In this workshop we introduce the Mechanical Fatigue module to predict life on a stepped shaft using a stress based approach. Axial and bending load cases are calculated independently followed by solution combination for the simple non-proportional load case of fully reversed bending under constant axial tension. Goodman mean stress correction is implemented. Workbench parameterization is implemented to obtain fatigue life for various step radii values.

In this workshop, users implement a strain based approach within the Mechanical Fatigue Module for fully reversed loading near or exceeding the material yield strength. Morrow mean stress correction is implemented with emphasis on using the correct stress output for compressive mean stress adjustment.

In this workshop, users learn how to import unidirectional time history load data from a test track into the Mechanical Fatigue Module. Stress life calculations are performed using Rainflow methodologies for various amplitude vs mean stress bin values with Goodman mean stress correction. Emphasis on the tradeoff between accuracy and solver time with respect to binning is given.

In this workshop, students define a random vibration PSD spectrum and learn how to calculate 1 sigma, 2 sigma, and 3 sigma stresses. Fatigue life is calculated using the Steinberg Method. Students learn how to create a user defined result to calculate zero crossing frequency and validate the Mechanical Fatigue Module results using hand calculations.

In this workshop, students learn how to calculate maximum stresses and deflections on a motor bracket subject to harmonic loading. Students utilize the Mechanical Fatigue Module to calculate the expected time to failure of the bracket when the harmonic load frequency corresponds to the first natural frequency.

Workshop 2A-2D – Hex Meshing with Multizone, Virtual Topology and SpaceClaim

The objective of this set of workshops is to provide the student with several skills for generating a hexahedral mesh. This includes meshing with Multizone, slicing in SpaceClaim (and creating a multibody part for a conformal mesh), and inflation meshing.

Workshops 3 – Inflation Meshing with Multizone

In this workshop, students learn how to combine Multizone meshing with the Inflation mesh control. Certain scenarios, like Hertzian contact where the high stress is typically not at the surface of the structure, require a very fine mesh from the surface of the part into the volume. Inflation meshing allows this level mesh refinement. Coupled with hex meshing via Multizone, this makes a useful combination of mesh controls.

Workshops 4 & 5 – Thin Model Sweep Meshing

The objective of this workshop is to provide a skillset that allows complete hex meshing of thing structural components, like C-channels, weldments, and plates. These types of components can be tricky to hex mesh and retain good element quality. Students will learn Thin Sweep meshing, and how to use this feature in combination with Virtual Topology and Edge Biasing, to generate an all-hex mesh.

Workshops 6 & 7 – Practical Meshing Applications

These two workshops are open-ended workshops that have complex assemblies and specific requirements on the mesh size. A combination of SpaceClaim and meshing skills learned in the previous workshops will be required to generate an all-hex mesh for these assemblies.

Workshop 8 – Meshing with Shell Elements and Mesh Connections: Basic Bracketry

Students learn how to create shell finite elements in this workshop and how to create coincident nodes at the interfaces where multiple components touch. This former requires simplification of thin solid geometry to surface geometry using SpaceClaim, which is then automatically meshed with shell elements using the Ansys mesher. The latter simplifies the welded connection between the components; rather than modeling the weld geometry or using bonded contact, a set of coincident nodes are generated via Mesh Connections.

Workshop 9 – Meshing with Shell Elements and Mesh Connections: Complex Loader Arm

This workshop takes what is learned in the previous workshop and applies it to a more complex CAD assembly. Students will work on a large, welded structure of a terrain loader arm. The skills learned in the previous workshop to generate a surface CAD assembly and use Mesh Connections, as well as those skills in prior workshops to create an all-hex mesh on solid CAD that cannot be modeled with surfaces, are combined in this single workshop.

Workshop 2.1 – Rotary Draw Bending

This workshop involves bending a “Profile” by 70 degrees using a rigid tool. In this example, the rigid “Rotating Die” and “Clamp Die” will rotate about the Y axis dragging the “Profile” along as it slides along the stationary Mandrel. The “Pressure Die” translates axially along the Z axis while it maintains pressure against the “Profile” as it’s formed over the circular trajectory of the “Rotating Die”.

Workshop 2.2 – Drop Test Wizard

This workshop demonstrates the use of the Drop Test Wizard built into Ansys Mechanical to set up and simulate dropping a circuit board from a height of 1 meter.

Workshop 3.1 – Postprocessing with LS-PrePost

This workshop navigates into the LS-PrePost environment to review some of the postprocessing capabilities with LS-PrePost interface, which is included with Ansys LS-DYNA.

Workshop 4.1 – Impact on Tubes  

In this workshop two nested (concentric tubes) are struck by an impactor approaching at an initial velocity of 30 meters per second. The tubes are connected at outer ends through caps and supported by rotatable cylinder.

Workshop 5.1 – Quasi-static

This workshop utilizes the tube impact test example that involves dropping a tool to hit the tubes. In this workshop; however, we conduct a Quasi-static analysis to study the load from a hydraulic cylinder. The speed of the cylinder is based on the hydraulic pump and the controls system and can take a few seconds to run. It would take a long time to run this in the physical time frame, but the concept of Quasi-static simulation can help accelerate it.

Workshop 7.1 – Meshing

This workshop gives users experience with generating a uniform mesh for both solids and shells with a specific number of element divisions on curved geometry.

Workshop 8.1 – Drop Test

In this workshop we perform a drop test simulation in which we drop a mobile phone from a height of 1.5 meters.

Workshop 8.2 – Bird Strike

In this workshop an impact simulation is performed in order to study the effect of a bird strike on an aircraft wing section. The bird is modeled using Smooth Particle Hydrodynamics (SPH).

This workshop gives the user some experience with using multiple rosettes, multiple oriented selection sets, and tapering of core materials to define complex composite layups.

In this workshop users will learn how to use selection rules to modify the composite layup of a class 40 boat in order to increase its reserve against failure.

This workshop continues Workshop 1 – Basic Sandwich Panel. The layup is modified and reinforced in order to increase the panel’s strength, and the mesh is refined in order to obtain more accurate results. Selection rules and tapers are employed in order to create a desired layup. 

In this workshop, users will generate and evaluate a composite model of a doubly-curved tensile test specimen. This model will use solid elements instead of shell elements in order to accurately capture stress distributions in thick geometry where plane stress assumptions do not apply.

This workshop demonstrates the use of cut-off rules for ply tapering. It also goes through the procedure of applying a resin material to wedge elements that represent the tapered section where a ply starts or ends in a solid composite model.

This workshop will take users through the complete process of modeling, solving, and post-processing a composite model. Solid geometry will be used to generate a variable core thickness in a complex pattern.

The boat model from Workshop 3 will be used to practice with a variety of post-processing tools, including sampling points to obtain through-thickness results.

This workshop will use Workbench parameters to modify the laminate of a composite part. Multiple designs will be evaluated in order to identify which design has the best performance in terms of several composite failure modes.

This workshop is nearly identical to the previous workshop with the difference being that the fast solution method is used instead of the full method. This method assumes a uniform temperature distribution and applies to relatively thin (less than 5 mm) composite structures.

In this workshop users will build on what they learned in the previous workshops to not only predict the composite curing process induced distortions but also compensate for them in the tooling geometry to produce a composite structure that meets the original design specifications. Attendees will also learn how to simulate post-cure trimming operations.