1 ME-430 INTRODUCTION TO COMPUTER AIDED DESIGN TORSIONAL ANALYSIS Using Pro/MECHANICA Pro/ENGINEER Wildfire 2.0 Dr. Herli Surjanhata The U-Joint shown in the figure below is made of steel. A torsion load of 10,000 IN- LB is uniformly applied over the top portion surface of the U-Joint. Determine the von Mises stresses, and maximum deflection under the given torsion load and boundary conditions. Check the convergence of your analysis. Step 1: Using Pro/ENGINEER, create a base feature as shown in the Figure below. It is done by extruding both sides the section shown with 2 inches blind depth. Create two rounds with R = 1 inch on the left and right bottom of the base feature. 2 Create co-axial holes of 0.75 inch in diameter on both sides of the part. Add the cylindrical portion of the part as shown below. The diameter is 1.50 inches, and use extrude to the next surface option. Note that the radius of the round is 0.2 inch. 3 Make the following cut on the cylinder. Round the bottom of the cut with R = 0.05 inch. Change the units to IPS (inches-pounds-seconds) by selecting 4 Edit -> Setup -> Units Choose Inch Pound Second (IPS). Click on Set button. Select Interpret dimensions. OK -> Close Done Step 2: Transfer the model to Integrated Mode of Pro/MECHANICA. From Applications pull-down menu, select Mechanica and the following window appears. Check the units to make sure it is correct. Click Continue button if the system of units is correct and consistent. 5 From Model Type menu, select Structure. OK. Step 3: Define the material of U-Joint. From Properties pull-down menu, select Materials From the Materials in Library list, select STEEL. Click the Assign button, then Part - Pick the U- Joint. OK. Click the Edit button. 6 Click on Failure Criterion tab. U-Joint is made of steel, and steel is ductile. The most suitable failure criteria is distortion energy theory. Select Distortion Energy (von Mises) as failure criterion. Assuming the yield’s stress of steel 60,000 psi and factor of safety 1.5, we will enter the tensile yield stress 40,000 psi. Click on OK, then Close the Materials dialog box. Step 4: Create a surface region for applying the torque on some portion of the top part of U- Joint. Insert -> Surface Region Or click on the toolbar located on the right. Sketch -> Done Pick FRONT datum plane as sketching plane, and select Top then pick TOP datum plane in the graphics area. 7 Pick the necessary additional references, and use rectangle to sketch the following section. Click on . For the surface or surfaces to be split, Pick the top cylindrical part of the U-Joint as shown. Click on OK -> OK. The surface region for applying the torque has been created. 8 Step 5: To simulate the application of a torsion load on a cylindrical shaft in Pro/MECHANICA using the Total Load Applied at Point (TLAP) functionality, a datum point located on the applied surface must be created. This will be used for defining the load and since we will use Total Load at Point (TLAP) and Moment, the location does not matter. Click on Datum Point Tool icon . 9 Pick on the surface (region), and locate the point with respect to top surface and right datum plane. Note again the location does not matter as long as it is located on the surface where torsion will be applied. Step 6: Create a cylindrical coordinate system on the top of the U-Joint. Click on . 10 Change the Type to Cylindrical. Pick three datum planes – FRONT, RIGHT, and DTM1. Click on Orientation tab to modify the orientation of coordinate system such that the Z-axis is pointing up or down. Click on OK. Step 7: Apply the boundary conditions or constraints on the left and right holes of U-Joint. Insert -> Displacement Constraints or click on the Constraint window appears [...]... on Enter the name of the load as “TorsionLoad” Click the arrow button under the Surfaces Pick the top surface region previously created for applying the torsion load – see Figure below Click the arrow button under the Properties Pick the Cylindrical Coordinate System CSO 12 Click on button Change the type of Distribution to Total Load At Point Click on the arrow button under Distribution, and pick... tab, and change the type to Displacement, and the Component to Magnitude Check Overlay Undeformed in the Display Options tab Click the OK and Show button 19 We are also interested in convergence of the Max Von Mises Stress Click the Copy button - in the Result Window, and name it as convm Set the following: 20 Set the Display type to Graph Set the Quantity to Measure icon to Click select the Max Von... failed due to the applied loads If the failure index value is equal to or more than "1" at any point in the model then the material is considered to have failed at that point Click the Copy button - in the Result Window, and name it as Fail_index Set the following: Set the Display type to Fringe Set the Quantity to Failure Index Click OK Click icon In the Display Result Window, make sure to highlight... Displacement, Local Strain Energy and Global RMS Stress Click the OK button 14 Step 10: Run the design study by selecting Click the Yes button Click the Display study status to review the button progress of the analysis Make sure you have “Run Completed” message Click Close in the Run Status dialog box Step 8: Review design study results to review the Click on results of design study The Result Window Definition... pick the datum point PNT0 Under Moment, enter 10000 in-lb torsion in the Z component Click on Preview to ensure the correct direction OK, then click OK button in the Force/Moment window Step 9: Define the STATIC analysis by: Click on 13 Analyses and Design Studies dialog box opens From File pull down menu, select New Static Enter the name of analysis as “U_Joint” Select Multi-Pass Adaptive method Maximum... Display type to Graph Set the Quantity to Measure icon to Click select the Max Von Mises Stress Click OK button 21 Click OK Click icon In the Display Result Window, make sure to highlight convm ONLY, and click the OK button 22 From Format pull down menu, select Graph Select Graph Display tab if you wish to change the background color Change also the color of Text Style, Points, Lines of Y Axis, X Axis and... default U_Joint Design Study and Analysis have been selected Click on Display Options tab Make sure you fill in the following form (window) as shown below: 16 Click the OK and Show button From Format pull down menu, select Result Window Change the background to White From Info pull down menu, select View Max Repeat the procedure and select View Min 17 Click the Copy button 18 Enter the name as “displ”... and click the OK button The von Mises stress plot will be displayed Insert -> Cutting/Capping Surfs The Results Surface Definition dialog box appears 27 OK 28 File -> Export -> Image Change the Output Format to JPEG Under Output Options, check To File, and enter the name for the output file (JPEG format) e.g U_joint cut surface Click on OK Edit -> Delete Cutting Surf We will be back to von_Mises stress... Display Result Window, make sure to highlight Fail_index ONLY, and click the OK button 25 The result shown above indicates that there are many areas where the Failure Index is more that 1.0 These are the areas where material will fail Based on this information, redesign of the U Joint can be done to bring the failure index to below 1.0 in the entire model Save the results windows as u_joint Click 26 Enter... will be back to von_Mises stress distribution display Insert -> Cutting/Capping Surfs The Results Surface Definition dialog box appears 29 Change the Type to Capping Surface OK Export the image to a file in JPEG format The JPEG files can be inserted into Words report 30 . 1 ME-430 INTRODUCTION TO COMPUTER AIDED DESIGN TORSIONAL ANALYSIS Using Pro/MECHANICA Pro/ENGINEER Wildfire 2.0 Dr. Herli. created. 8 Step 5: To simulate the application of a torsion load on a cylindrical shaft in Pro/MECHANICA using the Total Load Applied at Point