: Predict Electric Motor Performance
• Design for real-life operating conditions with a
wide variety of loads and manufacturing Torque 2D
213.75

variability.
Curve Info
Moving1.Torque
Setup1 : Transient
Moving1.Torque_22_
Imported
200.00 Moving1.Torque_2em
Imported
Moving1.Torque_3em
Imported

— Solution 180.00

Torque (N)
Y1 [NewtonMeter]
• Calculate electromagnetic loss and use these 160.00

results to calculate the thermal effects with CFD

• Look at further thermal and stress analysis in a
140.00

structural analysis.
123.75
2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
Time [ms]

— Value of Simulation Time (ms)

Single physics simulation, assuming a

• In this case, the actual magnet temperature was magnet temperature of 22C

more than 30 degrees C higher than the 3-way Multiphysics simulation shows that
the actual magnet temperature: 53C
assumed one with a corresponding big hit in
performance. Including all the physics provides 16% drop in
predicted
a more thorough understanding of how your performance
product operate.

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ANSYS Maxwell

 ANSYS Maxwell is an industry leading high-performance interactive

software package that uses finite element analysis (FEA) to solve electric
or magnetic problems.
 Maxwell solves the electromagnetic field problems by solving Maxwell's
equations in a finite region of space with appropriate boundary conditions
excitations and initial conditions in order to obtain a solution.

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Maxwell Strengths

 Ease of use brings usability and productivity

— Adaptive Mesh Technology
— Automatic and complete workflow setup generation for electrical machines
 Transient with rigid motion and circuit coupling.
 Multi-physics and robust design.
— Workbench integration (CAD integration, multiphysics, automated load
transfer)
— Parametric variations
— Optimization, DOE, DFSS.
 Advanced material modeling
— Permanent magnet magnetization and demagnetization.
— Permanent magnet temperature dependency.
— Core Loss Calculation (electrical steel and ferrite) with feedback on field
solution.
 High Performance Computing capabilities
— Use of multiple cores to solve frequency sweeps

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Maxwell and Workbench

 Maxwell is integrated in Workbench environment. The main advantages of

this integration for the user are:
 Multiphysics analysis.
— Maxwell is coupled to ANSYS Mechanical (thermal and stress solver) and
Fluent (thermal)
 CAD Integration.
— Through Workbench, Maxwell has bi-directional link with CAD sources.
 Parametric variations

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Maxwell GUI

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Maxwell Solvers

 Magnetic Solvers

— Magnetostatic Solver
• Solves Static magnetic fields caused by DC currents and permanent magnets. Can
solve both Linear and nonlinear materials.
— Eddy Current Solver
• Solves sinusoidally-varying magnetic fields in frequency domain. Solves only for
linear materials in 3D. Considers displacement currents. Induced fields such as skin
and current proximity effects are also considered.
— Transient Magnetic
• Solves Transient magnetic fields caused by time-varying or moving electrical
sources and permanent magnets in Linear or Non-linear materials. Induced fields
such as skin and current proximity effects are considered.

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Maxwell v17.0
Updates
Time Decomposition Method (TDM)

 New method: domain decomposition along time-axis allows to solve all

time steps simultaneously instead of sequentially

t0 t1 t2 t3 t4 … t_end

 using either:
a single box multiple boxes a cluster a Virtual Private Cloud

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Non Linear Material in Eddy Current

 Saturable materials can be used in the Eddy current solver:

— Enter BH curve the same way as in Transient solver
— Maxwell will iterate the determine the equivalent operating point

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Winding Support Eddy Current Solvers

 Winding setup is the same as transient except additional phase input

New Winding Definition

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Harmonic Stress Coupling

 With Maxwell eddy current solver

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Coupled CFD Material Property Updates

 CFD can call on the fly Maxwell and update element by element
permeability or conductivity
 Applications: advanced induction heating, liquid steel stirring

Crucible

Coils

Outlet Level of conductive losses computed by

liquid ANSYS Maxwell
from ANSYS Fluent

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Multiphysics Capabilities

(*) Enable Electric Arc simulations or advanced Induction Heating simulations

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Maxwell Demo

Induction Heating Coil

Maxwell Demo

 Start with reverse engineered geometry from SpaceClaim.

