See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/355547114

Design and Analysis of Mechanical Cradle -Theoretical Calculation and ANSYS

Structural Analysis Simulation

Technical Report · November 2020

DOI: 10.13140/RG.2.2.11780.04483

CITATIONS READS

0 387

1 author:

Vimal Ramanathan
INTI International University
7 PUBLICATIONS 0 CITATIONS

SEE PROFILE

All content following this page was uploaded by Vimal Ramanathan on 25 October 2021.

The user has requested enhancement of the downloaded file.

Design and Analysis of Mechanical Cradle – Theoretical Calculation and
ANSYS Structural Analysis Simulation

Vimal Ramanathan

Faculty of Engineering and Quantity Surveying, INTI International University, Jalan BBN
12/1, Bandar Baru Nilai, 71800 Nilai, Negeri Sembilan. Malaysia2Affiliation with full
address

rvimal2025@gmail.com

Table of Contents
1.0 Abstract ........................................................................................................................... 1
2.0 Background .......................................................................................................................... 1
Compression spring ............................................................................................................... 1
Rack and pinion ..................................................................................................................... 2
Bearing ................................................................................................................................... 3
3.0 Design Overview ................................................................................................................. 5
CAD Designs ......................................................................................................................... 5
Spring with Hook ................................................................................................................... 5
Rack and Pinion ..................................................................................................................... 8
608 Bearing .......................................................................................................................... 10
Base Body ............................................................................................................................ 11
Assembly.............................................................................................................................. 12
Gear Interference Analysis ANSYS .................................................................................... 14
4.0 Static Analysis ................................................................................................................... 23
Bearing ................................................................................................................................. 23
Spring ................................................................................................................................... 24
5.0 Fatigue Analysis................................................................................................................. 26
Rack and Pinion ................................................................................................................... 26
Bending stress ...................................................................................................................... 26
6.0 Force Analysis ................................................................................................................... 31
Simulation Results ............................................................................................................... 33
Gear Interference 1.70 N...................................................................................................... 33
Gear Interference 55.83 N.................................................................................................... 34
 Compression Spring 1.70 N ................................................................................................. 35
Compression Spring 55.83 N ............................................................................................... 35
7.0 Conclusion ......................................................................................................................... 36
8.0 Reference ........................................................................................................................... 37
9.0 Appendices ......................................................................................................................... 38
Project* .................................................................................................................................. 38
Contents ............................................................................................................................ 39
Units.................................................................................................................................... 39
Model (C4) ......................................................................................................................... 39
Geometry ....................................................................................................................... 39
Coordinate Systems ................................................................................................... 42
Connections ................................................................................................................. 42
Mesh ............................................................................................................................... 44
Static Structural (C5) ...................................................................................................... 45
Solution (C6)................................................................................................................. 48
Chart ................................................................................................................................... 59
Chart 2 ................................................................................................................................ 60
Chart 3 ................................................................................................................................ 61
Chart 4 ................................................................................................................................ 62
Material Data..................................................................................................................... 63
Structural Steel ............................................................................................................ 63
Project* .................................................................................................................................. 65
Contents ............................................................................................................................ 66
Units.................................................................................................................................... 66
Model (C4) ......................................................................................................................... 66
Geometry ....................................................................................................................... 66
Coordinate Systems ................................................................................................... 69
Connections ................................................................................................................. 69
Mesh ............................................................................................................................... 71
Static Structural (C5) ...................................................................................................... 72
Solution (C6)................................................................................................................. 75
Chart ................................................................................................................................... 86
Chart 2 ................................................................................................................................ 87
 Chart 3 ................................................................................................................................ 88
Chart 4 ................................................................................................................................ 89
Material Data..................................................................................................................... 90
Structural Steel ............................................................................................................ 90
Compression Spring at 1.70N .............................................................................................. 92
Project* .................................................................................................................................. 92
Contents ............................................................................................................................ 93
Units.................................................................................................................................... 93
Model (D4) ......................................................................................................................... 93
Geometry ....................................................................................................................... 93
Coordinate Systems ................................................................................................... 95
Mesh ............................................................................................................................... 95
Static Structural (D5) ...................................................................................................... 96
Solution (D6)................................................................................................................. 99
Chart ................................................................................................................................. 108
Chart 2 .............................................................................................................................. 108
Chart 3 .............................................................................................................................. 109
Chart 4 .............................................................................................................................. 110
Material Data................................................................................................................... 111
Structural Steel .......................................................................................................... 111
Compression Spring at 55.83N .......................................................................................... 113
Project* ................................................................................................................................ 113
Contents .......................................................................................................................... 114
Units.................................................................................................................................. 114
Model (D4) ....................................................................................................................... 114
Geometry ..................................................................................................................... 114
Coordinate Systems ................................................................................................. 116
Mesh ............................................................................................................................. 116
Static Structural (D5) .................................................................................................... 117
Solution (D6)............................................................................................................... 120
Chart ................................................................................................................................. 129
Chart 2 .............................................................................................................................. 129
Chart 3 .............................................................................................................................. 130
Chart 4 .............................................................................................................................. 131
Material Data................................................................................................................... 132
Structural Steel .......................................................................................................... 132
1.0 Abstract
Mechanical cradle consisting of three mechanism is designed in AutoCAD and theoretical
calculation in reference to design of machine elements formula was used to conduct an
analysis on the design. The safety factor was then calculated based on the loading that was
selected as the most suitable for the mechanism. Moreover, the maximum force of each
mechanism in relation to isolated mechanism forces found through force analysis is then used
and the safety factor is found. For the rack and pinion, gear interference analysis was carried
out theoretically and simulation in ANSYS. For the compression spring, the static structural
analysis was carried out in simulation using ANSYS. The data was then analyzed and the
safety factor found exceeds the limit for safety standard.

2.0 Background
Compression spring

Compression Springs have been wounded in an open helical spring or designed to counteract
compression along the wind axis. Helical compression is the most frequently used metal spring
configuration. Though frequently fitted on a guide rod or in the hole, the pumps can work
automatically. If a load is applied to the compression spring and shortened, then it pushes the
load against itself. Push resistance is available from compression springs and is one of the most
efficient energy storage devices available. Compression springs are actually one of the most
efficient energy storage devices in various applications, ranging from automotive engines to
large push presses to main devices and paddling appliances, cellphones, electronics and
sensitive devices. Anywhere you need a push button the most basic installation. Conical type
fountains are usually used in applications requiring low solid height and increased surge
resistance.

Key Parameters

Stress: The size of the spring determines the stresses, together with load and deflection
requirements. The coiled wire is twisted when a compressed spring is loaded. On the surface

1
of the wire, the load is greatest; since the spring is deflected, there is a variety of stresses.
Spring life is dominated by stress and stress. In order to achieve similar lives, the wider the
operative stress range, the lower the maximum stress. When the stress range is narrow, or the
spring is subjected only to static loads, relatively high stresses may be used.

Wind Direction: Coil compression springs, like a screw thread, are wound in either the
direction of the left hand or the direction of the right.

Counting coils: there are two primary counting methods, the active coil count, and the total coil
count, applicable to springs.

Ends: There are four basic compression spring type configurations. The end of spring can be
ground, or soil and the end spindles can be open or shut.

Outside diameter: diameter of the cylindrical surface, which forms a spring's outer surface.

Hole diameter: this is the space measurement in which a compression spring would be inserted.
It is the diameter of an attachment part to a spring compression and is often confused with a
spring's dimension. The hole diameter should be designed tolerance and spring expansion
under load greater than the external diameter of your compression spring.

Rod Diameter: The rod that passes through a compression spring. Rod Diameter: This rod can
basically serve as a guiding shaft to minimize jumping under load. It is a combination part.
Roll diameter should be less than the factoring tolerance of your compression spring, but not
too small or otherwise it will lose the ability to minimize spring buckling.

Free Length: when it is not loaded, the length of a spring. NOTE: The anchor ends can be
included in the case of extension springs.

