Introduction

Objectives: Holistic understanding of the ANSYS workflow, boundary conditions, post processing, and optimization of setup for faster run times (incl meshing, simulating with symmetry, research others)

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• Using regulation specified loading conditions in Appendix F of the FSGP regs, set up and execute a front, rear, and side impact loading test

Fundamentals of ANSYS

Usually you want to start by opening ANSYS Workbench to outline your simulation and get yourself organized. Think of this as the setup portal.

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Notice how many different types of simulations you can do.

Most of frame stuff would be static structural though so mainly go with that.

This is where you identify everything so your sim can be as accurate possible. The identifiers in question are:

1. Engineering data (pick your material)

2. Geometry (the shape of the thing you are simming)

3. Modeling information (a mesh dividing the geometry into a finite number of elements) This is what makes FEA, FEA.

4. Setup information (ex: boundary conditions and loads)

What do those symbols next to the parameters mean?

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1. Ensure your file with the new material(s) is in .XML format

2. Go to “Engineering Data” tab in ANSYS Workbench Project

3. Select “File” --> “Import Engineering Data”

4. Select your indicated XML file w/materials

5. Select open

6. Your materials should be there now

Lets start with Geometry.

• Right click Geometry → New SpaceClaim Geometry.

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Now our engineering data is good. Next, lets move onto “Model”. This is where ANSYS mechanical starts.

We’re gonna create a mesh first.

1. On the left side, under the “Outline” window select “Mesh”.

2. Then go to “Mesh” on the top bar, and select sizing.

3. From there click the green box to select a body.

4. Press “No selection” next to Geometry on the bottom left and press apply so Software knows what geometry is being simmed.

5. Then in same area define Element size as 10mm (enter 0.01 because units in meters).

6. Press generate mesh.

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Now lets apply the load.

1. Select Static Structural in the feature tree.

2. Go to Environment top tab and press fixed in supports, then select each square end of the beam and press apply for geometry in the bottom left.

3. Now press force. Select Split area.

4. Define the force by components, not vector (bottom left)

5. Apply -2000 N force to Y component.

Now let’s sim.

1. Press solve on top left.

   1. This basically tells the simulation to compile and interpret your inputted data.

2. Now lets click “Solution” and go to “Deformation” and select total.

3. Lets click “Stress” and press “Equivalent Stress”.

   1. What we just did here is tell ANSYS what exact data we want to see from it. Note that there are so many diff types of things we could test for.

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SpaceClaim doesn’t really seem worth it to 3D model. SolidWorks, even OnShape, is way better.

Woahhhhh colors O.o

11/9/2024 Torsional Rigidity - Static Structural Deformation Analysis on Early 22-24 Frame Iteration

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Process:

1. 7mm Mesh on entire structure

   1. This frame was a .SLDPRT and not .SLDASM so did not have to individually select each pipe member.

2. Completely fixed the back panel of the frame (rectangle with asterisk shaped cross brace pattern at the back

   1. This section will NOT move at all

3. Applied +1500 N y-direction force on the front left hardpoints

4. Applied -1500 N y-direction force on the front right hardpoints

5. Solved first time

6. Solved for “Equivalent Stress” and “Total Deformation”

   1. Screenshot above is total deformation (see top left)

Notes and Observations:

1. This frame is not torsionally rigid enough

2. Make sure to keep your element size realistic

   1. If you have elements smaller than 7mm, don’t try to set element size to 7mm because you can’t mesh empty space

3. ANSYS is a D1 RAMmaxxer - make sure your applications are closed during “solve” period

   1. If you don’t think you have sufficient RAM for solve to complete, close ALL other applications. The solve WILL terminate w/o sufficient RAM

4. Useful tool to debug solves is checking the Solution Information sheet under the “Outline” tree

   1. Helped me understand the RAM issue

5. When you select multiple points/edges/faces that aren’t connected to each other (in terms of selection), the indicated force will apply at the centroid of the selection

   1. Ex: my selection of the hardpoints to sim torsional rigidity

   2. Oftentimes, the force will appear at the first selected point/edge/face, even though it’s actually at the centroid.