1. Swaybar-Shaft Assembly Workshop 8 Bonded Contact

2. Workshop Supplement October 30, 2001 Inventory #001572 W8-2 8. Bonded Contact Swaybar-Shaft Assembly Description A swaybar-shaft assembly is subjected to a vertical force of 500 kgf at the right end of the swaybar. The objective is to determine the overall stresses in the assembly. Use bonded contact to simulate the assembly, and replace the right two- thirds of the swaybar with a "rigid region" (constraint equations). As a follow-up, join the two parts using a Boolean glue operation and redo the analysis.

3. Workshop Supplement October 30, 2001 Inventory #001572 W8-3 8. Bonded Contact Swaybar-Shaft Assembly Loads and Material Properties

4. Workshop Supplement October 30, 2001 Inventory #001572 W8-4 8. Bonded Contact Swaybar-Shaft Assembly 1.Enter ANSYS in the working directory specified by your instructor using “bonded- contact” as the jobname. 2.Read input from the file “bonded-contact.inp” to 1) mesh the model, 2) create rigid links, and 3) apply constraints and loads: –Utility Menu > File > Read Input from … –Or issue: /INP,bonded-contact,inp 3.Create the bonded contact elements between the shaft and the swaybar: Procedure shown on following pages

5. Workshop Supplement October 30, 2001 Inventory #001572 W8-5 8. Bonded Contact Swaybar-Shaft Assembly 3.(cont’d) a) Create the contact elements: –Main Menu > Preprocessor > -Modeling- Create > Contact Pair > Contact Wizard … Select “Flexible” and “Areas”, then [Pick Target …] Pick area 48, then [OK] HINT: drag mouse until Area 48 is selected or type 48 into the input window, then Enter For ambiguous pick, hit NEXT until “48” is selected Pick [Next >] Select “Areas”, then [Pick Contact …] Pick area 22, then [OK] Pick [Next >] Pick [Optional settings …] Set the “Normal Penalty Stiffness” to 100 Select “Bonded (always)” for Behavior of contact surface Select the “Initial Adjustment” tab Select “Exclude everything” for Initial penetration [OK] [Create >] [Finish]

6. Workshop Supplement October 30, 2001 Inventory #001572 W8-6 8. Bonded Contact Swaybar-Shaft Assembly 3.(cont’d) b) select type 5 elements and their nodes and then plot the target surface contact elements: –Utility Menu > Select > Entities... –Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair … Select “Target Surface” and check “normals shown” under Options [Display] –Utility Menu > Plot > Elements –Or issue: ESEL,S,TYPE,,5 NSLE /PSYMB,ESYS,1 /PNUM,TYPE,1 EPLOT

7. Workshop Supplement October 30, 2001 Inventory #001572 W8-7 8. Bonded Contact Swaybar-Shaft Assembly 3.(cont’d) c) Select type 6 elements and their nodes and then plot the contact surface contact elements: –Utility Menu > Select > Entities... –Main Menu > Preprocessor > -Modeling- Create > Contact Pair > View Pair … Select “Contact Surface” and check “normals shown” under Options [Display] –Utility Menu > Plot > Elements –Or issue: ESEL,S,TYPE,,6 NSLE /PSYMB,ESYS,1 /PNUM,TYPE,1 EPLOT d) Close the “View Contact Pair…” window [Close]

8. Workshop Supplement October 30, 2001 Inventory #001572 W8-8 8. Bonded Contact Swaybar-Shaft Assembly 4.Select everything, turn off all symbols except constraint equations, then plot elements: –Utility Menu > Select > Everything –Utility Menu > PlotCtrls >Symbols > For Individual : Miscellaneous > Constraint Equations –Utility Menu > Plot > Elements –Or issue: ALLSEL /PBC,CE,,1 /AUTO,1 EPLOT

9. Workshop Supplement October 30, 2001 Inventory #001572 W8-9 8. Bonded Contact Swaybar-Shaft Assembly 5.Enter the solution processor and turn off solution controls. Then choose the PCG solver, set the number of equilibrium iterations to one, and solve: –Main Menu > Solution > Unabridged Menu –Main Menu > Solution > -Load Step Opts- Solution Ctrl.. Set to “Off”, then [OK] –Main Menu > Solution > -Analysis Type- Sol’n Control... Pick the “Sol’n Options” tab Select “Pre-Condition CG” Pick the “Nonlinear” tab Enter “1” for the number of Equilibrium Iterations [OK] Read and then close yellow warning message window –Pick the “SAVE_DB” button in the Toolbar (or select: Utility Menu > File > Save as Jobname.db) –Main Menu > Solution > -Solve- Current LS –Or issue: /SOLU SOLCONTROL,OFF EQSLV,PCG NEQIT,1 SAVE SOLVE

10. Workshop Supplement October 30, 2001 Inventory #001572 W8-10 8. Bonded Contact Swaybar-Shaft Assembly 6.Unselect element 8000 (MASS21 element), then enter POST1 and plot the nodal von Mises stresses: –Utility Menu > Select > Entities... –Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu... –Or issue: ESEL,U,,,8000 /POST1 /AUTO,1 PLNSOL,S,EQV

11. Workshop Supplement October 30, 2001 Inventory #001572 W8-11 8. Bonded Contact Swaybar-Shaft Assembly 7.Plot von Mises stresses for elements associated with volume component “v_bar”: –Utility Menu > Select > Comp/Assembly > Select Comp/Assembly … –Utility Menu > Select > Everything Below > Selected Volumes –Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu... –Or issue: CMSEL,S,v_bar ALLSEL,BELOW,VOLU PLNSOL,S,EQV

12. Workshop Supplement October 30, 2001 Inventory #001572 W8-12 8. Bonded Contact Swaybar-Shaft Assembly 8.Plot von Mises stresses for elements associated with volume component “v_shaft”: –Utility Menu > Select > Comp/Assembly > Select Comp/Assembly … –Utility Menu > Select > Everything Below > Selected Volumes –Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu... –Or issue: CMSEL,S,v_shaft ALLSEL,BELOW,VOLU PLNSOL,S,EQV

13. Workshop Supplement October 30, 2001 Inventory #001572 W8-13 8. Bonded Contact Swaybar-Shaft Assembly 9.Now rerun the stress analysis, with the swaybar and shaft volumes glued together, by reading input from the file “swaybar-shaft-glued.inp”: –Utility Menu > File > Read Input from … –Or issue: /INP,swaybar-shaft-glued,inp 10.After the solution completes, the nodal solution for SEQV is displayed for the swaybar (i.e. v_bar volume component):

14. Workshop Supplement October 30, 2001 Inventory #001572 W8-14 8. Bonded Contact Swaybar-Shaft Assembly 11.Plot von Mises stresses for elements associated with volume component “v_shaft”: –Utility Menu > Select > Comp/Assembly > Select Comp/Assembly … –Utility Menu > Select > Everything Below > Selected Volumes –Main Menu > General Postproc > Plot Results > -Contour Plot- Nodal Solu... –Or issue: CMSEL,S,v_shaft ALLSEL,BELOW,VOLU PLNSOL,S,EQV 12.Exit ANSYS.