Faculty Simulaion Lab Manual

RISE KRISHNA SAI PRAKASAM GROUP OF INSTITUTIONS SIMULATION LAB
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Computer-aided design is essentially based on a versatile and powerful

technique called computer graphics, which basically means the criterion and manipulation of
pictures on a display device with the aid of a computer. Computer graphics originated at the
Massachusetts institute of technology (MIT) in 1950 when the first computer-driven display, linked
to a Whirl wind computer, and was used to generate some pictures. The first important step
forward in computer graphics came in 1963 when a system called SKETCHPAD was
demonstrated at the Lincoln Laboratory of MIT. This system consists of a cathode ray tube(CRT)
driven by TX2 computer. The CRT had a keyboard and a lightpen. Pictures could be drawn on the
screen and then manipulated interactively by the user via the lightpen.
This demonstration clearly showed that the CRT could potentially be used as a
designer’s electronic drawing board with common graphic operations such as scaling, translation,
rotation, animation and simulation automatically performed at the ‘push of a button’. At that time,
these systems were very expensive; therefore they were adopted only in such major industries as
the aircraft and automotive industries where their use in design justified the high capital costs.
Another crucial factor preventing computer graphics from being generally applied to engineering
industries was that there was a lock of appropriate graphics and application software to run on these
systems. However, a computer-based design system was clearly emerging. Since these pioneering
developments in computer graphics, which had captured the imagination of the engineering industry
all over the world, new and improved hardware, which is faster in processing speed, larger in
memory, cheaper in cost and smaller in size, have become widely available.
Sophisticated software techniques and packages have also been gradually
developed. Consequently, the application of CAD in industry has been growing rapidly. Initially
CAD systems primarily were automated righting stations in which computer controlled plotters
produced engineering drawings. The system were later linked to graphic display terminals
where geometric model describing part dimensions were created and the resulting data base in the
computer was then used to produce drawings. Now a day, CAD systems can do much more than
righting. Some systems have analytical capabilities that allow parts to be evaluated with techniques
such as the finite element method. There are also kinematics analysis programs that enable the
motion of mechanism to be studied. In addition, CAD system includes testing techniques to
perform model analysis on structures, and to evaluate the irresponsive to pinpoint any possible
DEPARTMENT OF MECHANICAL ENGINEERING Page1

effects. Computer Aided Design is the process of developing and using computer assisted design
tools in the design process. The advent of computers has contributed to significant advance in
calculation, data handling and utilization applications. The ability to use the computers in this
application is as enhances the capability of the design team significantly. Drafting and
geometric modeling play significant roles in CAD. Three different CAD systems are referred to
in the module. The syllabus includes: historical development, the design process, traditional
drawing practice and the development of the CAD industry, system hardware, computers micros to
mainframes, output devices, storage, workstations, networked systems, examples of CAD systems;
simple entity descriptions :points, lines, arcs, made-edge lists, free-form curves, free-form surfaces;
transformations :pan, rotate and scale,3D transformations, observer angles, perspective, depth
cueing; geometric modeling: wireframe modelers, surface modelers, solid modelers (CSG and B-
rep), hidden line removal and mass properties; user interface: input devices, menus, graphics
interface language, parametric.
LEARNING OBJECTIVES:
1. To understand and handle design problems in a systematic manner.
2. To be able to use the capabilities provided by computers for calculations, data handling
and visualization applications.
3. To gain practical experience in handling 2D drafting and 3D modeling software
systems
4. To be able to apply CAD in real life applications.
ROLEOFCOMPUTERSINDESIGN:
As manual design process has several risk factors including human fatigue and the
evaluation of design based on his previous experience. With the advent of computer and the
development in the field of computer graphics, various design & manufacturing process takes place
new fast with minimum or optimum error. Implementation of computer in the design stage becomes
the subset of design process. Once the conceptual design materializes in the designer mind the
geometric model starts by the appropriate CAD software. The choice of geometric model to CAD is
analogous to the choice. The various design related tasks which are performed by a modern
computer-aided design system can be grouped into four functional areas:
1. Geometric Modeling.
2. Engineering Analysis.

3. Design review and evaluation.

4. Automated drafting.
Geometric Modeling:
It is concerned with the computer compatible mathematical description of the geometry
of an object. The mathematical description allows the image of the object to be displayed &
manipulated on a graphics terminal through signals from the CPU of the CAD system. The software
that provides geometric modeling capabilities must be designed for efficient use both by the
computer & the human designer.
During the geometric modeling computer converts the command into a mathematical model,
stores it in the computer data files, and display it as an image on the CRT screen. Object can be
represented by geometric model by wireframe, surface model or solid model. Another feature of
CAD system is color graphics capability. By means of color, it is possible to display more
information on the graphics screen.
Engineering Analysis:
The analysis may involve stress-strain calculation, heat transfer computation etc., of the
system being displayed. It is often necessary that specific programs be developed by the
engineering analysis group to solve particular design problem. In other situation, commercially
programs available used to perform the engineering analysis. Analysis may be:
a. Mass property analysis.
b. Finite element analysis.
The analysis of mass properties is the analysis feature of CAD system which provides
properties of solid object being analyzed, such as the surface area, weight, volume, centre of
gravity and moment of inertia. In FEA the object is divided into large number of finite elements
which form interconnecting network concentrated nodes. By using a computer with significant
computational Capabilities, the entire object can be analyzed for stress-strain, heat transfer
coefficient at nodes. By determining the interrelating behaviors of all nodes in the system, the
behavior of the entire object can be assessed.

Design review &Evaluation;

Checking the accuracy of the design can be accomplished conveniently on the
graphical terminal. Semi-automatic dimensioning and tolerance routines which assign size
specification to surface indicated by the user help you to reduce the possibility of
dimensioning errors. One of the most important evaluation features available on some
computer aided design systems is KINEMATICS. The available kinematics packages provide
the capability to animate the motion of the simple designed mechanisms such as hinged
component & linkages. Commercial kinematics software available is ADAMS (Automatic
Dynamic Analysis of Mechanical Systems).
Automated Drafting:
It involves the creation of hard-copy engineering drawings directly from the CAD data
base. Most of the CAD systems are capable of generating as many as six views of the parts.
Engineering drawings can be made into company drafting standard by programming the standards
into the CAD system. Implementation of computer in the design stage becomes the subset of
design process. Once the conceptual design materializes in the designer mind the geometric model
starts by the appropriate CAD software. The choice of geometric model to CAD is analogous to the
choice of a mathematical model to engineering analysis. A valid geometric model is created by
definition translator, which converts the designer input into the proper data base format. In order to
apply engineering analysis in geometric model, interface algorithms are provided by the system to
extract the required data from the model data base to perform the analysis. In case of FEA, these
algorithms from the finite element modeling package of the system. Design testing&
evaluation may require changing the geometric model before finalizing it. When the final design
is achieved the drafting & detailing of the model starts followed by documentation & production of
final drawings.

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The components of a typical CAD system are illustrated in the following figure. The central
processing unit (CPU) is the brain of the entire system. It contains of integrated circuits of (IC)
of three parts – ALU, controller and main memory unit. The arithmetic logic unit (ALU)
consists of electronic circuits, which perform logic and mathematical operations. Controller
circuits are used to regulate various operations carried out in the computer. Main memory
circuits store processed data, such as results of calculations and program instructions inside the
computer. Hundreds of electronic circuits are reduced and etched on chip as small as a pinhead.
The CPU is, therefore, one of the miracles of modern electronic technology.
In the CAD system, the functions of the CPU as follow:
i) To receive information from the workstation and display the output on a CRTscreen.
ii) To red the data stored in a secondary memory storage unit.
iii) Togiveinstructionstooutputdevicessuchasplotterstocreatepermanent drawings.
iv) To transmit data to and from magnetic tapes.
In addition to main memory circuits in CPU, secondary storage capacity is provided to reduce the
cost of the main computer. The functions of the secondary storage unit are as follows:
i) To store files related to the engineering drawings;
ii) To store CAD software ; and
iii) To store programs required to give instructions to output devices like plotters.
The secondary storage unit consists of magnetic tapes and disks. Magnetic tape is similar to
the tape used in a tape recorder. It consists of Mylar tape coated with magnetic material. The data
are stored in the form photo magnetized spots. The data can be erased and reused. The data are
stored sequentially, i.e. to find a certain piece of data on the tape; one must wind the tape till the
data are reached. This is called the sequential access method. Magnetic tapes are cheap but the
access time for data retrieval is more due to sequential access. They are mainly used for archiving
drawings.
There are two types of magnetic disks – flexible and hard. The appearance of flexible disk
is similar to that of a phonographic record. It is, however, thin and flexible compared with records,
hence name floppy disk. The flexible disk is made of plastic like material – Mylar – with a thin
coating of magnetic material such as ferric oxide. The data can be stored on the one side of the disk
(single) or on both surfaces (dual). The standard diameters of floppy disks are 131mm and 200mm

the disk is always kept in a square vinyl jacket for protection against dust particles and scratching.
There is a small cut section in the jacket, called window. Reading and writing is accomplished
through this window by means of a drive-head. The speed of rotation of the disk is usually
300r.p.m. The construction of the hard disk is similar to that of a flexible disk. It is, however, made
from thin aluminum plate coated with ferric oxide. The disk is usually sealed in an airtight
container and rotates at a much faster speed of 3600rpm. This increases speed of storage and
retrieval of information. A hard disk is more durable than a floppy disk. Cost is the main limitation
of this disk. There are two methods to store data on flexible as well as hard disks– sequential and
random access methods. In the sequential search method, data are stored in a sequence and the
drive head has to search for a piece of information, starting from the beginning of the
track. This increases the search depending upon the location of the information. The random
access method is also called the direct access method. In this method, data stored on the disk are
divided into two or more sections. When the section number is specified, the drive head directly
moves to the relevant section and starts searching the data. Random access method is a faster
method of data retrieval.
The computer systems used for CAD are of three types – mainframe, mini and micro. The
mainframe system consists of a large capacity computer kept in a remote air-conditioned room.
Strict environmental controls are needed for this system. The workstations are located at some
distance from this central system. The mainframe system executes a number of functions, CAD
being one of them. This system is more powerful than mini or micro systems, with fast
computing speeds. Due to large memory capacity it can process the most difficult programs.
Compared with the mainframe system, the microcomputer is small and inexpensive. It,
however, operates at a slightly lower speed and is not able to process some of the difficult
programs, which can be run on the mainframe system. Minicomputers are usually housed in an air-
conditioned room. The microcomputer is the smallest type of CAD system. It does not require strict
environmental controls. A graphic display station and keyboard is normally combined in to a micro
unit. These units are called desktop computers. A microcomputer system is called a dedicated
system, because it operates for the sole purpose of one user at a time. This system is cheap and
easily available, but has limited capacity and speed.

