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Cad CFD Lab Manual PDF

The document provides an overview of CAD/CAM software and discusses the significance of 2D drafting, 3D geometric modeling, finite element analysis, and computer aided manufacturing. It then describes specific 3D CAD software programs like CATIA and PTC Creo Parametric, highlighting their key features and benefits for designing and modeling components.

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0% found this document useful (0 votes)

334 views

Cad CFD Lab Manual PDF

Uploaded by

sumanth

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 77

PRAGATI ENGINEERING COLLEGE (A)

(Approved by AICTE, Permanently Affiliated to JNTUK Kakinada & Accredited by NAAC „A‟ Grade)
1-378, ADB Road, Surampalem – 533 437, Near Peddapuram, E.G.Dist., A.P.
Ph.: (08852) – 252233, 252234, 252235 Fax: (08852) – 252232
DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO CAD/CAM & 2D, 3D MODELING SOFTWARE

CAD/CAM involves the use of computers in the design and manufacture of a
component, product or system. In general design involves the functions like conceptual
designing, modifying an existing design, drafting, 3D geometric modeling, static/dynamic
analysis, optimization etc., And controlling the manufacturing plan to operations. A CAD work
station consists of software and the supporting hardware to enable a cad engineer to carry out the
aforesaid functions.

A design firm may adopt CAD/CAM for the following reasons,

1. To increase the productivity.

2. To improve the quality and quantity.

3. To improve communications.

4. To achieve cost effectiveness.

SIGNIFICANCE OF COMPUTER AIDED 2-D DRAFTING:

Computer aided 2D drafting has the following advantages over manual drafting.

 Saves time, effort and cost in the following operations,

 Modifying an existing drawing.
 Transportability.
 Enables reliable,
 Storage and backup of drawings.
 Quality of drawings due to lesser dependability on operator skill.
 Provides flexibility in,
 Viewing features of a drawing through layers.
 Reusability of certain portions of drawing and usage of standard libraries.

SIGNIFICANCE OF 3-D GEOMETRIC MODELING:

Computer aided 3D geometric modeling has the following advantages over computer
aided 2D drafting.

CAD/CFD LAB Page 1

PRAGATI ENGINEERING COLLEGE (A)
(Approved by AICTE, Permanently Affiliated to JNTUK Kakinada & Accredited by NAAC „A‟ Grade)
1-378, ADB Road, Surampalem – 533 437, Near Peddapuram, E.G.Dist., A.P.
Ph.: (08852) – 252233, 252234, 252235 Fax: (08852) – 252232
DEPARTMENT OF MECHANICAL ENGINEERING

1. Aids in better visualization of components parts, assemblies etc…

2. Feature based and parametric modeling utilities simplify the process of modifying a
model.
3. Utilities like interference checking, intelligence and associativity helps in modeling
assemblies.
4. Ease of creating/editing conceptual designs.
5. Reusability of some 3D geometric model for performing various failure analyses,
optimization etc…And generating production drawings.
6. Minimizes errors in production drawings as all the views are generated from the same
3D model.

SIGNIFICANCE OF COMPUTER AIDED FINITE ELEMENT ANALYSES (FEA):

Finite element analyses help in

 Performing failure analyses.

 Optimizing the design.
 Simulating Experimental tests that are constrained by practical Implications.

SIGNIFICANCE OF COMPUTER AIDED MANUFACTURING (CAM):

Computer aided in manufacturing software helps in

 Generation of CNC programs for machining the components.

 Simulation of machining process for verifying CNC programs.
 Necessary for Computer Integrated manufacturing.

3D CAD:

Three dimensional (3D) CAD programs come in a wide variety of types, intended for
different applications and levels of detail, overall,3D CAD programs to create a realistic model
of what the design project will look like allowing designers to solve potential problems earlier
and with lower production costs. Some 3D CAD programs include Autodesk Inventor, Co create
solid Designer, Pro/engineer, Solid Edge, Solid works, Uni-graphics NX and VX ,CAD,CATIA.

CAD/CFD LAB Page 2

CATIA enables the creation of 3D parts, from 3D sketches, sheet metal, composites,
molded, forged or tooling parts up to the definition of mechanical assemblies. The software
provides advanced technologies for mechanical surfacing. It provides tools to complete product
definition, including functional tolerances as well as kinematics definition. CATIA provides a
wide range of applications for tooling design, for both generic tooling and mold & die

Customer requirements may change and time pressures may continue to mount ,but your
product design needs remain the same regardless of your projects scope, you need the powerful,
easy to use, affordable solution that pro/engineer provides.

CATIA Benefits:

 Unsurpassed geometry creation capabilities allow superior product differentiation and

manufacturability
 A shared environment for the entirety of the system
 Perfect compatibility without data conversions
 Design modification immediately propagated down to the shop floor
 Integrated development and manufacturing cycles
 ISO code simulation
 High level of automation and standardisation
 Dramatically improve machining quality
 Increase collaboration amongst teams and disciplines
 Enhance workload management of your machine tools
 Promote automation and standardisation throughout your organisation
 Reduce programming, polishing, production cycle and product modification running
times
 Decrease product development costs

CATIA can be packaged in different versions to suit your needs from Dassault systems.
From robust part modeling to advanced surfing, powerful assembly, modeling and simulation,
your needs will be met with this scalable solution. CATIA consists of modules each Module
specialized in specific design field,the main modules are

CAD/CFD LAB Page 3

 Part Design: Design parts using a solid modeling approach

 Sketcher: Create 2D profiles with associated constraints, which is then used to create
other 3D geometry.
 Assembly Design: Assemble parts together with constraints
 Drafting: Create drawings from parts or assemblies
 Generative Shape Design: Design parts using a surface modeling approach

CATIA features:

All relevant:

In CATIA for all the modules are all related. This means that the product development process
in a particular modification can be extended to the whole design, the sometime, automatically
update all the project documentation, including assembly, design drawings, and manufacturing
data. Encourage all relevant at any point in the development cycle to modify without any loss.
Making it possible for concurrent engineering, it can make some of the features developed later
to plat its role in advance.

Feature based parametric modeling:

CATIA is user familiar with the characteristics of the structure as a geometric model of product
elements these features are common mechanical objects and can be easily pre-set to be
modified.

Data management:

Accelerating market need in short period of time to develop more products. To

achieve such efficiency, multi-disciplinary engineers must be allowed the same time develop the
same product. The developed data management module is designed to manage concurrent fields
easily.

Assembly management:

In CATIA the basic structure can be formed using some tools such as “engagement”, ”insert”,
”align” and so very easy to assemble parts together, while maintaining the design intent.

CAD/CFD LAB Page 4

Advanced features to support the construction of large and complex assembly and management
of these assembly unlimited number of parts.

Easy to use:

Menu is designed for the joint level appears to provide a logical option and pre-selected
the most common option, but also provides a brief description and a complete menu of online
help, this form alloys easy to learn and use.

Introduction to PTC Creo Parametric 3.0

Learning Objectives
• Understand the advantages of using PTC Creo Parametric.

• Know the system requirements of PTC Creo Parametric.

• Get familiar with important terms and definitions in PTC Creo Parametric.

• Understand important options in the File menu.

• Understand the importance of Model Tree.

• Understand the functions of mouse buttons.

• Use the options of default toolbars.

• Customize the Ribbon.

• Understand the functions of browser.

• Understand the use of Appearance Gallery.

• Render stages in PTC Creo Parametric.

• Change the color scheme of the background in PTC Creo Parametric.

Welcome to PTC Creo Parametric. If you are a new user of PTC Creo Parametric
software, you are going to join hands with thousands of users of this high-end CAD/CAM/CAE
tool worldwide. If you are a user of the previous releases of this software, you are going to
upgrade your designing skills because of the tremendous improvement in this latest release such
as flexible modeling, freestyle modeling, and so on. Also, the interface of PTC Creo Parametric

CAD/CFD LAB Page 5

is very user friendly. You will find a tremendous reduction in the time taken to complete a
design using this solid modeling tool.

PTC Creo Parametric is a powerful software used to create complex designs with great
precision. The design intent of a three-dimensional (3D) model or an assembly is defined by its
specification and its use. You can use the powerful tools of PTC Creo Parametric to capture the
design intent of a complex model by incorporating intelligence into the design. Once you
understand the feature-based, associative, and parametric nature of PTC Creo Parametric, you
can appreciate its power as a solid modeling tool. To make the designing process simple and
quick, the designing process have been divided into different modules in this software package.
This means each step of the designing is completed in a different module. For example,
generally a design process consists of the following steps:

• Sketching using the basic sketch entities

• Converting the sketch into features and parts

• Assembling different parts and analyzing them

• Documenting parts and the assembly in terms of drawing views

• Manufacturing the final part and assembly

All these steps are divided into different modes of PTC Creo Parametric namely, the Sketch
mode, Part mode, Assembly mode, Drawing mode, and Manufacturing mode.

Despite making various modifications in a design, the parametric nature of this software
helps preserve the design intent of a model with tremendous ease. PTC Creo Parametric allows
you to work in a 3D environment and calculates the mass properties directly from the created
geometry. You can also switch to various display modes like wireframe, shaded, hidden, and no
hidden at any time with ease as it does not affect the model but only changes its appearance.

CAD/CFD LAB Page 6

Features of PTC Creo Parametric:

Different features of the software are discussed next.
Feature-Based Nature:
PTC Creo Parametric is a feature-based solid modeling tool. A feature is defined as the smallest
building block and a solid model created in PTC Creo Parametric is an integration of a number
of these building blocks. Each feature can be edited individually to bring in the desired change
in the solid model. The use of feature-based property provides greater flexibility to the parts
created. For example, consider the part shown in Figure 1-1. It consists of one counter bore hole
at the center and six counter bore holes around the Bolt Circle Diameter (BCD).

