Executive Summary - EDGEedge.rit.edu/edge/P17301/public/Final Documents/Test... · Web viewBending moment (lbf.in)-0.18605 0.31775 0 0.36821 Bearing Connector-2 Entities: 2 face(s)

Sam Zimmerman2/4/2017

Static Analysis of Latera/Axial Transfer LinkageExecutive SummaryIn order to determine the static stress properties of the proposed Axial/Lateral transfer linkage, a series of Solidworks models and individual static stress analyses were run. Included are the two most telling models, analyzing the torsional stress applied to the linkage. It was found that the lateral and axial loads were negligible compared to the applied torsional load, so those analyses were not included in this report. It was found that the original design could not withstand more than 1 kip-ft of torsional load, as shown in the second included report. The first included report describes a new design that has been strengthened to be able to withstand the required 50 kip-ft torsional load. Drawings and costs for the new design will be included in the final drawing package.

Analyzed with SOLIDWORKS Simulation Simulation of CrossPieceFullAssembly 1


Simulation of Increased Size Transfer Linkage in Torsional Loading

Date: Saturday, February 04, 2017Designer: Sam Zimmerman

Study name: Static 1

Analysis type: Static

Table of ContentsDescription..................................................1

Assumptions................................................2

Model Information......................................2

Study Properties..........................................6

Units............................................................6

Material Properties.....................................7

Loads and Fixtures.......................................8

Connector Definitions.................................9

Contact Information..................................11

Mesh information......................................12

Sensor Details............................................14

Resultant Forces........................................15

Study Results.............................................16

Conclusion.................................................22

DescriptionSecond improved design for Lateral/Axial linkage. All load is applied in torsion (50 kip-ft or 600,000 in-lb). Lateral and axial forces are assumed to be negligible. All rod-end bearings are taken directly from manufacturer’s website and scaled appropriately.



AssumptionsRod ends are assumed to be fixed by linear bearings with no deflection.

Stress is assumed to be fully transferred into rod-end bearings (threads are not modeled)

It is assumed that the direction of the torsion is constant. If the amplitude of the torsional vibration is larger than the static stress, there will be significant slack in the system to be analyzed.

The nuts holding the cross-bolts were not modeled due to interaction issues.

The contact surfaces were assumed to be constant, and that the bearings would not shift during operation.

Lateral and Axial forces are neglected.