The workstation is a visible part of the CAD system, which provides interaction between
the operator and the system. There are two elements of a basic workstation – a CRT display and an
alphanumeric keyboard. Other input devices, such as cursor control devices, digitizers and graphic
tablets, are provided on elaborate workstations. Graphic display terminals and input devices are
discussed in the forthcoming sections. The output devices used with the CAD systems are pen
plotters, hardcopy units and electrostatic plotters.
A geometric modeling is defined as the complete representation of an object that includes in both
graphical and non-graphical information. In computer-aided design, geometric modeling is
concerned with the computer compatible mathematical description of the geometry of an object. In
CAD system, the mathematical description of an object geometry to displayed and manipulated on
a graphics terminal through signal from CPU of the. The software that provides geometric
modeling capabilities must be designed for efficient use of both by the computer and the
human designer.
To use geometric modeling, the designer construct the graphical image of the object on the
CRT screen of the IGS system by inputting three types of commands to the computer. The first type
of command generates basic geometric elements such as points, lines and circles. The second
command types is used to accomplish scaling, rotation or other transformations of these elements.
The third type of command causes the various elements to be joined into desired shape of the object
being created on the ICG system.
During this geometric modeling process the computer converts the commands into mathematical
model, stores it in the computer data files and displays it as an image on the screen. The model can
be subsequently being called from the data files for review, analysis or alteration. The most
advanced method of geometric modeling is solid modeling in three dimensions. This method uses
solid geometry shapes called primitives to construct the object.
Basically there are three types of modeling, they are
1. wiref rame Modeling
2. Surface Modeling
3. Solid Modeling

WIRE FRAME MODEL-INTRODUCTION:

This is the basic form of modeling; here the objects drawn will be simple but more
verbose, geometric model that can be used to represent it mathematically in the computer. It is
sometimes referred as a stick figure or an edge representation of the object. Typical CAD/CAM
system provides users with possibly three modes to input coordinates: Cartesian, Cylindrical or
Spherical. Each mode has explicit or implicit inputs. Explicit input could be absolute or
incremental coordinates. Implicit input involves user digitizes..A wire frame model consists of
points, lines, arcs, circles &curves. Early wire frame modeling techniques developed in 1960’s
were 2-dimensional. They are not centralized &associative. Later in 1970’s the centralized,
associative database concepts enabled modeling of 3D objects as wire frame models that can be
subject to 3-dimensional transformations.
WIREFRAMEENTITIES
WireframeEntitiesaredividedinto2typesare:
a. Synthetic Entities----------Splines & Curves
b. Analytic Entities---------- Points, lines, Circles, arcs, conics, fillet, chamfer
Applications:
1. Two-dimensional drafting.
2. Numerical control tool path generation.
Advantages:
1. It is simple to construct model.
2. Less computer memory to store the object.
3. CPU time to retrieve, edit or update a wireframe model is less.
4. Does not require extensive training.

Disadvantages:
1. It is ambiguous representation of real object.
2. It lack in visual coherence and information to determine the object.
3. User or terminal time needed to prepare & or input data increases with complexity of
object.
4. Inability to detect interference between components.
5. No facility for automatic shading.
6. Difficult in calculating Physical properties like Mass, surface area, centre of gravity etc.,
Surface Modeling:
A surface model of an object is more complete and less ambiguous representation than it
wire frame model. It is also richer in associated geometric contents, which make it more suitable for
engineering and design applications. Surface model takes one step beyond wire frame models by
providing information on surfaces connecting the object edges. Creating a surface has some
quantitative data such as point & tangents & some qualitative data like desired shape & smoothness.
Choice of surface form depends on type of application.
Surface Entities:
Similar to wire frame entities, existing CAD / CAM systems provide designers with both
analytic and synthetic surface entities. Analytic entities include plane surface, ruled surface, surface
of revolution and tabulated cylinder. Synthetic entities include the bi-cubic Hermite spline surface,
B-spline surface, rectangular and triangular Bezier patches, rectangular and triangular Coons
patches, and Gordon surface. The mathematical properties of some of these entities are covered in

this chapter for two purposes. First, it enables users to correctly choose the proper surface entity for
the proper application. For example, a ruled surface is a linear surface and does not permit any twist
while a B-spline surface is a general surface. Second users will be in a position to better understand
CAD/CAM documentation and the related modifiers to each surface entity command available on a
system. The following are descriptions of major surface entities provided by CAD/CAM systems
Application:
1. Calculating mass properties.
2. Checking for interference between mating parts.
3. Generating cross-sectioned views.
4. Generating finite element mesh.
Advantages:
1. They are less ambiguous than wireframe model.
2. Surface model provides hidden line and surface algorithms to add realism to the displayed
geometry.
3. Surface model can be utilized in volume and mass property calculations, finite element
modeling, NC path generation, and cross section &interference detections.
4. Change in finite element mesh size produce more accurate results in FEA
Disadvantages:
1. Surface models are generally more complex and thus require more terminal and CPU
2. Time and computer storage to create than wireframe models.
3. Surface models are sometimes awkward to create and may require unnecessary
manipulations of wireframe entities.
4. It requires more training to create.
5. It does not provide any topological information.
Solid Modeling:
A solid model of an object is more complete representation than its surface model. It is
unique from the surface model in topological information it stores which potentially permits
functional automation and integration. Defining an object with the solid model is the easiest of the
available three modeling techniques. Solid model can be quickly created without having to define
individual locations as with wire frames. The completeness and unambiguity of solid models are
attributed to the information that is related database of these models stores (Topology--It determine

the relational information between objects.)

To model an object completely we need both geometry & topological information. Geometry is
visible, whereas topological information are stored in solid model database are not visible to user.
Two or more primitives can be combined to form the desire solid. Primitives are combined by
Boolean Operations.
Different Boolean operations are:
1. Union(U)
2. Intersection(n)
3. Difference(-)
SOLIDENTITIES
There are a wide variety of primitives available commercially to users.However, the four
most commonly used are the block, cylinder, cone and sphere. These are based on the four natural
quadrics: planes cylinders, cones and spheres.

Exercise – 1
Aim : To create a 2D view of the given diagram using Auto CAD.

Procedure:
1. Type limits in command menu & set value to 297,290.
2. Change the units to millimeters from inches and also precision to 0 by clicking format
-> units ->ok.
3. To set the paper size type zoom -> enter and type a -> enter in Command bar.
4. Draw the 3 concentric circles with diameters 94, 74 & 54
5 .Draw the two axis lines from centre of circles
6. Draw the vertical line from the centre of circle
7. From the modify tool bar, use the array command to draw the 6holes with 12dia from
centre of circles
8. Now draw the 300 line by use the vertical line
9. Then mirror the 300 line, with vertical line
10. Again draw the concentric of radius 100 from centre of circle
11. From the modify toolbar, use the offset command to draw the 12 & 23 distance
circle.
12. Draw 2 circles. With radius 23 & 12 on the 100R circle where the 300 line co-inside.
13. From modify toolbar, mirror these circle to represent the another side.
14. And offset vertical line from Centre of circle with a distance both side of vertical
line.
15. From modify toolbar, use the fillet command to represent fillet of radius 10 &9 to the
offset line.
16. Trim the unwanted lines to get required 2D drawing.

Result: Hence the required 2D diagram is created using Auto CAD.

Exercise – 2
Aim: To create a 2D view of the given diagram using Auto CAD.
Procedure:
1. Type limits in command menu & set values to 45, 45
2. Change the units to millimeters from inches and also precision to 0 by clicking
format -> units -> ok.
3. To set the paper size type zoom -> enter and type a -> enter in command bar
4. Draw the 3 concentric circles of diameters 85, 62, 32
5. Draw the 2 axes lines from the center of the circles
6. Draw the circle with 14dia on 62dia of circle and offset of the vertical line with
distance 4 to both sides of the vertical line
7. Then trim the unwanted lines
8. Use the array command from modify tool bar to represent the 6 holes with 14 dia of
center of the circles
9. Offset the vertical and horizontal axes with 47 and 52 distance
10. And draw the 2 circles with 14 radius and 12 dia at coincide of the offset axes
11. From the modify tool bar select the fillet command to represent the 12R fillet
12. Then mirror this to require the 2D drawing
13. Finally trim the unwanted lines and circles


Exercise – 3
Aim: To create a 2D view of the given diagram using Auto CAD.
Procedure:
4. Draw the 2 axes lines
5. Draw 2 concentric circles of diameter 58 and 40 above the axes
6. Draw the 10dia circle on the 40dia of the circle
7. And use the array command from modify tool bar to represent the 8 holes with 10dia
from centre ofthe circles.
8. Draw the 2 concentric circles of diameter 58 & 36 below the axes
9. Draw the circles of the diameter 8 on the circle of 36dia
10. Use the array command from the modify tool bar to represent the 6 holes with 8dia
11. Draw the 2 concentric circles of diameter 22 and 20 radius at the right side of the
vertical line from the vertical axes.
12. Fillet the circles of radius 20 with 15 radiuses.
13. And again draw the circles of diameter 16& 20R at left side of the vertical line from
the vertical axes.
14. And chamfer the circles of radius 20 with 58dia circle
15. Then trim the unwanted lines to get the required 2D drawing.


Exercise – 4
Aim: To create a 2D isometric view of the given diagram using Auto CAD.
Procedure:
3. To set the paper size type zoom -> enter and type a -> enter in command bar.
4. Go to drafting settings and turn on isometric snap..
5. Use the F5 key to change between the views of isometric planes.
6. Start from the front view and draw the the line of length of line 104 using the F8 key
(O snap key) and continue with the 48 length line.
7. Change to top plane and draw the 72mm line.
8. Continue in the same fashion to complete the whole figure.
9. Give the dimensions from the dimension tool bar as in diagram.
Result: Hence the required 2D isometric diagram is created using Auto CAD.

Exercise – 5
Aim: To create a 2D isometric view of the given diagram using Auto CAD
Procedure:
format -> units ->ok.
4. Go to drafting settings and turn on isometric snap. Use the F5 key to change
between the views of isometric planes.
5. Start from the front view and draw the the line of length of line 54.
6. Draw the semi-circle using the Iso circle option from the ellipse command.
7. Continue drawing using F5 and F8 snap keys.
8. Give proper dimensions to the figure and practice at home.
Result: Hence the required 2D isometric diagram is created using Auto CAD.

Viva-voice question and answers

1. What is meant by AutoCAD?
A: AutoCAD is one of the cad system software introduced in dec1982 by Autodesk ltd
in Sausallia, California of USA. It has hit the technical world like shock wave
revolutionizing the manner of drawing preparation.
2. What is the diff between CAD & CADD?
A: CAD-computer aided design
CADD-computer aided design and drafting
3. What are the applications of CAD?
 Design of machine elements, CNC machine tools, robotics etc
 Panel design and circuit layout
 Mapping ,building plans, contour plotting and structural drawing
 Interior design and modeling
4. Define absolute co-ordinates?
A: Values locating a point in space that describes its displacement from origin (0,0,0)
point of the drawing.
5. Define polar coordinates.

A: Values are locating a point in space that describes its location relative to the last
point picked as defined by an angle and s distance.
6. Define angular dimension?
A: A dimension that measures the angle between two lines or the angle inscribed by an
arc segment
7. Define aligned dimension?
A: A linear dimension measuring the distance between two points. The dimension line
for an aligned dimension is parallel to a line between points.
8. What is By layer?
A: A value that can be assigned to colours and line types so that objects receive their
colour and line type properties according to the layer they are on.’
9. What is command line?
A: A text window at the bottom of the screen that’s displays command: prompt. This is
where you see what you are entering through the keyboard.
10. What is command prompt?
A: A prompt at the command line, when no commands are currently running.
11. What is cross hair cursor?
A: A form of the cursor that consists of a horizontal line and a vertical line intersecting
at their midpoints, resembling the crosshair in a sighting device.
12. Define dimension variables?
A: A group of settings and values that control the appearance of dimensions.
13. Define current UCS?
A: The user co-ordinate system that is active in a drawing. It determines the positive X,
Y and Z direction.
14. What is .dwg?
A: The file extension and format for the standard AUTOCAD drawing.
15. Define graphics window?
A: The appearance of your screen when AUTOCAD is running. It consists of the
drawing area and surrounding toolbars, menu bars the command window and the
status bar.
16. Define line type?