Diameter of the wire: This is the raw material for spring size measurement. Conventional
springs are constructed from round wires specified in diameter. Check our Compression Spring
Measurement Guide.

Rack and pinion

The pinion rotates causes a rack's linear movement that by means of pinion steering turns the
wheels of the truck to the left or to the right. Racking systems and pinions are a common
component of the railways. Tracks on locomotives and train cars interact with pinions in order
to help trains movement steeply.

2
It is only attached to a toothed bar gear. The bar is connected to a series of tie rods. The rack
design for the generation tool is used to identify the details and sizes of the teeth, such as an
elevator or shaper cutter. Simple linear actuators often consist of a combination of rack and
pinion. Power is used by hand or by a linear motor on the pinion's shaft rotation.

With the gear system, the rack and pinion system is used to turn the circular movement of the
steering wheel into a linear movement required to turn the wheels. The equipment consists of
a tube of metal. The pipe is linked by openings on each end to an axial rod. When the steering
wheel turns to turn and move the rack, the pinion gear is connected to the steering board. The
spindle end of a tie-rod is connected to the axial rod.

The majority of consumers are familiar with steering car and small truck pinion systems, but
there are several other applications to the rack and pinion combinations. In addition to
supporting steep gradients in trains, the rack and pinion systems provide better frequencies
control, in snowy and icy conditions. Stairlift.com states that pinion and rack systems are
standard components in most escalators. Hydraulic or electric energy is often used to control
the pinion and rack mechanism.

Bearing
In providing both rotation and linear motion within devices, bearings are crucial in a way that
limits friction and evenly disperses the amount of stress placed on the system that could cause
some catastrophic system failure in other circumstances. Meanwhile the seals both maintain
the lubricant required to function properly for the bearing, while also avoiding contamination
in the form of harmful particles entering the system.

3
Ball bearings and roller bearings are the two major categories of anti-friction bearings. Ball
bearings are not as common as solid spheres that rotate very quickly but are only used in
specific types of applications that range from large pumps and compressors to miniature servo
motors with moderate or heavy loads.

A little more widely used are roller bearings. Dual rings with rolling elements that run inside
their tracks feature these types of bearings. They have the same envelope dimensions as ball
bearings, but because of the bigger surface contact areas, they can deliver higher radial load
ratings.

There are several subcategories of roller bearings:

• Cylindrical rollers: These rollers contact the outer rings much more deeply than other
types of roller bearings and can distribute the load they carry across a wider surface.

• Tapered rollers: At each end, these rollers are narrower but have an all-around shape
different from other kinds of roller bearings.

• Needle rollers: These rollers are like cylindrical rollers but on average, they are both
longer and wider.

4
 • Symmetrical barrel rollers: These rollers are self-aligning and, on both sides, have
the same shape and dimensions.

Asymmetrical barrel rollers: These barrel rollers, though also self-aligning, have different
shapes and lengths on each side making them asymmetrical.

3.0 Design Overview

CAD Designs
Spring with Hook

5
6
Using the formula shown above, the spring is designed according to the mechanism body and
other mechanism used. The hook is added into the spring to attach it to the body of the design
and the attachment is rigid. The hook on the above end is to attach the load to compress the
spring therefore the force acting on the mechanism will decrease and increase according to
the load applied and the potential energy of the spring.

7
Rack and Pinion

8
9
Based on the pressure angle and the number of teeth formula, the spur gear and the rack are
designed accordingly. The calculation is shown above. The system is then assembled into a
working mechanism.

608 Bearing

The SKF 608 bearing design is taken from the SKF references with the technical data sheet
provided for the calculation and to suit the need. The bearing is selected based on the size
needed for the mechanism to operate. The maximum force able to withstand by the bearing is
then found using the technical data sheet provided by the manufacturer.

10
Base Body

11
The base body for the bearing is designed based on the calculation shown above. The body is
designed as such the fulcrum is set in the middle and the spring will be attached at each end,
equal distance from the center. Therefore, the design will be in static equilibrium. The force
analysis is then calculated and shown below.

Assembly

12
The assembly shows the three mechanism attached in a design to form a mechanical cradle.
The design is symetric and it is in static equilibrium. The spur gear and the bearing is
connected using a shaft therefore, the velocity will be the same for both the rotational
mechanism. The analysis is further done and shown below under static analysis, fatigue
analysis and force analysis.

13
Gear Interference Analysis ANSYS

Ansys 2019 R3 is used to run the simulation for the gear interference analysis. Open the Workbench
Ansys 2019 R3. Choose Static Structural. Select Geometry, right click on it and select Design Modeler.
It will open Design Modeler.

Rename the parts as, Gear and Rack. Save the file and proceed to Workbench Home Page.

14
Double click on Modal in Workbench Static Structural Project file. It would generate the model in the
geometry and under geometry, the Rack and Gear would be shown.

Material selection is chosen as steel. The figure above shows the details regarding the data sheet of
structural steel that will be used for the simulation.

15
The coordinate system is chosen as the default which is in the XZ plane. The orientation is followed
the figure shown above.

The connection tab is chosen and the contacts are automatically generated based on the
interference between the parts. There will be contact region shown. Additionally, the bonded
contact region can be generated based on the selection of the parts and the location.

16
For the bonded rack to gear connection, the contact body is chosen as the rack teeth, target body is
chosen as the spur gear teeth.

17
Meshing is done. Three selection is done to run the meshing, firstly body sizing. The size is chosen as
0.01m.

Secondly, the automatic method is chosen to run the simulation on this criteria set by the software.

18
Under the tab static structural the number of steps is chosen as 10. To make sure the simulation
runs 10 times therefore 10 sets of data will be generated. Under graph and tabular data, there
would be 10 columns generated, providing values to generate a chart/graph.

19
Constraints to set the environment for simulation is selected here under the static structural tab.
Fixed support is chosen as the 3 faces in the rack. As the simulation environment the force affect on
the rack is, the interference. The condition selected is the rack stationary, as there will not be any
force action on it.

The moment constraint is selected at the center of the gear, as shown in the figure above. The face
is selected and the global coordinate is selected as the force is action on z-axis which rotates the
gear along the axis as well. The force is chosen as 116.94 Nm.

20
Frictionless support constraint is selected at the center of the gear as well. The face of the gear is
selected as there would need to be a constraint allowing for the gear to rotate freely without the
inclusion of external factors acting on it.

The solution is then generated based on the criteria set above. The controlled environment
simulation is based on the conditions set that the interference is based on the moment acting on the
gear due to the downforce reaction on the spoiler. The parameter that are considered and can be
considered will be discussed in discussion and shown in further studies section. The results
generated are then shown in results section displaying many factors that could be generated with
consideration of the parameters.

21
22
4.0 Static Analysis
Bearing

23
The formula from design of machine elements formula book is used to find the maximum
force based on the data sheet provided by the manufacturer. Since the bearing size has
already been selected for the design, the maximum force is calculated using the same formula
used to select the appropriate bearing based on the force applied. From this formula, the
maximum force is then found to be 96.7 N. This force is then used as the reference later on
for the simulation to identify the safety factor.

Spring

24
25
The spring is designed according to the parameters set, shown above and in design overview.
The k constant is then found using the formula shown in design overview for the two
materials, structural steel and ABS plastic. The k constant found is then substituted into
spring potential energy formula to find the compressed length. For this data to be found, the
load applied is made constant at 100g.

5.0 Fatigue Analysis

Rack and Pinion
Bending stress

26
27
28
29
The gear interference analysis theoretical calculation is done to find the safety factor which is
then compared to the simulation results. The safety factor has to be above 1 also not as a
large number as it will be difficult to form a conclusion as a machine is too safe.

