1. Design Simulation Basics Chapter Two

2. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-2 Chapter Overview In this chapter, the basics of using Design Simulation to perform analyses will be covered, which include: –The Design Simulation GUI and operation –Introduction to the Simulation Wizard –Basic Analysis Procedure The capabilities described in this section are generally applicable to the ANSYS DesignSpace Entra licenses and above, unless explicitly noted with the lower-left hand table.

3. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-3 A. Launching Design Simulation Recall that there are two ways of running Design Simulation –Configured from within ANSYS Workbench … –… or directly from a supported CAD system Model shown is from a sample Solid Edge assembly.

4. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-4 … Design Simulation Interface The components of the user interface are shown below: Short descriptions of each component are covered next Tree Outline Details ViewGraphics Window Toolbars Simulation Wizard Menus Workbench Tabs

5. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-5 … GUI – Workbench Tabs The Workbench Tabs allow the user to switch between Design Simulation, the Workbench Project page, and other Workbench modules within a given session.

6. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-6 … GUI – Menus The menus provide much of the functionality present in Design Simulation. Covering each menu item may be tedious, so only the more commonly used menu items are covered below: –“File > Save” to save the.dsdb Design Simulation database –“File > Clean” to delete mesh and/or results from database –“Edit > Select All” to select all current entities in the window –“Units” to change units on-the-fly –“Tools > Control Panel” to customize settings and options –“Help > Help Topics” to invoke online documentation

7. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-7 … GUI – Toolbars There are four sets of toolbars to provide users quick access to functionality also found in the menus. –The toolbars can be repositioned anywhere on the top of the Design Simulation window –The “Context” toolbar, as will be illustrated later, will change, depending on what branch is active in the “Outline” tree. –Tooltips appear if the cursor is placed over the toolbar button –A “Unit Conversion” toolbar is also available (not shown) Standard Toolbar Graphics Toolbar Named Selection Toolbar Context Toolbar

8. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-8 … GUI – Toolbars The “Standard” toolbar is shown below: The “Graphics” toolbar is used very often: –The left mouse button can be either in “selection” mode or “graphics manipulation” mode. The above toolbar buttons grouped as “select entities” and “graphics manipulation” control the left-mouse button behavior. –The selection of entities of the CAD geometry can be done either by individual selection or by box-selection. This is controlled by the “Select Mode” icon Save.dsdbBring up Simulation WizardSolve Model Graphics ManipulationSelect entitiesSelect modeWireframeFit AllSelect adjacent entities

9. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-9 … GUI – Outline Tree The Outline Tree provides an easy way of organizing the model, materials, mesh, loads, and results for the analysis –The Outline Tree is analogous to the “tree” found in many CAD software. However, instead of sketches and features, this tree contains analysis-related items –The “Model” branch contains the input data required for the analysis whereas the “Engineering Data” branch holds generic material and convection data –The four main sections of the “Model” branch include “Geometry,” “Contact” (if present), “Mesh,” and “Environment.” –The “Environment” branch contains the loads as well as the “Solution” branch, which holds results for postprocessing. –Other branches (not covered here) are also available.

10. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-10 … GUI – Outline Tree The Outline Tree shows icons for each branch, along with a status symbol. Examples of the status symbols are below: –Checkmark indicates branch is fully defined/OK –Question mark indicates item has incomplete data (need input) –Lightning bolt indicates solving is required –Exclamation mark means problem exists 1 –“X” means that item is suppressed (will not be solved) –Transparent checkmark means body or part is hidden –Red lightning bolt indicates item is currently being evaluated –Minus sign means that mapped face meshing failed 1 Example is opening a Design Simulation database which contains a capability not available with the current ANSYS license used. The user should become familiar with the basic status symbols shown here, so he/she can easily determine if the model is OK.

11. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-11 … GUI – Details View The Details View provides a means of inputting data. The contents will change, depending on branch selected. –White field: shows current input data Data in white text field can easily be changed by clicking on it, then entering data, as needed Some white fields require the user to select geometric entities on the screen, then click on “Apply”. Others require text data input from keyboard or selecting item from pull-down menu. –Gray field: shows informative data Data in gray fields cannot be modified. These fields usually provide information or results data, such as the maximum stress or number of nodes generated by the mesher. –Yellow field: incomplete input data Data in yellow fields indicate that not enough information has been supplied. Users need to fill in data completely in order to solve model.

12. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-12 … GUI – Graphics Window The Graphics Window shows the geometry and results. It can also provide worksheet (tabular) listings, the HTML report, and a Print Preview option as well. Geometry TabWorksheet Tab Print Preview TabReport Preview Tab

13. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-13 … GUI – Simulation Wizard The Simulation Wizard is an optional component, a useful aid to remind users steps required to complete an analysis –The Simulation Wizard provides a list of required steps and the status of them –Green checkmark indicates the item is complete –Green “i” shows an item to verify –A greyed minus sign shows that the item cannot be performed yet until the previous step is completed –A red question mark means that there is an incomplete branch related to this item, analogous to the “?” status symbol on the Outline Tree –An “x” means that the item is not performed yet –A lightning bolt means that the item is ready to be solved by selecting on the Standard Toolbar The Simulation Wizard can be toggled on/off by selecting the button on the Standard Toolbar

14. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-14 B. Startup Panel When first attaching a model to Design Simulation, the Startup Panel is shown, allowing the user to select a Simulation Template –This startup panel can be turned off in “Tools > Control Panel > Startup”

15. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-15 … Startup Panel The benefit of the Startup Panel is that the appropriate results and Simulation Wizard will appear –Templates and Wizards are only available for analyses supported in DesignSpace licenses –“Stress Branch” is selected in the example below. Note that results and the Stress Wizard are automatically chosen

16. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-16 … Simulation Wizard By selecting an item on the “Required Steps” checklist, a callout appears, illustrating how that function is performed. –In the example below, “Verify Materials” was selected, and the callout shows the user where this item can be changed.

17. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-17 … Simulation Wizard The Simulation Wizard is very useful to analysts or other engineers who do not use Design Simulation every day –Reduces learning curve, as callouts show user where the item is in GUI –Besides basic functionality, callouts for more advanced items are also available as shown on right

18. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-18 C. Basic Procedure Every analysis involves four main steps: –Preliminary Decisions What type of analysis: Static, modal, etc.? What to model: Part or Assembly? Which elements: Surface or Solid Bodies? –Preprocessing Attach the model geometry Define and assign material properties to parts Mesh the geometry Apply loads and supports Request results –Solve the Model –Postprocessing Review results Check the validity of the solution Preprocessing Solution Postprocessing Preliminary Decisions

19. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-19 … Basic Procedure A sample analysis using the Stress Wizard will be shown in this section. The Wizards in Design Simulation aid the user in following the basic analysis template discussed previously, and these steps below will be covered in the next slides: –Attach/import geometry –Assign material properties –(Mesh geometry) A default mesh will be supplied by Design Simulation if this step is not performed –Apply loads and supports –Request results –Solve model –Review results/postprocessing

20. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-20 … Attach Geometry Earlier, it was shown that geometry can be attached to Design Simulation in two ways –Direct from CAD system For supported CAD packages only using plug-in mode –From within Workbench Project page For all supported formats, using plug-in or reader mode Attaches active CAD model (plug-in mode) Browse for CAD file (reader mode) Directly launches Design Simulation and attaches geometry (plug-in mode) Method 1Method 2

21. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-21 … Assign Material Properties After importing a model, the Stress Branch template was chosen, and the Stress Wizard appears –“Verify Materials” is selected, and the callout shows how to change material properties in the pull-down menu After “Verify Materials” is selected, all of the parts from the “Geometry” branch are highlighted, and the Details view shows how to change the material.

22. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-22 … Assign Material Properties Notice that the Details View allows the user to select a material from a pull-down menu –The default material property is “Structural Steel” but can be changed –By selecting “browse …” the user can select a material property file (XML format) –Although a few material properties are supplied with Design Simulation, as with any other input data, the user should use his/her own material data values.

23. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-23 … Assign Material Properties Materials may be individually selected for each part –Note that the part name is obtained from the CAD model Multiple instances of the same part are differentiated by number –Multiple parts can be highlighted and changed at once Use Shift-Left mouse button to highlight all items in range Use Ctrl-Left mouse button to individually add/remove selection By using a combination of Shift- Left mouse button and Ctrl-Left mouse button, eight parts are highlighted on the Outline Tree The user can then change all materials at once in the Details View by selecting the material pull-down menu. Note that DesignSpace Entra is limited to analysis of single parts.

24. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-24 … Assign Material Properties Material properties are listed under the “Engineering Data” branch in the Outline Tree –Values can be changed in Graphics Window (Worksheet View) –The Context Toolbar allows users to add a material Select “Material > New Material” from Context Toolbar Right-click on material in Outline Tree to export to XML file. This is required to reuse the material for other analyses. After adding a new material, the user can assign that new material from the pull-down menu of the part Details View

25. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-25 … Assign Material Properties Default settings for material properties can be changed in the “Tools menu > Control Panel: Engineering Data” –The default material can be changed from “Structural Steel” –Items to be always available in drop-down menu can be added –New materials can be added from various locations

26. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-26 … Insert Loads & Supports After verifying and assigning materials, the “Insert Loads” item is selected from the Stress Wizard –Structural (and thermal) loads are applied from the pull-down icon in the Context toolbar. After “Insert Loads” is selected, notice that the “Environment” branch is highlighted. By highlighting the “Environment” branch, the Context toolbar and Details view change.

27. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-27 … Insert Loads & Supports Loads and supports are applied on geometric entities There are two ways to accomplish this: –Select geometry entity in Graphics Window first, then select load or support from Context Toolbar –Select load or support from Context Toolbar first, select geometry entities in Graphics Window, then click on “Apply” in Details View.

28. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-28 … Insert Loads & Supports After assigning the load on geometric entities, the user can enter additional data in the Details view, if necessary. –Notice that, in the Outline Tree, the associated load branch symbol status will also change to ‘completed’ (checkmark)

29. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-29 … Insert Loads & Supports For some structural loads, direction is often needed: –Selection is done in Details View of load If “Components” is chosen, enter X, Y, or Z Components of loading If “Vector” is chosen, select geometry and enter magnitude of loading Defaults can be set in “Tools > Control Panel > Miscellaneous > Load Orientation Type” –The World Coordinate System can be referenced Direction is shown with triad in Graphics Window World Coordinate System orientation and origin from CAD system For this situation, use “Define By: Components” in “Details” view. Then enter x, y, and/or z components for load

30. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-30 … Insert Loads & Supports –On the other hand, existing geometry can be referenced: In the “Details” view, select “Define By: Vector” to use existing geometry for vector orientation Three types of existing geometry can be used –Normal to planar face or along axis of cylindrical face –Along straight edge or normal to cylindrical edge –Two vertices defining vector Click on “Direction” and select geometry used for vector orientation. If vector is pointing in opposite direction, use the arrows in the Graphics window to toggle the direction. Click on “Apply” when done. Enter magnitude for loading in “Magnitude.”

31. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-31 … Mouse Controls At this point, it will be useful to review mouse controls in the Graphics Window: –The left mouse button is used to select geometric entities OR to manipulate the graphics display Left mouse button behavior is controlled by Graphics Toolbar User can select items (vertex, edge, surface, body) or manipulate the view (rotate, pan, zoom in/out, box zoom) Select mode can be single-select or box-select –In single-select mode, click-drag with left mouse button to “paint select” multiple items –Use Ctrl-Left mouse button in single-select mode to select or unselect multiple entities –In box-select mode, click-drag from left to right selects entities fully enclosed in bounding box –In box-select mode, click-drag from right to left selects any entity partially enclosed in bounding box

32. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-32 … Mouse Controls –In select mode, the middle mouse button changes view Click-drag middle mouse button to dynamically rotate model Shift-Middle mouse button pans model If present, the wheel can be used to zoom in/out (This way, user does not always have to toggle left mouse button between select mode and graphics manipulation mode) –The right mouse button provides context-sensitive pop-up menu if clicked once in Graphics Window Click-drag right mouse button to box zoom in area of interest Click right mouse button once and select “Fit” to fit model in view Single-click right mouse button provides context- sensitive pop-up menu Click-drag right mouse button allows user to box-zoom in region

33. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-33 … Applying Loads and Supports By taking advantage of the mouse controls, it can be relatively easy to apply a load (or support) to multiple faces –In example below, user can use Ctrl-left mouse button to single-select surfaces (highlighted in green) –Use of middle mouse button allows user to rotate model to more easily select certain surfaces in ‘back’ of model

34. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-34 … Insert Results By selecting the Stress Branch template in the beginning, some results are already requested. However, the user can request other results, if needed. –By selecting “Insert Results” in the Stress Wizard, the callout shows how to add results Note that the “Solution” branch is now highlighted. Because the “Solution” branch is selected, the Context toolbar and Details view changes. Results, such as stress, strain, and deformation can be requested from the pull- down icons on the Context toolbar. New result items will then appear under the “Solution” branch.

35. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-35 … Solving the Model After verifying materials, applying loads and supports, and inserting results, the model is ready to be solved. –Selection of “Solve” in the Stress Wizard produces a callout showing the user that the lightning bolt icon is used to initiate a solution Starting the solution will include automatically meshing the model if it has not been done so previously. The solution may take a few minutes to a few hours, depending on how large the model is and the hardware used. A progress bar will be shown to indicate roughly how long the solution will take. The solution can also be stopped via the progress bar.

36. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-36 … Solving the Model (ANSYS Details) For regular ANSYS users, it may be useful to note that the solution is performed in batch mode. –An ANSYS input file is generated, and the details of the Output File can be viewed under the “Solution” branch by selecting the “Worksheet” tab In Worksheet view of the “Solution” branch, use the F5 key to refresh the contents of the Output File. The location of the input file “ds.dat,” output file “solve.out,” and scratch files are located in the TEMP directory by default. This solver directory can be changed under “Tools > Control Panel > Solution > Solver Working Directory”

37. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-37 … View Results After the solution is complete, the user can View Results –The type of results is dependent on the analysis performed –Contour, vector plots, and animations can be viewed To view results, as the callout shows, the appropriate branch needs to be selected.

38. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-38 … View Report In preparation for generating the HTML report, one can add figures and comments from the Standard Toolbar –Select a branch first, such as “Equivalent Stress” –Then select the appropriate Standard Toolbar button:

39. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-39 … View Report After adding any figures or comments, select “View Report” –Preliminary information can be entered, such as author name –Select “Generate Report” to create HTML report The HTML Report can be selected under the “Solution” branch via “Report Preview” tab, as the callout indicates.

40. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-40 … View Report The HTML report will be displayed in Design Simulation –Comments and figures added will appear in the report The HTML report generator includes all input and results associated with the simulation, providing complete documentation of the analysis. This provides time-saving yet customizable report that can easily be generated by the user.

41. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-41 … View Report Reports are always dynamically generated, so the user needs to save the report, otherwise it will be overwritten –The report can be “published” as HTML files in a different directory or an internal web server, emailed, or sent to Microsoft Word or PowerPoint

42. Training Manual Design Simulation Basics February 2, 2004 Inventory #002010 2-42 Workshop 2 – Design Simulation Basics Goal: –Using the Stress Wizard, set up and solve a structural model for stress, deflection and safety factor. D. Workshop 2