A: The style of appearance of a line. AUTOCAD styles include continues, dashed, dash
dot. And so on.
17. What is a hatch patterns?
A: A pattern of lines dots and other shapes that fills in a closed area.
18. Define MIRROR?
A: A command that makes a copy of selected objects and flips the copy around a
specified line to produce a reciprocal image of those objects.
19. What is an ortho mode?
A: An on/off setting that, when on forces lines to be drawn and objects to be moved in a
horizontal or vertical direction only.
20. What are the advantages of CAD?
A: Greater productivity of the designer, improvement of design quality Easier design,
calculation and analysis, quicker rate producing drawings, more accuracy of
drawings, colour graphics is possible
21. What is an object snap mode?
A: Any of a set of tools precisely picking strategic points on an object, including end
point, midpoint, center, and so on. It is casually called osnap.
22. Define block?
A: The description of an association of AutoCAD objects that is stored with the
drawing file and include a name, an insertion point, and a listening of objects in the
association.
23. Define relative co-ordinates?
A: Values are locating a point in space that describes its displacement from last point
picked in the drawing rather than from the origin.
Shortcut key for all the commands
1. Line –l
2. Circle –c
3. Move –m
4. Copy –co
5. Hatching –bh
6. Explode –x

7. Trim –tr
8. Mirror-mi
9. Offset –o
10. Dimension style –d
11. Text-t
12. Text edit –ed
13. Rotate –ro
14. Fillet –f
15. Break –br
16. Arc- a
17. Polygon –pol
18. Ellipse –el
19. Multiline –mline
20. Poly line-pline
Function keys
1. F1 - Help
2. F2 - Command window on/off
3. F3 - Object osnap on/off
4. F4 - Tablet on/off
5. F5 - Isoplane top/right/left
6. F6 - Co-ordinate display on/off
7. F7 - Grid on/off
8. F8 - ortho on/off
9. F9 - snap on/off
10. F10 - Polar tracking on/off
11. F11 - Object snap tracking on/off

INTRODUCTION TO PRO-E
To start the Sketch mode, first has to start the Pro/ENGINEER Wildfire 4.0. Let’s now follow the
steps given below to start the Sketch mode.
1. Select the File menu on the menu bar in the FWENGINEER Wildfire 4,0 main window, as
shown in following Figure :

2. The File menu options appear. Now clickthe New option, as shown following figure. New
block will appears.
3. Now select the sketch button to

enter into the Sketch mode, as shown in
Figure.
4. Specify a name to the sketch. To assign a name to the sketch either accepts the default name
specified in the text box beside the Name label or specifies a new name. In our case, we
have accepted the default name.
5. Next, click the OK button. as shown in Figure

The Pro/ENGINEER Wildfire 4.0 window with the Sketch mode appears. Now the
Sketch mode is ready to use. However, to draw any sketch of a feature, the Sketcher Tools
toolbar is used; let’s explore the Sketcher Tools toolbar to draw sketches.
SKETCHER TOOLS TOOLBAR
The Sketcher Tools toolbar contains various buttons that are used to draw sketching
entities such as lines, circles and rectangles. The sketcher Tools toolbar also contains buttons to
dimension and constrain the sketching entities. The sketching entities when used together create a
sketch a feature. The Sketcher Tools toolbar is situated at the right tool chest in the
Pro/Engineer Wildfire 4.0window within the Sketch mode, as shown in Figure.
Working with sketching entities

Sketching entities are the basic entities used to draw a 2D sketch of a 3D feature. In
Pro/Engineering Wildfire 4.0, sketching entities can be drawn in two ways: first, by using the
buttons available on Sketcher Tools toolbar and second, by accessingoptions given in the Sketch
menu. Sketching entities that are most commonly used to draw a 2D sketch are as follows;
 Point
 Line
 Rectangle
 Circle
 Arc;
 Circular fillet
 Elliptical fillet
 Spline
 Text
POINT
Points are geometrical entities that are used to dimension the vertices. Following are the
steps to create points:
1. Click the Point ( ) button on the Sketcher Tool bar.

2. Now, click anywhere on the Drawing Area to place a point,

Repeat step 2to create more points
LINE
In Pro/engineering Wildfire 4.0, three different types of lines can be drawn. The
following three buttons are available on the sketcher Tools toolbar.
 Line (): Draws a simple line.

 Line Tangent (): Creates a tangent between two entities,
 Centerline (): Defines the avis of revolution to create a revolved feature, mirrors the
sketched entities, and so on.
EXP- Date:

Solid Modal-1
Aim: To prepare the solid modal of given figure with required dimension using Pro-E.
Software used: Pro-E wild fire 4.0.
Procedure:
1. Extrude: select the front plane and draw the orthographical view of given fig. According to
dimensional as similar to auto cadand extrude. The component of 17cm.
2. Extrude cut:
a) Select the front plane of extrude part and draw the orthographic view of given fig. with
taking reference and select the extrude cut command with 8.4cm.
b) Selectfront plane Draw the Orthographic view of given fig by taking references, select
extrude cut command with 13cm.
Precautions:

1. Be fare the actual drawing limits of the drawing area must be changed accordingly.
2. Try to fit the drawing in the middle of graphical window.
3. Try to prepare the tree to get exact model.
Result:
Thus the solid modelling of given fig with required dimensions in SI unitsis prepared by
using Pro-E.
EXP- Date:

Solid Modal-2
Aim:
To prepare the solid model of given fig with required dimensions in isometric representation by using Pro-E.
Software used: Pro-E wild fire4.0.
Procedure:
1. Extrude: Select the top plane and draw the orthographical view like shown
fig.According to dimensions and extrude the component 16mm.
2. Extrude: Select the right side plane and draw the orthographical view like shown fig.
According to dimensions and extrude the component 16mm.
3. Extrude: Select the front plane and draw the orthographical view like shown fig.
According to dimensions and extrude the component on both sides64 mm.

4. Extrude cut: Select the top plane and draw the orthographical view like shown fig.
According to dimensions and extrude the component up to cut the required part.
5. Extrude: Select the front plane and draw the orthographical view like shown fig.
According to dimensions and extrude the component on both sides 64 mm
6. Extrude cut: Select the top plane and draw the rectangle to cut like shown fig. According
to dimensions and extrude the component up to cut the required part.

Precautions:
1. Be fare starting the actual drawing limits of the drawing area must be changed accordingly.
2. Try to fit the drawing in the middle of graphical window.
3. Try to prepare the tree to get exact model.
Result:
Thus the solid model of given figure with required dimensions in isometric representation is
prepared by using pro-E wild fire.


EXP- DATE:
ASSEMBLY MODELING
Aim: To prepare the solid modal of given figure with required dimension using Pro-E.

S.no no. of parts Part name Material

1 1 Body Cast iron
2 1 Cap Cast iron
3 1 Brasses Gun metal
4 2 Square Headed bolt Mild steel
5 2 Nut Mild steel
6 2 Lock nut Mild steel
Software used: Pro-E wild fire 4.0.
Procedure:
All the components that you have created are assembled in an assembly file having an extension
.asm. You need to open a new assembly file to create an assembly of all the components.
1. Choose the Create a new object button from the File toolbar to display the new dialog box.
2. Select the Assembly radio button in the Type area of the new dialog box. In the Sub-type
area of the new dialog box the Design radio button is selected by default. Enter the name of
the assembly in the Name edit box as PEDESTALBEARING.
3. Choose OK to proceed to the Assembly environment.
Assembling the Casting with the Default Datum Planes
4. Choose ASSEMBLY > Component > Assemble. The Open dialog box is displayed.
5. Select casting from the Open dialog box and choose the Open button. The Component
Placement dialog box is displayed with the Show component in the assemblywindow
whilespecifying constraints button selected by default.
6. Select Assemble component at a default location button from the Component Placement
dialog box.
7. The Placement Status area shows Fully Constrained. Choose OK. The
ComponentPlacement dialog box is closed and the Casting is assembled with the default
datum planes.
Assembling the Cap with the Casting:
8. Choose ASSEMBLY > Component > Assemble to display the Open dialog box.
9. Select the cap and choose Open to display the Component Placement dialog box.

10. Select the Mate option from the Type drop-down list. You are prompted to select a mating
surface.
11. Select the top face of the Casting as the first mating face. Now, use the
CTRL+ALT+middlemouse button to rotate the Cap and then select the lower flat face of the
Cap as the other mating face.
12. Enter a value of 4 in the Message Input Window. If this window is not displayed thenselect
the Offset drop-down list and select 0.0. Now, enter offset distance of 4 and pressENTER.
13. Choose the Specify a new constraint button and then select the Align option from theType
drop-down list.
14. Select the axis of the left hole on the Casting as the first aligning axis and then select theaxis
of the left hole on the Cap as the second aligning axis.
15. Clear the Allow Assumptions check box by selecting it. The status displayed in the
Placement Status area is PartiallyConstrained.The Cap is still assembled to the Casting.
To know which degree of freedom of the Cap with the Casting is not constrained, perform
the next step.
16. Use CTRL+ALT+middle mouse button to move the Cap. You will notice that the second
hole of both the Cap and the Casting needs to be aligned.
17. If the Automatic option is not displayed in the Type drop-down list, choose Specify a
newconstraint button from the Constraints area in the Component Placement dialog
box.The GET SELECT submenu is displayed. Select the Align option from the Type drop-
down list.
18. Align the axis of the right hole on the Casting with the axis of the right hole on the Cap
byselecting them as shown in Figure. The Placement Status area shows FullyConstrained.
Choose OK to exit the Component Placement dialog box.

19. After assembling the Cap, the assembly should look similar to the one shown in Figure.
Assembling the Brasses with the Casting

20. Choose ASSEMBLY > Component > Assemble to display the Open dialog box.
21. Select brasses and choose Open to display the Component Placement dialog box.
22. Select the Mate option from the Type drop-down list and mate the face of the Brasses
withthat of the Casting as shown in Figure
.
23. Select the Insert option from the Type drop-down list and insert the oil hole of the
Brassesinto that of the Casting as shown in Figure 9-65. You will notice that the Brasses
assemblewith the wrong orientation. Also, some more constraints are left to be defined.
24. Use CTRL+ALT+left mouse button to move the Brasses and then select the Align
optionfrom the Type drop-down list.
25. Select the TOP datum plane from the Brasses and then select the face of the Castingshown
in above Figure. The red arrow is displayed and you are prompted to enter the offsetdistance
in the direction of the arrow.

26. Enter a distance of -4 in the Message Input Window and press ENTER. The
PlacementStatus area shows Fully Constrained.
27. If the join feature of the oil hole is at the top then choose the Change orientationof the
constraint button from the Component Placement dialog box. The oilhole is now
oriented correctly. Choose OK to exit the Component Placementdialog box.
After assembling the Brasses, the assembly should look similar to the one shown
inFigure.
28. Similarly, assemble the remaining components and then resume the components thatwere
suppressed earlier. The final assembly is shown in Figure below.
Result: Thus the solid modeling of given fig with required dimensions in SI units is prepared by
using Pro-E.

Pro-e viva question and answers
1. What is the difference between object reference and geometric associability?

A. Object reference is a data management term that has to do with the way one object
references another. Geometric associability has to do with how a parts geometry can
be changed from the part or drawing.
2. What are the file extensions given to sketches, parts, assemblies, drawings?
A. Sketches – .sec, Parts- .prt, Assemblies- .asm, Drawings- .drw
3. How should you create a new part or assembly? Why?
A. You should always create a new part or assembly using the copy from option in the
new dialog box and copy a start part. This ensures the proper layer setup, saved
views, datum planes, parameters, etc.
4. What is the use of config.pro file?
A. The config.pro file contains configuration options which control the behavior of
Pro/ENGINEER. This file also contains user macros which are called map keys.
5. What is a trail file?
A. The trail file is a record of every menu pick and screen pick and keyboard input
during an entire session of pro/engineer. This file can be retrieved and edited and
replayed to retrieve work lost during an unexpected failure of a session.
6. What is the meaning of “store back”?
A. ‘Store back’ refers to the behavior in which an object is stored back to the directory
from where it was opened not necessarily the current working directory.
7. What is the difference between File -> Erase and File -> Delete?
A. File erase removes the object from the ram of the computer and file delete removes
the object from the disk or hard drive of the computer.
8. What is the difference between File -> Save and File -> Backup?
A. File save stores the object in the directory where it was opened from and file backup
copies the object to the specified directory using the same name.
9. After performing a File, Save As, what is the current object?
A. After performing a file saves as command the current object is not a new object it is
the old object.

