Summary

This report documents design and analysis information created and maintained using the ANSYS DesignSpace® engineering software program. Each scenario listed below represents one complete engineering simulation.

Scenario 1

 "A" Frame TIS Loading = Real Load * 1.5 = 195t

Based on the ACIS® part "A_frame_3.sat".

Considered the effect of structural loads.

Calculated safety factors and margins based on maximum equivalent stress along with structural and frequency results.

No convergence criteria defined.

No alert criteria defined.

See Scenario 1 below for supporting details.

Scenario 2

"A" Frame Real Loading 130t

Based on the ACIS® part "A_frame_3.sat".

Considered the effect of structural loads.

Calculated safety factors and margins based on maximum equivalent stress along with structural and frequency results.

No convergence criteria defined.

No alert criteria defined.

See Scenario 2 below for supporting details.

Scenario 3

"A" Frame Test Loading 250t

Based on the ACIS® part "A_frame_3.sat".

Considered the effect of structural loads.

Calculated safety factors and margins based on maximum equivalent stress along with structural results.

No convergence criteria defined.

No alert criteria defined.

See Scenario 3 below for supporting details.

Introduction

The ANSYS DesignSpace CAE (Computer-Aided Engineering) software program was used in conjunction with 3D CAD (Computer-Aided Design) solid geometry to simulate the behavior of mechanical parts under thermal/structural loading conditions. ANSYS DesignSpace automated FEA (Finite Element Analysis) technologies from ANSYS, Inc. to generate the results listed in this report.

Each scenario presented below represents one complete engineering simulation. The definition of a simulation includes known factors about a design such as material properties per part, contact behavior between parts (in an assembly), and types and magnitudes of loading conditions. The results of a simulation provide insight into how the parts may perform and how the design might be improved. Multiple scenarios allow comparison of results given different loading conditions, materials or geometric configurations.

Convergence and alert criteria may be defined for any of the results and can serve as guides for evaluating the quality of calculated results and the acceptability of values in the context of known design requirements.

Solution history provides a means of assessing the quality of results by examining how values change during successive iterations of solution refinement. Convergence criteria sets a specific limit on the allowable change in a result between iterations. A result meeting this criteria is said to be "converged".

Alert criteria define "allowable" ranges for result values. Alert ranges typically represent known aspects of the design specification.

The discussions below follow the organization of information in the ANSYS DesignSpace "Explorer" user interface. Each scenario corresponds to a unique branch in the Explorer "Outline". Names emphasized in "double quotes" match preferences set in the user interface.

All values are presented in the "Metric (mm, kg, MPa, °C, s)" unit system.

Notice

Do not accept or reject a design based solely on the data presented in this report. Evaluate designs by considering this information in conjunction with experimental test data and the practical experience of design engineers and analysts. A quality approach to engineering design usually mandates physical testing as the final means of validating structural integrity to a measured precision.

Scenario 1

"A" Frame TIS Loading = Real Load * 1.5 = 195t

""A" Frame TIS Loading = Real Load * 1.5 = 195t" obtains geometry from the ACIS® part "A_frame_3.sat".

 

·        The bounding box for the model measures 6,830.0 by 2,945.0 by 250.0 mm along the global x, y and z axes, respectively.

·        The model weighs a total of 1,795.71 kg.

 

Table: Parts

 

Figure 1 : Geometry

 

Mesh

·        "Mesh"(Fig 2) , associated with ""A" Frame TIS Loading = Real Load * 1.5 = 195t" has an overall relevance of 0.

·        "Mesh" contains 11122 nodes and 5382 elements.

 

No mesh controls specified.

 

Figure 2 : Mesh

 

  Environment Real Load * 1.5 = 195t

"Environment Real Load * 1.5 = 195t"(Fig 3) contains all loading conditions defined for ""A" Frame TIS Loading = Real Load * 1.5 = 195t" in this scenario.