Now, consider a case where you need to change all the outer counter bore holes to drill holes
keeping the central counter bore hole and the BCD for the outer holes same. Also, you need to
change the number of holes from six to eight. In a non feature-based software package, you will
have to delete the entire part and then create a new part based on the new specifications.
Whereas, PTC Creo Parametric allows you to make this modification by just modifying some
values in the same part, see Figure 1-2. This shows that the solid parts created in PTC Creo
Parametric are a combination of various features that can be modified individually at any time.

ure 1-1 Model displaying the counter bore holes Figure 1-2 Model after making the
modifications
Bidirectional Associative Property:
There is bidirectional associatively between all modes of PTC Creo Parametric. The
bidirectional associative nature of a software package is defined as its ability to ensure that if
any modifications are made in a particular model in one mode, then those modifications are also

CAD/CFD LAB Page 7

reflected in the same model in other modes. For example, if you make any change in a model in
the Part mode and regenerate it, the changes will also be highlighted in the Assembly mode.
Similarly, if you make a change in a part in the Assembly mode, after regeneration, the change
will also be highlighted in the Part mode. This bidirectional associativity also correlates the
two-dimensional (2D) drawing views generated in the Drawing mode and the solid model
created in the Part mode of PTC Creo Parametric. This means that if you modify the
dimensions of the 2D drawing views in the Drawing mode, the change will be automatically
reflected in the solid model and also in the assembly after regeneration. Likewise, if you modify
the solid model in the Part mode, the changes will also be seen in the 2D drawing views of that
model in the Drawing mode. Thus, bidirectional associativity means that if a modification is
made to one mode, it changes the output of all the other modes related to the model. This
bidirectional associative nature relates various modes in PTC Creo Parametric.
Figure 1-3 shows the drawing views of the part shown in Figure 1-1 generated in the Drawing
mode. The views show that the part consists of a counter bore hole at the center and six counter
bore holes around it

Figure 1-3 Drawing views of the model before modifications

CAD/CFD LAB Page 8

Now, when the part is modified in the Part mode, the modifications are automatically reflected
in the Drawing mode, as shown in Figure 1-4. The views in this figure show that all outer
counter bore holes are converted into drilled holes and the number of holes is increased from six
to eight.

Figure 1-4 Drawing views of the model after modifications

Figure 1-5 shows the Crosshead assembly. It is clear from the assembly that the diameter of the
hole is more than what is required (shown using dotted lines). In an ideal case, the diameter of
the hole should be equal to the diameter of the bolt.

Figure 1-5 Crosshead assembly illustrating difference in diameter of the hole and the bolt

CAD/CFD LAB Page 9

The diameter of the hole can be changed easily by opening the file in the Part mode and making
the necessary modifications in the part. This modification is reflected in the assembly, as shown
in Figure 1-6. This is due to the bidirectional associative nature of PTC Creo Parametric.
Since all modes of PTC Creo Parametric are interrelated, it becomes very easy to modify your
model at any time.

Parametric Nature:
PTC Creo Parametric is parametric in nature, which means that the features of a part
become interrelated if they are drawn by taking the reference of each other. You can redefine the
dimensions or the attributes of a feature at any time. The changes will propagate automatically
throughout the model. Thus, they develop a relationship among themselves.

This relationship is known as the parent-child relationship. So if you want to change the
placement of the child feature, you can make alterations in the dimensions of the references and
hence change the design as per your requirement. The parent-child relationship will be discussed
in detail while discussing the datums in later chapters.

Figure 1-6 Assembly after modifying the diameter of the hole

CAD/CFD LAB Page 10

Getting Started With PTC Creo Parametric:

Install the PTC Creo Parametric on your system; the shortcut icon of PTC Creo Parametric will
automatically be created on the desktop. You can start it by double-clicking on its shortcut icon
on the desktop.
You can also start it by choosing the Start button at the lower left corner of the screen and then
choose
All Programs > PTC Creo > PTC Creo Parametric 3.0, if you are using Windows 7.

Figure 1-7 shows the initial screen that appears when you start PTC Creo Parametric.

Figure 1-7 Initial screen appearance after starting Creo Parametric

Important terms and definitions:

Some important terms that will be used in this book while working with PTC Creo Parametric
are discussed next.

Entity:
An element of the section geometry is called an entity. The entity can be an arc, line, circle,
point, conic, coordinate system, and so on. When one entity is divided at a point, then the total
number of entities are said to be two.

CAD/CFD LAB Page 11

Dimension:

It is the measurement of one or more entities.

Constraint:
Constraints are logical operations that are performed on the selected geometry to make it
more accurate in defining its position and size with respect to the other geometry.
Parameter:
It is defined as a numeric value or a word that defines a feature. For example, all
dimensions in a sketch are parameters. The parameters can be modified at any time.
Relation:
A relation is an equation that relates two entities.

Weak Dimensions and Weak Constraints:

Weak dimensions and weak constraints are temporary dimensions or constraints that
appear in light blue color. These are automatically applied to the sketch. They are removed from
the sketch without any confirmation from the user. The weak dimensions or the weak constraints
should be changed to strong dimensions or constraints if they seem to be useful for the sketch.
This only saves an extra step of dimensioning the sketch or applying constraints to it.

Strong Dimensions and Strong Constraints:

Strong dimensions and strong constraints appear in dark blue color. These dimensions
and constraints are not removed automatically. All dimensions added manually to a sketch are
strong dimensions.

File menu options:

The options that are displayed when you choose File from the menu bar are discussed
next.

Select Working Directory:

A working directory is a directory on your system where you can save the work done in
the current session of PTC Creo Parametric. You can set any directory existing on your system
as the working directory. Before starting the work in PTC Creo Parametric, it is important to

CAD/CFD LAB Page 12

specify the working directory. If the working directory is not selected before saving an object
file, then the object file will be saved in a default directory. This default directory is set at the
time of installing PTC Creo Parametric. If the working directory is selected before saving the
object files that you create, it becomes easy to organize them. In PTC Creo Parametric, the
working directory can be set in the following two ways:

Using the Navigator:

When you start a PTC Creo Parametric session, the navigator is displayed on the left of
the drawing area. This navigator can be used to select a folder and set it as the working
directory.

To do so, click on the Folder Tree node displayed at the bottom of the navigator; the expanded
Folder Tree area will be displayed. Browse to the required location using the nodes available
next to the folders and then select the desired folder. The selected folder will become the
working directory for the current session. Alternatively, right-click on the folder that you need to
set as the working directory; a shortcut menu will be displayed, as shown in Figure 1-8. Choose
the Set Working Directory option from this shortcut menu to set the

Selected folder as the working directory. To make a new folder, Figure 1-8 Shortcut menu
choose the New Folder option from the shortcut menu.

Using the Select Working Directory Dialog Box:

To specify a working directory, choose File > Manage Session > Select Working Directory
from the menu bar; the Select Working Directory dialog box will be displayed, as shown in

CAD/CFD LAB Page 13

Figure 1-9. Using this dialog box, you can set any directory as the working directory.

Figure 1-9 The Select Working Directory dialog box

Choose the arrow at the upper left corner of the Select

Working Directory dialog box; a flyout will be
displayed, as shown in Figure 1-10. This flyout displays
some of the drives present on your computer along with
the Favorites folder. The Favorites folder contains all
directories that you saved as
favorites. The procedure to save the favorite Figure 1-10 The flyout displayed directories
will be discussed later. When the Select
Working Directory dialog box is invoked by default, it displays the contents of the default
directory. However, you can change the default directory that appears every time you open this
dialog box. Various options in the Select Working Directory dialog box are discussed next.
File name:
The File name edit box displays the name of the directory selected in the Select
Working Directory dialog box. You can select a directory using the flyout, as discussed

CAD/CFD LAB Page 14

earlier or by entering the path of any existing directory in this edit box.
Type:
The Type drop-down list has two options, Directories and All Files (*). If you select the
Directories option, all directories present get listed, and if you select the All Files (*) option, then all
files along with the directories are listed in the dialog box.
Organize:
When you choose the Organize button from the Select Working Directory dialog box,
a flyout will be displayed. The options in this flyout are used to create a new directory or rename
an existing directory. You can also cut, copy, paste, and delete the existing folders using the
options in the flyout. Moreover, you can add any existing folder in the Common Folders by
using the Add to common folders option in this flyout, refer to Figure 1-11.

Figure 1-11 The Organize flyout

Views:
When you choose the Views button from the Select Working Directory dialog box, a flyout
will be displayed. The options in this flyout are discussed next.
List: The List radio button is used to view the contents of the current folder or drive. These
include files and folders in the form of a list.

Details: The Details radio button is used to view the contents of the current folder or drive in the
form of a table, which displays the name, size, and date on which it was last modified.

CAD/CFD LAB Page 15

Tools
When you choose the Tools button from the Select Working Directory dialog box, a flyout
will be displayed, as shown in Figure 1-12. The options in this flyout are discussed next.

Figure 1-12 The Tools flyout

Address Default: When you choose this option, the ‘Look In’ Default dialog box will be
displayed. Figure 1-13 shows this dialog box with the options in the drop-down list. If you
select the Default option from the drop-down list and then invoke the File Open dialog box,
it will display the directory that is set as default. If you select the Working Directory option
from the drop-down list and then invoke the File Open dialog box, it will display the
working directory that is set. If you select the In Session option and then invoke the File
Open dialog box, the File Open dialog box will open with the In Session folder selected by
default. Similarly, you can set the

CAD/CFD LAB Page 16

Exp.No: Date:

SCREW JACK BY 2D DRAFTING

AIM: To model the components of screw jack by using CATIA V5/PTC Creo Parametric 3.0
software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

Screw jacks are used for raising heavy loads through very small heights. In this, the
screw 3 works in the nut 2 which is press fitted into the main body 1. The Tommy bar 7 is
inserted into a hole through the enlarged head of the screw and when this is turned, the screw
will move up or down, thereby raising or lowering the load.

TOOLS USED:

 Circle
 Extrude
 Revolve
 Line
 Array
 Fillet
 Arc
 Offset

RESULT

CAD/CFD LAB Page 17

Exp.No: Date:

STUFFING BOX BY 2D DRAFTING

AIM: To model the components of stuffing Box by using CATIA V5/PTC Creo Parametric 3.0
software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

It is used to prevent loss of fluid such as steam, between sliding and turning parts of
machine elements. In a steam engine, when the piston rod reciprocates through the cylinder
cover; stuffing box provided in the cylinder cover, prevents leakage of steam from the cylinder.
Figure shows the various parts of a stuffing box. At the base of stuffing box body 1, a
Bush 3 is placed such that the beveled edge of the bush is at the inner side of the body. Gland 2
is placed at the other end of the body and is connected to the main body by means of studs 4 and
nuts5. The space between the reciprocating rod and the bush and the gland is packed with a
packing material such as mineral fibers, leather, rubber or cork.
COMMANDS USED:

 Circle
 Extrude
 Rectangle
 Ellipse
 Offset

RESULT

CAD/CFD LAB Page 18

Exp.No: Date:

SCREW JACK BY 3D MODELING

AIM: To model and assemble the components of screw jack by using CATIA V5/PTC Creo
Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

TOOLS USED:

 Circle
 Extrude
 Revolve
 Line
 Rectangle
 Trim
 Fillet
 Arc
 Offset

RESULT:

CAD/CFD LAB Page 19

Exp.No: Date:

REVOLVING CENTER BY 3D MODELING

AIM: To model and assemble the components of Revolving Centre by CATIA V5/PTC Creo
Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