10. If I use Window in Pro/E and Close without saving my model, have I lost my work?
A. No.
11. Name six common assumptions the sketcher will make.
A. Six common assumption the sketcher will make are as follows – Horizontal and
vertical, equal length lines, equal radius or diameter, co-linearity, 90 and 180 degree
arcs, points on the same horizontal or vertical, points on other entities, tangency,
symmetry, parallel and perpendicular lines.
12. What is the difference between One Side and Both Sides in extrusion?
A. One-side extrudes only one specified direction from the sketching plane. Both sides
extrude both sides of the sketching planes.
13. How do you change dimensions of a feature?
A. Modify > pick the feature > pick the dimension > enter the new value > select
regenerate.
14. What is the model tree?
A. The model tree is a graphical representation of the features and/or components in the
model.
15. Define “Parametric Feature Based Modeling” ?
A. Parametric means driven by parameters. Feature based means you define a series of
instructions (features) to tell the system your design intent. Modeling means creating
computer images coupled with geometric information defining a part or assembly.
16. What is datum planes created ‘on the fly’?
A. The datum plane created on the fly means it was created when you were in the
middle of creating something else and it goes away after the thing you really wanted
was created. These are created using the ‘make datum’ command.
17. List five uses of datum planes.
A. Five uses of datum plane are as follows – Sketching plane, reference plane,
dimension and alignment references, geometric tolerance, creating cross sections.
18. List three uses of datum axes.
A. Three uses of datum axes are as follow – Dimension and alignment references,
centerlines on drawings, geometric tolerance, coaxial hole.

19. List two uses of a datum coordinate system.

A. Datum coordinate system is used while exporting to iges and stl.
20. Name a feature that can both add and remove material.
A. Rounds and chamfers are the features which can both add or remove the material.
21. When do feature relation evaluate?
A. When the feature regenerates.
22. What is a constraint relation in Pro/Engineer?
A. A constraint relation is used to put limits on parameters (usually dimensions) based
design intent and/or manufacturing limitations.
23. Name four types of parameters?
A. Integer, real number, string, yes/no.
24. What is a logic statement?
A. Logic statements are a series of relations that test parameter values and perform
actions based on the results of the test.
25. Why should you comment relations?
A. You should comment relations so that other users can understand what you are
trying to accomplish with the relations.
26. What does ‘sort relations’ do?
A. Sorts the relations in case of circular references within the relations.
27. Can you add motion to a part in Pro/Engineer?
A. Yes.
28. How do you add a model parameter in a drawing note?
A. Use ampersand and then the parameter name (&material).
29. What is the difference between “Move” and “Move Text”?
A. Move allows you to move the selected item anywhere. Move text allows you to
move the selected item only parallel to the elbow.
30. Name the four types of tolerance formats available in Pro/Engineer?
A. Nominal (no tolerance shown), plus/minus, plus/minus symmetric, limits.
31. Which of the tolerance formats should you not use?
A. Plus/minus (because manufacturing people want the model at the mean size not the
nominal size).

32. What is a drawing symbol?

A. A symbol is a collection of draft entities that are stored together for reuse on other
drawings.
33. Can a drawing reference more than one assembly?
A. Yes.
34. Can a Pro/Engineer drawing be opened in AutoCAD?
A. No. (Yes, but only after translation to dxf or iges or dwg).
35. Can the units of a part be changed without changing the size of the part?
A. Yes.
36. What are the steps required to get just one components default datum planes displayed in an
assembly?
A. Using layers, blank the layer containing the default datum planes, pick the plus sign
next to that layer in the layer display dialog box and then pick the component that
you want to see the planes in and then pick the show icon.
37. Why the above mentioned steps should be carried out?
A. To be sure that when creating a feature, you are using the datum planes in that part
so that you don’t make unwanted external references (parent/child relationships).
38. What does ‘save status’ in the layer menu do?
A. Save status permanently sets the layer displays status of the model so that when the
model is saved and opened again the layer display is still set that way.
39. What function in layers should you not use?
A. It is normally recommended that beginners not use the isolate function in layer
display.
40. When copying a feature, what is the difference between ‘dependent’ and ‘independent’ in
Pro/Engineer?
A. Dependent means that the copy feature will change when the original feature is
changed. Independent means that the new feature will not change when you change
the original feature.
41. What is different about a feature that has a dependent copy?
A. When redefining a feature that has a dependent copy, the alignment function in the
sketcher is not available.

42. How do you make a dependent copy feature independent from its original feature?
A. Use modify, make independent.
43. What is the pro_group_dir for in Pro/Engineer?
A. This configuration option is used to tell the system where you are keeping your
udf’s.
44. What should you do if creating features that are to be included in a user defined feature?
A. Limit the number of parents. If multiple features are to be included in the udf, they
should share as many parents as possible to reduce the number of prompts required
to place the udf into another part.
45. In family tables, what is a ‘generic’ and what is an ‘instance’?
A. In Pro/Engineer the generic is the original model. The instances are created by the
system based on the combination of the generic and the table.
46. What type of view should be the first view added to a drawing ?
A. General and you must orient it using save views from the model.
47. Why should you use Display Mode on drawing views?
A. Because by default, drawing views get their hidden line removal from the
environment. Each user’s environment may be different thus causing the drawing
views to look different when another user opens the drawing.
48. What is a ‘show’ dimension?
A. A dimension from the model.
49. If you erase a dimension, is it gone forever?
A. No.
50. Why is it a good idea to start drawings early in the part design?
A. Because it’s easier to show the dimensions from the model a few features at a time.
Start the drawing early and have the drawing process be a parallel process with
creating the part. In other words, create a couple features, go to the drawing, show
the dimensions from the feature on the drawing, go back to the model, create a
couple more features, show those dimensions on the drawing, etc.
51. What is the best way to show dimensions?
A. Use preview and pick the features from the model tree.

52. How are the default number of decimal places and default tolerance values determined for
parts and assemblies?
A. They are built into the start part and start assembly.
53. List four types of assembly constraints.
A. Mate, align, insert, orient.

INTRODUCTION TOANSYS
ANSYS stands for Analysis system. ANSYS is a general-purpose finite-element modeling

package for numerically solving a wide variety of mechanical problems. These problems include
static/ dynamic, structural analysis (both linear and nonlinear), heat transfer, and fluid problems, as
well as acoustic and electromagnetic problems.
In general, a finite-element solution may be broken into the following three stages.
1. Preprocessing: defining the problem
The major steps in preprocessing are
a) Define key points/lines/areas/volumes,

b) Define element type and material/geometric properties
c) Mesh lines/areas/ volumes as required. The amount of detail required will depend
on the dimensionality of the analysis, i.e., 1-D, 2-D, axisymmetric, and 3D.
2. Solution: assigning loads, constraints, and solving
It is necessary to specify the loads (point or pressure), constraints (translational and

rotational), and finally solve the resulting set of equations.
3. Post processing: In this stage one may wish to seethe results

a) Lists of nodal displacements
b) Element forces and moments
c) Deflection plots
d) Stress contour diagrams or temperature maps.
STARTING THE PROGRAM
There are two methods to use ANSYS. The first is by means of the graphical user interface
or GUI. This method follows the conventions of popular Windows based programs. The
second is by means of command files.
The command file approach has a steeper learning curve for many, but it has the advantage
that the entire analysis can be described in a small text file, typically in less than 50 lines of

commands. This approach enables easy model modifications and minimal file space
requirements.
The ANSYS environment contains two windows: the Main Window and an Output
Window. Within the Main Window there are five divisions as shown in fig-1.
1. Utility Menu: The Utility Menu (1) contains functions that are available throughout the
ANSYS session, such as file controls, selections, graphic controls, and parameters.
2. Input Line: The Input Line (2) shows program prompt messages and allows to type in
commands directly.
3. Toolbar: The Toolbar (3) contains push buttons that execute commonly used ANSYS
commands. More push buttons can be made available if desired.
4. Main Menu: The Main Menu (4) contains the primary ANSYS functions, organized by
preprocessor, solution, general postprocessor, and design optimizer. It is from this menu
that the vast majority of modeling commands are issued.
5. Graphics Windows: The Graphics Window (5) is where graphics are shown and
graphical picking can be made. It is here where the model in its various stages of
construction and the ensuing results from the analysis can be viewed.
Figure - 1

The Output Window shown in Figure - 2, displays text output from the program, such as
listing of data, etc. It is usually positioned behind the Graphics Window and can be put to the
front if necessary.
Figure –2
PREPROCESSING STAGE
1. BUILDING A MODEL:
The ANSYS program has many finite-element analysis capabilities, ranging from a
simple linear static analysis to a complex nonlinear transient dynamic analysis. Building a
finite-element model requires more time than any other part of the analysis. First, a job
name and analysis title has to be specified. Next, the PREP7 preprocessor is used to define
the element types, element real constants, material properties, and the model geometry. It is
important to remember that ANSYS does not assume a system of units for intended
analysis. Except in magnetic field analyses, any system of units can be used so long as it is
ensured that units are consistent for all input data. Units cannot be set directly from the GUI.
In order to set units as the international system of units (SI) from ANSYS Main Menu,
select Preprocessor→Material Props→ Material Library →Select Units. Figure - 3
shows the resulting frame.

Figure – 3
2. DEFINING ELEMENT TYPES AND REAL CONSTANTS:
The ANSYS element library contains more than 100 different element types. Each
element type has a unique number and a prefix that identifies the element category. In order
to define element types, one must be in PREP7.From ANSYS Main Menu, select
Preprocessor → Element Type → Add/Edit/Delete. In response, the frame shown in
Figure - 4 appears.
Figure – 4

Click on (A) Add button and a new frame, shown in Figure - 5, appears. Select an
appropriate element type for the analysis performed, e.g., (A) Solid and (B) 8node 183 as
shown in Figure - 5.
Figure – 5
Element real constants are properties that depend on the element type, such as cross-
sectional properties of a beam element. As with element types, each set of real constant has
a reference number and the table of reference number versus real constant set is called the
real constant table. Not all element types require real constant, and different elements of the
same type may have different real constant values.
ANSYS Main Menu command Preprocessor → modeling → Create →Elements
→Element Attributes can be used to define element real constant. Figure - 6 shows a frame
in which one can select element type. According to Figure - 6, an element type already
selected is (A) Plane 183 for which real constant are being defined. A corresponding (B)
Material number, allocated by ANSYS when material properties are defined is also shown
in the frame.

Figure - 6
3. DEFINING MATERIAL PROPERTIES
Material properties are required for most element types. Depending on the
applications, material properties may be linear or nonlinear, isotropic, orthotropic or
anisotropic, constant temperature or temperature dependent. As with element types and real
constants, each set of material properties has a material reference number. The table of
material reference numbers versus material property sets is called the material table. In one
analysis there may be multiple material property sets corresponding with multiple materials
used in the model. Each set is identified with a unique reference number. Although material
properties can be defined separately for each finite-element analysis, the ANSYS program
enables storing a material property set in an archival material library file, then retrieving the
set and reusing it in multiple analyses. Each material property set has its own library file.
The material library files also make it possible for several users to share commonly used
material property data.
In order to create an archival material library file, the following steps should be
followed:
1. Tell the ANSYS program what system of units is going to be used.
2. Define properties of, for example, isotropic material. Use ANSYS Main
Menu and select Preprocessor → Material Props →Material Models.A
frame shown in figure-7.

Figure - 7
As shown in Figure - 7, (A) Isotropic was chosen. Clicking twice on Isotropic calls
up another frame shown in Figure-8.
Figure - 8
Enter data characterizing the material to be used in the analysis into appropriate field.
For example, (A) EX = 2.1E+009 and (B) PRXY = 0.33 as shown in Figure - 8. If the
problem requires a number of different materials to be used, then the above procedure
should be repeated and another material model created with appropriate material number
allocated by the program.4.

4. CONSTRUCTION OF THE MODEL

1. Creating The Model Geometry:
Once material properties are defined, the next step in an analysis is generating a finite-
element model nodes and element adequately describing the model geometry. There are
two methods to create the finite element model: solid modeling and direct generation.
With solid modeling, the geometry of shape of the model is described, and then the
ANSYS program automatically meshes the geometry with nodes and elements. The size
and shape of the elements that the program creates can be controlled. With direct
generation, the location of each node and the connectivity of each element is manually
defined. Several convenience operations, such as copying patterns of existing nodes and
elements, symmetry reflection, etc., are available.
2. Applying Loads:
Loads can be applied using either PREP7 preprocessor or the SOLUTION processor.
Regardless of the chosen strategy, it is necessary to define the analysis type and analysis
options, apply loads, specify load step options, and initiate the finite-element solution. The
analysis type to be used is based on the loading conditions and the response which is
wished to calculate. For example, if natural frequencies and mode shapes are to be
calculated, then a modal analysis ought to be chosen. The ANSYS program offers the
following analysis types: static (or steady-state), transient, harmonic, modal, spectrum,
buckling, and sub structuring. Not all analysis types are valid for all disciplines. Modal
analysis, for instance, is not valid for thermal models. Analysis options allow for
customization of analysis type. Typical analysis options are the method of solution, stress
stiffening on or off, and Newton-Rap son options. In order to define the analysis type and
analysis options, use ANSYS Main Menu and select Main Menu: Preprocessor → Loads
→Analysis Type → New Analysis. In response to the selection, the frame shown in
Figure-9 appears.