30
6.0 Force Analysis

31
Force analysis is done to find the force that acts on the spur gear and the bearing. For the
analysis, the bearing is selected and the force is the same as both is symmetrical in distance
and connected through shaft. Therefore, for the analysis, 100g load as per stated above for the
spring potential energy analysis is used here, to find the horizontal force that will be acting on
the bearing. The deformation angle is assumed to be 30 degrees as there were not enough
data to find the exact deformation and experimentation is needed to be carried out to find the
exact value. Therefore, the assumption is made to be 30 degrees for the load of 100g and also
the maximum loading. If for future research, the exact value of deformation is found, the
values can be replaced although the method shown is proven to provide results that shows
sufficient principle of the design of machine element concept of three mechanisms. Using the
force shown the gear interference analysis is carried out. Further more, the maximum force
for the bearing found is then used in the force analysis method above and the maximum
vertical force acting on the system that is within the safety limit of the bearing is then found.
The force is then divided by 9.8, to find the allowable mass. This value obtained is then used
to carry out the simulation to identify the difference in factor of safety within the two values
obtained based on 100g load and 5.70kg.

32
Simulation Results
Gear Interference 1.70 N
Safety Factor

The safety factor for the 1.70N is within the maximum limit of 15. This shows the
mechanism is safe for the force being applied of 100g load.

Von-Mises Stress

33
The stress for the 1.70N is average 58473 Pa. This shows the mechanism is safe for the force
being applied of 100g load with the result of the safety factor. The report generated for the
simulation is shown in appendices completed with the figures and chart.

Gear Interference 55.83 N

The stress for the 1.70N is average 192030 Pa. This shows the mechanism is safe for the
force being applied of 5.83kg load with the result of the safety factor. The report generated
for the simulation is shown in appendices completed with the figures and chart.

34
Compression Spring 1.70 N

The deformation is then found through the ANSYS static structural, the average deformation
is 2.9121e-003 m for the load of 1.7N

Compression Spring 55.83 N

The deformation is then found through the ANSYS static structural, the average deformation
is 9.5636e-002 m for the load of 55.83N

35
7.0 Conclusion
The design analysis is carried out and from the gear interference analysis theoretical, it can be
concluded that due to certain parameters not found as it would needed to be determined
through experimentation, the values were then assumed at an approximate value. Singular
assumption has made a huge difference in the data found , nevertheless the factor of safety is
still larger than expected. This is due to the force able to withstand by the material is above
the material properties and the mechanism is said to be in within the safe region of operation.
Although, there were other parameters that was not taken into consideration such as vibration
and friction which would have resulted in a further decrease of safety factor. Though, those
parameters is found through experimentation and further research is needed to be able to
carry such analysis, it was left out and kept it within the range of the course structure. With
the assistance provided by the instructor, it is analyzed to be a complete design analysis that
is within the working safety range.

36
8.0 Reference
[1] Leespring.com. 2020. Compression Springs - Learn About | Lee Spring. [online]
Available at: <https://www.leespring.com/learn-about-compression-
springs#:~:text=Compression%20Springs%20are%20open%2Dcoil,or%20fitted%20inside%
20a%20hole.> [Accessed 24 November 2020].

[2] Winkler, J., 2020. Compression Springs - Helical & Metal Coil Springs | Century Spring.
[online] Century Spring. Available at:
<https://www.centuryspring.com/products/compression-springs/> [Accessed 25 November
2020].

[3] mbmckee.com. (n.d.). What Are Mechanical Bearings and How Do They Work? [online]
Available at: https://mbmckee.com/2019/04/what-are-mechanical-bearings-and-how-do-they-
work/ [Accessed 24 Nov. 2020].

[4] Alternate Dzign - One Stop solution for web consultancy, p., 2020. Bijon Corporation Pte
Ltd. [online] Bijon.com.sg. Available at: <http://www.bijon.com.sg/product03.php>
[Accessed 4 October 2020].

37
9.0 Appendices
Gear Interference 1.70N

Project*
First Saved Saturday, October 31, 2020
Last Saved Wednesday, November 25, 2020
Product Version 2019 R3
Save Project Before Solution No
Save Project After Solution No

38
Contents
• Units

• Model (C4)
o Geometry
▪ Parts
o Materials
o Coordinate Systems
o Connections
▪ Contacts
▪ Contact Region
▪ Contact Region
o Mesh
▪ Mesh Controls
o Static Structural (C5)
▪ Analysis Settings
▪ Loads
▪ Solution (C6)
▪ Solution Information
▪ Results
▪ Stress Tool
▪ Safety Factor
o Chart
o Chart 2
o Chart 3
o Chart 4

• Material Data
o Structural Steel

Units
TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (C4)
Geometry
TABLE 2
Model (C4) > Geometry
Object
Geometry
Name
State Fully Defined
Definition
C:\Users\vimal\OneDrive\Desktop\Others\Dharani\Design\DH_files\dp0\Geom\DM\Geo
Source
m.agdb
Type DesignModeler
Length Unit Meters

39
 Element
Program Controlled
Control
Display
Body Color
Style
Bounding Box
Length X 0.47452 m
Length Y 0.2715 m
Length Z 2.5191e-002 m
Properties
Volume 1.1307e-003 m³
Mass 8.8757 kg
Scale
Factor 1.
Value
Statistics
Bodies 2
Active
2
Bodies
Nodes 10405
Elements 1677
Mesh
None
Metric
Update Options
Assign
Default No
Material
Basic Geometry Options
Parameter
Independent
s
Parameter
Key
Attributes Yes
Attribute
Key
Named
Yes
Selections
Named
Selection
Key
Material
Yes
Properties
Advanced Geometry Options
Use
Associativit Yes
y
Coordinate
Yes
Systems
Coordinate
System
Key
Reader
Mode
Saves No
Updated
File

40
 Use
Yes
Instances
Smart CAD
Yes
Update
Compare
Parts On No
Update
Analysis
3-D
Type
Clean
Bodies On No
Import
Stitch
Surfaces None
On Import
Decompos
e Disjoint Yes
Geometry
Enclosure
and
Yes
Symmetry
Processing

TABLE 3
Model (C4) > Geometry > Parts
Object Name Geom\Rack Geom\Gear
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 0.47452 m 0.23745 m
Length Y 6.15e-002 m 0.23622 m
Length Z 2.5e-002 m 2.2372e-002 m
Properties
Volume 5.4917e-004 m³ 5.8149e-004 m³
Mass 4.311 kg 4.5647 kg
Centroid X 0.45 m
Centroid Y 7.2352e-002 m 0.20006 m
Centroid Z 1.25e-002 m 1.0995e-002 m
Moment of Inertia Ip1 1.3081e-003 kg·m² 1.5928e-002 kg·m²
Moment of Inertia Ip2 8.2078e-002 kg·m² 1.5927e-002 kg·m²
Moment of Inertia Ip3 8.2937e-002 kg·m² 3.1489e-002 kg·m²
Statistics

41
 Nodes 3104 7301
Elements 450 1227
Mesh Metric None
CAD Attributes
Color:175.143.175
Color:159.175.143

TABLE 4
Model (C4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 2
Material Assignments 0

Coordinate Systems
TABLE 5
Model (C4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Connections
TABLE 6
Model (C4) > Connections
Object Name Connections
State Fully Defined
Auto Detection
Generate Automatic Connection On Refresh Yes
Transparency
Enabled Yes

TABLE 7
Model (C4) > Connections > Contacts
Object Name Contacts Contacts 2
State Fully Defined
Definition
Connection Type Contact
Scope
Scoping Method Geometry Selection

42
 Geometry All Bodies
Auto Detection
Tolerance Type Slider
Tolerance Slider 0.
Tolerance Value 1.3682e-003 m
Use Range No
Face/Face Yes
Face-Face Angle Tolerance 75. °
Face Overlap Tolerance Off
Cylindrical Faces Include
Face/Edge No
Edge/Edge No
Priority Include All
Group By Bodies
Search Across Bodies
Statistics
Connections 1
Active Connections 1

TABLE 8
Model (C4) > Connections > Contacts > Contact Regions
Object Name Contact Region
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 4 Faces
Target 4 Faces
Contact Bodies Geom\Rack
Target Bodies Geom\Gear
Protected No
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 1.3682e-003 m
Suppressed No
Advanced
Formulation Program Controlled
Small Sliding Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Pinball Region Program Controlled
Geometric Modification
Contact Geometry Correction None
Target Geometry Correction None