When long bars are machined on a lathe, they are supported on two centers. One of
which is Called a live centre and the other, a dead centre, fixed in the tail-stock. The live centre
fits into the main spindle and revolves with the work it supports. Because of the relative motion
between the work piece and the dead centre in the tail-stock barrel, over-heating and wear of the
centre takes place in the long run. To eliminate this, the dead centre is replaced with a live or
anti-friction bearing centre, which revolves with the work like a live centre.
Figure shows the details of a revolving centre using antifriction bearings. The radial
Bearing 6 and thrust bearing 7 used in the design are meant for resisting the possible radial and
axial loads respectively. The sleeve 4 is press fitted in the barrel 1 to provide end support to the
centre 3. The sleeve is positioned in the barrel by the cover 5. Another cover 2 is fixed on the
front side of the barrel by means of the screws 8 to retain the radial bearing in position.
TOOLS USED:

 Circle
 Fillet
 Revolve
 Line
 Rectangle
 Chamfer
 Arc
 Offset

CAD/CFD LAB Page 20

RESULT:

CAD/CFD LAB Page 21

Exp.No: Date:

PLUMMER BLOCK BY 3D MODELING

AIM: To model and assemble the components of Plummer Block by using CATIA V5/PTC
Creo Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

This bearing is used for long shafts, requiring intermediate support, especially when the
shaft cannot be introduced into the bearing, end-wise. The bottom half 2 of the bearing brass is
placed in the base 1 such that, the snug of the bearing enters into the corresponding recess in the
base; preventing rotation of the brasses. After placing the journal (shaft) on the bottom half of
the bearing brass, kept in the base; the upper half of the bearing brass 3 is placed and the cap 4 is
then fixed to the base, by means of two bolts with nuts 5. The bearing is made of two halves so
that the support can be introduced at any location of the long shaft.
TOOLS USED:
 Circle
 Extrude
 Rectangle
 Trim
 Revolve
 Line
 hexagon
 Fillet
 Arc
 Offset
RESULT:

CAD/CFD LAB Page 22

Exp.No: Date:

PISTON BY 3D MODELING

AIM: To model and assemble the components of Piston of petrol engine by using CATIA
V5/PTC Creo Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

A piston is cylindrical in form and reciprocates in a cylinder. The petrol engine piston is
generally die-cast in aluminum alloy. It is connected to the small end of the connecting rod by
means of a gudgeon pin. Figure shows the details of the petrol engine piston assembly.
Five piston rings 4 are positioned in the piston 1; four at the top and one at the bottom. The top
piston rings, known as compression rings, prevent leakage of gases from combustion chamber
into the crank case. The bottom one; oil or scraper ring, prevents the lubricating oil from
entering the combustion chamber.
The piston is connected to the small end of the connecting rod, by means of the gudgeon
or piston pin 2; the axial movement of which is prevented by piston plugs 3.
TOOLS USED:

 Circle
 Extrude
 Revolve
 Line
 Sweep
 Trim
 Chamfer
 Fillet
 Arc

CAD/CFD LAB Page 23

 Rectangle

RESULT:

CAD/CFD LAB Page 24

Exp.No: Date:

KNUCKLE JOINT BY 3D MODELING

AIM: To model and assemble the components of Knuckle joint by using CATIA V5/PTC Creo
Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:

This is a pin joint and is used to connect two circular rods subjected to axial loads.
Compared to a socket and spigot joint, wherein the axes of both the rods should be in the same
plane; in the knuckle joint, one of the rods can be swiveled through some angle about the
connecting pin, i.e., the axes of the two rods could be inclined to each other.
The eye end of the rod 2 is inserted into the fork end 1 of the other rod. Then, pin 3 is
inserted through the holes in the ends of the rods and held in position by the collar 4 and taper
pin 5.

TOOLS USED:

 Circle
 Extrude
 Revolve
 Line
 Curve
 Hexagon
 Arc
 Offset

RESULT:

CAD/CFD LAB Page 25

Exp.No: Date:

ECCENTRIC BY 3D MODELING

AIM: To model and assemble the components of Eccentric by using CATIA V5/PTC Creo
Parametric 3.0 software.

TECHNICAL REQUIREMENTS:

 P.C.
 CATIA V5/ PTC Creo Parametric 3.0 Software.

DESCRIPTION:
It is used to provide a short reciprocating motion, actuated by the rotation of a shaft.
Eccentrics are used for operating steam valves, small pump plungers, shaking screens, etc. The
components of an eccentric are shown in isometric views for easy understanding of their shapes.
Rotary motion can be converted into a reciprocating motion with an eccentric, but the reverse
conversion is not possible due to excessive friction between the sheave and the strap. The crank
arrangement, in a slider crank mechanism however, allows conversion in either direction.

The sheave 2 which is in the form of a circular disc with a stepped rim is keyed on the
shaft. When the shaft rotates, the sheave rotates eccentrically because of the eccentrically placed
hole in it and imparts reciprocating motion to eccentric rod 6. The straps 1 are semi-circular
elements with an annular recess to accommodate the stepped rim of the sheave. These are held
together on the sheave by means of strap bolts 4, with packing strips 3 placed between them.
The eccentric rod is fixed to the eccentric strap by means of the studs and nuts 5.

TOOLS USED:

 Circle
 Extrude
 Revolve
 Line
 Array

CAD/CFD LAB Page 26

 Fillet
 Arc
 Offset

RESULT:

CAD/CFD LAB Page 27

INTRODUCTION TO FINITE ELEMENT ANALYSIS AND ANSYS

The basic idea in the finite element method is to find the solution of a complicated
problem by replacing it with a simpler one. Since the actual problem is replaced by a simpler
one in finding the solution, we will be able to find only an approximate solution rather than the
exact solution. The existing mathematical tools will not be sufficient to find the exact solution
(and sometimes, even an approximate solution) of most of the practical problems. Thus in the
absence of any other convenient method to find even the approximate solution of a given
problem, we have to prefer the finite element method. Moreover, in the finite element method, it
will often be possible to improve or refine the approximate solution by spending more
computational effort. In finite element method, the continuum (solution region) is considered as
built up of many small, interconnected sub regions called finite elements.

BRIEF HISTORY OF FE METHOD

In 1943 paper, the mathematician Courant described a piecewise polynomial solution for
the torsion problem. His work was not noticed by engineers and the procedure was impractical
at that time due to lack of digital computers. In the 1950s, work in the aircraft industry
introduced the FE method to practicing engineers. A classic papers described FE work that was
prompted by a need to analyze delta wings, which are too short for beam theory to be reliable.
The name “finite element” was coined in 1960. By 1963 the mathematical validity of the FE
method was recognized and the method was expanded from its structural beginnings to include
heat transfer, magnetic fields and other areas. Large general purpose FE software began to
appear in 1970s. By late 1980s the software was available on microcomputers, complete with
color graphics and pre and postprocessors.

GENERAL PROCEDURE OF THE FINITE ELEMENT METHOD

In the finite element method, the actual continuum or body is represented as an

assemblage of subdivisions called finite elements. These elements are considered to be
interconnected at specified joints called nodes or nodal points. The nodes usually lie on the
element boundaries where adjacent elements are considered to be connected. Since the actual
variation of the field variable (like displacement, stress, temperature, pressure or velocity) inside
the continuum is not known, the variation of the field variable inside a finite element can be

CAD/CFD LAB Page 28

approximated by a simple function. The field equations (like equilibrium equations) for the
whole continuum are written the new unknowns will be the nodal values of the field variable.
By solving the field equations, which are generally in the form of matrix equations, the nodal
values of the field variable will be known.

STEP-BY-STEP PROCESS OF FEM:

DISCRETIZATION OF THE STRUCTURE

The first step in the finite element method is to divide the structure into subdivisions or
elements. This requires the structure to be modeled with suitable elements.

SELECTION OF A PROPER INTERPOLATION OR DISPLACEMENT MODEL

As the displacement solution of a complex structure under any specified load conditions
is not exact, it is assumed to some suitable solution within an element to approximate the
unknown solution.

DERIVATION OF ELEMENT STIFFNESS MATRICES AND LOAD VECTORS

The stiffness matrix and the load vector of element are derived for the assumed
displacement model by using equilibrium conditions.

ASSEMBLAGE OF ELEMENT EQUATIONS

Since the structure is composed of several finite elements, the individual element
stiffness matrices and load vectors are to be assembled in suitable manner.

[ K ]  P

Where K is assembled stiffness matrix, ø is nodal displacements vector, P nodal forces

vector.

SOLUTION OF NODAL DISPLACEMENTS

The overall equilibrium equations have to be modified to account for the boundary
conditions of the problem. After the applying the boundary conditions, the equilibrium equations
can be expressed as

[K]ø=P

CAD/CFD LAB Page 29

For linear problems, the vector ø can be solved easily, but for nonlinear sequence of steps are
required for solving [K]and P.

COMPUTATION OF ELEMENT STRESSES AND STRAINS

From the known nodal displacements ø, required element strains and stresses can be
computed by using necessary equations or structural mechanics.

ELEMENT SHAPE

Most finite elements are geometrically simple to meet the fundamental premise of finite
element method that a continuum of arbitrary shape can be accurately modeled by and
assemblage of elements. This fundamental premise also implies that element dimensionality is
the same as the continuum dimensionality.

ONE DIMENSIONAL ELEMENT

In one-dimensional element, there is one independent variable and elements are line
segments, as shown in below figure. The number of nodes per elements depends on the nodal
variable (degrees of freedom) and the continuity requirements between the elements.

TWO DIMENSIONAL ELEMENTS

Historically, triangular elements were developed first because they were easy to develop
and formulate by hand. The three-node flat triangular element is the simplest two-dimensional
element. The ten-node triangular element has nine nodes on its boundary (called exterior nodes)
and one node inside the boundary (called interior node). A quadrilateral element has a minimum
of four nodes and as many as twelve nodes. In addition to modeling plane stress and strain
problems, two-dimensional elements can be used to model axi-symmetric problems. In this case,
an element represents the cross section of an axi-symmetric element whose thickness is given by
the length of its arc segment. In general, two-dimensional elements can model two- and two-and
half-dimensional objects (continuum).

THREE DIMENSIONAL ELEMENTS

Three-dimensional elements are usually three-dimensional counterparts of two-

dimensional elements. These elements can be used to discretize three-dimensional objects

CAD/CFD LAB Page 30

(continuums). Creating (and visualizing) three dimensional finite element meshes is usually
labor-intensive and an error-prone process. Thus, using preprocessors and automatic mesh
generation algorithms are beneficial in discretizing three-dimensional objects.

The exterior node of any element can be divided into two types: corner and mid side
nodes. Corner nodes are the minimum required nodes to define the element shape and, as the
name implies, are located at the corners of the element. Mid-side nodes are added to improve the
elements; they are located along the sides of the element.