Figure-9
Select the type of analysis that is appropriate for the problem at hand by activating (A)
Static button for example. The word loads used here includes boundary conditions, i.e.,
constraints, supports, or boundary field specifications. It also includes other externally and
internally applied loads.
Loads in the ANSYS program are divided into six categories: DOF constraints,
forces, surface loads, body loads, inertia loads, and coupled field loads. Most of these loads
can be applied either on the solid model (key points, lines, and areas) or the finite-element
model (nodes and elements).There are two important load related terms. A load step is
simply a configuration of loads for which the solution is obtained. In a structural analysis,
for instance, wind loads may be applied in one load step and gravity in a second load step.
Load steps are also useful in dividing a transient load history curve into several segments.
Sub steps are incremental steps taken within a load step. They are mainly used for accuracy
and convergence purposes in transient and nonlinear analyses. Sub steps are also known as
time steps which are taken over a period of time. Load step options are alternatives that can
be changed from load step to load step, such as number of sub steps, time at the end of a
load step, and output controls. Depending on the type of analysis performed, load step
options may or may not be required.
SOLUTION STAGE:
To initiate solution calculations, use ANSYS Main Menu selecting Solution →

Solve → Current LS. Figure-10 shows resulting frame.

Figure-10
After reviewing the summary information about the model, click (A) OK button to start the
solution. When this command is issued, the ANSYS program takes model and loading
information from the database and calculates the results. Results are written to the results file
and also to the database. The only difference is that only one set of results can reside in the
database at one time, while a number of result sets can be written to the results file. Once the
solution has been calculated, the ANSYS postprocessors can be used to review the results.
POSTPROCESSING STAGE:
Two postprocessors are available
1. POST1: The general postprocessor is used to review results at one sub step (time step)
over the entire model or selected portion of the model. The command to enter POST 1
requires selection from ANSYS Main Menu General Postprocessor. Using this
postprocessor contour displays, deformed shapes, and tabular listings to review and
interpret the results of the analysis can be obtained. POST1 offers many other
capabilities, including error estimation, load case combinations, calculations among
results data, and path operations.
2. POST26: The time history postprocessor is used to review results at specific points in
the model over all time steps. The command to enter POST26 is as follows: from
ANSYS Main Menu select Time Hist Postprocessor. Graph plots of results data
versus time (or frequency) and tabular listings can be obtained. Other POST26
capabilities include arithmetic calculations and complex algebra.

EXP- Date:
DEFLECTION AND STRESSES IN TRUSSES
Problem Description:
Determine the nodal deflections, reaction forces, and stress for the truss system shown
below (E = 200GPa, A = 3250mm2).
(Modified from Chandrupatla&Belegunda, Introduction to Finite Elements in Engineering, p.123)
AIM: Determine the nodal deflections, reaction forces, and stress for the truss system by using
ANSYS software.
Software used: ANSYS Software 10.0.
PROCEDURE
1. Give the Simplified Version a Title (such as 'Bridge Truss Tutorial'). In the Utility menu
bar select File > Change Title:
The following window will appear:

Enter the title and click 'OK'. This title will appear in the bottom left corner of the 'Graphics'
Window once you begin. Select Utility Menu > Plot >Replot
2. Enter Key points
The overall geometry is defined in ANSYS using key points which are the ends of each truss.
 We are going to define 7 key points for the simplified structure as given in the
following table
key point coordinate

x y
1 0 0
2 1800 3118
3 3600 0
4 5400 3118
5 7200 0
6 9000 3118
7 10800 0
 (these keypoints are depicted by numbers in the above figure)

 From the 'ANSYS Main Menu' select:
Preprocessor > Modeling > Create >Keypoints> In Active CS
The following window will then appear:

 Enter key point number 1 in the appropriate box, and enter the x,y coordinates: (0,0)in
their appropriate boxes (as shown above). Click 'Apply' to accept what you have
typed.
 Enter the remaining key points using the same method.
Form Lines
The key points must now be connected. We will use the mouse to select the key points to
form the lines.
 In the main menu select: Preprocessor > Modeling > Create > Lines > Lines >in Active
Coord. The following window will then appear:
 Use the mouse to pick key point #1 (i.e. click on it). It will now be marked by a
small yellow box.

 Now move the mouse toward key point #2. A line will now show on the screen
joining these two points. Left click and a permanent line will appear.
 Connect the remaining key points using the same method.
 When you're done, click on 'OK' in the 'Lines in Active Coord' window, and
minimize the 'Lines' menu and the 'Create' menu. Your ANSYS Graphics window
should look similar to the following figure.
 Disappearing Lines
please note that any lines you have created may 'disappear' throughout your analysis.
However, they have most likely NOT been deleted. If this occurs at any time from
the Utility Menu select:
Plot > Lines
3. Define the Type of Element
It is now necessary to create elements. This is called 'meshing'. ANSYS first needs to know
what kind of elements to use for our problem:

 From the Preprocessor Menu, select: Element Type > Add/Edit/Delete. The
following window will then appear:
 Click on the 'Add...' button. The following window will appear:
 For this example, we will use the 2D spar element as selected in the above figure.
Select the element shown and click 'OK'. You should see 'Type 1 LINK1' in the
'Element Types' window.
 Click on 'Close' in the 'Element Types' dialog box.
4. Define Geometric Properties
We now need to specify geometric properties for our elements:
 In the Preprocessor menu, select Real Constants > Add/Edit/Delete

 Click Add... and select 'Type 1 LINK1' (actually it is already selected). Click on
'OK'. The following window will appear:
 As shown in the window above, enter the cross-sectional area (3250mm):

 Click on 'OK'.
 'Set 1' now appears in the dialog box. Click on 'Close' in the 'Real Constants'
window.
5. Element Material Properties
You then need to specify material properties:
 In the 'Preprocessor' menu select Material Props > Material Models

 Double click on Structural > Linear > Elastic > Isotropic
We are going to give the properties of Steel. Enter the following field:
EX 200000
 Enter these properties 200000 and click on 'OK'.
Note: You may obtain the note 'PRXY will be set to 0.0. This is Poisson’s ratio and
is not required for this element type. Click 'OK' on the window to continue. Close
the "Define Material Model Behavior" by clicking on the 'X' box in the upper right
hand corner.

6. Mesh Size
The last step before meshing is to tell ANSYS what size the elements should be. There are a
variety of ways to do this but we will just deal with one method for now.
 In the Preprocessor menu select Meshing > Size Cntrls>Manual Size> Lines > All
Lines
 In the size 'NDIV' field, enter the desired number of divisions per line. For this
example we want only 1 division per line, therefore, enter '1' and then click 'OK'.
Note that we have not yet meshed the geometry; we have simply defined the element
sizes.
7. Mesh
Now the frame can be meshed.
 In the 'Preprocessor' menu select Meshing > Mesh > Lines and click 'Pick All' in the
'Mesh Lines' Window
Your model should now appear as shown in the following window

Plot Numbering
To show the line numbers, key point numbers, node numbers...
 From the Utility Menu (top of screen) select PlotCtrls> Numbering...

 Fill in the Window as shown below and click 'OK'

Solution Phase: Assigning Loads and Solving
You have now defined your model. It is now time to apply the load(s) and constraint(s) and solve
the resulting system of equations.
Open up the 'Solution' menu (from the same 'ANSYS Main Menu').
1. Define Analysis Type
First you must tell ANSYS how you want it to solve this problem:
 From the Solution Menu, select Analysis Type > New Analysis.
 Ensure that 'Static' is selected; i.e. you are going to do a static analysis on the truss as
opposed to a dynamic analysis, for example.
 Click 'OK'.
2. Apply Constraints
It is necessary to apply constraints to the model otherwise the model is not tied
down or grounded and a singular solution will result. In mechanical structures, these
constraints will typically be fixed, pinned and roller-type connections. As shown above, the
left end of the truss bridge is pinned while the right end has a roller connection.
 In the Solution menu, select Define Loads > Apply > Structural > Displacement >
On Key points

 Select the left end of the bridge (Keypoint 1) by clicking on it in the Graphics
Window and click on 'OK' in the 'Apply U,ROT on KPs' window.
 This location is fixed which means that all translational and rotational degrees of
freedom (DOFs) are constrained. Therefore, select 'All DOF' by clicking on it and
enter '0' in the Value field and click 'OK'.
Note: You will see some blue triangles in the graphics window indicating the
displacement constraints.
 Using the same method, apply the roller connection to the right end (UY
constrained). Note that more than one DOF constraint can be selected at a time in the
"Apply U, ROT on KPs" window. Therefore, you may need to 'deselect' the 'All
DOF' option to select just the 'UY' option.

4. Apply Loads
As shown in the diagram, there are four downward loads of 280kN, 210kN, 280kN, and
360kN at key points 1, 3, 5, and 7 respectively.
 Select Define Loads > Apply > Structural > Force/Moment > on Key points.
 Select the first Key point (left end of the truss) and click 'OK' in the 'Apply F/M on
KPs' window.
 Select FY in the 'Direction of force/mom'. This indicate that we will be applying the
load in the 'y' direction
 Enter a value of -280000 in the 'Force/moment value' box and click 'OK'. Note that
we are using units of N here; this is consistent with the previous values input.
 The force will appear in the graphics window as a red arrow.
 Apply the remaining loads in the same manner.
The applied loads and constraints should now appear as shown below.

3. Solving the System
We now tell ANSYS to find the solution:
 In the 'Solution' menu select Solve > Current LS. This indicates that we desire the
solution under the current Load Step (LS).
 The above windows will appear. Ensure that your solution options are the same as
shown above and click 'OK'.
 Once the solution is done the following window will pop up. Click 'Close' and close
the /STATUS Command Window..
Post processing: Viewing the Results
1. Hand Calculations
 We will first calculate the forces and stress in element 1 (as labeled in the problem
description).

2. Results Using ANSYS
Reaction Forces
A list of the resulting reaction forces can be obtained for this element
 From the Main Menu select General Postproc> List Results > Reaction Solu.
 Select 'All strucforc F' as shown above and click 'OK'
These values agree with the reaction forces calculated by hand above.

Deformation
 In the General Postproc menu, select Plot Results > Deformed Shape. The
following window will appear.
 Select 'Def + undef edge' and click 'OK' to view both the deformed and the un-
deformed object.
 Observe the value of the maximum deflection in the upper left hand corner
(DMX=7.409). One should also observe that the constrained degrees of freedom
appear to have a deflection of 0 (as expected!)
Deflection
For a more detailed version of the deflection of the beam,
 From the 'General Postproc' menu select Plot results > Contour Plot > Nodal
Solution. The following window will appear.

 Select 'DOF solution' and 'USUM' as shown in the above window. Leave the other
selections as the default values. Click 'OK'.

 Looking at the scale, you may want to use more useful intervals. From the Utility
Menu select Plot Controls > Style > Contours > Uniform Contours...
 Fill in the following window as shown and click 'OK'.
You should obtain the following.

 The deflection can also be obtained as a list as shown below. General Postproc>
List Results > Nodal Solution select 'DOF Solution' and 'ALL DOFs' from the lists
in the 'List Nodal Solution' window and click 'OK'. This means that we want to see a
listing of all degrees of freedom from the solution.
 Are these results what you expected? Note that all the degrees of freedom were
constrained to zero at node 1, while UY was constrained to zero at node 7.
 If you wanted to save these results to a file, select 'File' within the results window (at
the upper left-hand corner of this list window) and select 'Save as'.
Axial Stress
 From the General Postprocessor menu select Element Table > Define Table
 Click on 'Add...'

