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UNIVERSITY OF HOUSTON

COMPUTER-AIDED DESIGN
MID-TERM
PROJECT 1
Spring 2017

STUDENT: EVAN JAMES I.D.: 1297585

INSTRUCTOR: Dr. Pascali DATE: 3/9/2017

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TABLE OF CONTENT

INTRODUCTION: (3)

PROCEDURE: (4 - 8)

DISCUSSION: (9)

CONCLUSION: (10)

RESULTS:
Analytical Calculations (11 14)
Ansys: Maximum Shear Stress (15)
Ansys: Safety Factor (16)
Creo: Maximum Shear Stress (17)
Creo: Maximum Principle Stress (18)
Creo: Minimum Principle Stress (19)
Creo: Safety Factor (20)
Percent Error Analysis: (21)

DEFINTIONS: (22)

REFERENCES: (23)

APPENDICES: (24)
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INTRODUCTION:
Shaft is to rotate at 900 rpm as it transmits 7000 Nm torque from a API 17D standard torque tool
to a generator and this is the only loading case on the shaft. The material specified in the design
is A500 Steel. To goal of this project is to determine/evaluate the following cases for the shaft.
a) Maximum shear stress on the shaft
b) Principal stresses on the shaft
c) Material yield criteria for selected material
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PROCEDURE
To help visualize the effects of combined stress, it is helpful to know how an element of a
certain load carrying member combined with normal and shear stresses act. For this
project, we will consider a two-dimensional stress condition, as illustrated in Figure 1-1.
The x- and y-axes are aligned with corresponding axes on the member being analyzed.

Figure 1-1.
In this project, our model is undergoing a torsional load causing a Shear stress.
The double-subscript notation helps to orient the direction of shear stresses. For example,

indicates the shear stress acting on the element face that is perpendicular to the x-
axis and parallel to the y-axis.

In Figure 1-1, is positive, and is negative. Their magnitudes must be equal to

maintain the element in equilibrium.
One must understand that It is necessary to determine the magnitudes and the
signs of each of these stresses to show them properly on the stress element. To, illustrate
the process we will follow the definition of principal stress equations.
With the stress element defined, the objectives of the remaining analysis are to
determine the maximum normal stress and the maximum shear stress. The formulas
needed are as follows.
Maximum Normal Stresses: Principal Stresses
The combination of applied normal and shear stresses produce the maximum normal
stress called the maximum principal stress. The magnitude of Sigma can be computed
from the following equation:

The combination of the applied stresses that produce the minimum normal stress is called
the minimum principal stress, its magnitude can be computed from the following
equation.
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Maximum Shear Stress

On a different orientation of the stress element, the maximum shear stress will occur. Its
magnitude can be computed from

Torsional Deformation
When a shaft experiences torque, it pursues a twisting motion in the shaft about a certain
axis, in this case the Z axis. Torsional deformation is also referred to as angle of twist
which is computed from the following equation

Holographic Analysis
We will study the effects of stress on an element undergoing torsional loading using
Holographic Anamorphous. One must understand the directions and magnitudes of each
stress acting on the element. To implement Anamorphosis one must see the model from a
unique perspective requiring the viewer to use a special device to observe from a specific
vantage point to reconstitute the element. This project was developed to calculate shear
stress, angle of twist and polar moment of inertia parameters of a shaft which is under
torsion.
Note that Torsion is causing the object to twist due to an applied load. When the shaft
twists, one end rotates relative to the other and shear stresses are produced. Shear stress is
zero on the axis passing through the center of a shaft under torsion and maximum at the
outside surface of a shaft. On an element where shear stress is maximum, normal stress is
zero.
Note that the shaft has a dimensional change in
its geometry. The location of various stresses is
most likely to concentrate at discontinuities in a
member. The ratio of peak stress near stress riser
to average stress over the member is called stress
concentration factor. For fillet in a stepped
circular shaft we refer to the chart shown in
Figure 1-2 to determine the stress concentration
factor known as "Kt". The value of "Kt" will be
used to determine the maximum shear stress
acting on the element.
Figure 1-2
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Creating the model