 Add coil geometry in DesignModeler

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Maxwell Demo

 Add a Maxwell 3D model to project and drag geometry onto it.

 Open geometry in Maxwell3D and draw a Region for air domain

— Coils must terminate on surface of domain
— Use offset o 0 in –Z direction

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Maxwell Demo

 Assign material properties to bodies

— Coil – Copper
— Gear – Steel_stainless

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Maxwell Demo

 Define analysis type:

— Eddy current

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Maxwell Demo

 Assign current excitations to coil face on surface

— Use a variable “amps” for current

Automatically asks
for definition of
variable if not
already defined

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Maxwell Demo

 Assign current excitations to second coil face on surface

— Use same variable “amps” for current.
— Reverse direction

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Maxwell Demo

 Add a Solution Setup.

— In solution setup we specify the convergence tolerance on the adaptive
meshing
— No manual meshing required

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Maxwell Demo

 Solution setup
— Specify the frequency to solve for.
— Can use a frequency range if desired
— Can use HPC to solve all frequencies in range simultaneously

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Maxwell Demo

 Solution converges after 3 adaptive mesh refinements.

— Note: Stainless steel is non-magnetic (Permeability of 1.) therefore the skin
depth is relatively large so a relatively coarse mesh can be used thus the
solution converges in just a few adaptive remeshes.

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Maxwell Demo

 Mesh for final adaptive pass

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Maxwell Demo

 B field

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Maxwell Demo

 Ohmic Losses (W/m3)

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Maxwell Demo

 Maxwell losses transferred to Mechanical or Fluent by a simple drag and

drop in Workbench

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What About ANSYS EMAG?

 EMAG was the sole low frequency tool of ANSYS before the acquisition of
Ansoft in 2008.

— Development efforts for EMAG were limited in recent years.

— Maxwell is the “go-forward” low-frequency electromagnetic tool
— All new R&D efforts for low-frequency electromagnetics are done in Maxwell.

 Maxwell is more efficient and is easier to use than EMAG and is now fully
integrated in Workbench.

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Conjugate Heat
Transfer using
ANSYS Fluent
Mike Kuron
Fluent Demo Overview

 Conjugate Heat Transfer analysis

with ANSYS Fluent
— Induction heat generation loads
imported from Maxwell
— Predict transient temperature field
with natural convection
— New overset meshing method in
Fluent
— Updated Fluent GUI
— New Report Definitions for solution
monitoring and post-processing

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Overset Meshing

 Overset meshing connects overlapping mesh regions through

interpolation, enabling:
— Part swapping
— Structured, flow aligned meshes around individual parts
— Moving mesh without remeshing or smoothing (Beta)

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Overset Meshing

 An overset interface needs to contain:

— At least one background & one component mesh
— Each component mesh needs to have an overset BC
 Connectivity between meshes is established when the flow is initialized
— “Dead cells”: cells that fall outside of the domain
— “Solve cells”: where flow equations are solved
• “Donor cells”: subset of solve cells, sending data to:
• “Receptor cells”: cells receiving interpolated data

Component mesh

Overset BC Wall BC’s

Background mesh Solve cells

(including Donors)

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Overset Meshing – ANSYS Mesher
 Background mesh: Gear + Surrounding Flow Domain
 Component mesh: Coil + Internal Flow + External Flow
 Conformal meshes within both the background and component domains

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Overset Meshing – ANSYS Mesher
 Named selections for overset mesh
— Identify overset BC location

 New capped faces with section planes

— Easier to visualize than hollowed out
parts
— Can be activated/deactivated in the
Section Planes menu

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Updated Fluent Ribbon GUI

 New ribbon GUI similar to SpaceClaim.