The following tables list local loads and supports applied to specific geometry.

  Structural Loading

 

Table 2 : Structural Loading

Structural Loads
Name	Type	Magnitude	Vector	Reaction Force	Reaction Vector
"Fixed Support"	Surface Displacement	0.0 mm	[- x, 0.0 mm y, - z]	956,442.77 N	[0.0 N x, 956,442.77 N y, 0.0 N z]
"Fixed Support 2"	Surface Displacement	0.0 mm	[0.0 mm x, - y, 0.0 mm z]	5.85×10-3 N	[-3.54×10-3 N x, 0.0 N y, 4.66×10-3 N z]
"Force"	Surface Force	1.91×106 N	[0.0 N x, -1.91×106 N y, 0.0 N z]	N/A	N/A
"Fixed Support 3"	Surface Displacement	0.0 mm	[- x, 0.0 mm y, - z]	956,507.23 N	[0.0 N x, 956,507.23 N y, 0.0 N z]

 

 

 

 

Figure 3: Environment Real Load * 1.5 = 195t

 

Solution

"Solution" contains the calculated response for ""A" Frame TIS Loading = Real Load * 1.5 = 195t" given loading conditions defined in "Environment Real Load * 1.5 = 195t".

It was selected that the program would choose the solver used in this solution.

 

Structural Results

 

 

Table 3: Structural Results

Values
Name	Figure	Scope	Orientation	Minimum	Maximum	Alert Criteria
"Equivalent Stress"	4	""A" Frame TIS Loading = Real Load * 1.5 = 195t"	Global	0.93 MPa	253.06 MPa	None
"Total Deformation"	5	""A" Frame TIS Loading = Real Load * 1.5 = 195t"	Global	2.09×10-4 mm	2.89 mm	None
"Directional Deformation X"	6	""A" Frame TIS Loading = Real Load * 1.5 = 195t"	X Axis	-0.53 mm	0.53 mm	None
"Directional Deformation Y"	7	""A" Frame TIS Loading = Real Load * 1.5 = 195t"	Y Axis	-2.89 mm	0.29 mm	None
"Directional Deformation Z"	8	""A" Frame TIS Loading = Real Load * 1.5 = 195t"	Z Axis	-0.05 mm	0.03 mm	None

 

·        Convergence tracking not enabled.

 

 

Figure 4: "Equivalent Stress" Contours

Figure 5: "Total Deformation" Contours

 

Figure 6: "Directional Deformation X" Contours

 

Figure 7:"Directional Deformation Y" Contours

 

Figure 8: "Directional Deformation Z" Contours

Equivalent Stress Safety

 

 

Table 4: Stress Limit

 

 

Table 5: Safety Result

 

 

·        Convergence tracking not enabled.

 

 

Figure 9: "Safety Factor" Contours

Frequency Results

Frequency results apply to all active parts in ""A" Frame TIS Loading = Real Load * 1.5 = 195t".

 

Table 6: Natural Frequencies

 

 

·        Convergence tracking not enabled.

 

 

Figure 10: "1st Frequency Mode In Range" Contours

 

Figure 11: "2nd Frequency Mode In Range" Contours

 

Figure 12: "3rd Frequency Mode In Range" Contours

 

Scenario 2

 “A" Frame Real Loading 130t"

""A" Frame Real Loading 130t" obtains geometry from the ACIS^® part "A_frame_3.sat".

 

·        The bounding box for the model measures 6,830.0 by 2,945.0 by 250.0 mm along the global x, y and z axes, respectively.

·        The model weighs a total of 1,795.71 kg.

 

Table : Parts

 

 

 

Figure 13:  Geometry

 

 

Mesh

·        "Mesh"(Fig 14) , associated with ""A" Frame Real Loading 130t" has an overall relevance of 0.

·        "Mesh" contains 11122 nodes and 5382 elements.

 

No mesh controls specified.