For this project, I decided to use a free online CAD system called on shape. On shape is
the first and only full-cloud 3D Cad system that lets everyone on a design team work
together using any web browser, phone, or tablet.
To begin visit www.onshape.com and create a free account to sign in.
After signing in users have access to a dashboard shown in Figure 2.
Press create to begin the creation process. Select the sketch icon

located on the top tool bar. Select the Front plane

to begin building the smaller cylinder by creating a circle

using the circle icon with a diameter of 60mm. To

adjust system units, select the icon located on the top tool bar

and select Workspace Units. Next locate the extrude icon to

enter a value of 76.66mm. Repeat the sketching process selecting
Front for the drawing plane. Create a circle with a diameter of 100mm. Select the extrude

icon and enter a value of 10mm. Notice the reverse extrusion icon which allows
users to extrude in the opposite direction.
Once the body has been built we can now create the fillet by selecting the fillet icon

and entering a fillet radius of 5mm. Congrats we have completed the model. Once
satisfied with the design export the model as a IGES by proceeding to the lower part of
the screen and right clicking on the model tab to select export.
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ANSYS
In terms of loading, dynamic means energetic, an element that experiences a constant
loading and unloading in a repeated fashion, while static means stationary or fixed. In this
project, our model is stationary and fixed. To begin the analysis, select static structural
from the loading type menu on the left side of the screen.
Since we have created a model we can easily import the IGES file into Ansys. Right click
geometry and select browse to search for the location of the IGES file. After imported
double click on engineering data to edit the material properties. The material used is AISI
1137 Cold-Drawn steel with a yield strength of 565 and an ultimate stress of 656.
Other properties such as Young's modulus and poisons ratio can be set but for structural
steels these usually remain the same. Once we have completed our property settings and
successfully imported our model we can now add the loading conditions to analyze the
shaft. By right clicking on "model" select edit to open the "mechanical" window where
we will first generate a mesh to closely approximate the geometries domain. Click mesh
and look below to edit "element size". For this project, I chose an element size of 0.1
mm. As you edit the element size notice the network of wire and thread becomes closure
the smaller the element size. Right click and select "generate mesh" to complete mesh
settings. Next in our procedure we must tell Ansys where we would like our model to be
fixed. As shown in Figure 1-3 our model is attached to the torque tool by six bolts but for
simulation purposes we will only select the outer surfaces of the larger diameter circle to
simulate its fixture. Right click on static structural and select insert/support/fixed and
while holding the shift key select the end surface and outer surface. On the left side of the
window Confirm selection by finding the highlighted geometry selection and click apply.
We have now successfully added fixed supports to our model. Using the same process,
we will add a moment to the opposite end of the shaft. In the same fashion right click
static structural and select insert/loads/moment and click the surface of the smaller
cylindrical as shown in Figure 1-4. On the left side of the window Confirm selection by
finding the highlighted geometry selection and click apply. Next scroll down a bit in the
same window to enter the applied torque load of 7000 Nm. Now that we have indicated
our stress conditions we can now tell Ansys what to solve. For this project, we are
solving for maximum stress, normal stress and a safety factor for this material. Right
click solution and choose insert/stress/maximum stress. Repeat and select
insert/stress/normal stress. Repeat and select insert/stress/stress tool. As you select these
solutions you can see them appear as nodes under solution tree. Now we are ready to
solve by right clicking solution and selecting solve to begin the solving process.
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PTC Creo Parametric