 As shown above, enter 'SAXL' in the 'Lab' box. This specifies the name of the item
you are defining. Next, in the 'Item,Comp' boxes, select 'By sequence number' and
'LS,'. Then enter 1 after LS, in the selection box
 Click on 'OK' and close the 'Element Table Data' window.
 Plot the Stresses by selecting Element Table > Plot Elem Table
 The following window will appear. Ensure that 'SAXL' is selected and click 'OK'
 Because you changed the contour intervals for the Displacement plot to "User
Specified" - you need to switch this back to "Auto calculated" to obtain new values
for VMIN/VMAX.
Utility Menu >PlotCtrls> Style > Contours > Uniform Contours...
Again, you may wish to select more appropriate intervals for the contour plot
 List the Stresses

 From the 'Element Table' menu, select 'List Elem Table'

 From the 'List Element Table Data' window which appears ensure 'SAXL' is
highlighted
 Click 'OK'
Result: The required nodal deflections, reaction forces and stress for given the truss system has
found out.

EXP- Date:
CANTILEVER BEAM
Aim: The cantilever beam shown in the following figure, Find nodal deflections, reaction forces,
and stress:
Procedure:
Preprocessing: Defining the Problem
1. Give the Simplified Version a Title (such as 'Verification Model').
Utility Menu > File > Change Title
2. Enter Key points
For this simple example, these key points are the ends of the beam.
 We are going to define 2 key points for the simplified structure as given in the
following table
coordinate
keypoint
x y z
1 0 0 0
2 500 0 0

 From the 'ANSYS Main Menu' select:

Preprocessor > Modeling > Create >Keypoints> In Active CS
3. Form Lines
The two key points must now be connected to form a bar using a straight line.
 Select: Preprocessor > Modeling> Create > Lines > Lines > Straight Line.
 Pick key point 1 (i.e. click on it). It will now be marked by a small yellow box.
 Now pick key point 2. A permanent line will appear.
 When you're done, click on 'OK' in the 'Create Straight Line' window.
It is now necessary to create elements on this line.
 From the Preprocessor Menu, select: Element Type > Add/Edit/Delete.

 Click on the 'Add...' button. The following window will appear:
 For this example, we will use the 3D elastic straight pipe element as selected in
the above figure. Select the element shown and click 'OK'. You should see 'Type
1 PIPE16' in the 'Element Types' window.
 Click on the 'Options...' button in the 'Element Types' dialog box. The following
window will appear:

 Click and hold the K6 button (second from the bottom), and select 'Include Output'
and click 'OK'. This gives us extra force and moment output.
 Click on 'Close' in the 'Element Types' dialog box and close the 'Element Type'
menu.
5. Define Geometric Properties
We now need to specify geometric properties for our elements:
 In the Preprocessor menu, select Real Constants > Add/Edit/Delete
 Click Add... and select 'Type 1 PIPE16' (actually it is already selected). Click on
'OK'.
Enter the following geometric properties:
 Outside diameter OD: 25

 Wall thickness TKWALL: 2

This defines an outside pipe diameter of 25mm and a wall thickness of 2mm.
 Click on 'OK'.
 'Set 1' now appears in the dialog box. Click on 'Close' in the 'Real Constants'
window.
You then need to specify material properties:
 In the 'Preprocessor' menu select Material Props > Material Models...

 Double click Structural > Linear > Elastic and select 'Isotropic' (double click on
it)
 Close the 'Define Material Model Behavior' Window.
We are going to give the properties of Aluminum. Enter the following field:
 EX 70000
 PRXY 0.33
 Set these properties and click on 'OK'.
7. Mesh Size
 In the Preprocessor menu select Meshing > Size Cntrls>Manual Size> Lines > All
Lines
 In the size 'SIZE' field, enter the desired element length. For this example we want
an element length of 2cm, therefore, enter '20' (i.e 20mm) and then click 'OK'. Note
that we have not yet meshed the geometry; we have simply defined the element
sizes.
(Alternatively, we could enter the number of divisions we want in the line. For an
element length of 2cm, we would enter 25 [i.e 25 divisions]).

8. Mesh
Now the frame can be meshed.
 In the 'Preprocessor' menu select Meshing > Mesh > Lines and click 'Pick All' in the
'Mesh Lines' Window
9. Saving Your Work
Utility Menu > File > Save as.... Select the name and location where you want to save your
file.
 From the Solution Menu, select 'Analysis Type > New Analysis'.
 Ensure that 'Static' is selected and click 'OK'.
 In the Solution menu, select Define Loads > Apply > Structural > Displacement >
On Key points
 Select the left end of the rod (Key point 1) by clicking on it in the Graphics Window
and click on 'OK' in the 'Apply U, ROT on KPs' window.
 This location is fixed which means that all translational and rotational degrees of
freedom (DOFs) are constrained. Therefore, select 'All DOF' by clicking on it and
enter '0' in the Value field and click 'OK'.
3. Apply Loads
As shown in the diagram, there is a vertically downward load of 100N at the end of the bar
 In the Structural menu, select Force/Moment > on Key points.

 Select the second Key point (right end of bar) and click 'OK' in the 'Apply F/M'
window.
 Click on the 'Direction of force/mom' at the top and select FY.
 Enter a value of -100 in the 'Force/moment value' box and click 'OK'.
 The force will appear in the graphics window as a red arrow.
The applied loads and constraints should now appear as shown below.
4. Solving the System
We now tell ANSYS to find the solution:
 Solution > Solve > Current LS
1. Hand Calculations
Now, since the purpose of this exercise was to verify the results - we need to calculate what
we should find.

Deflection:
The maximum deflection occurs at the end of the rod was found to be 6.2mm as shown
above.
Stress:
The maximum stress occurs at the base of the rod and was found to be 64.9MPa as shown
above (pure bending stress).
Deformation
 From the Main Menu select General Postproc from the 'ANSYS Main Menu'. In
this menu you will find a variety of options, the two which we will deal with now
are 'Plot Results' and 'List Results'
 Select Plot Results > Deformed Shape.
 Select 'Def + undef edge' and click 'OK' to view both the deformed and the
undeformed object.

 Observe the value of the maximum deflection in the upper left hand corner (shown
here surrounded by a blue border for emphasis). This is identical to that obtained via
hand calculations.
Deflection
For a more detailed version of the deflection of the beam,
 From the 'General Postproc' menu select Plot results > Contour Plot > Nodal
Solution.
 Select 'DOF solution' and 'USUM'. Leave the other selections as the default values.
Click 'OK'.

 You may want to have a more useful scale, which can be accomplished by going to
the Utility Menu and selecting Plot Controls > Style > Contours > Uniform
Contours
 The deflection can also be obtained as a list as shown below. General Postproc>
List Results > Nodal Solution ... select 'DOF Solution' and 'ALL DOFs' from the
lists in the 'List Nodal Solution' window and click 'OK'. This means that we want to
see a listing of all translational and rotational degrees of freedom from the solution.
If we had only wanted to see the displacements for example, we would have chosen
'ALL Us' instead of 'ALL DOFs'.

 Are these results what you expected? Again, the maximum deflection occurs at node
2, the right end of the rod. Also note that all the rotational and translational degrees
of freedom were constrained to zero at node 1.
 If you wanted to save these results to a file, use the mouse to go to the 'File' menu (at
the upper left-hand corner of this list window) and select 'Save as'.
Stresses
For line elements (ie beams, spars, and pipes) you will need to use the Element Table to
gain access to derived data (ie stresses, strains).
 From the General Postprocessor menu select Element Table > Define Table...
 Click on 'Add...'

 As shown above, in the 'Item,Comp' boxes in the above window, select 'Stress' and
'von Mises SEQV'
 Click on 'OK' and close the 'Element Table Data' window.
 Plot the Stresses by selecting Plot Elem Table in the Element Table Menu
 The following window will appear. Ensure that 'SEQV' is selected and click 'OK'
 If you changed the contour intervals for the Displacement plot to "User Specified"
you may need to switch this back to "Auto calculated" to obtain new values for
VMIN/VMAX.
Utility Menu >PlotCtrls> Style > Contours > Uniform Contours ...

Again, select more appropriate intervals for the contour plot
 List the Stresses
 From the 'Element Table' menu, select 'List Elem Table'

 From the 'List Element Table Data' window which appears ensure 'SEQV' is
highlighted
 Click 'OK'
Note that a maximum stress of 64.914 MPa occurs at the fixed end of the beam as
predicted analytically.
Bending Moment Diagrams
To further verify the simplified model, a bending moment diagram can be created. First, let's
look at how ANSYS defines each element. Pipe 16 has 2 nodes; I and J, as shown in the
following image.

To obtain the bending moment for this element, the Element Table must be used. The
Element Table contains most of the data for the element including the bending moment data
for each element at Node I and Node J. First, we need to obtain obtain the bending moment
data.
 General Postproc> Element Table > Define Table... . Click 'Add...'.
 In the window,
A. Enter IMoment as the 'User label for item' - this will give a name to the data
B. Select 'By sequence num' in the Item box
C. Select 'SMISC' in the first Comp box
D. Enter SMISC,6 in the second Comp box
E. Click 'OK'
This will save all of the bending moment data at the left hand side (I side) of each
element. Now we need to find the bending moment data at the right hand side (J
side) of each element.
 Again, click 'Add...' in the 'Element Table Data' window.

1. Enter JMoment as the 'User label for item' - again, this will give a name to
the data
2. Same as above

3. Same as above
4. For step D, enter SMISC,12 in the second Comp box
5. Click 'OK'
 Click 'Close' in the 'Element Table Data' window and close the 'Element Table'
Menu. Select Plot Results > Contour Plot > Line Elem Res...
 From the 'Plot Line-Element Results' window, select 'IMOMENT' from the pull
down menu for LabI, and 'JMOMENT' from the pull down menu for LabJ. Click
'OK'. Note again that you can modify the intervals for the contour plot.

 Before the explanation of the above steps, enter help pipe16 in the command line as
shown below and then hit enter.
 Briefly read the ANSYS documentation which appears, pay particular attention to
the Tables near the end of the document (shown below).
PIPE16 Item, Sequence Numbers, and Definitions for the ETABLE Commands
node I
name item e Definition
MFORX SMISC 1 Member

MFORY SMISC 2 forces at the
MFORZ SMISC 3 node
MMOMX SMISC 4 Member

MMOMY SMISC 5 moments at
MMOMZ SMISC 6 the node
Note that SMISC 6 (which we used to obtain the values at node I) correspond to
MMOMZ - the Member moment for node I. The value of 'e' varies with different
Element Types; therefore you must check the ANSYS Documentation files for each
element to determine the appropriate SMISC corresponding to the plot you wish to
generate.
RESULTS: The required nodal deflections, reaction forces and stress for given the Beam element
has found out.

EXP- Date:
SIMPLE CONDUCTION PROBLEM
The Simple Conduction Example is constrained as shown in the following figure. Thermal
conductivity (k) of the material is 10 W/m*C and the block is assumed to be infinitely long.
Aim: Find the temperature distribution by Thermal conductivity in a member as shown in figure.
Procedure
1. Give example a Title
2. Open preprocessor menu
ANSYS Main Menu > Preprocessor /PREP7
3. Create geometry
Preprocessor > Modeling > Create > Areas > Rectangle > By 2 Corners > X=0, Y=0,
Width=1, Height=1

Preprocessor > Element Type > Add/Edit/Delete... > click 'Add' > Select Thermal
Mass Solid, Quad 4Node 55
For this example, we will use PLANE55 (Thermal Solid, Quad 4node 55). This
element has 4 nodes and a single DOF (temperature) at each node. PLANE55 can only be
used for 2 dimensional steady-state or transient thermal analysis.
Preprocessor > Material Props > Material Models > Thermal > Conductivity >
Isotropic > KXX = 10 (Thermal conductivity)
6. Mesh Size
Preprocessor > Meshing > Size Cntrls> Manual Size > Areas > All Areas > 0.05
7. Mesh
Preprocessor > Meshing > Mesh > Areas > Free > Pick All
Solution > Analysis Type > New Analysis > Steady-State

For thermal problems, constraints can be in the form of Temperature, Heat Flow,
Convection, Heat Flux, Heat Generation, or Radiation. In this example, all 4 sides of the
block have fixed temperatures
3. Solution > Define Loads > Apply
Note that all of the -Structural- options cannot be selected. This is due to the type of
element (PLANE55) selected.
4. Thermal > Temperature > On Nodes
Click the Box option (shown below) and draw a box around the nodes on the top
line.