BASIC GOVERNING EQUATION IN FEM

Large size problems handled by modern digital computers connected with the static and
dynamic linear analysis of complicated machines or structures are generally of the form.

[M ]{U}[C ]{U } [ K ]{U } { f (t )}

Where [M] Represents the global mass matrix
[C] Represents the global damping matrix.
[K] Represents the global stiffness matrix.
f(t) Represents force function vector in time.
{U} Represents the nodal acceleration vector.

{U } Represents the nodal velocity vector.

{U } Represents the nodal displacement vector.

Case 1 When [M] and [C] are absent, [K] and f(t) are constants ,the result is a static linear
problem.
Case 2 When [M] and [C] are absent, [K] is a function of U and f(t)is constant ,the result is a
non-linear problem.
Case 3 When f(t) and[C] are absent ,[M] and [K] are constants, one gets an eigen value
problem.
Case 4 When [M], [C], [K] are constants and {f(t)} is a periodic forcing function, the result is
multi degrees of freedom steady state vibration problem.
Case 5 When [M], [C], [K] are constants and {f(t)} is a transient function of time, the result is
a transient vibration problem.

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IMPLEMENTATION OF FE SOFTWARE

The theory of FE includes matrix manipulations, numerical integration, equation solving,

and other procedures carried out automatically by commercial software. FE analysis involves
three stages of activity, they are preprocessing, processing, post processing.

Preprocessing involves the preparation of data, such as nodal coordinates, connectivity,

boundary conditions, and loading and material information.

Processing stage involves stiffness generation, stiffness modification, and

solution of equations, resulting in the evaluation of nodal variables. Other derived quantities,
such as gradients or stresses, may be evaluated at this stage.

Post processing stage deals with the presentation of results. Typically, the deformed
configuration, mode shapes, temperature, and stress distribution are computed and displayed at
this stage. A complete finite element analysis is logical interaction of the three stages. The
preparation of data and post processing require considerable effort if all data are to be handled
manually. The tedium of handling the data and the possibility of errors creeping in as the
number of elements increase are discouraging factors for the finite element analyst.

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ANSYS

The ANSYS is a multipurpose computer program useful to solve Finite Element

problems that occur in several class of engineering analysis. ANSYS is capable of solving
different type of problems such as static and dynamic structural problems, steady state, transient
and heat transfer problems, mode frequency and buckling eigenvalue problems, static or time-
varying magnetic analysis, and various types of field and coupled-field applications. The
program contains many special features which allow non linearities or secondary effects to be
included in the solution, such as plasticity, large strain, hyper elasticity, creep, swelling, large
deflection, contact, stress stiffening, temperature dependency, material anisotropy and radiation.
Other special features are sub structuring, sub modeling, random vibration, free convection field
analysis, acoustics, magnetic, piezoelectric, coupled field analysis and design optimization have
been added to the program. These features contribute further making ANSYS a multi-purpose
analysis tool for varied engineering disciplines.

The ANSYS program has been in commercial use since 1970, and has been used
extensively in the aerospace, automotive, construction, electronic, energy services
manufacturing, nuclear, plastics, oil, and steel industries. In addition, many consulting firms and
hundreds of universities use ANSYS for their analysis in the above mentioned fields. A
graphical user interface is available throughout the program, to guide new users through the
learning process and provide more experienced users with multiple windows, pull down menus,
dialogue boxes, tool bars and on line documentation.

The ANSYS element library contains more than sixty elements for static and dynamic
analysis, over twenty for heat transfer analysis and includes numerous magnetic, field and
special purpose elements. This variety of elements allow the ANSYS program to analyse 2D and
3D frame structures piping systems, axi-symmetric 3D shells and non-linear problems including
contact (interfaces) and cables. The input data for an ANSYS analysis are prepared using pre-
processor. The general pre-processor contains powerful solid modeling and mesh generation
capabilities and is also used to define all other analysis input data viz. geometric properties like
real constants (cross section areas, Moments of inertia, stiffness values, etc.), material properties
(Young‟s modulus, Poison‟s ratio, etc.), constraints, loads, etc.. Parametric input, user files,
macros and extensive on-line documentation, graphics capabilities are available throughout the

CAD/CFD LAB Page 33

ANSYS program including isometric, perspective, section, edge and hidden line display of three
dimensional structures, X-Y graphs of output results and contours display of solution results.

The analysis results are reviewed using postprocessors, which have the ability to display
distorted geometry, stress and strain contours, flow field, safety factor contours, contours of
potential field results (thermal, electric, magnetic), vector field and to display more sharper and
time history graphs. The post processors can also be used for algebraic operations, database
manipulations, differentiation and integration of calculated results. Root-cum-square operations
can be performed on seismic modal results. Response spectra may be generated from dynamic
analysis results. Results from various loading modes may be combined for harmonically loaded
axi-symmetric structures.

ANSYS ANALYSIS STEPS

The ANSYS program has many finite element analysis capabilities raging from a simple,
linear, static analysis to a complex, non-linear, transient dynamic analysis. A typical ANSYS
analysis has three distinct steps.

 Build the model

 Apply loads and obtain the solution
 Review the results.
BUILDING A MODEL
This is the first step and is most time taking step than any other part of the analysis of
ANSYS. First, the Job name and analysis title are to be specified which follows element type,
element real constants, material properties and the model geometry to be defined by using PREP
7 pre-processor.

DEFINING THE JOB-NAME

The job name is a name that identifies the ANSYS job. The extension or suffix for the
files created on job name is “jobname.db”. The jobname becomes the first part of the name of all
files, the analysis creates.

DEFINING THE ANALYSIS TITLE

Utility menu> File> Change title

CAD/CFD LAB Page 34

This defines the title for the analysis. ANSYS then includes the defined title on all graphic
displays and on the solution output.

DEFINING UNITS
ANSYS program does not assume a system of units for analysis. Except in
magnetic field analysis, we can use any system of units so long as the same system is used for
all the data entered. Units must be consistent forall input data.

DEFINING ELEMENT TYPES

The ANSYS element library contains more than 100 different element types.
Each element type has a unique number and a prefix that identifies the element category such
as, BEAM 4, PLANE 77, SOLID 96, etc.
The element type determines the following things:
 The degree of freedom set (which in turn implies the discipline – structural,
thermal, magnetic, electric, quadrilateral, brick etc.)
 Whether the element lies in two-dimensional or three-dimensional space.by using
GUI (Graphic User Interface) path and the input to the element type can be
given as Main Menu>Pre-processor>Element Type> Add/Edit/Delete.
Here are the main element types which are present in element library of ANSYS

BEAM PIPE
COMBINATION PLANE
CONTACT SHELL
FLUID SOLID
HYPERELASTIC SOURCE
INFINITE SURFACE
LINK USER
MASS INTERFACE
MATRIX VISCOELASTIC (or Visco- plastic)

Table Element types present in ANSYS

CAD/CFD LAB Page 35

DEFINING ELEMENT REAL CONSTANTS

Element real constants are properties that depend on the element type, such as
cross-sectional properties of a beam element viz. area, moment of inertia, height, mass per unit
length, thickness etc., Not all element types require real constants, and different elements of the
same type may have different real constant values. Each set of real constants has a reference
number; and while defining the elements, the appropriate real constant reference number
has to be specified by using, Main menu> Pre-processor> Create> Elements> Element
attributes.

DEFINING MATERIAL PROPERTIES

Most element types require material properties. Depending on the application, material
properties can be classified as:

 Linear or non linear

 Isotropic, Orthotropic or anisotropic.
 Constant temperature or temperature-dependent.
As with element types and real constants, each set of material properties has a material
reference number. Within one analysis there may be multiple material property sets. ANSYS
identifies each set with a unique reference number. The material property sets can be stored as
material library files and can be reused in multiple analyses. Material properties can be defined
using the following procedure: Main menu > Pre-processor> Material props.

CREATING THE MODEL GEOMETRY

Once the material properties are defined, the next step in analysis is generating a finite
element model-nodes and elements-that adequately describe the model geometry. ANSYS offers
two methods to create the finite element model:
1. Solid modeling and
2. Direct generation.

With “Solid modeling”, the geometric shape of the model can be described, then
meshing the geometry with nodes and elements by using ANSYS program. With “Direct
generation”, the location of each node and the connectivity of each element can be defined

CAD/CFD LAB Page 36

manually. Several convenience operations viz. copying patterns of existing nodes and elements,
symmetry reflection, etc. are available.

APPLYING LOADS AND OBTAIN RESULTS

Defining the analysis type and analysis options, applying loads, specifying load steps
options, and initiating the finite element solution can be done by using SOLUTION processor.
PREP 7 pre-processor also can be used for applying loads.

DEFINING THE ANALYSIS TYPE AND ANALYSIS OPTIONS

Different analysis steps can be chosen based on the loading conditions and the response
to calculate. The important types of analyses that can be carried in ANSYS (the structural sub
part) are

o Static
o Harmonic
o Transient dynamic
o Modal
o Eigen buckling etc.,
Not all analysis types are valid for all disciplines. Analysis options allow to customize
the analysis type. Typical analysis options are the method of solution, stress stiffening on or off,
and Newton-Raphson option. To define the analysis type and analysis options, the equivalent
GUI path is: Main menu> Solution> Analysis type> New analysis. Once the analysis type and
analysis options are defined, the next step is to apply loads. Some structural analysis types
require other items to be defined first, such as master degrees of freedom and gap conditions.

APPLYING LOADS

Loads in the ANSYS program are divided into six categories:

o DOF constrains
o Forces
o Surface loads
o Body loads
o Inertia loads

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o Coupled – field Loads

Loads can be applied either on the solid model (key points, lines and areas) or on the
finite element model (nodes and elements). Two important load-relation terms are “Load step”
and “Sub step”. A Load step is simply a configuration of loads to obtain a solution. Load steps
are useful in dividing a transient load history curve into several segments. “Sub steps” are
incremental steps taken within a load step. These are used mainly for accuracy and convergence
purposes in transient and non-linear analysis. Sub steps are also known as time steps- steps taken
over a period of time. In transient analysis, time represents actual time, in seconds, minutes or
hours. In a static or steady-state analysis, time simply acts as a counter to identify load steps and
sub steps.

SPECIFYING LOAD STEPS OPTIONS

Load steps options are options that we change from load step to load step, such as
number of sub steps, time at the end of a load step, and output controls. Depending on type of
analysis, load steps options may or may not be required.