Model Information

Model name: CrossPieceFullAssembly

Current Configuration: Default

Solid Bodies

Document Name and Reference Treated As Volumetric Properties Document Path/Date

Modified

Bolt 2 Solid Body Mass:32.0309 lb

Volume:112.944 in^3

Density:0.283599 lb/in^3

Weight:32.0092 lbf

C:\Users\smz7804\AppData\Local\Temp\

swx31024\VC~~\CrossPieceFullAssem

bly\Copy of Bolt^CrossPieceFullA

ssembly.SLDPRT



Feb 04 16:15:04 2017

Bolt 3

Solid Body

Mass:32.0309 lb

Volume:112.944 in^3


Weight:32.0092 lbf


swx31024\VC~~\CrossPieceFullAssem

bly\Copy of Bolt^CrossPieceFullA

ssembly.SLDPRT

Feb 04 16:15:04 2017

Bolt 1

Solid Body

Mass:62.5603 lb

Volume:220.594 in^3


Weight:62.5179 lbf


swx31024\VC~~\CrossPieceFullAssembly\Copy of Copy of

Bolt^CrossPieceFullAssembly.SLDPRT

Feb 04 16:15:04 2017

Transfer Linkage 1

Solid Body

Mass:112.594 lb

Volume:397.019 in^3


Weight:112.518 lbf

C:\Users\smz7804\Downloads\

LoadAppSetup\LoadAppSetup\

CrossPiece.SLDPRT

Feb 04 15:55:46 2017

Transfer Linkage 2 Solid Body Mass:112.594 lb

Volume:397.019 in^3




CrossPiece.SLDPRT



Weight:112.518 lbfFeb 04 15:55:46 2017

Shaft 1

Solid Body

Mass:111.369 lb

Volume:392.699 in^3


Weight:111.294 lbf



Expanded.SLDPRT

Feb 04 15:46:09 2017

Bearing Housing 1Solid Body

Mass:81.5943 lb

Volume:287.71 in^3


Weight:81.5389 lbf


swx31024\VC~~\ExpandedShaftBearin

g\Copy of PRODUCT_NAME_1_2ÊxpandedShaftBear

ing.sldprt

Feb 04 15:50:07 2017

Bearing Ball 1Solid Body

Mass:34.9457 lb

Volume:123.222 in^3


Weight:34.922 lbf


swx31024\VC~~\ExpandedShaftBearin

g\Copy of PRODUCT_NAME_2_2ÊxpandedShaftBear

ing.sldprt

Feb 04 15:50:07 2017

Bearing Race 1 Solid Body Mass:14.8989 lb C:\Users\smz7804\



Volume:52.535 in^3


Weight:14.8888 lbf

AppData\Local\Temp\swx31024\VC~~\

ExpandedShaftBearing\Copy of

PRODUCT_NAME_3_2ÊxpandedShaftBear

ing.sldprt

Feb 04 15:50:07 2017


Mass:41.7763 lb

Volume:147.307 in^3


Weight:41.7479 lbf



PRODUCT_NAME_1_2.sldprt

Feb 04 16:15:03 2017


Mass:17.8922 lb

Volume:63.0898 in^3


Weight:17.8801 lbf




Feb 04 16:15:03 2017

Bearing Race 2 Solid Body Mass:7.62823 lb

Volume:26.8979 in^3


Weight:7.62305 lbf




Feb 04 16:15:03 2017




Mass:41.7763 lb

Volume:147.307 in^3


Weight:41.7479 lbf




Feb 04 16:15:03 2017


Mass:17.8922 lb

Volume:63.0898 in^3


Weight:17.8801 lbf




Feb 04 16:15:03 2017

Bearing Race 3Solid Body

Mass:7.62823 lb

Volume:26.8979 in^3


Weight:7.62305 lbf




Feb 04 16:15:03 2017

Shaft 2 Solid Body Mass:57.021 lb

Volume:201.062 in^3



LoadAppSetup\LoadAppSetup\Shaft.SLDPRT



Weight:56.9823 lbfFeb 04 14:35:15 2017

Shaft 3

Solid Body

Mass:57.021 lb

Volume:201.062 in^3


Weight:56.9823 lbf

C:\Users\smz7804\Downloads\LoadAppSetup\LoadAppSetup\Shaft.SLDPRT

Feb 04 14:35:15 2017



Study PropertiesStudy name Static 1

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type Automatic

Inplane Effect: Off

Soft Spring: On

Inertial Relief: Off

Incompatible bonding options More accurate (slower)

Large displacement Off

Compute free body forces Off

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Users\smz7804\Downloads\



LoadAppSetup\LoadAppSetup)

UnitsUnit system: English (IPS)

Length/Displacement in

Temperature Fahrenheit

Angular velocity Hertz

Pressure/Stress psi



Material PropertiesModel Reference Properties Components

Name: AISI 4340 Steel, normalized

Model type: Linear Elastic Isotropic

Default failure criterion: Max von Mises Stress

Yield strength: 102977 psi

Tensile strength: 160992 psi

Elastic modulus: 2.97327e+007 psi

Poisson's ratio: 0.32

Mass density: 0.283599 lb/in^3

Shear modulus: 1.1603e+007 psi

Thermal expansion coefficient:

6.83333e-006 /Fahrenheit

ALL

Curve Data:N/A



Loads and FixturesFixture name Fixture Image Fixture Details

Fixed-6

Entities: 2 face(s)

Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction force(lbf) 0.0860597 0.25313 -0.187048 0.326294

Reaction Moment(lbf.in) 0 0 0 0

Load name Load Image Load Details

Torque-2

Entities: 1 face(s)

Reference: Face< 1 >

Type: Apply torque

Value: 600000 lbf.in



Connector Definitions

Connector Name Connector Details Connector Image

Rigid Connector-4

Entities: 2 face(s)

Type: Rigid

Rigid Connector-4

Rigid Connector-5

Entities: 2 face(s)

Type: Rigid

Rigid Connector-5

Rigid Connector-6 Entities: 2 face(s)

Type: Rigid

Rigid Connector-6




Pin/Bolt/Bearing Connector

Model Reference Connector Details Strength Details

Bearing Connector-1

Entities: 2 face(s)

Type: Bearing

No Data

Connector Forces

Type X-Component Y-Component Z-Component Resultant

Axial Force (lbf) 0 0 -610.22 610.22

Shear Force (lbf) -807.19 -472.64 0 935.38

Bending moment (lbf.in) -0.18605 0.31775 0 0.36821



Bearing Connector-2

Entities: 2 face(s)

