TAGLIATELA COLLEGE OF ENGINEERING

MECH 6627
Computer Aided Engineering
Analysis – Test Correlation Assignment

Submitted To :
Professor, GEORGE BAUER

Submitted By :
Dilipkumar Badugu

STUDENT ID : 00864812
November 11, 2024
Task 1: Stress Concentration, Plate with a Hole
Example 1 :
Plate geometry dimensions :
Thickness : 0.5 inches
Length : 6 inches
Width : 3 inches
Diameter : 1.25 inches

Selected geometry for this example 1 in this task 1

Applied load =10000 Ibs
Material properties and reference

I have used ASTM A36 Steel material for this

Example
Reference:
https://www.matweb.com/search/datasheet.aspx?MatGUID=a
fc003f4fb40465fa3df05129f0e88e6
Mesh plots

Mesh plot for this Example 1 in this task 1

Element types

Mesh Element type plot for this Example 1 in this

task 1
Node & Element count

Mesh Node & Element count figure for this

Example 1 in this task 1
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 1 in this task 1
Loads and boundary condition plots

Fixed support plot for this Example 1 in this task 1

 Force applied plot for this Example 1 in this task 1

Loads and boundary condition plot for this Example

1 in this task 1
Deformation plot

Deformation plot for this Example 1 in this task 1

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 1 in

this task 1

Normal stress unaveraged plot for this Example 1 in

this task 1

Force surface Normal stress averaged plot for this

Example 1 in this task 1
 Force surface Normal stress averaged plot for this
Example 1 in this task 1
Equivalent stress

Equivalent stress averaged plot for this Example 1

in this task 1

Equivalent stress unaveraged plot for this Example

1 in this task 1
Theory correlation and comment on model/element
accuracy
Calculation reference: Peterson, Stress Concentration Factors:

Excel calculations and Ansys result calculations

along with formulas used for calculations for this
Example 1 in this task 1
Comparison
Calculated Ktg = 3.811
Calculated σ Max = 25411.59 Psi
Calculated σ = 6666.666667 Psi
Ansys Results
Applied load, P=10,000 Ibs
Ktg = 3.8155
σ = 6668.8 Psi
σ Max = 25445 Psi
Comments
Calculated Ktg = 3.811 and Ansys calculations Ktg =
3.8155 have Very close correlation.
Calculated σ Max = 25411.59 Psi and Ansys calculations σ
Max = 25445 Psi have Very close correlation.
 Calculated σ = 6666.666667 Psi and Ansys σ = 6668.8
Psi have Very close correlation.
Applied load for both hand calculated and simulations
are 10,000 psi.
The Excel-calculated values for Ktg, σ Max, σ, are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.

Example 2 :
Plate geometry dimensions :
Thickness : 0.5 inches
Length : 8 inches
Width : 4 inches
Diameter : 1.5 inches

Selected geometry for this example 2 in this task 1

Applied load =10000 Ibs

Material properties and reference

I have used ASTM A36 Steel material for this

Example
Reference:
https://www.matweb.com/search/datasheet.aspx?MatGUID=a
fc003f4fb40465fa3df05129f0e88e6

Mesh plots

Mesh plot for this Example 2 in this task 1

Element types

Mesh Element type plot for this Example 2 in this

task 1
Node & Element count

Mesh Node & Element count figure for this Example

2 in this task 1
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 2 in this task 1
Loads and boundary condition plots

Force applied plot for this Example 2 in this task 1

Fixed support plot for this Example 2 in this task 1

Loads and boundary condition plot for this Example

2 in this task 1
Deformation plot

Deformation plot for this Example 2 in this task 1

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 2 in

this task 1
 Normal stress unaveraged plot for this Example 2 in
this task 1

Force surface Normal stress averaged plot for this

Example 2 in this task 1
Equivalent stress

Equivalent stress averaged plot for this Example 2

in this task 1
 Equivalent stress unaveraged plot for this Example
2 in this task 1
Theory correlation and comment on model/element
accuracy
Calculation reference: Peterson, Stress
Concentration Factors:

Excel calculations and Ansys result calculations

along with formulas used for calculations for this
Example 2 in this task 1
Comparison
Calculated Ktg =3.624625
Calculated σ Max =18123.125 Psi
Calculated σ =5000 Psi
Ansys Results
Applied load, P=10,000 Ibs
Ktg = 3.707087874
σ = 5001.5 Psi
σ Max = 18541 Psi
Comparison
Calculated Ktg = 3.624625 and Ansys calculations Ktg =
3.707087874 have Very close correlation.
Calculated σ Max = 18123.125 Psi and Ansys calculations
σ Max = 18541 Psi have Very close correlation.
Calculated σ = 5000 Psi and Ansys σ = 5001.5 Psi have
Very close correlation.
Applied load for both hand calculated and simulations
are 10,000 psi.
The Excel-calculated values for Ktg, σ Max, σ, are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.
Task 2: Bending Stress and Deflection in a
Cantilever Beam
Example 1 :
Plate geometry dimensions :
Height, h : 2 inches
Length, L : 20 inches
Width, b : 1 inches