INITIATING THE SOLUTION

To initiate solution calculation, the following GUI path has to be chosen:
Main menu> Solution> Current LS (or) Main menu> Solution> Solution method (or) Main
menu> Solution> From LS files

ANSYS then calculates the results by taking model and loading information from the
data base. Results are written to the results file (Jobname.RST, Jobname.RTH, Jobname.RMG
or Jobname.RFL) and also to the data base. The only difference is that only one set of results can
reside in the data base at one time, which user can write all sets of results (for all sub steps) to
the results file.

REVIEW THE RESULTS

Once the solution has been calculated, we can use the ANSYS post-processors to review
the results. Two post processors are available:

POST1 (general post processor) and POST 26

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o POST 1, the general post processor, can be used to review results at one sub step (time
step) over the entire model or selected portion of the model. The GUI path is : Main
menu> General Postprocessor
The result displays, deformed shapes, and tabular listings to review and interpret the results
of the analysis. POST1 offers many other capabilities, including error estimation, load case
combinations, calculations among results date and path operations.

o POST 26, the time history post processor, can be used to review results at specific points
in the model over all time steps. The GUI path is: Main menu> Time History Post proc.
Results obtained give the graph plots of results data versus time (or frequency) and
tabular listings. Other POST 26 capabilities include arithmetic calculations and complex
algebra.

CAD/CFD LAB Page 39

Exp.No: Date:

TWO DIMENSIONAL TRUSSES

PROBLEM DESCRIPTION
Determine the nodal deflections, reaction forces, and stress for the truss system shown below
(E = 200GPa, A = 3250mm2).

A. PREPROCESSING: DEFINING THE PROBLEM

1. Enter Key points :
From the 'ANSYS Main Menu' select:
Preprocessor > Modeling > Create > Key points > In Active CS
Key point 1(0, 0)
Key point 2(1800, 3118)
Key point 3(3600, 0)
Key point 4(5400, 3118)
Key point 5(7200, 0)
Key point 6(9000, 3118)
Key point 7(10800, 0)
2. Form Lines
In the main menu select: Preprocessor > Modeling > Create > Lines > Lines > In Active
coord
3. Define the Type of Element
From the Preprocessor Menu, select: Element Type > Add/Edit/Delete
Click on the 'Add...' button
2D spar element is selected. Select the element shown and click 'OK'. 'Type 1 LINK1' in
the 'Element Types' window is highlighted.

CAD/CFD LAB Page 40

4. Define Geometric Properties

In the Preprocessor menu, select Real Constants > Add/Edit/Delete
Click Add... and select 'Type 1 LINK1' (actually it is already selected). Click on 'OK'.
Enter the cross-sectional area (3250mm)
5. Element Material Properties
In the 'Preprocessor' menu select Material Props > Material Models
Double click on Structural > Linear > Elastic > Isotropic
Give the properties of Steel. Enter the following field: EX 200000

6. Mesh Size
 In the Preprocessor menu select Meshing > Size Cntrls > ManualSize > Lines > All
Lines
 In the size 'NDIV' field, enter the desired number of divisions per line. For this example
we want only 1 division per line, therefore, enter '1' and then click 'OK'. Note that we
have not yet meshed the geometry; we have simply defined the element sizes.
7. Mesh
 In the 'Preprocessor' menu select Meshing > Mesh > Lines and click 'Pick All' in the
„Mesh Lines‟ Window.
 Plot Numbering
From the Utility Menu (top of screen) select PlotCtrls > Numbering...

B. SOLUTION PHASE: ASSIGNING LOADS AND SOLVING

1. Define Analysis Type
From the Solution Menu, select Analysis Type > New Analysis.
Ensure that 'Static' is selected; i.e. you are going to do a static analysis on the truss as
opposed to a dynamic analysis
2. Apply Constraints

 In the Solution menu, select Define Loads > Apply > Structural > Displacement > On
keypoints

 Select the left end of the bridge (Keypoint 1) by clicking on it in the Graphics Window
and click on OK' in the 'Apply U,ROT on KPs' window

 This location is fixed which means that all translational and rotational degrees of

CAD/CFD LAB Page 41

freedom (DOFs) are constrained. Therefore, select 'All DOF' by clicking on it and enter
'0' in the Value field and click 'OK'.

 Using the same method, apply the roller connection to the right end (UY constrained).
Note that more than one DOF constraint can be selected at a time in the "Apply U,ROT
on KPs" window. Therefore, you may need to 'deselect' the 'All DOF' option to select
just the 'UY' option.
3. Apply Loads

 As shown in the diagram, there are four downward loads of 280kN, 210kN, 280kN, and
360kN at key points 1, 3, 5, and 7 respectively

 Select Define Loads > Apply > Structural > Force/Moment > on Key points.

 Select the first Key point (left end of the truss) and click 'OK' in the
'Apply F/M on KPs' window.

 Select FY in the 'Direction of force/mom'. This indicate that we will be applying the load
in the 'y' direction

 Enter a value of -280000 in the 'Force/moment value' box and click 'OK'. Note that we
are using units of N here, this is consistent with the previous values input
4. Solving the System
In the 'Solution' menu select Solve > Current LS. This indicates that we desire the
solution under the current Load Step (LS).

C. POSTPROCESSING: VIEWING THE RESULTS

1. Hand Calculations
2. Results Using ANSYS
 Reaction forces
 From the Main Menu select General Postproc > List Results > Reaction Solu.
 Select 'All struc forc F' as shown above and click 'OK'
 Deformation
 In the General Postproc menu, select Plot Results > Deformed Shape. The following
window will appear.
 Select 'Def + undef edge' and click 'OK' to view both the deformed and the undeformed

CAD/CFD LAB Page 42

object
Observe the value of the maximum deflection in the upper left hand corner
(DMX=7.409). One should also observe that the constrained degrees of freedom appear
to have a deflection of 0 (as expected)
 Deflection
 From the 'General Postproc' menu select Plot results > Contour Plot > Nodal Solution.
The following window will appear.
 Select 'DOF solution' and 'USUM' as shown in the above window. Leave the other
selections as the default values. Click 'OK'.
 From the Utility Menu select Plot Controls > Style > Contours > Uniform Contours...
 The deflection can also be obtained as a list as shown below. General Postproc > List
Results > Nodal Solution select 'DOF Solution' and 'ALL DOFs' from the lists in the
'List Nodal Solution' window and click 'OK'. This means that we want to see a listing of
all degrees of freedom from the solution
 Note that all the degrees of freedom were constrained to zero at node 1, while UY was
constrained to zero at node 7.
 Axial Stress
 From the General Postprocessor menu select Element Table > Define Table
 Click on 'Add...'
 As shown above, enter 'SAXL' in the 'Lab' box. This specifies the name of the item you
are defining. Next, in the 'Item,Comp' boxes, select 'By sequence number' and 'LS,'.
Then enter 1 after LS, in the selection box
 Click on 'OK' and close the 'Element Table Data' window.
 Plot the Stresses by selecting Element Table > Plot Elem Table
 Ensure that 'SAXL' is selected and click 'OK'
 Utility Menu > PlotCtrls > Style > Contours > Uniform Contours ...
 From the 'List Element Table Data' window which appears ensure 'SAXL' is highlighted
Click 'OK'

CAD/CFD LAB Page 43

Exp.No: Date:

ANALYSIS OF A 3-D TRUSS STRUCTURE

PROBLEM DESCRIPTION
The cross sections of each of the truss members are 1.56e-3 sq meter. Assume the structure is
made of aluminum with modulus of elasticity E=75 GPa. The structure is constrained in the X,
Y and Z directions at the bottom three corners. The tower is loaded at the top tip. The load is in
the YZ plane and makes an angle of 75 with the negative Y axis direction. The load value is
2500 N.

CAD/CFD LAB Page 44

A.
1) Modeling The Structure
i) Workplane>Change Active CS to..>Global Cartesian.
ii) Preprocessor>Modeling>Create>Keypoints>In active CS
Enter the 10 keypoints
iii) Preprocessor>Modeling>Create>Lines>Lines>In Active Coord
iv) Utility Menu>PlotCtrls>Pan Zoom Rotate window to rotate the model and see its 3D
nature.
2) Material properties
i) Preprocessor>Material Props>Material Models. In the window that comes up which
is shown below, for Material Model 1, choose Structural>Linear>Elastic>Isotropic
ii) Double click Isotropic for Material Model 1.
iii) Fill in 7.5e10 for the Young's modulus and 0.3 for minor Poisson's Ratio. Click OK
3) Element properties
i) Click Preprocessor>Element Type>Add/Edit/Delete... In the 'Element Types'
window that opens click on Add...
ii) Type 1 in the Element type reference number
iii) Click on Structural Link and select 3D spar. Click OK. Close the 'Element types'
window.
iv) So now we have selected Element type 1 to be a structural Link- 3D spar (cable)
element. The trusses will be modeled as elements of type 1, i.e. structural link
element. This finishes the selection of element type.
v) Go to Preprocessor>Real Constants
vi) In the "Real Constants" dialog box that comes up click on Add
vii) In the "Element Type for Real Constants" that comes up click OK.
viii) Type 1.56e-3 for cross sectional area and click on OK
4) Meshing
i) Preprocessor>Meshing>Size Controls>Manual Size>Lines>All Lines. In the menu
that comes up type 1 in the field for 'Number of element divisions'. Click on OK.
ii) Now go to Preprocessor>Meshing>Mesh>Lines. Select all the lines and click on OK
in the "Mesh Lines" dialog box. Now each line is a truss element (Element 1).