Type: Bearing

No Data

Connector Forces


Axial Force (lbf) 0 0 36.384 36.384

Shear Force (lbf) -1139.9 809.99 0 1398.4

Bending moment (lbf.in) -0.31885 -0.44873 0 0.55048

Bearing Connector-3

Entities: 2 face(s)

Type: Bearing

No Data

Connector Forces


Axial Force (lbf) 0 0 -104.05 104.05

Shear Force (lbf) -49.593 -5464.7 0 5464.9




Contact Information

Contact Contact Image Contact Properties

Global Contact

Type: Bonded

Components: 1 component(s)

Options: Compatible mesh



Mesh informationMesh type Solid Mesh

Mesher Used: Standard mesh

Automatic Transition: Off

Include Mesh Auto Loops: Off

Jacobian points 4 Points

Element Size 1.13147 in

Tolerance 0.0565737 in

Mesh Quality High

Remesh failed parts with incompatible mesh Off

Mesh information - DetailsTotal Nodes 57553

Total Elements 34155

Maximum Aspect Ratio 79.304

% of elements with Aspect Ratio < 3 71.9

% of elements with Aspect Ratio > 10 1.63

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:16



Computer name: GLE-2260-16



Sensor Details

Sensor name Location Sensor Details

Displacement1

Value : 3.593 mm

Entities :

Result :Displacement

Component :URES: Resultant Displacement

Criterion :Model Max

Step Criterion : Across all Steps

Step No.:1

Alert Value: NA

Stress1

Value : 7.28506e+008 N/m^2

Entities :

Result :Stress

Component :VON: von Mises Stress



Step No.:1

Alert Value: NA




Stress2

Value : 1.63615e+008 N/m^2

Entities :1 face(s)

Result :Stress


Criterion :Average of Selected Entities


Step No.:1

Alert Value: NA

Resultant ForcesReaction forcesSelection set Units Sum X Sum Y Sum Z Resultant

Entire Model lbf 0.0860597 0.25313 -0.187048 0.326294

Reaction MomentsSelection set Units Sum X Sum Y Sum Z Resultant

Entire Model lbf.in 0 0 0 0





Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 4.56381e-005 ksi

Node: 7219

105.661 ksi

Node: 41137

CrossPieceFullAssembly-Static 1-Stress-Stress1



Name Type Min Max

Displacement1 URES: Resultant Displacement 0 in

Node: 54104

0.141457 in

Node: 19118

CrossPieceFullAssembly-Static 1-Displacement-Displacement1



Name Type Min Max

Strain1 ESTRN: Equivalent Strain 3.81478e-009

Element: 6355

0.00225681

Element: 24818

CrossPieceFullAssembly-Static 1-Strain-Strain1



Name Type

Displacement1{1} RFX: X Reaction Force

CrossPieceFullAssembly-Static 1-Displacement-Displacement1{1}



Name Type Min Max

Factor of Safety1 Automatic (isosurface shows FOS<20) 0.974597

Node: 41137

100

Node: 2

CrossPieceFullAssembly-Static 1-Factor of Safety-Factor of Safety1



Name Type

Displacement2 URES: Resultant Displacement




Name Type

Displacement3 Deformed shape



Conclusion


Based on the above systems, it is postulated that the system as designed should withstand the 50 kip-ft applied torque. The minimum factor of safety is 0.97 and located at a point of high numerical instability (the contact between the bearing and the bolt). This may be avoided by finding exceptionally high-strength materials (ceramics or titanium alloys) for use in the bearings and bolts. Volumetric and material property information is provided earlier in this report.



Simulation of Reduced Torsional Load Scenario

Date: Saturday, February 04, 2017Designer: Sam Zimmerman

Study name: Static 1

Analysis type: Static

Table of ContentsDescription................................................................1

Assumptions..............................................................2

Model Information....................................................2

Study Properties........................................................5

Units..........................................................................5

Material Properties...................................................6

Loads and Fixtures.....................................................7

Connector Definitions...............................................8

Contact Information................................................10

Mesh information....................................................11

Sensor Details..........................................................13

Resultant Forces......................................................13

Beams......................................................................14

Study Results...........................................................15

Conclusion...............................................................20

DescriptionSimulation of the old linkage design with the maximum torsional load. This scenario reduces the load to 12,000 in-lb (1 kip-ft). Lateral and axial forces are neglected.



AssumptionsRod ends are assumed to be fixed by linear bearings with no deflection.