TABLE 9
Model (C4) > Connections > Contacts 2 > Contact Regions

43
 Object Name Contact Region
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 4 Faces
Target 4 Faces
Contact Bodies Geom\Rack
Target Bodies Geom\Gear
Protected No
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 1.3682e-003 m
Suppressed No
Advanced
Formulation Program Controlled
Small Sliding Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Pinball Region Program Controlled
Geometric Modification
Contact Geometry Correction None
Target Geometry Correction None

Mesh
TABLE 10
Model (C4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 0.54728 m
Average Surface Area 1.5094e-003 m²
Minimum Edge Length 8.4189e-003 m

44
 Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 10405
Elements 1677

TABLE 11
Model (C4) > Mesh > Mesh Controls
Object Name Automatic Method Body Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Bodies
Definition
Suppressed No
Method Automatic
Element Order Use Global Setting
Type Element Size
Element Size 1.e-002 m
Advanced
Defeature Size Default
Behavior Soft

Static Structural (C5)

TABLE 12
Model (C4) > Analysis
Object Name Static Structural (C5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural

45
 Solver Target Mechanical APDL
Options
Environment Temperature 22. °C
Generate Input Only No

TABLE 13
Model (C4) > Static Structural (C5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 10.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Rotordynamics Controls
Coriolis Effect Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Combine Restart Files Program Controlled
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Program Controlled
Advanced
Inverse Option No
Output Controls
Stress Yes
Surface Stress No
Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled
Analysis Data Management
Solver Files Directory C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files Directory

46
 Save MAPDL db No
Contact Summary Program Controlled
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks

TABLE 14
Model (C4) > Static Structural (C5) > Analysis Settings
Step-Specific "Step Controls"
Step End Auto Time Define Carry Over Initial Minimum Maximum
Step
Time Stepping By Time Step Substeps Substeps Substeps
1 1. s
2 2. s Program
3 3. s Controlled
4 4. s
5 5. s On Substeps Off 1. 1. 10.
6 6. s
7 7. s
Program
8 8. s
Controlled
9 9. s
10 10. s

TABLE 15
Model (C4) > Static Structural (C5) > Loads
Object Name Fixed Support Frictionless Support Moment
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 3 Faces 1 Face
Definition
Type Fixed Support Frictionless Support Moment
Suppressed No
Define By Components
Coordinate System Global Coordinate System
X Component 0. N·m (ramped)
Y Component 0. N·m (ramped)
Z Component 1.7 N·m (ramped)
Behavior Deformable
Advanced
Pinball Region All

FIGURE 1
Model (C4) > Static Structural (C5) > Moment

47
Solution (C6)
TABLE 16
Model (C4) > Static Structural (C5) > Solution
Object Name Solution (C6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
MAPDL Elapsed Time 14. s
MAPDL Memory Used 128. MB
MAPDL Result File Size 15.625 MB
Post Processing
Beam Section Results No
On Demand Stress/Strain No

TABLE 17
Model (C4) > Static Structural (C5) > Solution (C6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Identify Element Violations 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility

48
 Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 18
Model (C4) > Static Structural (C5) > Solution (C6) > Results
Total Directional Equivalent Elastic
Object Name Equivalent Stress
Deformation Deformation Strain
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Total Directional Equivalent Elastic Equivalent (von-
Type
Deformation Deformation Strain Mises) Stress
By Time
Display Time Last
Calculate Time
Yes
History
Identifier
Suppressed No
Orientation X Axis
Coordinate Global Coordinate
System System
Results
Minimum 0. m -2.8142e-008 m 1.9898e-012 m/m 0.21079 Pa
Maximum 2.8142e-008 m 1.5506e-008 m 4.2964e-007 m/m 85268 Pa
Average 1.1729e-008 m -2.1047e-009 m 3.0898e-008 m/m 5847.3 Pa
Minimum Occurs
Geom\Rack Geom\Gear Geom\Rack
On
Maximum Occurs
Geom\Gear
On
Minimum Value Over Time
Minimum 0. m -2.8142e-008 m 1.9898e-012 m/m 0.21079 Pa
Maximum 0. m -2.8142e-008 m 1.9898e-012 m/m 0.21079 Pa
Maximum Value Over Time
Minimum 2.8142e-008 m 1.5506e-008 m 4.2964e-007 m/m 85268 Pa
Maximum 2.8142e-008 m 1.5506e-008 m 4.2964e-007 m/m 85268 Pa
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10
Integration Point Results
Display Option Averaged
Average Across
No
Bodies

49
 FIGURE 2
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation

TABLE 19
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
0. 2.8142e-008 1.1729e-008
6.
7.
8.
9.
10.

FIGURE 3
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation > Figure

50
 FIGURE 4
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation

51
 TABLE 20
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
-2.8142e-008 1.5506e-008 -2.1047e-009
6.
7.
8.
9.
10.

FIGURE 5
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation > Figure

52
 FIGURE 6
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain

53
 TABLE 21
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain
Time [s] Minimum [m/m] Maximum [m/m] Average [m/m]
1.
2.
3.
4.
5.
1.9898e-012 4.2964e-007 3.0898e-008
6.
7.
8.
9.
10.

FIGURE 7
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain > Figure

54
 FIGURE 8
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress

55
 TABLE 22
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1.
2.
3.
4.
5.
0.21079 85268 5847.3
6.
7.
8.
9.
10.

FIGURE 9
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress > Figure

56
 TABLE 23
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Safety Tools
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material

TABLE 24
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Results
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results

57
 Display Option Averaged
Average Across Bodies No
Results
Minimum > 10
Minimum Occurs On Geom\Rack
Minimum Value Over Time
Minimum 15.
Maximum 15.
Maximum Value Over Time
Minimum 15.
Maximum 15.
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10

FIGURE 10
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor

TABLE 25
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1.
2.
3.
4. 15. 15. 15.
5.
6.
7.

58
 8.
9.
10.

FIGURE 11
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor > Figure

Chart
FIGURE 12
Model (C4) > Chart

59
 TABLE 26
Model (C4) > Chart
Steps Time [s] [A] Total Deformation (Min) [m] [B] Total Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
0. 2.8142e-008
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 2
FIGURE 13
Model (C4) > Chart 2

60
 TABLE 27
Model (C4) > Chart 2
Steps Time [s] [A] Directional Deformation (Min) [m] [B] Directional Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
-2.8142e-008 1.5506e-008
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 3
FIGURE 14
Model (C4) > Chart 3

61
 TABLE 28
Model (C4) > Chart 3
Steps Time [s] [A] Equivalent Elastic Strain (Min) [m/m] [B] Equivalent Elastic Strain (Max) [m/m]
1 1.
2 2.
3 3.
4 4.
5 5.
1.9898e-012 4.2964e-007
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 4
FIGURE 15
Model (C4) > Chart 4

62
 TABLE 29
Model (C4) > Chart 4
Steps Time [s] [A] Equivalent Stress (Min) [Pa] [B] Equivalent Stress (Max) [Pa]
1 1.
2 2.
3 3.
4 4.
5 5.
0.21079 85268
6 6.
7 7.
8 8.
9 9.
10 10.