CAD/CFD LAB Page 45

5) Boundary conditions and constraints

i) Preprocessor>Loads>Define Loads>Apply>Structural>Displacement>On key points
ii) Select the keypoint on which you want to apply displacement constraints
iii) Select UX, UY, UZ and click OK.
iv) Preprocessor>Loads>Define Loads>Apply>Structural>Forces/Moment>On Nodes.
v) Select the top node.
vi) Click on OK in the 'Apply F/M on Nodes' window
vii) Enter the value of the Z-component of the force
viii) Repeat the procedure to apply the Y-component of force.
6) Solution
i) Main Menu>Solution>Analysis Type>New Analysis.
ii) Select static and click on OK
iii) Solution>Solve>Current LS.
7) Post-processing
i) General Postprocessing>List Results>Nodal Solution
ii) General Postprocessing>List Results>Element Solution. Now select LineElem
Results
8) Modifications
i) You can also plot the displacements and stress.
ii) General Postprocessing>Plot Results>Contour Plot>Element Solution.
iii) Select a stress to be plotted and click OK

RESULT:

CAD/CFD LAB Page 46

Exp.No: Date:

CANTILEVER BEAM

PROBLEM DESCRIPTION

Loads will not be applied to the beam shown below in order to observe the deflection caused by
the weight of the beam itself. The beam is to be made of steel with a modulus of elasticity of
200 GPa

A. PREPROCESSING: DEFINING THE PROBLEM

1. Give example a Title

2. Preprocessor menu
ANSYS Main Menu > Preprocessor
3. Define Keypoints
Preprocessor > Modeling > Create > Keypoints > In Active CS...
Keypoint 1(0, 0)
Keypoint 2(1000,0)
4. Create Lines

CAD/CFD LAB Page 47

Preprocessor > Modeling > Create > Lines > Lines > In Active Coord
5. Define the Type of Element
Preprocessor > Element Type > Add/Edit/Delete...
For this problem we will use the BEAM3 (Beam 2D elastic) element. This element has 3
degrees of freedom (translation along the X and Y axes, and rotation about the Z axis).
6. Define Real Constants
Preprocessor > Real Constants... > Add...
In the 'Real Constants for BEAM3' window, enter the following geometric properties:
Cross-sectional area AREA: 500
Area moment of inertia IZZ: 4166.67
Total beam height: 10
7. Define Element Material Properties
Preprocessor > Material Props > Material Models > Structural > Linear > Elastic >
Isotropic
Young's modulus EX: 200000
Poisson's Ratio PRXY: 0.3
8. Define Element Density
Enter Density DENS: 7.86e-6
9. Define Mesh Size
Preprocessor > Meshing > Size Cntrls > ManualSize > Lines > All Lines...
10. Mesh the frame
Preprocessor > Meshing > Mesh > Lines > click 'Pick All'
B. SOLUTION PHASE: ASSIGNING LOADS AND SOLVING
1. Define Analysis Type
Solution > Analysis Type > New Analysis > Static
2. Apply Constraints
Solution > Define Loads > Apply > Structural > Displacement > On Keypoints
Fix keypoint 1 (ie all DOF constrained)
3. Define Gravity
Select Solution > Define Loads > Apply > Structural > Inertia > Gravity...
Define an acceleration of 9.81m/s2 in the y direction.

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4. Solve the System

Solution > Solve > Current LS
C. POSTPROCESSING: VIEWING THE RESULTS
1. Hand Calculations
2. Show the deformation of the beam
General Postproc > Plot Results > Deformed Shape ... > Def + undef edge

RESULT:

CAD/CFD LAB Page 49

Exp.No: Date:

PLANE STRESS ANALYSIS-PLATE WITH A HOLE

PROBLEM DESCRIPTION

Figure 01 shows an overview of the problem. A square plate 0.1m wide and 0.1m high is taken.
It has a thickness of 0.001m and is subjected to a tensile load of 1000 N. It has a circular hole
located in the centre of the plate with a diameter of 0.01m. We are going to make two different
models of this problem, as shown in figure 02. First we will model the entire problem unsing
plane stress elements then we will exploit symmetry and create another model that only requires
1/4 of the plate to be modelled but will still give the same solution!

Figure 01: Overview of the "Plate with a Hole Problem"

Figure 02: The two modelling approaches we are going to use to model the "plate with
a hole" problem. The Full Model (left) and the 1/4 Model (Right).

CAD/CFD LAB Page 50

Step 1: Launch ANSYS

Step 2: Define Element Type
1. In the Main Menu select Preprocessor > Element Type > Add/Edit/Delete
2. Click on Add in the dialog box that appears:
3. Select Solid in the left hand menu and Quad 8 node 183 in the right hand menu and then
click OK
4. This defines element type 1 as a 2D quadratic 8-node quadrilateral element (i.e. a rectangle
with curved edges)
5. Now we must define how this element behaves. Click on Options in the Element Types
dialog box
6. In the element type options dialog box that appears, make sure that the Element behavior is
set to "Plane Stress with thickness
7. Click Close to close the Element Type dialog box."
Step 3: Define The Plate Thickness (Real Constant)
1. In the Main Menu select Preprocessor > Real Constants > Add/Edit/Delete
2. Click on Add in the dialog box that appears.
3. Click on OK to define a real constant for element type 1 PLANE 183.
4. Enter the value for the plate thickness: 0.001 m and then click OK
5. Click on Close to close the real constants dialog box.
Step 4: Define the Material Behaviour
1. In the Main Menu click on Preprocessor > Material Props > Material Models, the Define
Material Model Behaviour dialog box will now appear.
2. Expand the options in the right hand pane of the dialog box: Structural > Linear > Isotropic
3. In the dialog box that pops up, enter suitable material parameters for steel ( E = 210 x 109
Pa, Poissons ratio = 0.3):
4. Click on Ok to close the dialog box in which you entered the material parameters.
5. Close the Define Material Model Behaviour dialog box by clicking on the X in the upper
right corner.
Step 5: Create the Plate Geometry
1. In the Main Menu click on Preprocessor > Modelling > Create > Areas > Rectangle > By 2
Corners

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2. The WP X and WP Y boxes are used to define the coordinates for the lower left coordinates
of the rectangle and the width and height are entered in the other boxes. Set the lower left
corner at the coordinates (0,0) and make the width and height equal to 0.1 m
3. We will now create the hole: Preprocessor > Modelling > Create > Areas > Circle > Solid
Circle
4. We must place the centre of the circle at the centre of the square so enter 0.05 for WP X and
WP Y. The radius of the circle is 0.005 m
5. Now, we are going to subtract the circle area from the rectangular area to give the correct
plate with a hole geometry:
6. Preprocessor > Modelling > Operate > Booleans > Subtract > Areas
7. The Subtract Areas pick box will appear. If you look at the bottom of the main menu you
will see a prompt asking you to "Pick or enter base areas from which to subtract". This
means we need to pick the square first. Click on the square with your mouse
8. This means that ANSYS is not entirely sure which area you meant to pick (either the circle
or the rectangle). Take a look at the screen and if the entire rectangle has changed colour (to
indicate that it is picked) then you can just click on OK in this dialog box. If things don't
look ok then click on Next or Prev to toggle between selecting the two areas.
9. Now click on OK in the Subtract Areas pick box.
10. A new Subtract Areas pick box will immediatly appear and the message at the bottom of the
main window will change to "Pick or enter areas to be subtracted". This means we need to
pick the circle. Click on the circle with your mouse. Use the "multiple entities" dialog box if
required to ensure it is only the circle that is selected and then click on OK to close the
Subtract Areas dialog box
Step 6: Mesh the Geometry
1. In the Main Menu click on Preprocessor > Meshing > Mesh Tool
2. This will open the Mesh Tool window.
3. We are now going to use the Mesh Tool to set the size of the elements to all be a constant
size before we begin the meshing process. In the Mesh Tool click on Areas > Set
4. Use your mouse to click on the plate geometry. Once you have clicked on it, the Element
Size at Picked Areas dialog box will appear. Enter 0.001 m for the Element Edge Length to
define the size of each element

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5. Click on OK to close the dialog box.

6. Now we must divide the plate up into elements. In the Mesh Tool window click on Mesh.
7. You should see the plate divided up into quadrilateral finite elements:
Step 7: Apply the Boundary Conditions
1. In the Main Menu click on Preprocessor > Loads > Define Loads > Apply > Structural >
Displacement > On Lines
2. Pick the vertical line on the left hand side of the plate and the click OK in the picker dialog
box.
3. In the dialog box that appears make sure that only UX is selected as we only want to
constrain this line in the X (i.e. horizontal) direction.
4. Preprocessor > Loads > Define Loads > Apply > Structural > Displacement > On Nodes
5. Click on the node at the centreline of the plate on the left hand edge and then click on OK
6. In the dialog box that appears make sure the DOFs to be constrained is set to UY only and
then click on OK
Step 8: Couple the Nodes on the Right Hand Edge and Apply the Force
1. In the Main Menu click on Preprocessor > Coupling/ Ceqn > Couple DOF
2. Make sure that the box option is selected in the Define Coupled DOFs pick box
3. Draw a box around the nodes on the right hand edge of the plate finite element model by
clicking your left mouse button and holding it down to draw the box. Release the left mouse
button when the box is the size you require.
4. Now, click on OK to close the picker dialog box.
5. The next dialog box asks you for a Set Reference Number – enter any number you wish (I
have used 99 in the image below). The dialog box also asks you which degree of freedom
you wish to couple: make sure that this is set to UX
6. Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment > On Nodes
7. Click on any of the nodes on the right hand edge of the plate and then click on OK to close
the picker dialog.
8. Change the force direction to FX and enter a Force/Moment value of 1000 in order to apply
1000 N.
Step 9: Solve the Problem
1. In the Main Menu select Solution > Analysis Type > New analysis

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2. Make sure that Static is selected in the dialog box that pops up and then click on OK to
dismiss the dialog
3. Select Solution > Solve > Current LS to solve the problem
4. A new window and a dialog box will pop up. Take a quick look at the infromation in the
window ( /STATUS Command) before closing it.
5. Click on OK in the dialog box to solve the problem.
6. Once the problem has been solved you will get a message to say that the solution is done,
close this window when you are ready.
Step 10: Examine the Results
1. In the Main Menu select General Postproc > Plot Results > Deformed Shape
2. Select Def + undef edge in order to show both the deformed and undeformed shapes.
3. In the Main Menu select General Postproc > Plot Results > Contour Plot > Nodal Solu >
Stress > X-Component of Stress

RESULT:

CAD/CFD LAB Page 54

Exp.No: Date:

PLANE STRAIN ANALYSIS-PRESSURE VESSEL

PROBLEM DESCRIPTION

Determine the principal stresses in the pressure vessel due to the applied loading and boundary
conditions. A two-dimensional plane strain element will be used for this analysis. We will use SI
system units for this tutorial: length = m, mass = kg, time = sec, force = N, stress/pressure = Pa.
In this case the vessel is made from steel (E = 207 Gpa, v = 0.27) and the internal pressure is
10,000 Pa.

Figure 1: Details of the Pressure Vessel - all dimensions in mm.

Figure 2: Plane Strain and 1/4 Symmetry Plane Strain Models of the Pressure Vessel

CAD/CFD LAB Page 55

Step 1: Launch ANSYS.