 

Figure : Mesh

  

Environment Real Load 130t

"Environment Real Load 130t"(Fig 15) contains all loading conditions defined for ""A" Frame Real Loading 130t" in this scenario.

The following tables list local loads and supports applied to specific geometry.

Structural Loading

  

Table : Structural Loads

 

 

Figure : "Environment Real Load 130t"

 

 

Solution

"Solution" contains the calculated response for ""A" Frame Real Loading 130t" given loading conditions defined in "Environment Real Load 130t".

It was selected that the program would choose the solver used in this solution.

 

Structural Results

 

 

Table : Structural Results

 

·        Convergence tracking not enabled.

 

 

Figure 16: "Equivalent Stress" Contours

 

 

Figure 17: "Total Deformation" Contours

 

Figure 1: "Directional Deformation X" Contours

 

Figure : "Directional Deformation Y" Contours

 

Figure : "Directional Deformation Z" Contours

 

Equivalent Stress Safety

 

 

Table : Stress Limit

 

 

Table : Safety Result

 

·        Convergence tracking not enabled.

 

 

Figure 21: "Safety Factor" Contours

 

 

Frequency Results

Frequency results apply to all active parts in ""A" Frame Real Loading 130t".

 

Table 12: Natural Frequencies

 

·        Convergence tracking not enabled.

 

 

 

Figure 22: "1st Frequency Mode In Range" Contours

 

Figure 23: "2nd Frequency Mode In Range" Contours

 

Figure 24: "3rd Frequency Mode In Range" Contours

 

Scenario 3

“A" Frame Test Loading 250t

""A" Frame Test Loading 250t" obtains geometry from the ACIS^® part ""A_frame_3.sat".

 

·        The bounding box for the model measures 6,830.0 by 2,945.0 by 250.0 mm along the global x, y and z axes, respectively.

·        The model weighs a total of 1,795.71 kg.

 

Table 13: Parts

 

 

 

Figure 25: Geometry

 

 

Mesh

·        "Mesh"(Fig 26) , associated with ""A" Frame Test Loading 250t" has an overall relevance of 0.

·        "Mesh" contains 11122 nodes and 5382 elements.

 

No mesh controls specified.

 

Figure 26: Mesh

 

 

Environment Test Load 250t

"Environment Test Load 250t"(Fig 27) contains all loading conditions defined for ""A" Frame Test Loading 250t" in this scenario.

The following tables list local loads and supports applied to specific geometry.

5.2.1            Structural Loading

 

 

Table 14: Structural Loads

 

 

 

Figure 27: "Environment Test Load 250t”

 

 

 

 Solution

"Solution" contains the calculated response for ""A" Frame Test Loading 250t" given loading conditions defined in "Environment Test Load 250t".

It was selected that the program would choose the solver used in this solution.

 

Structural Results

 

 

Table 15: Structural Results

 

·        Convergence tracking not enabled.

 

Figure 28: "Equivalent Stress" Contours

 

Figure 29: "Total Deformation" Contours

 

Figure 30: "Directional Deformation X" Contours

 

Figure 31: "Directional Deformation Y" Contours

 

Figure 32: "Directional Deformation Z" Contours

 

 

Equivalent Stress Safety

 

 

Table 16: Stress Limit

 

 

Table 17: Safety Result

 

·        Convergence tracking not enabled.

 

 

Figure 33: "Safety Factor" Contours

 

 

Conclusions

The lowest safety factor of 0.85 occurs in the TIS loading scenario, where the max stress is 253.06 MPa. This is a very localized stress due to the constraints, and will have no effect in the real loading situation.

In the real life load case the safety factor is 1.27, with the max stress being 168.71 MPa, this being below the yield of the material.

In the case of loading with 250 tons which gives a 0.95 safety factor, with a max stress of 227.05 MPa, the stress is again very localized due to the constraints.

In conclusion the frame can be tested to 250 tons without any damage.