Stress is assumed to be fully transferred into rod-end bearings (threads are not modeled)

It is assumed that the direction of the torsion is constant. If the amplitude of the torsional vibration is larger than the static stress, there will be significant slack in the system to be analyzed.

The nuts holding the cross-bolts were not modeled due to interaction issues.

The contact surfaces were assumed to be constant, and that the bearings would not shift during operation.

Lateral and Axial forces are neglected.





Model Information

Model name: CrossPieceFullAssembly

Current Configuration: Default

Solid Bodies

Document Name and Reference Treated As Volumetric Properties Document Path/Date

Modified

Bolt 2 Solid Body Mass:0.977504 lb

Volume:3.44678 in^3



LoadAppSetup2\LoadAppSetup\

Bolt.SLDPRT



Weight:0.976841 lbfFeb 04 16:17:36 2017

Bolt 3

Solid Body

Mass:0.977504 lb

Volume:3.44678 in^3


Weight:0.976841 lbf



Bolt.SLDPRT

Feb 04 16:17:36 2017

Bolt 1

Solid Body

Mass:0.977504 lb

Volume:3.44678 in^3


Weight:0.976841 lbf



Bolt.SLDPRT

Feb 04 16:17:36 2017

Transfer Linkage 1

Solid Body

Mass:5.0271 lb

Volume:17.7261 in^3


Weight:5.02369 lbf



CrossPiece.SLDPRT

Feb 04 16:17:36 2017

Transfer Linkage 2 Solid Body Mass:5.0271 lb C:\Users\smz7804\Downloads\

LoadAppSetup2\



Volume:17.7261 in^3


Weight:5.02369 lbf

LoadAppSetup\CrossPiece.SLDPRT

Feb 04 16:17:36 2017


Mass:1.27491 lb

Volume:4.49547 in^3


Weight:1.27405 lbf




Feb 04 16:17:44 2017


Mass:0.545998 lb

Volume:1.92525 in^3


Weight:0.545628 lbf




Feb 04 16:17:44 2017


Mass:0.232795 lb

Volume:0.820859 in^3


Weight:0.232637 lbf




Feb 04 16:17:44 2017




Mass:1.27491 lb

Volume:4.49547 in^3


Weight:1.27405 lbf




Feb 04 16:17:44 2017


Mass:0.545998 lb

Volume:1.92525 in^3


Weight:0.545628 lbf




Feb 04 16:17:44 2017


Mass:0.232795 lb



Weight:0.232637 lbf




Feb 04 16:17:44 2017


Mass:1.27491 lb

Volume:4.49547 in^3


Weight:1.27405 lbf




Feb 04 16:17:44 2017




Mass:0.545998 lb

Volume:1.92525 in^3


Weight:0.545628 lbf




Feb 04 16:17:44 2017


Mass:0.232795 lb



Weight:0.232637 lbf




Feb 04 16:17:44 2017

Shaft 1

Solid Body

Mass:1.74014 lb

Volume:6.13592 in^3


Weight:1.73896 lbf


LoadAppSetup2\LoadAppSetup\Shaft.SLDPRT

Feb 04 16:17:44 2017

Shaft 2 Solid Body Mass:1.74014 lb

Volume:6.13592 in^3



LoadAppSetup2\LoadAppSetup\Shaft.SLDPRT



Weight:1.73896 lbfFeb 04 16:17:44 2017

Shaft 3

Solid Body

Mass:1.74014 lb

Volume:6.13592 in^3


Weight:1.73896 lbf

C:\Users\smz7804\Downloads\LoadAppSetup2\LoadAppSetup\Shaft.SLDPRT

Feb 04 16:17:44 2017



Study PropertiesStudy name Static 1

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type Automatic

Inplane Effect: Off

Soft Spring: On

Inertial Relief: Off

Incompatible bonding options More accurate (slower)

Large displacement Off

Compute free body forces Off

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Users\smz7804\Downloads\



LoadAppSetup\LoadAppSetup)

UnitsUnit system: English (IPS)

Length/Displacement in

Temperature Fahrenheit

Angular velocity Hertz

Pressure/Stress psi



Material PropertiesModel Reference Properties Components

Name: AISI 4340 Steel, normalized

Model type: Linear Elastic Isotropic

Default failure criterion: Max von Mises Stress

Yield strength: 102977 psi

Tensile strength: 160992 psi

Elastic modulus: 2.97327e+007 psi

Poisson's ratio: 0.32

Mass density: 0.283599 lb/in^3

Shear modulus: 1.1603e+007 psi

Thermal expansion coefficient:

