1. Image courtesy of Engineering Center LTD, Russia MA9206-2: Digital Prototyping Mechanical Simulation Overview John Holtz, Peter Maxfield Product Design

2. Welcome

3. Overview Inventor Simulation  Static & Modal Analysis  Dynamic Simulation Algor Simulation  Fluid Flow & Thermal  Unsteady Fluid Flow  Mechanical Event Simulation (MES)  MES with Nonlinear Materials  Frequency Response

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5. MFG Simulation Suite

6. Autodesk Inventor Simulation Completes the Digital Prototyping toolset Integrated Stress Analysis and Rigid Body Dynamics Make your first article production quality

7. Autodesk Inventor Simulation 3D Joints & Forces Dynamic Performance Studies Assembly Stress Calculations Optimization Studies

8. Stress Analysis R2010 introduces:  Assembly support  High speed solver  Automatic p- and h- refinement  Local mesh & solver convergence

9. Stress Analysis R2010 introduces:  Parametric studies  Optimization  Multiple simulations  Ribbon interface

10. Interface  Improved browser  Multiple simulations  Fast editing  New task-based ribbon  Familiar object names & editing methods

11. Solver Fast, adaptive solver delivers solutions quickly and accurately Batch solve for multiple studies Convergence can be localized

12. Simplification Exclude components and features CAD model remains unaffected Improves solve time without sacrificing results

13. Parametric Studies Explore design alternatives Identify key dimensions Smart sampling for efficient solves Optimized

14. Safety Factor Track the effect of a Parameter on the current Result Plot Rib Thickness (mm)

15. Optimization – Goal Seeking Automatic Optimization Adjust Value

16. Promote to Model One step to update design with optimized parameters

17. Dynamic Simulation Rigid Body Motion Not just geometric constraints but mechanical joints Forces, Torques, Gravity, Contacts, Springs, Dampeners, Graphers, Traces, Time steps...

18. Joints Three main choices for building constraints:  Automatic Conversion  Manual Conversion  Manual Authoring All bodies are rigid and all joints are ideal

19. Motion Loads

20. Autodesk Algor Simulation

21.  Analysis Types (partial list)  Linear Static Stress  Linear Dynamic Stress (modal, response spectrum, random vibration, buckling load, transient stress)  Nonlinear Stress (large displacement, nonlinear materials)  Thermal (steady state and transient)  Electrostatic (current and voltage; field and voltage)  Fluid Flow (steady and unsteady; open channel flow)  Coupled (combine the effects of fluid flow and thermal in one analysis)

22. Autodesk Algor Simulation  Element Types  Line elements  Truss (axial only)  Beam (axial and bending)  Springs  Area elements  Plate and shell  Membrane  Composite plate  Volume elements  3-D solid  2-D solid (planar and axisymmetric)

23. Examples

24. Compressor and Motor Base Frequency Response A base structure for a compressor and motor was modeled with a combination of beam and plate elements. A Frequency Response analysis (or sine sweep) was performed to simulate an imbalance in the motor. The stress and deflection of the structure over the range of operating frequencies is the result of the analysis.

25. Compressor and Motor Base

26. Flow Around Dome Unsteady Fluid Flow The air flow around a 31 foot (9.4 meter) diameter dome is revealed by displaying the streamlines. By performing such analyses, the placement of outdoor accoutrements can be chosen to minimize the impact on visitors.

27. Hyperelastic Bellows Mechanical Event Simulation (MES) with Nonlinear Material Models Mechanical Event Simulation (MES) includes a number of material models which include the effects of nonlinear material behavior. MES was used to analyze a rubber bellows subjected to a longitudinal displacement. The Mooney- Rivlin material properties were derived by curve fitting simple tension, equibiaxial, and pure-shear test data. The two images shows the displaced model and an outline of the undeformed model.

28. Hyperelastic Bellows Contour shows the radial displacement. Note how the convolutes buckle at this elongation.

29. Hyperelastic Bellows Contour shows the strain.

30. Nonlinear Beam Mechanical Event Simulation A rectangular tube, fixed on each end and made from plastic is, loaded to full pressure (at 1.5 sec) and unloaded. The full load causes the material to exceed the yield strength. Thus, the beam retains a permanent deformation when the load is removed.

31. Nonlinear Beam Stress Contour at Maximum Load

32. Nonlinear Beam Stress Contour at No Load (Residual Stress)

33. Nonlinear Beam Stress Contour at No Load (Residual Stress)

34. Nonlinear Beam

35. Pinball Drop Target Mechanical Event Simulation A pinball strikes a target and results in dynamic stresses and deflection.

36. Heat Exchanger Coupled Fluid Flow and Thermal A heat exchanger with 7 fins and internal, non-pumped fluid. The fluid is heated by a pipe (red part) carrying hot fluid passing through the body of the exchanger. The fluid is cooled by air flowing over the fins. The heating and cooling of the internal fluid causes buoyancy effects which cause the fluid to circulate through the exchanger.

37. Heat Exchanger

40. Circuit Breaker Mechanical Event Simulation Three analyses were combined to calculate the performance of a circuit breaker. 1. Electric current passes through based on the resistance of the materials and voltage difference. 2. The current causes heat generation which causes a transient temperature distribution. 3. The differential expansion between the two materials in the bimetallic strip causes it to deform which releases the tripper.

41. Circuit Breaker