Material Data
Structural Steel
TABLE 30
Structural Steel > Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m

TABLE 31
Structural Steel > Color

63
 Red Green Blue
132 139 179

TABLE 32
Structural Steel > Compressive Ultimate Strength
Compressive Ultimate Strength Pa
0

TABLE 33
Structural Steel > Compressive Yield Strength
Compressive Yield Strength Pa
2.5e+008

TABLE 34
Structural Steel > Tensile Yield Strength
Tensile Yield Strength Pa
2.5e+008

TABLE 35
Structural Steel > Tensile Ultimate Strength
Tensile Ultimate Strength Pa
4.6e+008

TABLE 36
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22

TABLE 37
Structural Steel > S-N Curve
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

TABLE 38
Structural Steel > Strain-Life Parameters
Cyclic Strain
Strength Strength Ductility Ductility Cyclic Strength
Hardening
Coefficient Pa Exponent Coefficient Exponent Coefficient Pa
Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2

TABLE 39
Structural Steel > Isotropic Elasticity
Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa Temperature C
2.e+011 0.3 1.6667e+011 7.6923e+010

64
 TABLE 40
Structural Steel > Isotropic Relative Permeability
Relative Permeability
10000

Gear Interference 55.83N

Project*
First Saved Saturday, October 31, 2020
Last Saved Wednesday, November 25, 2020
Product Version 2019 R3
Save Project Before Solution No
Save Project After Solution No

65
Contents
• Units

• Model (C4)
o Geometry
▪ Parts
o Materials
o Coordinate Systems
o Connections
▪ Contacts
▪ Contact Region
▪ Contact Region
o Mesh
▪ Mesh Controls
o Static Structural (C5)
▪ Analysis Settings
▪ Loads
▪ Solution (C6)
▪ Solution Information
▪ Results
▪ Stress Tool
▪ Safety Factor
o Chart
o Chart 2
o Chart 3
o Chart 4

• Material Data
o Structural Steel

Units
TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (C4)
Geometry
TABLE 2
Model (C4) > Geometry
Object
Geometry
Name
State Fully Defined
Definition
C:\Users\vimal\OneDrive\Desktop\Others\Dharani\Design\DH_files\dp0\Geom\DM\Geo
Source
m.agdb
Type DesignModeler
Length Unit Meters

66
 Element
Program Controlled
Control
Display
Body Color
Style
Bounding Box
Length X 0.47452 m
Length Y 0.2715 m
Length Z 2.5191e-002 m
Properties
Volume 1.1307e-003 m³
Mass 8.8757 kg
Scale
Factor 1.
Value
Statistics
Bodies 2
Active
2
Bodies
Nodes 10405
Elements 1677
Mesh
None
Metric
Update Options
Assign
Default No
Material
Basic Geometry Options
Parameter
Independent
s
Parameter
Key
Attributes Yes
Attribute
Key
Named
Yes
Selections
Named
Selection
Key
Material
Yes
Properties
Advanced Geometry Options
Use
Associativit Yes
y
Coordinate
Yes
Systems
Coordinate
System
Key
Reader
Mode
Saves No
Updated
File

67
 Use
Yes
Instances
Smart CAD
Yes
Update
Compare
Parts On No
Update
Analysis
3-D
Type
Clean
Bodies On No
Import
Stitch
Surfaces None
On Import
Decompos
e Disjoint Yes
Geometry
Enclosure
and
Yes
Symmetry
Processing

TABLE 3
Model (C4) > Geometry > Parts
Object Name Geom\Rack Geom\Gear
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 0.47452 m 0.23745 m
Length Y 6.15e-002 m 0.23622 m
Length Z 2.5e-002 m 2.2372e-002 m
Properties
Volume 5.4917e-004 m³ 5.8149e-004 m³
Mass 4.311 kg 4.5647 kg
Centroid X 0.45 m
Centroid Y 7.2352e-002 m 0.20006 m
Centroid Z 1.25e-002 m 1.0995e-002 m
Moment of Inertia Ip1 1.3081e-003 kg·m² 1.5928e-002 kg·m²
Moment of Inertia Ip2 8.2078e-002 kg·m² 1.5927e-002 kg·m²
Moment of Inertia Ip3 8.2937e-002 kg·m² 3.1489e-002 kg·m²
Statistics

68
 Nodes 3104 7301
Elements 450 1227
Mesh Metric None
CAD Attributes
Color:175.143.175
Color:159.175.143

TABLE 4
Model (C4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 2
Material Assignments 0

Coordinate Systems
TABLE 5
Model (C4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Connections
TABLE 6
Model (C4) > Connections
Object Name Connections
State Fully Defined
Auto Detection
Generate Automatic Connection On Refresh Yes
Transparency
Enabled Yes

TABLE 7
Model (C4) > Connections > Contacts
Object Name Contacts Contacts 2
State Fully Defined
Definition
Connection Type Contact
Scope
Scoping Method Geometry Selection

69
 Geometry All Bodies
Auto Detection
Tolerance Type Slider
Tolerance Slider 0.
Tolerance Value 1.3682e-003 m
Use Range No
Face/Face Yes
Face-Face Angle Tolerance 75. °
Face Overlap Tolerance Off
Cylindrical Faces Include
Face/Edge No
Edge/Edge No
Priority Include All
Group By Bodies
Search Across Bodies
Statistics
Connections 1
Active Connections 1

TABLE 8
Model (C4) > Connections > Contacts > Contact Regions
Object Name Contact Region
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 4 Faces
Target 4 Faces
Contact Bodies Geom\Rack
Target Bodies Geom\Gear
Protected No
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 1.3682e-003 m
Suppressed No
Advanced
Formulation Program Controlled
Small Sliding Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Pinball Region Program Controlled
Geometric Modification
Contact Geometry Correction None
Target Geometry Correction None

TABLE 9
Model (C4) > Connections > Contacts 2 > Contact Regions

70
 Object Name Contact Region
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 4 Faces
Target 4 Faces
Contact Bodies Geom\Rack
Target Bodies Geom\Gear
Protected No
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 1.3682e-003 m
Suppressed No
Advanced
Formulation Program Controlled
Small Sliding Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Pinball Region Program Controlled
Geometric Modification
Contact Geometry Correction None
Target Geometry Correction None

Mesh
TABLE 10
Model (C4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 0.54728 m
Average Surface Area 1.5094e-003 m²
Minimum Edge Length 8.4189e-003 m

71
 Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 10405
Elements 1677

TABLE 11
Model (C4) > Mesh > Mesh Controls
Object Name Automatic Method Body Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Bodies
Definition
Suppressed No
Method Automatic
Element Order Use Global Setting
Type Element Size
Element Size 1.e-002 m
Advanced
Defeature Size Default
Behavior Soft

Static Structural (C5)

TABLE 12
Model (C4) > Analysis
Object Name Static Structural (C5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural

72
 Solver Target Mechanical APDL
Options
Environment Temperature 22. °C
Generate Input Only No

TABLE 13
Model (C4) > Static Structural (C5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 10.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Rotordynamics Controls
Coriolis Effect Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Combine Restart Files Program Controlled
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Program Controlled
Advanced
Inverse Option No
Output Controls
Stress Yes
Surface Stress No
Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled
Analysis Data Management
Solver Files Directory C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files Directory

73
 Save MAPDL db No
Contact Summary Program Controlled
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks

TABLE 14
Model (C4) > Static Structural (C5) > Analysis Settings
Step-Specific "Step Controls"
Step End Auto Time Define Carry Over Initial Minimum Maximum
Step
Time Stepping By Time Step Substeps Substeps Substeps
1 1. s
2 2. s Program
3 3. s Controlled
4 4. s
5 5. s On Substeps Off 1. 1. 10.
6 6. s
7 7. s
Program
8 8. s
Controlled
9 9. s
10 10. s

TABLE 15
Model (C4) > Static Structural (C5) > Loads
Object Name Fixed Support Frictionless Support Moment
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 3 Faces 1 Face
Definition
Type Fixed Support Frictionless Support Moment
Suppressed No
Define By Components
Coordinate System Global Coordinate System
X Component 0. N·m (ramped)
Y Component 0. N·m (ramped)
Z Component 55.83 N·m (ramped)
Behavior Deformable
Advanced
Pinball Region All

FIGURE 1
Model (C4) > Static Structural (C5) > Moment

74
Solution (C6)
TABLE 16
Model (C4) > Static Structural (C5) > Solution
Object Name Solution (C6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
MAPDL Elapsed Time 12. s
MAPDL Memory Used 128. MB
MAPDL Result File Size 15.625 MB
Post Processing
Beam Section Results No
On Demand Stress/Strain No

TABLE 17
Model (C4) > Static Structural (C5) > Solution (C6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Identify Element Violations 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility

75
 Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 18
Model (C4) > Static Structural (C5) > Solution (C6) > Results
Total Directional Equivalent Elastic
Object Name Equivalent Stress
Deformation Deformation Strain
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Total Directional Equivalent Elastic Equivalent (von-
Type
Deformation Deformation Strain Mises) Stress
By Time
Display Time Last
Calculate Time
Yes
History
Identifier
Suppressed No
Orientation X Axis
Coordinate Global Coordinate
System System
Results
Minimum 0. m -9.2422e-007 m 6.5371e-011 m/m 6.9201 Pa
Maximum 9.2422e-007 m 5.0924e-007 m 1.411e-005 m/m 2.8003e+006 Pa
Average 3.8519e-007 m -6.912e-008 m 1.0147e-006 m/m 1.9203e+005 Pa
Minimum Occurs
Geom\Rack Geom\Gear Geom\Rack
On
Maximum Occurs
Geom\Gear
On
Minimum Value Over Time
Minimum 0. m -9.2422e-007 m 6.5371e-011 m/m 6.9201 Pa
Maximum 0. m -9.2422e-007 m 6.5371e-011 m/m 6.9201 Pa
Maximum Value Over Time
Minimum 9.2422e-007 m 5.0924e-007 m 1.411e-005 m/m 2.8003e+006 Pa
Maximum 9.2422e-007 m 5.0924e-007 m 1.411e-005 m/m 2.8003e+006 Pa
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10
Integration Point Results
Display Option Averaged
Average Across
No
Bodies

76
 FIGURE 2
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation

TABLE 19
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
0. 9.2422e-007 3.8519e-007
6.
7.
8.
9.
10.

FIGURE 3
Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation > Figure

77
 FIGURE 4
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation

78
 TABLE 20
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
-9.2422e-007 5.0924e-007 -6.912e-008
6.
7.
8.
9.
10.

FIGURE 5
Model (C4) > Static Structural (C5) > Solution (C6) > Directional Deformation > Figure

79
 FIGURE 6
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain

80
 TABLE 21
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain
Time [s] Minimum [m/m] Maximum [m/m] Average [m/m]
1.
2.
3.
4.
5.
6.5371e-011 1.411e-005 1.0147e-006
6.
7.
8.
9.
10.

FIGURE 7
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Elastic Strain > Figure

81
 FIGURE 8
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress

82
 TABLE 22
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1.
2.
3.
4.
5.
6.9201 2.8003e+006 1.9203e+005
6.
7.
8.
9.
10.

FIGURE 9
Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress > Figure

83
 TABLE 23
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Safety Tools
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material

TABLE 24
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Results
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results

84
 Display Option Averaged
Average Across Bodies No
Results
Minimum > 10
Minimum Occurs On Geom\Rack
Minimum Value Over Time
Minimum 15.
Maximum 15.
Maximum Value Over Time
Minimum 15.
Maximum 15.
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10

FIGURE 10
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor

TABLE 25
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1.
2.
3.
4. 15. 15. 15.
5.
6.
7.

85
 8.
9.
10.

FIGURE 11
Model (C4) > Static Structural (C5) > Solution (C6) > Stress Tool > Safety Factor > Figure

Chart
FIGURE 12
Model (C4) > Chart

86
 TABLE 26
Model (C4) > Chart
Steps Time [s] [A] Total Deformation (Min) [m] [B] Total Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
0. 9.2422e-007
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 2
FIGURE 13
Model (C4) > Chart 2

87
 TABLE 27
Model (C4) > Chart 2
Steps Time [s] [A] Directional Deformation (Min) [m] [B] Directional Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
-9.2422e-007 5.0924e-007
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 3
FIGURE 14
Model (C4) > Chart 3

88
 TABLE 28
Model (C4) > Chart 3
Steps Time [s] [A] Equivalent Elastic Strain (Min) [m/m] [B] Equivalent Elastic Strain (Max) [m/m]
1 1.
2 2.
3 3.
4 4.
5 5.
6.5371e-011 1.411e-005
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 4
FIGURE 15
Model (C4) > Chart 4

89
 TABLE 29
Model (C4) > Chart 4
Steps Time [s] [A] Equivalent Stress (Min) [Pa] [B] Equivalent Stress (Max) [Pa]
1 1.
2 2.
3 3.
4 4.
5 5.
6.9201 2.8003e+006
6 6.
7 7.
8 8.
9 9.
10 10.

Material Data
Structural Steel
TABLE 30
Structural Steel > Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m

TABLE 31
Structural Steel > Color

90
 Red Green Blue
132 139 179

TABLE 32
Structural Steel > Compressive Ultimate Strength
Compressive Ultimate Strength Pa
0

TABLE 33
Structural Steel > Compressive Yield Strength
Compressive Yield Strength Pa
2.5e+008

TABLE 34
Structural Steel > Tensile Yield Strength
Tensile Yield Strength Pa
2.5e+008

TABLE 35
Structural Steel > Tensile Ultimate Strength
Tensile Ultimate Strength Pa
4.6e+008

TABLE 36
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22

TABLE 37
Structural Steel > S-N Curve
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

TABLE 38
Structural Steel > Strain-Life Parameters
Cyclic Strain
Strength Strength Ductility Ductility Cyclic Strength
Hardening
Coefficient Pa Exponent Coefficient Exponent Coefficient Pa
Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2

TABLE 39
Structural Steel > Isotropic Elasticity
Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa Temperature C
2.e+011 0.3 1.6667e+011 7.6923e+010

91
 TABLE 40
Structural Steel > Isotropic Relative Permeability
Relative Permeability
10000

Compression Spring at 1.70N

Project*
First Saved Wednesday, November 25, 2020
Last Saved Wednesday, November 25, 2020
Product Version 2019 R3
Save Project Before Solution No
Save Project After Solution No

92
Contents
• Units

• Model (D4)
o Geometry
▪ Solid
o Materials
o Coordinate Systems
o Mesh
o Static Structural (D5)
▪ Analysis Settings
▪ Loads
▪ Solution (D6)
▪ Solution Information
▪ Results
▪ Stress Tool
▪ Safety Factor
o Chart
o Chart 2
o Chart 3
o Chart 4

• Material Data
o Structural Steel

Units
TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (D4)
Geometry
TABLE 2
Model (D4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\Geom-
Source
1\DM\Geom-1.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 3.3999e-002 m
Length Y 4.3201e-002 m
Length Z 0.26672 m

93
 Properties
Volume 2.0864e-005 m³
Mass 0.16378 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 11076
Elements 4842
Mesh Metric None
Update Options
Assign Default Material No
Basic Geometry Options
Parameters Independent
Parameter Key
Attributes Yes
Attribute Key
Named Selections Yes
Named Selection Key
Material Properties Yes
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems Yes
Coordinate System Key
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update Yes
Compare Parts On
No
Update
Analysis Type 3-D
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint
Yes
Geometry
Enclosure and Symmetry
Yes
Processing

TABLE 3
Model (D4) > Geometry > Parts
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Structural Steel
Nonlinear Effects Yes

94
 Thermal Strain Effects Yes
Bounding Box
Length X 3.3999e-002 m
Length Y 4.3201e-002 m
Length Z 0.26672 m
Properties
Volume 2.0864e-005 m³
Mass 0.16378 kg
Centroid X 0.25031 m
Centroid Y -0.19984 m
Centroid Z -0.10375 m
Moment of Inertia Ip1 7.6892e-004 kg·m²
Moment of Inertia Ip2 7.6769e-004 kg·m²
Moment of Inertia Ip3 3.5552e-005 kg·m²
Statistics
Nodes 11076
Elements 4842
Mesh Metric None

TABLE 4
Model (D4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 2
Material Assignments 0

Coordinate Systems
TABLE 5
Model (D4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Mesh
TABLE 6
Model (D4) > Mesh
Object Name Mesh
State Solved
Display

95
 Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 0.27232 m
Average Surface Area 6.9127e-003 m²
Minimum Edge Length 1.2567e-002 m
Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 11076
Elements 4842

Static Structural (D5)