This project practices the use of three softwares PTC Creo Parametric, Visual Studios
and Ansys. In this section, we analyze the maximum stress on an element using PTC
Creo Parametric. Unlike Ansys, PTC has concerns with imported files. PTC believes it is
protecting integrity. For reasons known we will design our model using Creo Parametric
To Create a model, select new from the home tab and select part as type. To begin
creating a model select sketch from the top tool bar. Select front for the sketching plane
and press the sketch button to exit window. Next begin by creating a circle with a
diameter of 100 mm. Select the green check icon to complete sketch. Find the extrude
icon to extrude the circle to a depth of 10mm.Select the green check mark to complete
extrusion. Next, we repeat the same process but instead start by selecting the front surface
of the circle we just made to sketch from the surface of the previous extrusion. Create a
circle with a diameter of 60mm and find the extrude icon to extrude to a depth of
76.66mm. Select the green check icon to complete extrusion. We have now successfully
created the body of our model. Now we can add fillet between the two extrusion by
selecting the round icon located on the top tool bar under the model tab. Click the edge
between the larger circle and the smaller circle and create a fillet radius of 10mm. Select
the green check icon to complete fillet radius.
We have now successfully built a model fulfilling design requirements. Now we can
assign material properties the Creo can now analyze. To begin finding the maximum
shear stress we start by selecting simulate located under the Application tab in top
toolbar. After starting simulate apply the load and constraints. To add constraints, select
displacements under the home tab and select the back surface of the larger circle to
apply a fixed condition. Select ok to complete constraint. To simulate torque, we must
create a moment about the z axis. Select Force/Moment tab located at the top tool bar
under the home tab. Select the front surface of the smaller circle as our reference. At the
bottom of the force/moment window locate the section called moment and enter a value
of 7000 Nm for the Z axis input. Select ok to complete moment condition. A mesh can be
generated by selecting Auto Gem in the refine model tab.
Now that our environment conditions have been we can now select and enter the analyses
and studies tab located on the top tool bar under the home tab. To gather results, we must
first run a static analysis to pre-determine the effects of the element. Once you have
completed the static analysis select results.
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DISCUSSION:
As a student of mechanical engineering who is trained to solve problems using analytical
and computational methods. In most cases students can only imagine the actual size of a
structure or element that is being designed. With holographic Anamorphosis this is no
longer an excuse. To explain how holographic Anamorphosis relates to mechanical
engineering Figure 3 shows a holographic representation of the shaft we made earlier in
its actual dimensions. The shaft is to rotate at 1900 RPM as it transmits 7000 Newton
meters of torque from a 17D API standard Torque tool. The material specified in the
design is AISI 1137 Cold-Drawn steel. As shown in Figure 3 the diameters we made in
Creo and Ansys have been transferred to our holographic simulation. With these
diameters, we can calculate Modulus of Rigidity, power requirements, polar Moment of
Inertia, Normal Shear Stress, Angle of twist, Maximum Principle Stress, Minimum
Principle, Angle o Principle Stress, Angle of Maximum Shear Stress, stress concentration
factor, and Safety Factor. Figure 3

Each calculation is based on a

series of equations, refer to the
results sections to view equations.
to calculate normal shear stress on
the shaft notice that T" is equal
to 7000 newton meters of torque
to be transmitted. The larger shear
stresses occur on the smaller
diameter section of the shaft and
for that we will use "d" the
diameter of the smaller section
in the equation for polar moment of inertia. Polar moment of inertia is a circular beams
ability to resist torsion. Normal shear can be calculated using the polar moment of inertia
divided by the torque multiplied by the radius of the smaller diameter. Since our shaft is
purely under torsion the normal stresses acting in the X and Y plane are equal to that of
the shear stress though for making a maximum and minimum principle stress of 165.05
MPa, -165.05 MPa and a shear stress of 165.05 MPa.
There is a shoulder fillet in the shaft. Using the system, I created we can quickly calculate
the stress concentration factor "Kt" by clicking the start button to begin the simulation.
To calculate the Maximum stress, we must multiply the normal shear with the stress
concentration value.
The selected material is ductile since elongation at break is greater than 5%. For the
evaluation of yield criteria for a ductile material undergoing torsion we I used the
maximum shear stress theory which divides the yield strength by the maximum principle
stress minus the minimum principle stress, which should give us a value close to 1.712.
Copyrights owned by Evan James
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CONCLUSION:
In conclusion, we learned that stress is largely dependent on the materials property. Depending
on the Young's modulus of a material the modulus of rigidity may change, you can examine this
change using the Finite element analysis I created. By changing the modulus of rigidity, the
angle of which the material may twist due to a torsional load will change. These are matters that
are not always clear during lectures of a college class room, the ability to think of these very
small but essential elements of a design.
During my studies with Ansys I ran in to a problem with node limitations. Depending on the type
of license a user owns Ansys may choose to reject a engineers simulation if it is over a certain
number of nodes. To fix this problem I found that I needed to lower the modulus of rigidity to fit
the limits of the simulation. Because the results of a tensile test aren't always the same yielding a
different modulus of rigidity may results in a small variance in the simulated results vs hand
calculated results.
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RESULTS
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ANSYS: Maximum Shear Result

