Simulation (ANSYS Structural)

CURRENT INDUSTRY RULE: STANDARDISATION VIA SIMULATION NOT TESTING

Today with cutting edge technologies in almost every domain be it space, aero, auto or even medical equipment's the engineering verification and optimization have become testing challenges. Increase in steep demand for power, speed, automation, Eco-friendliness, miniaturization what not has added to the complexities.

The complexity of material model, manufacture and optimizing against competing parameters of weight, specific fuel consumption, life, reliability and cost.

This requires capturing static and dynamic responses, wear rate, other surface degradation and fatigue limits of materials that are: formed, fabricated, machined, sintered, manufactured from carbon fiber or metal matrix extremely accurately, subject varied set of loads, be it any source inertia, temperature, external loading, foreign object damage, wear and surface degradation and many other.

Therefore, simulation is the only way. Where 'n' number of experiments could be conducted with detailed material modelling, n number of load sets and even the component or system architecture could be optimized. This is far economical compared to physical testing. Further it is impossible to carry out advanced optimization via physical testing. Physical testing today is used to test only a few critical components that are already optimized via simulation to satisfy the statutory requirements.

Benefits of the current course

  • Strong simulation culture.
  • Real-time significance of simulation.
  • Result benchmarking
  • Industry best practices in simulation.
Introduction to ANSYS:
  • ANSYS capabilities, basic ANSYS terminology, and the ANSYS GUI
  • How to perform a complete ANSYS analysis… the basic steps involved
  • Building or importing solid models and meshing
  • Applying loads, solving, and reviewing results
  • Productivity enhancement tools- Optimization
Introduction to FEA
  • Introduction to numerical modelling and its role in the field of design's responses to those condition.
  • Understanding the concept of Physical system and FEA (How good is the approximation?)
  • Numerical vs Analytical Vs Experimental Analysis
  • Introduction to FEA and What if scenario, what to model and when to model, why FEA Needed.
  • Design not suitable to prototype testing such as surgical implants and Industrial Relevance (FEA model is useful)

This will develop an awareness of the power and limitations of FEA and help participants to understand the need of simulation. It will also help to understand the tool/steps required for their project.

Introduction to Design Modeler:
  • Pre-processing Workflow using ANSYS Workbench tools
  • Modelling 2D & 3D CAD model
  • How to share data to solve Multiphysics problem
  • Direct/feature based CAD modelling
  • Concepts of modelling from meshing perspective
  • Modes of geometry creation (bottom-up and top-down)
  • Performing parametric analyses
  • Geometry Simplification & Repair for corrupted Geometry

This section covers some of the tools available within ANSYS DM to prepare the geometry. It will empathies more on geometry modification and decomposition from FEA perspective and clean-up process for ill geometry.

Introduction to Mechanical:
  • Basics Analysis Procedure (preliminary decision)
  • General understanding of the user interface, as related to geometry import
  • Procedure for performing FEA simulations
  • including linear static, modal, and harmonic
  • structural analyses and nonlinear steady-state thermal analyses
  • Multi-step Analysis & Remote Boundary condition
  • meshing, application of loads and supports,
  • Constraint equation
  • Basic contact parameters
Introduction to Meshing:
  • Need of mesh and Its process
  • Meshing fundamentals (Efficiency, accuracy & quality)
  • Type of mesh/element (hex, Tet, prism, tri etc.)
  • Introduction to structured and unstructured meshes
  • Meshing Methods (Surface and Volume)
  • Meshing Controls (Global, local)
  • Conformal and non-conformal meshing
  • Issues to consider during mesh creation such as quality, aspect ratio
  • Mesh quality and its impact on the Solution
  • Tools to improve the quality in Meshing
  • Best practices for mesh creation

This will help participant to choose appropriate mesh setting and control as per the geometry and physics using ANSYS Meshing tool as meshing plays a significant role to get converge results and to minimize errors.

Introduction to Solver:
  • Introduction to the FEA Methodology
  • Well-posed boundary conditions and Loading condition
  • Adoption of solver types (direct elimination & Iterative types)
  • Steps Involves for formulation of solve matrix (formulate element matrix-assemble global matrix – solve the matrix)
  • Condition for insufficiently constrained model
  • How to monitor and judge solution convergence
  • Various error type and best practices to minimize them

This will help participant to understand the boundary condition, solver setting and models available in workbench and the background theory which helps him/her to make the right choices in their project and assignment.

Introduction to Post processor:
  • Result interpretation and post processing capabilities
  • Understanding the various option of probe tool, charts & Scoping the result for Interpretation of result
  • Error estimation understanding for post-processor
  • Optimal mesh convergence criteria (mesh adequacy)
  • Visualization of Result by using context tool bar (outline display, probe, displacement scaling)
  • Condition for stress singularities
  • Legend Control and Contour controls for post-processing.
  • Constraint equation display, result scoping and Exporting the result option.
  • Results validation

This will help participants to obtain precise quantitative and/or qualitative information about structural analysis. The post processing options allow control of the look-and-feel of the physics. User will also learn to present results in appropriate manner and validation with existing results.

Learning:
  • The objective of this course is to create confidence to solve complex problems in the field of structural Analysis by using the FEA.
  • To accomplish this objective, the course will present the theory in combination with substantial hands-on practice using ANSYS.
  • Tutorials are designed to investigate problem areas in greater depth to ensure that even new user understand the application and can avoid making mistake.
  • Lectures in the course are designed to cover the terminology and core concepts of mathematical approximation and Analysis.
  • The examples are taken from industry and some classical academic problem to show how the theory is applied in practice.
  • 25 workshops and 15 assignments will be given to the trainee, to create a strong foundation in learning the simulation tool to solve engineering problems