The following window will appear:
 Fill the window in as shown to constrain the side to a constant temperature of 500
 Using the same method, constrain the remaining 3 sides to a constant value of 100.Orange
triangles in the graphics window indicate the temperature constraints.
5. Solve the System
Solution > Solve > Current LS

Plot Temperature
General Postproc> Plot Results > Contour Plot > Nodal Solu ... > DOF solution,
Temperature TEMP
RESULT: The temperature distribution by Thermal conductivity in a member has found.

Harmonic Analysis of a Cantilever Beam
AIM: conduct a harmonic forced response test by applying a cyclic load (harmonic) at the end
of the beam. The frequency of the load will be varied from 1 - 100 Hz. The figure below
depicts the beam with the application of the load.
Software: Ansys 10.0
Procedure:

Solution: Assigning Loads and Solving
i. Define Analysis Type (Harmonic)
Solution > Analysis Type > New Analysis > Harmonic
ANTYPE,3
ii. Set options for analysis type:
 Select: Solution > Analysis Type > Analysis Options..
The following window will appear

 As shown, select the Full Solution method, the Real + imaginary DOF
printout format and do not use lumped mass approx.
 Click 'OK'
The following window will appear. Use the default settings (shown below).
iii. Apply Constraints

 Select Solution > Define Loads > Apply > Structural > Displacement
> On Nodes
The following window will appear once you select the node at x=0 (Note small changes
in the window compared to the static examples):
 Constrain all DOF as shown in the above window

iv. Apply Loads:

 Select Solution > Define Loads > Apply > Structural > Force/Moment
> On Nodes
 Select the node at x=1 (far right)
 The following window will appear. Fill it in as shown to apply a load with
a real value of 100 and an imaginary value of 0 in the positive 'y'
direction.
v. Set the frequency range

 Select Solution > Load Step Opts > Time/Frequency >Freq and
Substps...
 As shown in the window below, specify a frequency range of 0 - 100Hz,
100 substeps and stepped b.c.
By doing this we will be subjecting the beam to loads at 1 Hz, 2 Hz, 3 Hz, ....... 100 Hz.

We willspecify a stepped boundary condition (KBC) as this will ensure that the same
amplitude (100N) will be applied for each of the frequencies. The ramped option, on the
other hand, would ramp up the amplitude where at 1 Hz the amplitude would be 1 N and at
100 Hz the amplitude would be 100 N. You should now have the following in the ANSYS
Graphics window
vi. Solve the System

Solution > Solve > Current LS SOLVE
We want to observe the response at x=1 (where the load was applied) as a function of
frequency. We cannot do this with General Post Processing (POST1), rather we must use
TimeHistPostProcessing (POST26) POST26 is used to observe certain variables as a
function of either time or frequency.
i. Open the TimeHist Processing (POST26) Menu Select TimeHistPostprofrom
the ANSYS Main Menu.
ii. Define Variables
In here we have to define variables that we want to see plotted. By default, Variable 1 is
assigned either Time or Frequency. In our case it is assigned Frequency. We want to see
the displacement UY at the node at x=1, which is node #2. (To get a list of nodes and their
attributes, select Utility Menu > List > nodes)
 Select TimeHistPostpro> Variable Viewer... and the following window should
pop up.

 Select Add (the green '+' sign in the upper left corner) from this window and the
following window should appear
 We are interested in the Nodal Solution > DOF Solution > Y-Component of
displacement ClickOK.
 Graphically select node 2 when prompted and click OK. The 'Time History
Variables' window should now look as follows

iii. List Stored Variables

In the 'Time History Variables' window click the 'List' button, 3 buttons to the left of
'Add' The following window will appear listing the data:
vii. Plot UY vs. frequency

 In the 'Time History Variables' window click the 'Plot' button,
2 buttons to the left of 'Add'
The following graph should be plotted in the main ANSYS window.

Note: that we get peaks at frequencies of approximately 8.3 and 51 Hz. This corresponds with the
predicted frequencies of 8.311 and 51.94Hz.To get a better view of the response, view the log scale
of UY.
 Select Utility Menu >PlotCtrls> Style > Graphs > Modify Axis.
The following will appears.

 As marked by an 'A' in the above window, change the Y-axis scale to

'Logarithmic'
 Select Utility Menu > Plot >Replot
 You should now see the following
This is the response at node 2 for the cyclic load applied at this node from 0 - 100 Hz.
Result: The harmonic forced response test by applying a cyclic load (harmonic) at the end of the
beam with the frequency of the load will be varied from 1 - 100 Hz was conducted.

ANSYS via questions and answers
1. What does ANSYS stand for?

A: ANSYS stands for "Analysis System".
2. What are the different approximate solution methods?
A: Finite Element method, Finite difference method and quadrature method.
3. What do you mean by continuum?
a. A continuous sequence in which adjacent elements are not perceptibly different from
each other, although the extremes are quite distinct.
b. A continuous extent, succession, or whole, no part of which can be distinguished
from neighboring parts except by arbitrary division.
4. Define term node?
a. In the FEM, the structural system is modeled by a set of appropriate finite elements
interconnected at points called nodes
b. A node is a specific point in the finite element at which the value of the field
variable is to be determined.
c. Nodes are the selected finite points at which basic unknowns (displacements in
elasticity problems) are to be determined in the finite element analysis
5. Define term element?
a. In a continuum, unknowns are many. The FE procedure reduces such unknowns to a
finite no. by diving the solution regimes into small parts called elements
6. What is convergence?
A: Convergence refers to how close the FEM solution is to the exact solution
7. What are the type’s convergences?
A: h – method and p-method
8. What is p-convergence?
A: Large elements and complex shape functions are used in p-method problems. In
order to increase the accuracy of the solution, the complexity of the shape function
must be increased. The mesh does not need to be changed when using the p-method.
Increasing the polynomial order increases the complexity of the shape function. As
an initial run, the solution might be solved using a first order polynomial shape
function. A solution is obtained. To check the solution the problem will be solved

again using a more complicated shape function. For the second run, the solution may
be solved using a third order polynomial shape function. A second solution is
obtained. The output from the two runs is compared. If there is a large difference
between the two solutions, then the solution should be run using a third order
polynomial shape function. This process is repeated until the solution is not
changing much from run to run.
9. What is h convergence?
A: Simple shape functions and many small elements are used in h-method problems. In
order to increase the accuracy of the solution, more elements must be added. This
means creating a finer mesh. As an initial run, a course mesh is used to model the
problem. A solution is obtained. To check this solution, a finer mesh is created. The
mesh must always be changed if a more accurate solution is desired. The problem is
run again to obtain a second solution. If there is a large difference between the two
solutions, then the mesh must be made even finer and then solve the solution again.
This process is repeated until the solution is not changing much from run to run.
When using an h-method finite element program (such as ANSYS), the user
must run two or more solutions to ensure that the solution has converged. The user
runs the solution with one mesh and then changes the mesh and reruns the solution.
10. What is a higher order element?
A: If the interpolation polynomial is of the order two or more, the element is known as
higher order elements.
11. Give example for higher order elements.
A: Quadratic bar element, cubic bar element etc.
12. What do you mean by compatible elements?
A: The elements which deform without causing openings, overlaps or discontinuities
between the adjacent elements are known as compatible elements
13. What is geometric invariance?
A: Displacement shapes will not change in local coordinate system. This property is
known as geometric invariance.

14. Why do we use Pascal’s triangle in FEA?

A: In order to achieve geometric invariance the polynomial should contain terms that do
not violate symmetry; this is achieved by the use of Pascal triangle for 2Dcases and
Pascal tetrahedron for 3D cases.
15. What is stiffness matrix?
A: For an element, Stiffness matrix is a matrix such that { f } = [K] {Q}, [K] relates
nodal displacements to nodal force of a single element.
16. How to obtain stiffness matrix?
A: Using the formula for particular element.
17. What are the properties of stiffness matrix?
A: Non negative diagonal elements, Symmetry and sparsity.
18. What is displacement function?
A: The displacement function, uniquely defines strain within an element in terms of
nodal displacements.
19. How to identify order of elements?
A: The maximum power of the variable in the interpolation polynomial gives the order
or the order can be obtained by no. of nodes present.
20. Mention different types of elements.
A: Simplex elements, complex elements and multiplex elements; Based on their
geometry they are classified as 1D, 2D, 3D and axis symmetric elements.
21. Mention some application of FEA.
A: Stress analysis of bars, beams, trusses, buckling problems, Heat transfer problems,
fluid flow problems, bio medical areas etc.
22. What is connectivity?
A: Connectivity is a term used when a matrix or a table connects the stress, reactions,
displacements etc.
23. What are the methods to improve problem solution?
A: Use of higher order elements in order to get exact solutions
24. Define symmetry in matrix.
A: A symmetric matrix is a square matrix that is equal to its transpose

25. What is plane stress?

A: Plane stress is defined to be a state of stress in which the normal stress and shear
stress directed perpendicular to the plane are assumed to be zero e.g. thin plate with
hole
26. What is plane strain?
A: Plane strain is defined to be a state of strain in which normal strain and shear strain
normal to the XY plane are assumed to be zero.
27. What are the packages available for FEA?
A: STAAD-PRO, GT-STRUDEL, NASTRAN, NISA and ANSYS
28. Define potential energy.
A: Potential energy is energy which results from position or configuration
29. Define minimum potential energy.
A: Deformation and stress analysis of structural systems can be accomplished using the
principle of Minimum Potential Energy (MPE), which states that “For conservative
structural systems, of all the kinematically admissible deformations, those
corresponding to the equilibrium state extremize (i.e., minimize or maximize) the
total potential energy. If the extremum is a minimum, the equilibrium state is stable.
30. Write potential energy equation for cantilever beam.
𝑀2
A: 𝑈=∫ 𝑑𝑥
2𝐸𝐼
31. Mention 2 different methods to approach the model of physical system.
A: FEM and FDM
32. Difference between global coordinate and local coordinate?
A: Global coordinate relates to whole assembly and local coordinate relates to
individual part co-ordinate systems.
33. What is local coordinate?
A: For the convenience of deriving element properties, in FEM many times for each
element a separate coordinate system is used known as local coordinate system
34. What is global coordinate?
A: The coordinate system used to define the points in the entire structure is called
global coordinate system.

35. What is shape function?

A: Function which relates the field variable at any point within the element to the field
variables of nodal points is called shape function.
36. What are two general natural coordinate?
A: Zeta ξ and neta ή?
37. Mention the range of natural coordinate.

A: -1 to +1
38. Number of shape function in CST
A: 3
39. Number of shape function in quadrilateral.
A: 4
40. Explain one point formula and explain two point formulas.
+1
A: 1-point formula ∫−1 𝑓(𝜉)𝑑𝜉 =w1f (ξ), w1 = 2, ξ= 0
+1 1 1
2-point formula ∫−1 𝑓(𝜉)𝑑𝜉 =w1f (ξ1) +w2f (ξ2), w1= 1, ξ1 = , w2= 1, ξ2= −
√3 √3
41. Why we are using polynomial equation in FEA?
a. It is easier to formulate and computerize the finite element equations with
polynomial type interpolation functions. Specifically, it is easier to perform
differentiation or integration with polynomials.
b. It is possible to improve the accuracy of the results by increasing the order of the
polynomial.
42. Mention two schemes to represent band width?
A: Node numbering along longer edge and shorter edge.
43. What are forces involved in work potential?
A: Body forces and traction forces
44. What are anisotropic elements?
A: The property of the material is not same along all the directions; such materials are
called anisotropic elements.
45. What are isotropic elements?
A: The property of the material is same along all the directions; such materials are
called isotropic elements.