— Replaces pull down menus.
— Work left to right, hitting all important analysis steps.
— Outline tree still available

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Overset Meshing

 Overset setup procedure

— Each domain has been meshed individually
— Overset boundaries have been designated using named selections

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Overset Meshing

 Overset setup procedure

— Overset mesh gets created upon solution initialization

Background and Component Meshes Overset Mesh – Solve Cells

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Maxwell Volumetric Load Mapping

 Volumetric heat generation rates computed by Maxwell are mapped onto

the Fluent model

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Report Definitions

 New report definitions for solution monitoring

— Easier to plot and write data during run time
— Set up multiple monitors in one place

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Induction Heating Results

 Transient Temperature field

— Report definitions enable streamlined solution monitoring of the transient
induction coil heat up

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Summary

 First release of the overset mesh method in an on-going development

effort. Currently supports the following physics:
— Steady and transient (fixed mesh), 3D and 2D planar
— Pressure Based coupled solver
— Incompressible density method
— Single-phase or VOF multiphase
— Heat transfer
— k-epsilon and SST k-ω turbulence models
— BETA: moving mesh, compressible flow, VOF with surface tension, pressure-
far-field BC, Workbench support, Pressure-Based segregated algorithms

 Drag and drop Fluent solution cell to a Mechanical Analysis System

to transfer temperatures.

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 Structural
Analysis using
ANSYS Mechanical
Pat Cunningham
Structural Analysis of the Gear

1. Add the remaining components the gear/shaft

assembly.
2. Map the CFD temperatures onto the gear body.
3. Define the load step history of the assembly:
— Heat up the gear
— Move the shaft into the gear bore
— Cool the gear
— Move in the resisting gear into position
— Apply a torque the shaft.

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Mechanical Demo

 Add to the geometry the shaft and gear sections using SpaceClaim or
DesignModeler.

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Mechanical Demo

 Set the stiffness behavior of the shaft and the engaging gear.

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Mechanical Demo

 Define frictional contact between the gear and shaft and the two gears.
 Note: Asymmetric contact with the contact elements on the flexible body
(main gear) is required.

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Mechanical Demo

 Define a cylindrical body to ground joint on the shaft.

 Cylindrical is used so that we can insert the shaft into the heated gear and
then apply a torque.

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Mechanical Demo

 A translational joint is used to move the rigid gear section into place after
the main gear has cooled.

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Mechanical Demo

 The gear mesh consists of a brick mesh with inflation layers transitioning
to a tet mesh with refinement in the gear contact region.

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Mechanical Demo

 A remote displacement is used to constrain against rigid body motion

before the shaft and gear are in contact.
 The remote displacement is assigned to a Remote Point attach to the main
gear with a deformable connection to allow for free thermal growth.
 The remote displacement is deactivated when the gear is cooled and
contacts the shaft.

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Mechanical Demo

 A cylindrical joint limits the shaft to axial and rotational degrees of

freedom.
 Joint loads are used to insert the shaft into the heated gear and apply a
torque after it has returned to the reference temperature.

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Mechanical Demo

 A translational body to ground joint moves the engagement gear rigid body
into contact with the main.
 This joint resists the moment applied to the shaft cylindrical joint through
the contact region between the two gears. .

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Mechanical Demo

 Temperatures from the conjugate CFD analysis are mapped onto to the
gear body in the first load step.
 The temperature load is deactivated after the shaft is inserted into the
expanded gear.

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Mechanical Demo

 The contact tracker is used to monitor progress as the gear is thermal

expansion is removed.
 Note: Contact Trackers at v17 can be added and modified while the
solution is ongoing.

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Fatigue Simulation

Mike Bak
Fatigue Tool Capabilities

 The Fatigue Tool provides fatigue life prediction capability within

Mechanical.
— Now included with Mechanical Enterprise license.

 The main features include:

— Stress life (high cycle fatigue) and strain life (low cycle fatigue) approaches.
— Fatigue data defined in Engineering Data.
— Mean stress theory to account for non-zero mean stress cyclic loading.
— Constant amplitude, history data, or non-proportional loading.

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Procedure for Gear Shaft Fatigue

 In the current demonstration of the gear shaft, the following assumptions

are used for the fatigue calculation:
— The cyclic stress occurs once per revolution:
• A point on the gear sees the maximum stress state near the gear contact location
with the mating gear (load step 4 results).
• As it travels to the opposite side, the stress state is assumed to be equal to the
residual stress state (load step 3 results).