TABLE 7
Model (D4) > Analysis
Object Name Static Structural (D5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL

96
 Options
Environment Temperature 22. °C
Generate Input Only No

TABLE 8
Model (D4) > Static Structural (D5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 10.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Rotordynamics Controls
Coriolis Effect Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Combine Restart Files Program Controlled
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Program Controlled
Advanced
Inverse Option No
Output Controls
Stress Yes
Surface Stress No
Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled
Analysis Data Management
C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\SYS-
Solver Files Directory
1\MECH\
Future Analysis None
Scratch Solver Files
Directory

97
 Save MAPDL db No
Contact Summary Program Controlled
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks

TABLE 9
Model (D4) > Static Structural (D5) > Analysis Settings
Step-Specific "Step Controls"
Step Step End Time
1 1. s
2 2. s
3 3. s
4 4. s
5 5. s
6 6. s
7 7. s
8 8. s
9 9. s
10 10. s

TABLE 10
Model (D4) > Static Structural (D5) > Loads
Object Name Fixed Support Force
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face
Definition
Type Fixed Support Force
Suppressed No
Define By Vector
Magnitude 1.7 N (ramped)
Direction Defined

FIGURE 1
Model (D4) > Static Structural (D5) > Force

98
Solution (D6)
TABLE 11
Model (D4) > Static Structural (D5) > Solution
Object Name Solution (D6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 10.
Refinement Depth 2.
Information
Status Done
MAPDL Elapsed Time 6. s
MAPDL Memory Used 298. MB
MAPDL Result File Size 20.75 MB
Post Processing
Beam Section Results No
On Demand Stress/Strain No

TABLE 12
Model (D4) > Static Structural (D5) > Solution (D6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Identify Element Violations 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility

99
 Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 13
Model (D4) > Static Structural (D5) > Solution (D6) > Results
Object Name Total Deformation Equivalent Elastic Strain Equivalent Stress
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Total Deformation Equivalent Elastic Strain Equivalent (von-Mises) Stress
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Results
Minimum 0. m 3.0217e-007 m/m 45059 Pa
Maximum 9.1539e-003 m 1.2751e-004 m/m 2.4482e+007 Pa
Average 2.9121e-003 m 5.3391e-005 m/m 8.3366e+006 Pa
Minimum Occurs On Solid
Maximum Occurs On Solid
Minimum Value Over Time
Minimum 0. m 3.0217e-007 m/m 45059 Pa
Maximum 0. m 3.0217e-007 m/m 45059 Pa
Maximum Value Over Time
Minimum 9.1539e-003 m 1.2751e-004 m/m 2.4482e+007 Pa
Maximum 9.1539e-003 m 1.2751e-004 m/m 2.4482e+007 Pa
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10
Integration Point Results
Display Option Averaged
Average Across Bodies No

FIGURE 2
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation

100
 TABLE 14
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
0. 9.1539e-003 2.9121e-003
6.
7.
8.
9.
10.

FIGURE 3
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation > Figure

101
 FIGURE 4
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain

102
 TABLE 15
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain
Time [s] Minimum [m/m] Maximum [m/m] Average [m/m]
1.
2.
3.
4.
5.
3.0217e-007 1.2751e-004 5.3391e-005
6.
7.
8.
9.
10.

FIGURE 5
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain > Figure

103
 FIGURE 6
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress

104
 TABLE 16
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1.
2.
3.
4.
5.
45059 2.4482e+007 8.3366e+006
6.
7.
8.
9.
10.

FIGURE 7
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress > Figure

105
 TABLE 17
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Safety Tools
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material

TABLE 18
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Results
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results

106
 Display Option Averaged
Average Across Bodies No
Results
Minimum > 10
Minimum Occurs On Solid
Minimum Value Over Time
Minimum 10.212
Maximum 10.212
Maximum Value Over Time
Minimum 15.
Maximum 15.
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10

FIGURE 8
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Safety Factor

TABLE 19
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1.
2.
3.
4. 10.212 15. 14.935
5.
6.
7.

107
 8.
9.
10.

Chart
FIGURE 9
Model (D4) > Chart

TABLE 20
Model (D4) > Chart
Steps Time [s] [A] Total Deformation (Min) [m] [B] Total Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
0. 9.1539e-003
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 2
FIGURE 10
Model (D4) > Chart 2

108
 TABLE 21
Model (D4) > Chart 2
Steps Time [s] [A] Equivalent Elastic Strain (Min) [m/m] [B] Equivalent Elastic Strain (Max) [m/m]
1 1.
2 2.
3 3.
4 4.
5 5.
3.0217e-007 1.2751e-004
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 3
FIGURE 11
Model (D4) > Chart 3

109
 TABLE 22
Model (D4) > Chart 3
Steps Time [s] [A] Equivalent Stress (Min) [Pa] [B] Equivalent Stress (Max) [Pa]
1 1.
2 2.
3 3.
4 4.
5 5.
45059 2.4482e+007
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 4
FIGURE 12
Model (D4) > Chart 4

110
 TABLE 23
Model (D4) > Chart 4
Steps Time [s] [A] Safety Factor (Min) [B] Safety Factor (Max)
1 1.
2 2.
3 3.
4 4.
5 5.
10.212 15.
6 6.
7 7.
8 8.
9 9.
10 10.

Material Data
Structural Steel
TABLE 24
Structural Steel > Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m

TABLE 25
Structural Steel > Color

111
 Red Green Blue
132 139 179

TABLE 26
Structural Steel > Compressive Ultimate Strength
Compressive Ultimate Strength Pa
0

TABLE 27
Structural Steel > Compressive Yield Strength
Compressive Yield Strength Pa
2.5e+008

TABLE 28
Structural Steel > Tensile Yield Strength
Tensile Yield Strength Pa
2.5e+008

TABLE 29
Structural Steel > Tensile Ultimate Strength
Tensile Ultimate Strength Pa
4.6e+008

TABLE 30
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22

TABLE 31
Structural Steel > S-N Curve
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

TABLE 32
Structural Steel > Strain-Life Parameters
Cyclic Strain
Strength Strength Ductility Ductility Cyclic Strength
Hardening
Coefficient Pa Exponent Coefficient Exponent Coefficient Pa
Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2

TABLE 33
Structural Steel > Isotropic Elasticity
Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa Temperature C
2.e+011 0.3 1.6667e+011 7.6923e+010

112
 TABLE 34
Structural Steel > Isotropic Relative Permeability
Relative Permeability
10000

Compression Spring at 55.83N

Project*
First Saved Wednesday, November 25, 2020
Last Saved Wednesday, November 25, 2020
Product Version 2019 R3
Save Project Before Solution No
Save Project After Solution No

113
Contents
• Units

• Model (D4)
o Geometry
▪ Solid
o Materials
o Coordinate Systems
o Mesh
o Static Structural (D5)
▪ Analysis Settings
▪ Loads
▪ Solution (D6)
▪ Solution Information
▪ Results
▪ Stress Tool
▪ Safety Factor
o Chart
o Chart 2
o Chart 3
o Chart 4

• Material Data
o Structural Steel

Units
TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (D4)
Geometry
TABLE 2
Model (D4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\Geom-
Source
1\DM\Geom-1.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 3.3999e-002 m
Length Y 4.3201e-002 m
Length Z 0.26672 m

114
 Properties
Volume 2.0864e-005 m³
Mass 0.16378 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 11076
Elements 4842
Mesh Metric None
Update Options
Assign Default Material No
Basic Geometry Options
Parameters Independent
Parameter Key
Attributes Yes
Attribute Key
Named Selections Yes
Named Selection Key
Material Properties Yes
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems Yes
Coordinate System Key
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update Yes
Compare Parts On
No
Update
Analysis Type 3-D
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint
Yes
Geometry
Enclosure and Symmetry
Yes
Processing

TABLE 3
Model (D4) > Geometry > Parts
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Structural Steel
Nonlinear Effects Yes