Selected geometry for this Example 1 in this task 2

Applied load =10000 Ibs

Material properties and reference

I have used AISI 4340 Steel material for this

Example
Reference:
https://www.matweb.com/search/DataSheet.aspx?MatGUID=f
d2df45bffa54018b54989bc14092d9f
Mesh plots

Mesh plot for this Example 1 in this task 2

Element types

Mesh Element type plot for this Example 1 in this

task 2
Node & Element count

Mesh Node & Element count figure for this Example

1 in this task 2
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 1 in this task 2
Loads and boundary condition plots

Force applied plot for this Example 1 in this task 2

Fixed support plot for this Example 1 in this task 2

Loads and boundary condition plot for this Example

1 in this task 2
Deformation plot

Deformation plot for this Example 1 in this task 2

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 1 in

this task 2
 Normal stress unaveraged plot for this Example 1 in
this task 2
Equivalent stress

Equivalent stress averaged plot for this Example 1

in this task 2
 Equivalent stress unaveraged plot for this Example
1 in this task 2
peak bending stress ½ inch away from the fixed boundary
condition.

peak bending stress ½ inch away from the fixed

boundary condition averaged plot for this Example
1 in this task 2
 peak bending stress ½ inch away from the fixed
boundary condition unaveraged plot for this
Example 1 in this task 2
Theory correlation and comment on model/element
accuracy

Excel calculations and Ansys result calculations

along with formulas used for calculations for this
Example 1 in this task 2
Comparison
Calculated Deflection, Y=1.38 inches
Calculated stress value from 0.5/(1/2) inch away from
fixed end=292500 psi
Applied load, P=10000 ibs
Ansys Results
Deflection, Y=1.38 inches
 Stress value from 0.5/(1/2) inch away from fixed end=
290910 psi
Applied load, P=10000 ibs
Comments
Calculated Deflection, Y=1.38 inches and Ansys
Deflection, Y=1.38 inches have Very close correlation.
Calculated stress value from 0.5/(1/2) inch away from
fixed end=292500 psi and Ansys Stress value from
0.5/(1/2) inch away from fixed end= 290910 psi have
Very close correlation.
The Excel-calculated values for Deflection, Y and stress
value from 0.5/(1/2) inch away from fixed end are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.
Example 2 :
Plate geometry dimensions :
Height, h : 3 inches
Length, L : 25 inches
Width, b : 2 inches

Selected geometry for this example 2 in this task 2

Applied load =10000 Ibs
Material properties and reference

I have used 6061-T6 Aluminium Alloy material for

this Example.
Reference:
https://www.matweb.com/search/datasheet.aspx?MatGUID=b
8d536e0b9b54bd7b69e4124d8f1d20a
Mesh plots

Mesh plot for this Example 2 in this task 2

Element types

Mesh Element type plot for this Example 2 in this

task 2
Node & Element count

Mesh Node & Element count figure for this Example

2 in this task 2
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 2 in this task 2
Loads and boundary condition plots

Fixed support plot for this Example 2 in this task 2

 Force applied plot for this Example 2 in this task 2

Loads and boundary condition plot for this Example

2 in this task 2
Deformation plot

Deformation plot for this Example 2 in this task 2

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 2 in

this task 2

Normal stress unaveraged plot for this Example 2 in

this task 2
Equivalent stress

Equivalent stress averaged plot for this Example 2 in this

task 2

Equivalent stress unaveraged plot for this Example 2 in

this task 2
peak bending stress ½ inch away from the fixed boundary
condition.

peak bending stress ½ inch away from the fixed

boundary condition averaged plot for this Example 2 in
this task 2

peak bending stress ½ inch away from the fixed

boundary condition averaged plot for this Example 2 in
this task 2
Theory correlation and comment on model/element
accuracy

Excel calculations and Ansys result calculations along

with formulas used for calculations for this Example 2 in
this task 2
Comparison
Calculated Deflection, Y=1.16 inches
Calculated stress value from 0.5/(1/2) inch away from
fixed end=81666.67 psi
Applied load, P=10000 ibs
Ansys Results
Deflection, Y=1.16 inches
 Stress value from 0.5/(1/2) inch away from fixed end=
81539 psi
Applied load, P=10000 ibs
Comments
Calculated Deflection, Y=1.16 inches and Ansys
Deflection, Y=1.16 inches have Very close correlation.
Calculated stress value from 0.5/(1/2) inch away from
fixed end=81666.67 psi and Ansys Stress value from
0.5/(1/2) inch away from fixed end= 81539 psi have Very
close correlation.
The Excel-calculated values for Deflection, Y and stress
value from 0.5/(1/2) inch away from fixed end are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.
Task 3: Axial Stress Concentration Due to a
Shoulder Fillet
Example 1 :
Plate geometry dimensions :
Big Diamater, D : 2 inches
Small Diameter, d : 1 inches
Radius, r : 0.5 inches