Max
Min

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Procedure for Gear Shaft Fatigue

 The fatigue tool allows for three different types of cyclic loading:
— Constant amplitude.
• User identifies one result step that defines the maximum condition in the cyclic
loading.
• User defines the R-ratio for this loading that defines the ratio of the minimum stress
divided by the maximum stress.
• A fully-reversed loading is an R-ratio of -1.
— History data.
• User supplies an external file that contains a series of scale factors that are used to
scale one load set to define a complex load history.
• The fatigue calculation will extract the cyclic information using rainflow calculations.
— Non-proportional loading.
• The user specifies two load sets that represent the minimum and maximum load
conditions.
• This approach is used in this application to define the cyclic loading.

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Procedure for Gear Shaft Fatigue

 Strain life fatigue behavior used.

• Using Workbench structural steel built-in strain life data.

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Procedure for Gear Shaft Fatigue

 Stress life fatigue models high cycle fatigue.

— Assumes stresses below yield stress.
— Cycles from 100,000 to millions of cycles before failure.
— Defined using S-N data (stress range vs. cycles to failure).

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Procedure for Gear Shaft Fatigue

 Strain life fatigue models both low cycle and high cycle fatigue.
— Assumes that localized behavior could include plastic strains.
— A plot of the strain range versus cycles is a combination of the elastic and
plastic portions of the response.
— Strain life also needs information on the cyclic hysteresis behavior, defined
using the cyclic stress-strain data.

Strain life curve

Cyclic stress
strain
behavior

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Procedure for Gear Shaft Fatigue

 The cyclic loading is defined by two load steps.

— The maximum cyclic load condition is the applied torque response in Load
Step 4.
— The minimum cyclic load condition is the residual stress state in Load Step 3.

 Two separate load conditions can be used to define the cyclic load using
the non-proportional loading type.
— First, add a Solution Combination.
— Define the results from Load Steps 3 and 4 within the Solution Combination
Worksheet.

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Procedure for Gear Shaft Fatigue

 Add the Fatigue Tool under the Solution Combination.

— Assign the Analysis Type = Strain Life
— Assign the Loading Type = Non-Proportional

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Procedure for Gear Shaft Fatigue

 Additional fatigue settings:

— Fatigue Strength Factor:
• A reduction factor used to adjust for a real
world environment for surface finish,
fatigue data scatter, smaller probability of
failure, etc.
• Will use a factor of 0.50.

— Mean Stress Theory:

• Typical fatigue data is generated under
fully-reversed loading (i.e. mean stress =
0).
• This situation is rarely encountered in real
world problems. The mean stress theory
will adjust the strain amplitude in the cyclic
loading to account for non-zero mean
stress.
• Will use the Morrow option.

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Procedure for Gear Shaft Fatigue

 Insert Life under the Fatigue Tool.

— Scope to the critical region of the gear (ignore gear tooth region).
— The fatigue life contour shows a minimum life of 13,411,000 cycles.

 At 100 RPM, and assuming continual operation, the predicted fatigue life is
2235 hours of operation.

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Fatigue Summary

 Fatigue analysis predicts the life of a structure under cycle loading

conditions.
— The Fatigue Tool in ANSYS Mechanical performs fatigue analysis using Stress
Life or Strain Life approaches.
— Now included in the ANSYS Mechanical Enterprise licensing.

 Various cyclic load definitions are available:

— Constant amplitude
— History data
— Non-proportional

 Additional fatigue settings are available.

 Fatigue data defined in Engineering Data.

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 Fracture
Simulation

Mike Bak
New Fracture Enhancements in V17.0

 The following fracture enhancements are available in Release 17.0:

— Arbitrary cracks:
• Previously, could model a semi-elliptical crack, or a pre-meshed crack.
• Arbitrary cracks can be planar or non-planar arbitrary shapes.
• Use a surface body to define the crack surface.
• Meshed with tetrahedron elements.
• Supported by Static Structural and Transient Structural analyses.
• Support SIFS, J-Integral, VCCT, Material Force, T-Stress, and C*-Integral fracture
parameters.

— Tetrahedron crack meshes are now supported for all crack types.

— Material Force, T-Stress and C*-Integral fracture parameters are now available
for all crack definitions.