115
 Thermal Strain Effects Yes
Bounding Box
Length X 3.3999e-002 m
Length Y 4.3201e-002 m
Length Z 0.26672 m
Properties
Volume 2.0864e-005 m³
Mass 0.16378 kg
Centroid X 0.25031 m
Centroid Y -0.19984 m
Centroid Z -0.10375 m
Moment of Inertia Ip1 7.6892e-004 kg·m²
Moment of Inertia Ip2 7.6769e-004 kg·m²
Moment of Inertia Ip3 3.5552e-005 kg·m²
Statistics
Nodes 11076
Elements 4842
Mesh Metric None

TABLE 4
Model (D4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 2
Material Assignments 0

Coordinate Systems
TABLE 5
Model (D4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Mesh
TABLE 6
Model (D4) > Mesh
Object Name Mesh
State Solved
Display

116
 Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 0.27232 m
Average Surface Area 6.9127e-003 m²
Minimum Edge Length 1.2567e-002 m
Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 11076
Elements 4842

Static Structural (D5)

TABLE 7
Model (D4) > Analysis
Object Name Static Structural (D5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL

117
 Options
Environment Temperature 22. °C
Generate Input Only No

TABLE 8
Model (D4) > Static Structural (D5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 10.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Rotordynamics Controls
Coriolis Effect Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Combine Restart Files Program Controlled
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Program Controlled
Advanced
Inverse Option No
Output Controls
Stress Yes
Surface Stress No
Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled
Analysis Data Management
C:\Users\vimal\OneDrive\Desktop\DME\DME_files\dp0\SYS-
Solver Files Directory
1\MECH\
Future Analysis None
Scratch Solver Files
Directory

118
 Save MAPDL db No
Contact Summary Program Controlled
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks

TABLE 9
Model (D4) > Static Structural (D5) > Analysis Settings
Step-Specific "Step Controls"
Step Step End Time
1 1. s
2 2. s
3 3. s
4 4. s
5 5. s
6 6. s
7 7. s
8 8. s
9 9. s
10 10. s

TABLE 10
Model (D4) > Static Structural (D5) > Loads
Object Name Fixed Support Force
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face
Definition
Type Fixed Support Force
Suppressed No
Define By Vector
Magnitude 55.83 N (ramped)
Direction Defined

FIGURE 1
Model (D4) > Static Structural (D5) > Force

119
Solution (D6)
TABLE 11
Model (D4) > Static Structural (D5) > Solution
Object Name Solution (D6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 10.
Refinement Depth 2.
Information
Status Done
MAPDL Elapsed Time 5. s
MAPDL Memory Used 298. MB
MAPDL Result File Size 20.75 MB
Post Processing
Beam Section Results No
On Demand Stress/Strain No

TABLE 12
Model (D4) > Static Structural (D5) > Solution (D6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Identify Element Violations 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility

120
 Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 13
Model (D4) > Static Structural (D5) > Solution (D6) > Results
Object Name Total Deformation Equivalent Elastic Strain Equivalent Stress
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Total Deformation Equivalent Elastic Strain Equivalent (von-Mises) Stress
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Results
Minimum 0. m 9.9237e-006 m/m 1.4798e+006 Pa
Maximum 0.30062 m 4.1877e-003 m/m 8.0401e+008 Pa
Average 9.5636e-002 m 1.7534e-003 m/m 2.7378e+008 Pa
Minimum Occurs On Solid
Maximum Occurs On Solid
Minimum Value Over Time
Minimum 0. m 9.9237e-006 m/m 1.4798e+006 Pa
Maximum 0. m 9.9237e-006 m/m 1.4798e+006 Pa
Maximum Value Over Time
Minimum 0.30062 m 4.1877e-003 m/m 8.0401e+008 Pa
Maximum 0.30062 m 4.1877e-003 m/m 8.0401e+008 Pa
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10
Integration Point Results
Display Option Averaged
Average Across Bodies No

FIGURE 2
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation

121
 TABLE 14
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation
Time [s] Minimum [m] Maximum [m] Average [m]
1.
2.
3.
4.
5.
0. 0.30062 9.5636e-002
6.
7.
8.
9.
10.

FIGURE 3
Model (D4) > Static Structural (D5) > Solution (D6) > Total Deformation > Figure

122
 FIGURE 4
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain

123
 TABLE 15
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain
Time [s] Minimum [m/m] Maximum [m/m] Average [m/m]
1.
2.
3.
4.
5.
9.9237e-006 4.1877e-003 1.7534e-003
6.
7.
8.
9.
10.

FIGURE 5
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Elastic Strain > Figure

124
 FIGURE 6
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress

125
 TABLE 16
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1.
2.
3.
4.
5.
1.4798e+006 8.0401e+008 2.7378e+008
6.
7.
8.
9.
10.

FIGURE 7
Model (D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress > Figure

126
 TABLE 17
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Safety Tools
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material

TABLE 18
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Results
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results

127
 Display Option Averaged
Average Across Bodies No
Results
Minimum 0.31094
Minimum Occurs On Solid
Minimum Value Over Time
Minimum 0.31094
Maximum 0.31094
Maximum Value Over Time
Minimum 15.
Maximum 15.
Information
Time 10. s
Load Step 10
Substep 1
Iteration Number 10

FIGURE 8
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Safety Factor

TABLE 19
Model (D4) > Static Structural (D5) > Solution (D6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1.
2.
3.
4. 0.31094 15. 1.7999
5.
6.
7.

128
 8.
9.
10.

Chart
FIGURE 9
Model (D4) > Chart

TABLE 20
Model (D4) > Chart
Steps Time [s] [A] Total Deformation (Min) [m] [B] Total Deformation (Max) [m]
1 1.
2 2.
3 3.
4 4.
5 5.
0. 0.30062
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 2
FIGURE 10
Model (D4) > Chart 2

129
 TABLE 21
Model (D4) > Chart 2
Steps Time [s] [A] Equivalent Elastic Strain (Min) [m/m] [B] Equivalent Elastic Strain (Max) [m/m]
1 1.
2 2.
3 3.
4 4.
5 5.
9.9237e-006 4.1877e-003
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 3
FIGURE 11
Model (D4) > Chart 3

130
 TABLE 22
Model (D4) > Chart 3
Steps Time [s] [A] Equivalent Stress (Min) [Pa] [B] Equivalent Stress (Max) [Pa]
1 1.
2 2.
3 3.
4 4.
5 5.
1.4798e+006 8.0401e+008
6 6.
7 7.
8 8.
9 9.
10 10.

Chart 4
FIGURE 12
Model (D4) > Chart 4

131
 TABLE 23
Model (D4) > Chart 4
Steps Time [s] [A] Safety Factor (Min) [B] Safety Factor (Max)
1 1.
2 2.
3 3.
4 4.
5 5.
0.31094 15.
6 6.
7 7.
8 8.
9 9.
10 10.

Material Data
Structural Steel
TABLE 24
Structural Steel > Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m

TABLE 25
Structural Steel > Color

132
 Red Green Blue
132 139 179

TABLE 26
Structural Steel > Compressive Ultimate Strength
Compressive Ultimate Strength Pa
0

TABLE 27
Structural Steel > Compressive Yield Strength
Compressive Yield Strength Pa
2.5e+008

TABLE 28
Structural Steel > Tensile Yield Strength
Tensile Yield Strength Pa
2.5e+008

TABLE 29
Structural Steel > Tensile Ultimate Strength
Tensile Ultimate Strength Pa
4.6e+008

TABLE 30
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22

TABLE 31
Structural Steel > S-N Curve
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

TABLE 32
Structural Steel > Strain-Life Parameters
Cyclic Strain
Strength Strength Ductility Ductility Cyclic Strength
Hardening
Coefficient Pa Exponent Coefficient Exponent Coefficient Pa
Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2

TABLE 33
Structural Steel > Isotropic Elasticity
Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa Temperature C
2.e+011 0.3 1.6667e+011 7.6923e+010

133
 TABLE 34
Structural Steel > Isotropic Relative Permeability
Relative Permeability
10000

134

View publication stats