Step 2: Define Element Type
1. In the Main Menu select Preprocessor > Element Type > Add/Edit/Delete
2. Click on Add in the dialog box
3. Select Solid in the left hand menu and Quad 8 node 183 in the right hand menu and then
click OK
4. This defines element type 1 as a 2D quadratic 8-node quadrilateral element (i.e. a
rectangle with curved edges)
5. Now we must define how this element behaves. Click on Options in the Element Types
dialog box:
6. In the element type options dialog box that appears, make sure that the Element behavior
is set to "Plane Strain"
7. Click Close to close the Element Type dialog box.
Step 3: Define the Material Model
1. In the Main Menu click on Preprocessor > Material Props > Material Models, the Define
Material Model Behaviour dialog box will now appear.
2. Expand the options in the right hand pane of the dialog box: Structural > Linear >
Isotropic
3. In the dialog box that pops up, enter suitable material parameters for steel ( E = 207 x
109 Pa, Poissons ratio = 0.27):
4. Click on Ok to close the dialog box in which you entered the material parameters.
5. Close the Define Material Model Behaviour dialog box by clicking on the X in the
upper right corner.
Step 4: Create the Model Geometry
1. In the Main Menu click on Preprocessor > Modelling > Create > Areas > Circle >
Partial Annulus
2. Enter the values shown in the figure below to create a partial annulus representing the
1/4 model of the pressure vessel cross section
3. Utility Menu > PlotCtrls > Style > Colors >Reverse Video
Step 5: Mesh the Geometry
1. In the Main Menu click on Preprocessor > Meshing > Mesh Tool

CAD/CFD LAB Page 56

2. Click on Areas > Set

3. Use your mouse to click on the plate geometry. Once you have clicked on it, the Element
Size at Picked Areas dialog box will appear. Enter 0.001 m for the Element Edge Length
to define the size of each element
4. Click on OK to close the dialog box.
5. Now we must divide the plate up into elements. In the Mesh Tool window make sure
that Mapped meshing is selected and then click on Mesh.
Step 6: Apply the Boundary Conditions
1. In the Main Menu click on Preprocessor > Loads > Define Loads > Apply > Structural >
Displacement > Symmetry B.C. > On Lines
2. Pick the vertical line on the left hand side of the annulus and the horizontal line at the
bottom of the annuals, then click OK in the picker dialog box.
3. You should notice small "S" symbols appear near the lines to indicate that a symmetry
boundary condition has been applied.
Step 7: Apply the Internal Pressure Load
1. In the Main Menu click on Preprocessor > Loads > Define Loads > Apply > Structural >
Pressure > On Lines
2. Click on the curved line representing the internal wall of the pressure vessel and then
click on OK in the picker dialog box.
3. The "Apply Pres on a Line" dialog box will now appear. Enter 10000 as the pressure
value
Step 8: Solve the Problem
1. In the Main Menu select Solution > Analysis Type > New Analysis
2. Make sure that Static is selected in the dialog box that pops up and then click on OK to
dismiss the dialog.
3. Select Solution > Solve > Current LS to solve the problem
4. A new window and a dialog box will pop up. Take a quick look at the information in the
window ( /STATUS Command) before closing it
Step 9: Examine the Results
1. In the Main Menu select General Postproc > Plot Results > Deformed Shape
2. Select Def + undef edge in order to show both the deformed and undeformed shapes.

CAD/CFD LAB Page 57

3. Now let's examine the principal stresses: General Postproc > Plot Results > Contour Plot
> Nodal Solu > Stress > 1st Principal Stress, click on OK to display the plot
4. General Postproc > Plot Results > Contour Plot > Nodal Solu > Stress > 2nd Principal
Stress, click on OK
5. General Postproc > Plot Results > Contour Plot > Nodal Solu > Stress > 2nd Principal
Stress, click on OK

RESULT:

CAD/CFD LAB Page 58

Exp.No: Date:

AXI-SYMMETRIC-THICK CYLINDER

PROBLEM DESCRIPTION
Find the stresses in a thick open-ended cylinder with an internal pressure (such as a pipe
discharging to the atmosphere). The steel cylinder below has an inner radius of 5 inches and an
outer radius of 11 inches

1. Start ANSYS
Use a quadrilateral element with axi symmetric behavior.
2. Preprocessor -> Element Type -> Add/Edit/Delete -> Add -> select Quad 4 Node 42 ->
OK -> Options (Element Behavior)-> Axi symmetric -> OK -> Close
Enter material property data for steel.
3. Preprocessor -> Material Props -> Material Models . . . -> Structural -> Linear ->
Elastic -> Isotropic ->Enter Ex = 3.e7 and PRXY = 0.3 -> OK -> Close.
Create geometry for rectangle 1 inch by 6 inches starting 5 inches from Y axis. Note: In
ANSYS the Y axis is always the axis of symmetry for axi symmetric problems. This
rectangular area will be revolved 90 degrees about the Y axis to produce the desired volume.
4. Preprocessor -> Create -> Areas -> Rectangle ->By 2 Corners
Define two key points on the Y axis for revolving purposes.
Mesh the area and apply loads and boundary conditions.
• Preprocessor -> Mesh -> Areas -> Free (Pick rectangular area)

CAD/CFD LAB Page 59

• Preprocessor -> Loads ->Apply ->Displacement -> On Lines (Pick the bottom line of the
rectangle) uy = 0 along this line. This simply prevents rigid body motion in the Y direction. No
other displacement boundary conditions are required. The radial movement is prevented by the
'hoop' tension in the cylinder.
Preprocessor -> Loads ->Apply ->Pressure -> On Lines (Pick the left hand line of the
rectangle). Enter a pressure of 1000
7. Solution -> Solve -> Current LS ->OK
Check the deformed shape to see if it's reasonable. (The dotted line is the undeformed shape.)
8. General Post Processor -> Plot Results -> Deformed Shape . . . ->Def +undeformed -> OK
9. General Postprocessor -> Plot Results -> Element Solu . . . (Pick Sx then Sy then Sz and
examine each).
10. PlotCntls -> Numbering . . .-> Turn on Node & Element Numbers Zoom in on the inside and
outside walls of the cylinder
11. List -> Results ->Element Solution . . . -> Stress -> Components -> OK
12. List -> Results ->Element Solution . . . -> Stress -> Components -> OK.
13. General Postprocessor -> List -> Results -> Nodal Solution . . . DOF ->All DOFs -> OK

RESULT:

CAD/CFD LAB Page 60

CFD
Exp.No: Date:

LAMINAR PIPE FLOW

Problem Specification

Consider fluid flowing through a circular pipe of constant radius as illustrated above. The pipe
diameter D = 0.2 m and length L = 8 m. The inlet velocity Ū z = 1 m/s. Consider the velocity to
be constant over the inlet cross-section. The fluid exhausts into the ambient atmosphere which is
at a pressure of 1 atm. Take density ρ = 1 kg/ m 3 and coefficient of viscosity

µ = 2 x 10 -3 kg/(ms). The Reynolds number Re based on the pipe diameter is

where Ū z is the average velocity at the inlet, which is 1 m/s in this case.

Solve this problem using FLUENT. Plot the centerline velocity.

Preliminary Analysis

We expect the viscous boundary layer to grow along the pipe starting at the inlet. It will
eventually grow to fill the pipe completely (provided that the pipe is long enough). When this
happens, the flow becomes fully-developed and there is no variation of the velocity profile in the
axial direction, x (see figure below). One can obtain a closed-form solution to the governing
equations in the fully-developed region. You should have seen this in the Introduction to
Fluid Mechanics course. We will compare the numerical results in the fully-developed region
with the corresponding analytical results. So it's a good idea for you to go back to your textbook
in the Intro course and review the fully-developed flow analysis. What values would you expect

CAD/CFD LAB Page 61

for the centerline velocity and the friction factor in the fully-developed region based on the
analytical solution? What is the solution for the velocity profile?

Steps to solve problem

 Start the 2D ( 2d) version of FLUENT

 Read the grid file LaminarFlow.msh, from specified folder location
 Check the grid
 Scale the grid (if necessary)
 Display grid for verifying the mesh file
 The axisymmetric nature of the geometry must be specified. Under
Define>Models>Solver in Space select Axisymmetric.
 The Viscous Model parameters will be specified. In order to open the Viscous Model
Options Define>Models > Viscous… select Laminar.
 No need to enable the Energy Equatio.
 The properties of the fluid that is being modeled will be specified.
Define>Materials…. Change the values by given values and click Change/Create
then close panel.
 Define Boundary Conditions
o Set surface_body to fluid(air)
o Set Centreline to axis. When the dialog boxes appear click Yes to change the
boundary type.
o Set inlet to velocity_inlet. Click on Set, opens velocity inlet panel. Select
Velocity Specification Method to Components, and set the Axial-
Velocity (m/s) to 1 m/s.
o Select outlet in the Boundary Conditions menu, set to pressure-outlet. No
further changes are needed for the outlet boundary condition.

CAD/CFD LAB Page 62

o select pipe_wall in the Boundary Conditions menu, set to wall.

 In order to save your work (Click)File > Case…
 A second-order discretization scheme will be used to approximate the solution. In order
to implement the second order scheme click on Solution Methods then click on
Momentum and select Second Order Upwind.
 The flow field will be initialized to the values at the inlet. In order to carry out the
initialization click on Solution Initialization then click on Compute from and
select inlet. Then, click the Initialize button.
 In order to specify the residual criteria (Click) Solve>Monitors > Residuals select
plot.
 Prior, to running the calculation the maximum number of iterations must be set. To
specify the maximum number of iterations click on Solve>Iterate then set
the Number of Iterations to 100. Click on Iterate. Ensure Convergence of solution,
otherwise go for iteration again.
 After solution converges go to post-processing.

Results (post-processing):

 Velocity Vectors
o Select Display > Vectors…. Click on Display, it will display half
portion of pipe line.
o The laminar pipe flow was modeled asymmetrically; however, the plot can be
reflected about the axial axis to get an expanded sectional view. In order to carry
this out (Click) Display > Views... Under Mirror Planes, only the axis (or
centerline) surface is listed since that is the only symmetry boundary in the
present case. Select axis (or centerline) and click Apply.

Velocity Vectors

Velocity Contours

CAD/CFD LAB Page 63

 Centerline Velocity
o In order to start the process (Click) Plots > XY Plot... > Set Up
o In the Solution XY Plot menu make sure that Position on X Axis is selected,
and X is set to 1 and Y is set to 0.
o Select centerline under Surfaces since we are plotting the axial velocity along
the centerline.
o Now, click Plot. The plot of the axial velocity as a function of distance along the
centerline now appears.

CAD/CFD LAB Page 64

Exp.No: Date:

TURBULENT PIPE FLOW

Problem Specification

where Ū z is the average velocity at the inlet, which is 1 m/s in this case.

Solve this problem using FLUENT. Plot the centerline velocity.

Preliminary Analysis

At the Reynolds number Re = 10,000, the flow is usually completely turbulent.