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ANSYS: Safety Factor Result

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Creo Parametric: Maximum Shear Stress

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Creo Parametric: Maximum Principle Stress

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Creo Parametric: Minimum Principle Stress

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Creo Parametric: Safety Factor

Unlike Ansys, Creo doesnt have a function to calculate the safety factor of an element. Therefor
we must use the information given to manually calculate using the maximum shear stress theory
equation for safety factor which is defined by calculating the ultimate yield strength of the
material which is 565 MPa divided by the maximum principle stress minus the minimum
principle shear stress. As shown in graphs the maximum principle stress for the element as
calculated by Creo is 170 MPa and the maximum principle stress is 166.5 MPa. The sum of these
numbers give us a safety factor of 1.564

Figure 4
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PERCENT ERROR
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DEFINITIONS:
Homogeneous Material: Material that has the same material properties.

Modulus of elasticity (Youngs modulus): The rate of change between tensile or compressive

stress with respect to a elements tensile or compressive strain. Mostly studied for one direction

stress. Typical values: Aluminum: 69 GPa, Steel: 200GPa.

Modulus of rigidity (modulus of elasticity in shear): The rate of change in shear stress with re-

spect to shear strain for an element undergoing pure shear. Typical values Aluminum 6061-T6:

24 GPa, Structural Steel: 79.3 GPa.

Poissons ratio: The ratio between vertical strain and horizontal strain under the condition of uni-

form and uniaxial stress.

Stress Concentration Factor: The ratio of peak stress near stress riser to average stress over the

member is called stress concentration factor

Maximum Shear Stress Angle: The angle of maximum in-plane shear stress at some point.

Normal Stress: Stresses that act perpendicular to the cross section.

Principal Stress: Maximum and minimum normal stresses on an element.

Principal Angle: The angle of which principal stresses occur.

Shear stress: A form of a stress that acts parallel to the cross section.
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REFERENCES
Budynas.R , Nisbett.K . (2014) . Shigley's Mechanical Engineering Design . 10th edi-

tion. McGraw-Hill

Beer.F.P. , Johnston.E.R. (1992). Mechanics of Materials , 2nd edition. McGraw-Hill

Pilkey, W. D..(2005). Formulas for Stress, Strain, and Structural Matrices .2nd Edition John Wiley

& Sons

Young, W. C., Budynas, R. G.(2002). Roark's Formulas for Stress and Strain .7nd Edition

McGraw-Hill

Pilkey, W. D..(2005). Formulas for Stress, Strain, and Structural Matrices .2nd Edition John Wiley

& Sons
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APPENDICES:

Figure 4- Scaled Holographic visualization of model

View Video here:

https://www.youtube.com/watch?v=bFWZiuNGy6A
Comments:
System is pre alpha built control functions are not written for this video, user are only able to move the
model and view element properties. In later version users will be able to select start to begin simulation
and results will be seen in view.
In Figure 5 the results obtained from the system analysis are displayed
in the inspector window.

Figure 5
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