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Procedure for Gear Shaft Fracture

 In the current demonstration of the gear shaft, the following assumptions

are used for the fracture analysis:
— An arbitrary crack on the inside surface of a hole is modeled using a Static
Structural analysis.
— Since a finer mesh in the crack vicinity is required, submodeling technique is
used to isolate the crack region.
• Boundary conditions on the cut boundaries are taken from the full gear shaft
analysis using the automated submodeling technique.
— The stress intensity factor distribution along the crack front is sought.
• Can compare to the material fracture toughness to determine if the crack will
propagate due to the static loading.
• The fracture toughness is assumed to be equal to 180 ksi-in1/2.

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Procedure for Gear Shaft Fracture

 The procedure for the fracture analysis using the following steps:
— On the Project Page:
• Duplicate the Static Structural analysis of the gear shaft to create the submodel
analysis.
• Connect the original model Solution to the submodel Setup.
— In DesignModeler:
• Add a surface body that defines the arbitrary crack.
• Slice the model to obtain the submodel region.
• Suppress all geometry outside of the submodel region.

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Procedure for Gear Shaft Fracture

 The submodeling procedure in Mechanical:

— Under the Imported Load (from connecting to the full model), insert a Cut
Boundary Condition.
• Set the Source Time = 3 s (residual stress state).
— Scope to the three surfaces of the cut boundaries.
— Generate to obtain the submodeling boundary conditions.
— Temperature mapping is not required since the submodel is using the residual
condition load step in which the gear has cooled.

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Procedure for Gear Shaft Fracture

 Solving without a crack, the submodel solution should predict similar

results to the global model:

Global Principal Stress Submodel Principal Stress

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Procedure for Gear Shaft Fracture

 Of interest is the direction of the maximum principal stress:

— Note that an existing crack in the hole will tend to propagate perpendicular to
the maximum principal stress direction.

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Procedure for Gear Shaft Fracture

 The crack procedure in Mechanical:

— Under Geometry of the Surface Body, change the Behavior to Construction
Body.
• This indicates to Mechanical that this body is not a structural body to be meshed
and analyzed, but will be used to define the crack.
— Generate the base mesh.
• Must be a tetrahedron mesh in the crack region.
• Don’t need to mesh the crack region differently – this will be done during fracture
meshing.

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Procedure for Gear Shaft Fracture

 The crack procedure in

Mechanical:
— Under Model, insert Fracture.
— Under Fracture, insert an
Arbitrary Crack.
• Scope crack to the gear solid
body.
• Change the Coordinate System
to the local crack system (X-axis
must point inward toward crack).
• Identify the Surface Body to
define the crack.
• Set Largest Contour Radius to
0.05 in.
• Generate the fracture crack.

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Procedure for Gear Shaft Fracture

 Fracture mesh included in base tetrahedron mesh.

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Procedure for Gear Shaft Fracture

 Run analysis:
— Apply any other boundary conditions or loading (reapply frictionless support).
— Include submodeling cut boundary conditions.
— Generate the solution.

 Post-process the fracture analysis:

— Insert Fracture under Solution, and insert SIFS Result under Fracture.
— Select the arbitrary crack.
— Generate the stress intensity factor distribution along the crack front.

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Procedure for Gear Shaft Fracture

 The stress intensity factor distribution is calculated at six continually larger

contours about the crack front.
— The results should converge within a few contours.
— Contour plot of the 6th contour is shown.
— Plot of all contour solutions is also shown.
— Maximum value of 12.5 ksi-in1/2 is much less than the fracture toughness of
180 ksi-in1/2, so this crack would not be predicted to propagate under the given
loading.

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Fracture Summary

 ANSYS Mechanical has updated its fracture capability in V17.0 to include

an arbitrary crack definition.
— Like the planar semi-elliptical crack, the crack is not defined in the CAD
geometry, and the initial mesh does not include the crack.
— The arbitrary crack can be planar or non-planar, and is defined using a Surface
Body.
— The fracture procedure will automatically insert the defined crack into the un-
cracked body, performing the local meshing based on supplied settings.
— The distribution of the stress intensity factor along the crack front can be
obtained from the Fracture Tool under Solution.

 Fatigue crack propagation analysis could be performed to determine if and

how the crack would grow in the cyclic loading environment.
— Will address this type of analysis procedure using XFEM in a later
presentation.

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