A turbulent flow exhibits small-scale fluctuations in time. It is usually not possible to resolve
these fluctuations in a CFD calculation. So the flow variables such as velocity, pressure, etc. are
time-averaged. Unfortunately, the time-averaged governing equations are not closed i.e. they
contain fluctuating quantities which need to be modeled using a turbulence model. No
turbulence model is currently available that is valid for all types of flows and so it is necessary
to choose and fine-tune a model for particular classes of flows. In this exercise, you'll be turned
loose on variants of the k-ε model. But in the real world, tread with great caution: you should
evaluate the validity of your calculations using a turbulence model very carefully (which, ahem,
means that there is no getting away from studying fluid dynamics concepts and numerical

CAD/CFD LAB Page 65

methods very carefully). FLUENT should not be used as a black box. The k-ε models consist of
two differential equations: one each for the turbulent kinetic energy k and turbulent dissipation
ε. These two equations have to be solved along with the time-averaged continuity, momentum
and energy equations. So turbulent flow calculations are much more difficult and time-
consuming than laminar flow calculations. This is an exercise to whet your appetite for turbulent
flow calculations.
Steps to solve problem

 Start the 2D ( 2d) version of FLUENT

 The properties of the fluid that is being modeled will be specified.

Define>Materials…. Change the values by given values and click Change/Create
then close panel.( Density to 1.0 and Viscosity to 2e-5)

 Set operating condit ions under Define>Operating Conditions... , We'll use the
default value of 1 atm (101,325 Pa) as the Operating Pressure
 Define Boundary Conditions
o Set fluid to fluid(air)
o Set Centreline to axis. When the dialog boxes appear click Yes to change the
boundary type.

CAD/CFD LAB Page 66

o Set inlet to velocity_inlet. Click on Set, opens velocity inlet panel. Change
the Velocity Specification Method to Magnitude, Normal to
Boundary. Enter 1for Velocity Magnitude. This indicates that the fluid is
coming in normal to the inlet at the rate of 1 meter per second. Select Intensity
and Hydraulic Diameter next to the Turbulence Specification Method.
Then enter 1 for Turbulence Intensity and 0.2 for Hydraulic Diameter.
Click OK to set the velocity.
o Select outlet in the Boundary Conditions menu, set to pressure-outlet. No
further changes are needed for the outlet boundary condition.
o select pipe wall in the Boundary Conditions menu, set to wall.
 In order to save your work (Click)File > Case…
 A second-order discretization scheme will be used to approximate the solution. In order
to implement the second order scheme click on Solution Methods then click on
Momentum and select Second Order Upwind and also for the turbulence kinetic
energy equation which is part of the k-epsilon turbulence model.
 The flow field will be initialized to the values at the inlet. In order to carry out the
initialization click on Solution Initialization then click on Compute from and
select inlet. Then, click the Initialize button.
 In order to specify the residual criteria (Click) Solve>Monitors > Residuals select
plot.
 Prior, to running the calculation the maximum number of iterations must be set. To
specify the maximum number of iterations click on Solve>Iterate then set
the Number of Iterations to 100. Click on Iterate. Ensure Convergence of solution,
otherwise go for iteration again.
 After solution converges go to post-processing.

Results (post-processing):

 Velocity Vectors
o Select Display > Vectors…. Click on Display, it will display half
portion of pipe line.

o The laminar pipe flow was modeled asymmetrically; however, the plot can be
reflected about the axial axis to get an expanded sectional view. In order to carry
this out (Click) Display > Views... Under Mirror Planes, only the axis (or
centerline) surface is listed since that is the only symmetry boundary in the
present case. Select axis (or centerline) and click Apply.

CAD/CFD LAB Page 67

Velocity Vectors

Velocity Contours

CAD/CFD LAB Page 68

Exp.No: Date:

STEADY FLOW PAST A CYLINDER

Problem Specification

Consider the steady state case of a fluid flowing past a cylinder, as illustrated above. Obtain the
velocity and pressure distributions when the Reynolds number is chosen to be 20. The diameter
of the pipe is set to 1 m, the x component of the velocity is set to 1 m/s and the density of the
fluid is set to 1 kg/m^3. The dynamic viscosity be 0.05 kg/m*s.

Solution Domain

For an external flow problem like this, one needs to determine where to place the outer
boundary. A circular domain will be used for this simulation. The effects that the cylinder has on
the flow extend far. Thus, the outer boundary will be set to be 64 times as large as the diameter
of the cylinder. That is, the outer boundary will be a circle with a diameter of 64 m. The solution
domain discussed here is illustrated below.

Boundary Conditions

First, we will specify a velocity inlet boundary condition. We will set the left half of the outer
boundary as a velocity inlet with a velocity of 1 m/s in the x direction. Next, we will use a
pressure outlet boundary condition for the left half of the outer boundary with a gauge pressure

CAD/CFD LAB Page 69

of 0 Pa. lastly, we will apply a no slip boundary condition to the cylinder wall, as illustrated
below.

Steps to solve problem

 Start the 2D ( 2d) version of FLUENT

 Read the grid file FlowOverCylinder.msh, from specified folder location
 Check the grid
 Scale the grid (if necessary)
 Display grid for verifying the mesh file
 Keep the default values for solver. Under Define>Models>Solver.
 The properties of the fluid that is being modeled will be specified.
Define>Materials…. Change the values by given values and click Change/Create
then close panel. (set the Density to 1 kg/m^3 and set Viscosity to 0.05 kg/m*s)
 Set operating condit ions under Define>Operating Conditions... , We'll use the
default value of 1 atm (101,325 Pa) as the Operating Pressure
 Define Boundary Conditions
o Set fluid to fluid(air)
o Set farfield1 to velocity_inlet. Click on Set, opens velocity inlet panel.
Set Velocity Specification Method to Components, set X-Velocity to 1
m/s, and set Y-Velocity to 0 m/s
o Select FarField2 in the Boundary Conditions menu, set to pressure-outlet.
No further changes are needed for the outlet boundary condition.
o select cylinderwall in the Boundary Conditions menu, set to wall.
o Report > Reference Values. Set the Density to 1 kg/m^3. The other default
values will work for the purposes of this simulation.
 In order to save your work (Click)File > Case…

CAD/CFD LAB Page 70

 A second-order discretization scheme will be used to approximate the solution. In order

to implement the second order scheme click on Solution Methods then click on
Momentum and select Second Order Upwind.
 The flow field will be initialized to the values at the inlet. In order to carry out the
initialization click on Solution Initialization then click on Compute from and
select farfield1. Then, click the Initialize button.

 In order to specify the residual criteria (Click) Solve>Monitors > Residuals select
plot. Set the Absolute Criteria for , x-velocity and y-velocity all to 1e-6. Click ok.
 Prior, to running the calculation the maximum number of iterations must be set. To
specify the maximum number of iterations click on Solve>Iterate then set
the Number of Iterations to 1000. Click on Iterate. Ensure Convergence of solution,
otherwise go for iteration again.

 After solution converges go to post-processing.

Results (post-processing):

 Velocity Vectors
o Select Display > Vectors…. Click on Display, it will display velocity
vectors as shown below.

Velocity Vectors

CAD/CFD LAB Page 71

 Stream Lines
o Set Contours of to Velocity.. and set the box below to Stream Function.
Make sure Filled is not selected and click Display. The plots below were
created by setting levels to 40, deselecting Auto Range, setting Min (kg/s) to
31 and setting Max (kg/s) to 33.

 Vorticity
o Set Contours of to Velocity.. and set the box below to Vorticity
Magnitude. Then click Display. The plot below was created by by
setting levels to 60, deselecting Auto Range, setting Min (1/s) to 0.25 and
setting Max (1/s) to 9.

CAD/CFD LAB Page 72

 Drag Coefficient
o Reports > Forces Report
Then, click Print. The command pane will now display the following results:
the pressure force, the viscous force, the total force, the pressure force
coefficient, the viscous force coefficient and the drag force coefficient.

CAD/CFD LAB Page 73

Exp.No: Date:

FLUID FLOW AND HEAT TRANSFER

IN A MIXING ELBOW

Steps to solve problem

 Start the 3D ( 3d) version of FLUENT

 Read the grid file elbow.msh, from specified folder location
 Check the grid
 Scale the grid

CAD/CFD LAB Page 74

 Display grid for verifying the mesh file

 Keep the default values for solver. Under Define>Models>Solver.
 The Viscous Model parameters will be specified. In order to open the Viscous Model
Options Define>Models > Viscous… select k-epsilon (2eqn). Under k-epsilon
Model, pick Realizable so that we may get a more accurate result. Click OK.
 Enable the Energy Equation, under Define>Models > Energy…
 The properties of the fluid that is being modeled will be specified.
Define>Materials…. Change the values by given values and click Change/Create,
new name water then close panel.( Density to 1000,cp = 4216, k = 0.677
and Viscosity to 8e-4)
 Set operating condit ions under Define>Operating Conditions... , We'll use the
default value of 1 atm (101,325 Pa) as the Operating Pressure
 Define Boundary Conditions
o Set fluid to fluid (water)
o Set inlet to velocity_inlet-5. Click on Set, opens velocity inlet panel. Change
the Velocity Specification Method to Component. Enter 0.4 for X-
Velocity. Select Intensity and Hydraulic Diameter next to
the Turbulence Specification Method. Then enter 5 for Turbulence
Intensity and 4 for Hydraulic Diameter. Click Thermal tab, set temperature
to 293.15K. Click OK to set the velocity.

CAD/CFD LAB Page 75

o Set inlet to velocity_inlet-6. Click on Set, opens velocity inlet panel. Change
the Velocity Specification Method to Component. Enter 1.2 for Y-
Velocity. Select Intensity and Hydraulic Diameter next to
the Turbulence Specification Method. Then enter 5 for Turbulence
Intensity and 1 for Hydraulic Diameter. Click Thermal tab, set temperature
to 313.15K. Click OK to set the velocity.
o Select outlet in the Boundary Conditions menu, set to pressure-outlet.
Click on Set, opens pressure outlet panel. Select Intensity and Hydraulic
Diameter next to the Turbulence Specification Method. Then enter 5 for
Turbulence Intensity and 4 for Hydraulic Diameter.
o select pipe_wall in the Boundary Conditions menu, set to wall.
 In order to save your work (Click)File > Case…
 The flow field will be initialized to the values at the inlet. In order to carry out the
initialization click on Solution Initialization then click on Compute from and
select velocity_inlet-6. Then, click the Initialize button.
 In order to specify the residual criteria (Click) Solve>Monitors > Residuals select
plot.
 Prior, to running the calculation the maximum number of iterations must be set. To
specify the maximum number of iterations click on Solve>Iterate then set
the Number of Iterations to 200. Click on Iterate. Ensure Convergence of solution,
otherwise go for iteration again.
 After solution converges go to post-processing.

CAD/CFD LAB Page 76

Results (post-processing):

 Velocity Vectors

o Select Display > Vectors…. Select symentry. Click on Display

Velocity Vectors on symmetry plane

 Temperature Contours

o Select Display > Contours…. Select symentry. Click on Display

Temperature Contours on symmetry plane

CAD/CFD LAB Page 77

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