Selected geometry for this example 1 in this task 3

Applied load =10000 Ibs
Material properties and reference

I have used 304 Stainless steel material for this

Example.
Reference:
https://matweb.com/search/DataSheet.aspx?MatGUID=abc44
15b0f8b490387e3c922237098da
Mesh plots

Mesh plot for this Example 1 in this task 3

Element types

Mesh Element type plot for this Example 1 in this

task 3
Node & Element count

Mesh Node & Element count figure for this Example

1 in this task 3
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 1 in this task 3
Loads and boundary condition plots

Force applied plot for this Example 1 in this task 3

Fixed support plot for this Example 1 in this task 3

 Loads and boundary condition plot for this Example
1 in this task 3
Deformation plot

Deformation plot for this Example 1 in this task 3

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 1 in this

task 3

Normal stress unaveraged plot for this Example 1 in

this task 3
 Force surface Normal stress averaged plot for this
Example 1 in this task 3
Equivalent stress

Equivalent stress averaged plot for this Example 1

in this task 3
 Equivalent stress unaveraged plot for this Example
1 in this task 3
Theory correlation and comment on model/element
accuracy

Excel calculations and Ansys result calculations

along with formulas used for calculations for this
Example 1 in this task 3
Comparison
Calculated Ktg, From the graph (peak stress
concentration at the edge of a shoulder fillet) = 1.32
Calculated σ Max = 16380.64 Psi
Calculated σ = 12732.4 Psi
Applied load, P=10,000 Ibs
Ansys Results
Applied load, P=10,000 Ibs
Ktg (peak stress concentration at the edge of a shoulder
fillet) = 1.3165
σ = 12733 Psi
σ Max = 16763 Psi
Comments
Calculated Ktg = 1.32 and Ansys calculations Ktg =
1.3165 have Very close correlation.
Calculated σ Max = 16380.64 Psi and Ansys calculations σ
Max = 16763 Psi have Very close correlation.

Calculated σ = 12732.4 Psi and Ansys σ = 12733 Psi

have Very close correlation.
Applied load for both hand calculated and simulations
are 10,000 psi.
The Excel-calculated values for Ktg, σ Max, σ, are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.
Maximum stress concentration happen at shoulder fillet.
Example 2 :
Plate geometry dimensions :
Big Diameter, D : 3 inches
Small Diameter, d : 1.5 inches
Radius, r : 1 inches

Selected geometry for this example 2 in this task 3

Applied load =10000 Ibs
Material properties and reference
 I have used 304 Stainless steel material for this
Example.
Reference:
https://matweb.com/search/DataSheet.aspx?MatGUID=abc44
15b0f8b490387e3c922237098da
Reason for darkness of geometry in following plots due to
higher number of nodes for getting accurate results.
Mesh plots

Mesh plot for this Example 2 in this task 3

Element types
 Mesh Element type plot for this Example 2 in this
task 3
Node & Element count

Mesh Node & Element count figure for this Example

2 in this task 3
Element Quality bar chart distribution for model

Element Quality bar chart distribution for model

figure for this Example 2 in this task 3
Loads and boundary condition plots

Force applied plot for this Example 2 in this task 3

Loads and boundary condition plot for this Example

2 in this task 3
 Fixed support plot for this Example 2 in this task 3
Deformation plot

Deformation plot for this Example 2 in this task 3

Stress results plots with and without nodal averaging
Normal stress

Normal stress averaged plot for this Example 2 in

this task 3

Normal stress unaveraged plot for this Example 2 in

this task 3
 Force surface Normal stress averaged plot for this
Example 2 in this task 3
Equivalent stress

Equivalent stress averaged plot for this Example 2

in this task 3
 Equivalent stress unaveraged plot for this Example
2 in this task 3
Theory correlation and comment on model/element
accuracy

Excel calculations and Ansys result calculations

along with formulas used for calculations for this
Example 2 in this task 3
Comparison
Calculated Ktg, From the graph (peak stress concentration
at the edge of a shoulder fillet) = 1.24983
Calculated σ Max = 7072.59 Psi
Calculated σ = 5658.842 Psi
Applied load, P=10,000 Ibs
Ansys Results
Applied load, P=10,000 Ibs
Ktg (peak stress concentration at the edge of a shoulder
fillet) = 1.25
σ = 5658.9 Psi
σ Max = 7086.3 Psi
Comments
Calculated Ktg = 1.24983 and Ansys calculations Ktg =
1.25 have Very close correlation.
Calculated σ Max = 7072.59 Psi and Ansys calculations σ
Max = 7086.3 Psi have Very close correlation.

Calculated σ = 5658.842 Psi and Ansys σ = 5658.9 Psi

have Very close correlation.
Applied load for both hand calculated and simulations
are 10,000 psi.
The Excel-calculated values for Ktg, σ Max, σ, are
extremely close to the ANSYS results, showing a good
correlation. So, the simulation is correct.
Maximum stress concentration happen at shoulder fillet.