46. What are the 2 different approaches to study elasticity?

A: Elimination and penalty approach method
47. List the properties of shape functions.
1. Shape function at a specified point is unity and other than the specified point it is
zero.
2. Sum of shape functions is unity.
3. The differentiation of shape function is a constant
48. Define truss.
A: A framework, typically consisting of rafters, posts, and struts, supporting a roof,
bridge, or other structure
49. Different methods to solve weighed residual problem.
A: Galerkin method, Collocation method, Sub domain method
50. Which is the most accepted form of numerical integration in FEM?
A: Gaussian quadrature
51. List the different approaches to derive integral equation.
A: Gaussian quadrature, Simpson’s 1/3 rule etc
52. What are the different types of errors in FEA?
i. Modeling Error, User error, bugs, Discretization error, Rounding error,
manipulation error, Numerical error
53. Define Beam & Its types.
A: A bar subjected to forces and couples that lie in a plane containing its longitudinal
axis is called a beam Types include Cantilever beam, simply supported beam and
over hanging beam
54. Define adiabatic surfaces.
A: Adiabatic surfaces are surfaces which do not allow the flow of heat either into the
body or out the body.

Introduction to CNC
Computer Numerical Control (CNC) is over ’NC’ system that utilizes a dedicated, stored
program computer to perform same (or) all of the basic numerical control functions. Because of
trend towards down sting in computers most of the CNC system sold today use a microcomputer
based controller unit.
The external appearance of CNC machine is very similar to that of conventional NC

machine is numerical control can be defined as a form of programmable automation in which the
process is controlled by numbers, letters, symbols. The basic components of CNC system are,
1. Program of instructions:
The program of instruction is detailed step by step set of directions which tell the machine
tool what to do. It is coded in numerical (or) symbolic form on some type of I/P medium that can be
interpreted by the controller unit. The most common type I/P medium today is computer over the
years the other form of I/P media have been used, those are purchased cards magnetic tape and even
35 mm motion picture film. These are not used today due to wear and tear problems it is replaced
by mini computers.
Block Diagram
Program Computer Compute

InPut Processing memory
Control Unit
Machine
Control
Unit
Machine Tool

2. Machine control unit:
The second basic component of the CNC system is the controller unit. This consists of the
electronic and hard ware that read and interprets the program of instructions and converts it into
mechanical action of the machine tool. The digital O/P channels are connected to the servo motors
and other controls in the machine tool. Through these channels the instructions are sent to the
machine tool from controller unit. To make the certain that the instructions have been properly
executed by the machine feedback are sent to the controller via feedback channels.
3. Machine tool(or) other controlled process:
The third basic components of a CNC system is the machine tool (or) other controlled
Process. It is the part of NC system which performs useful work. In the most common example, the
machine tool consists of work table and spindle as well as the motors and controls necessary to
drive them. Because of this programming capacity both in terms of part program and system control
options. CNC is often referred to a soft wired NC. The general configuration of CNC system is
shown in figure.
Codes used in program:
The part program used word address. These words should be given in sequence as follows.
Sequence number tool
Preparatory code (G, M codes)
Feed rate (f) mm/min
Speed (r) rev/min
G-Codes:
G00 - Point to point between previous and end point defined in current block
G01 – Linear interpolation movement block must include x-y-z coordinates of each position feed
rate must also be specified.

G02 - Circular interpolation in clock wise. Block must include either are radius, are centre co-
ordinates of end position must also be specified.
G03 – Circular interpolation in counter clock wise. Block must include either are radius, are centre
co-ordinate of end position must also be specified.
G04 – Dwell for a specified time.
G10 – I/P of cutter off set data collected followed by P-code and R-code.
G17 – Selection of x-y plane in milling
G18 – Selection of y-z plane in milling
G19 – I/P values specifies in inches
G20 - I/P values specifies in inches
G21 - I/P values specifies in mm
G28 – Return to reference point
G32 – Thread cutting in turning
G40 – Cutter offset compensation for cutter radius
G41 – Cutter offset compensation, left of part surface. Cutter radius must be specified in block
G42 – Cutter offset compensation, right of part surface
G71 - Multiple turning
G72 – Multiple facing
G73 – Pattern repeating
G76 – Multiple threads
G90 – Programming in absolute coordinates
G91 – Programming in incremental coordinates

G92 – Specify location of coordinate axis system origin relative to starting location of cutting tool.
G94 – Facing cycle
G95 –Specify feed per revolution in milling & drilling
G98 – Specify feed per minute in turning
G99 –Specify feed per revolution in turning
M- codes:
M00 - Program stop, used in middle (turning) of program operator must restart machine
M01 – Optional Program stop; Active only when optimal stop button on control panel has been
depressed
M02 - End of program machine stop
M03 – Start spindle in clock wise direction for milling machine
M04 – Start spindle in counter clock wise direction for milling machine
M05 - Spindle Stop
M06 –Execute tool change, either manually (or) automatically, If manually operator must restart
machine.
M07 – Turn cutting fluid on flood
M08 - Turn cutting fluid on mist
M09 - Turn cutting fluid OFF
M10 – Automatically clamping of fixture, machine slides
M11 – Automatically unclamping
M13 – Start spindle in clock wise direction per milling machine and turning on cutting fluids.
M14 – Start spindle in counter clock wise direction for milling machine.

M19 –turn spindle OFF at oriented Position
M30 – End of program, machine stop

Exp- Date:
FACING ON CNC LATHE
Aim: To write the manual part program to the given dimensions for simple facing operation and
execute the CNC lathe.
Ø25
Ø55
Material required: Aluminum
Dimension: Diameter – ø 25 mm
Length – 60 mm.
(The material to be removed is 2 mm)
[ B I L L E T x 25 z 60 ]
N005 G28 U0 W0
N010 M06 T01
N015 M03 S1000
N020 G00 X25 Z1
N025 G01 Z -0.5 K40
N030 X0
N035 X25
N040 Z-1
N045 X0
N050 X25

N055 Z-1.5
N060 X0
G28 - G0 to reference point
M06 – tool change
M03 – spindle rotate cw
G00 – Linear interpolation
G03 – circular interpolation
M05 – spindle stop
M02 - Program End
N065 X25
N070 Z-2
N075 M05
N080 M30
N085 G28
Result: Thus the manual part program was written to the given dimension and executed in CNC
lathe.

Exp- Date:
FACING ON CNC TURNING
Aim: To write the manual part program to the given dimensions for tuning operation and execute in
CNC lathe.
Material required: Aluminum
Ø 22
Ø 25
60mm
ø ø22
60 m
All dimensions are in mm
Dimensions: Diameter – ø 25 mm
Length – 60 mm.
[Reduce the diameter 25 to 22 mm]
[Depth per pass equal to 0.5mm]
[ B I L L E T x 25 z 60 ]
N005 G28 U0 W0
N010 M06 T01

N015 M03 S1000
N020 G00 X25 Z1
N025 G01 Z -0.5 K40
N030 Z-60
N035 X25
N040 Z1
N045 X24
N050 Z-60
N055 X25
N060 Z1
M06 – tool change
M03 – spindle rotate cw
G00 – rapid traverse
G01 – linear interpolation
G03 – circular interpolation
M05 – spindle stop
M02 - Program End
N065 Z 23.5
N070 Z-60
N075 X25
N080 Z1

N085 X23
N090 Z-60
N095 X25
N100 Z1
N105 X 22.5
N110 Z-60
N120 X22Z-60
N125 M05 M30
N130 G28
Result: Thus the manual part program was written to the given dimensions and executed in CNC
lathe.

TAPER TURNING ON CNC LATHE
Aim: - To write the manual part program to the given dimensions for Taper turning operations and
execute in CNC Lathe (using multiple Turning cycle)
Material required: Aluminum (55 mm x Ф30mm)
Equipment required: CNC Lathe (Fanuc language)
Program:
Billet X30 Z55
N001 G28 U0 W0
N002 M03 S1000 F60
N003 M06 T01
N004 G00 X0 Z2
N005 G00 Z0
N006 G01 X10 Z0
N007 G01 X10 Z0
N008 G01 X30 Z-35
N009 G01 X30 Z-45
N010 G28 U0 W0
N011 M05 M30
Result: Thus the Manual part program was written to the given dimensions and executed in CNC
Lathe.

CNC-Viva Question and Answers

1. Explain about G codes?
A: G-code is the common name for the most widely used numerical
control (NC) programming language, which has many implementations. Used mainly
in automation, it is part of computer-aided engineering. G-code is sometimes called G
programming language
2. Mention few important G codes?
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
3. What are the uses M codes?
A: A word used to signal an action from a miscellaneous group of commands. M codes
change cutting tools, turn on or turn off the coolant, spindle, or workpiece clamps,
etc
4. Write about some important M codes?
M00 - Program stop; Mill and Lathe
M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M05 - Spindle off; Lathe and Mill
5. What is the use of box facing cycle?
A: Fanuc G94 facing cycle is used for simple facing (one-pass facing) however multiple
passes are possible by specifying the Z-axis location of additional passes
6. What is the difference between G00 and G01codes?
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
7. How to change the tool in CNC program?
M06 - Tool change;

8. How to change the tool speed in CNC lathe?

M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
9. What is the difference between absolute and incremental system?
A: Absolute positioning means that the tool locations are always defined in relation to
the zero point. Incremental positioning means that the next tool location must be
defined with reference to the previous tool location.
10. What are the axes to be considered while writing program for CNC lathe?
X and Z Axis
11. What is the code for threading cycle?
A: G92
12. What is the code for Incremental and absolute co-ordinate system?
A: G90 and G91
13. What is the code for coolant control?
 M7 - turn mist coolant on.
 M8 - turn flood coolant on.
 M9 - turn all coolant off.
14. What is use of dry run option?
A: A dry run (or a practice run) is a testing process where the effects of a possible
failure are intentionally mitigated

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RISE KRISHNA SAI PRAKASAM GROUP OF INSTITUTIONS SIMULATION LAB

Computer-aided design is essentially based on a versatile and powerful

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3. Design review and evaluation.

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Design review &Evaluation;

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WIRE FRAME MODEL-INTRODUCTION:

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the relational information between objects.)

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Aim : To create a 2D view of the given diagram using Auto CAD.

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Result: Hence the required 2D diagram is created using Auto CAD.

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1. Type limits in command menu & set values to 45, 45

4. Draw the 3 concentric circles of diameters 85, 62, 32

5. Draw the 2 axes lines from the center of the circles

7. Then trim the unwanted lines

9. Offset the vertical and horizontal axes with 47 and 52 distance

12. Then mirror this to require the 2D drawing

13. Finally trim the unwanted lines and circles

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Result: Hence the required 2D diagram is created using Auto CAD.

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Aim: To create a 2D view of the given diagram using Auto CAD.

4. Draw the 2 axes lines

5. Draw 2 concentric circles of diameter 58 and 40 above the axes

6. Draw the 10dia circle on the 40dia of the circle

8. Draw the 2 concentric circles of diameter 58 & 36 below the axes

9. Draw the circles of the diameter 8 on the circle of 36dia

12. Fillet the circles of radius 20 with 15 radiuses.

14. And chamfer the circles of radius 20 with 58dia circle

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Result: Hence the required 2D diagram is created using Auto CAD.

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4. Go to drafting settings and turn on isometric snap..

5. Use the F5 key to change between the views of isometric planes.

7. Change to top plane and draw the 72mm line.

8. Continue in the same fashion to complete the whole figure.

9. Give the dimensions from the dimension tool bar as in diagram.

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7. Continue drawing using F5 and F8 snap keys.

8. Give proper dimensions to the figure and practice at home.

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Viva-voice question and answers

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3. Now select the sketch button to

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SKETCHER TOOLS TOOLBAR

Working with sketching entities

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1. Click the Point ( ) button on the Sketcher Tool bar.