6.83333e-006 /Fahrenheit

ALL

Curve Data:N/A



Loads and FixturesFixture name Fixture Image Fixture Details

Fixed-6

Entities: 2 face(s)

Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction force(lbf) -0.000727226 721.116 0.00137212 721.116

Reaction Moment(lbf.in) 0 0 0 0

Load name Load Image Load Details

Torque-2

Entities: 1 face(s)

Reference: Face< 1 >

Type: Apply torque

Value: 12000 lbf.in



Connector Definitions


Rigid Connector-4

Entities: 2 face(s)

Type: Rigid

Rigid Connector-4

Rigid Connector-5

Entities: 2 face(s)

Type: Rigid

Rigid Connector-5

Rigid Connector-6

Entities: 2 face(s)

Type: Rigid

Rigid Connector-6



Pin/Bolt/Bearing Connector

Model Reference Connector Details Strength Details

Bearing Connector-1

Entities: 2 face(s)

Type: Bearing

No Data

Connector Forces


Axial Force (lbf) -0 -0 81.372 -81.372

Shear Force (lbf) -820.66 -77.956 0 824.36


Bearing Connector-2

Entities: 2 face(s)

Type: Bearing

No Data



Connector Forces


Axial Force (lbf) 0 0 200.79 200.79

Shear Force (lbf) -829.17 69.101 0 832.05

Bending moment (lbf.in) -0.027201 -0.3264 0 0.32754

Bearing Connector-3

Entities: 2 face(s)

Type: Bearing

No Data

Connector Forces


Axial Force (lbf) 0 0 -97.914 97.914

Shear Force (lbf) -33.226 119.58 0 124.11

Bending moment (lbf.in) 0.047071 0.01308 0 0.048855



Contact Information

Contact Contact Image Contact Properties

Global Contact

Type: Bonded

Components: 1 component(s)

Options: Compatible mesh



Mesh informationMesh type Solid Mesh

Mesher Used: Curvature based mesh

Jacobian points 4 Points

Maximum element size 0 in

Minimum element size 0 in

Mesh Quality High

Remesh failed parts with incompatible mesh Off

Mesh information - DetailsTotal Nodes 54875

Total Elements 31302

Maximum Aspect Ratio 103.48

% of elements with Aspect Ratio < 3 56.9

% of elements with Aspect Ratio > 10 5.53

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:17

Computer name: GLE-2260-16





Sensor Details


Displacement1

Value : 1.16011 mm

Entities :

Result :Displacement

Component :URES: Resultant Displacement



Step No.:1

Alert Value: NA

Stress1

Value : 1.03242e+009 N/m^2

Entities :

Result :Stress




Step No.:1

Alert Value: NA




Stress2

Value : 2.4019e+008 N/m^2

Entities :1 face(s)

Result :Stress


Criterion :Average of Selected Entities


Step No.:1

Alert Value: NA

Resultant ForcesReaction forcesSelection set Units Sum X Sum Y Sum Z Resultant

Entire Model lbf -0.000727226 721.116 0.00137212 721.116

Reaction MomentsSelection set Units Sum X Sum Y Sum Z Resultant

Entire Model lbf.in 0 0 0 0





Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 9.57471e-005 ksi

Node: 6511

149.739 ksi

Node: 50990

CrossPieceFullAssembly-Static 1-Stress-Stress1



Name Type Min Max

Displacement1 URES: Resultant Displacement 0 in

Node: 52756

0.0456734 in

Node: 51716




Name Type Min Max

Strain1 ESTRN: Equivalent Strain 1.0473e-008

Element: 552

0.0032975

Element: 28946

CrossPieceFullAssembly-Static 1-Strain-Strain1



Name Type

Displacement1{1} RFX: X Reaction Force

CrossPieceFullAssembly-Static 1-Displacement-Displacement1{1}



Name Type Min Max

Factor of Safety1 Automatic 0.687707

Node: 50990

100

Node: 11

CrossPieceFullAssembly-Static 1-Factor of Safety-Factor of Safety1



Name Type

Displacement2 URES: Resultant Displacement




ConclusionBy reducing the applied torsional load to 1 kip-ft, the old linkage design can be used with an overall factor of safety of 0.67 (again at a numerical instability point). It is again suggested to find ceramic or high-strength titanium alloy parts for the bearings and cross bolts.
