How to interpret stresses at edges of model

How to interpret stresses at edges of model

ericjkortAW8CL
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How to interpret stresses at edges of model

ericjkortAW8CL
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I am simulating the response of this bracket to a force applied to the top of the two bolts near the bottom. I have fixed the model at the three holes along the back flange (which will be lag bolted to a stud). 

 

The forces along the highlighted edges in the attached screenshot are >50% the estimated tensile strength of mild steel (though well below the yield strength), i.e. safety factor < 2. But the estimated displacement is around 0.05mm (about two thousandths). 

 

Should I be concerned that these brackets will meaningfully deform under the simulated force?

 

ericjkortAW8CL_0-1757604711827.png

 

 

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Message 2 of 10

bwalker145
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If you're well below yield, I wouldn't expect to see major permanent deformation; that assumes that the load is equally distributed across the fasteners/hole geometry. Did you have the back face constrained as well, as I'm assuming this mates against a flat face? Is this a static load?

What's with the 32k spike on the bottom hole? Is that just an abnormality giving you an artificially high peak? Just looks odd based on the surrounding color mapping.

Message 3 of 10

ericjkortAW8CL
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Explorer

The spike is just a single mesh cell, so I presume an artefact. 

 

It mates to a flat face, but I did not constrain the face as I assumed it is only truly constrained at the bolt holes (and a small surrounding area corresponding to the bolt head/washer.)

 

I modeled this as a static load.

 

 

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henderh
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Community Manager

I agree 100% with @bwalker145's comments. Without more background info, it is difficult to say if results shown are a reasonable simulation of real-life. I always check if the Inspect Panel > Reaction Forces are expected. These (of course) should be equal in magnitude, and opposite in direction to the applied loads for static equilibrium. Once you're convinced the Load Case & study setup is accurately capturing / abstracting the real operating conditions, and still witness unexpected result anomalies, you may have to further tweak the mesh or the Simulation Model itself.

 

The highest stresses that occur at edges shown in the screenshot are likely artificial stress concentrations. These can manifest at geometry with a Fixed constraint applied, and unfortunately an effect inherent in the FEM solution.

 

Other manifestations of artificial stress concentrations can exacerbate as the mesh density is increased. These mainly occur at sharp inside / re-entrant corners, that in real-life are not as perfectly sharp as the computer model has represented. Stress is pressure, which is force per unit area. If the area is made smaller and smaller (via changing the settings to generate a smaller and smaller mesh element) the area approaches zero, and stress goes to infinity (this is kind of an analogy). Usually these can be safely be ignored, or a tiny blend / fillet added to the Simulation Model to smooth out the effect.

Another gotcha of 'this isn't real-life results' may occur if there isn't a sufficiently dense mesh in the place(s) of interest in the model.  e.g. you need 3 layers thickness of solid elements to accurately simulate shear throughout the thickness of plate type bodies in bending. Fusion Simulation uses solid tetrahedral mesh elements exclusively, which are well suited for chunky bodies. However, thinner bodies are better suited using Shell elements instead. These element nodes have not only translational DOFs that solid tets employ, but add rotational DOFs (such as a DKT - Discrete Kirchoff Triangle shell element that Autodesk Inventor Stress Analysis, and Autodesk Inventor Nastran products offer). Using the correct element types in a 'mixed model' will capture the physics more accurately, and with far less elements needed (better results in less time). In your case, the bracket appears thick enough that solid elements should be fine IMO.

 

Hope this helps! Please let us know if you have additional questions, comments or suggestions.

Best regards,



Hugh Henderson
QA Engineer (Fusion Simulation)
Message 5 of 10

TheCADWhisperer
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Consultant

@ericjkortAW8CL 

Go to 30:36 in the video for discussion relevant to your question in Fusion.

https://www.youtube.com/watch?v=Q837ZYvVFDQ

 

You have to make engineering decisions about the relevance of a perceived issue.

If you throw enough material, time, money at a part you can be confident that it won't break but the real engineering challenge is to make the design just strong enough to be fit for function.  An example I used with students is the tailgate of a pickup truck.  You could make the tailgate nearly indestructible, but the truck would be unaffordable to most customers. Edges that see a lot of use (forces) tend to get deformed, but the overall part serves the intended function.

 

TheCADWhisperer_0-1757614702663.png

 

Message 6 of 10

ericjkortAW8CL
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Explorer

These are exceedingly helpful observations and suggestions.  I will go back and check my mesh settings to ensure “three layers”.

 

Aside from that the part certainly behaves in simulation as I expect. The part “feels” like plenty of tailgate for this truck (so to speak) and the simulation combined with the expert interpretive advice in the posts above align with that feeling. I can definitely live with a little edge wear and tear. 

(I am but a humble life long do-it-you selfer, so my time is free. But my project budget is finite. So still trying not to over-engineer to a ridiculous extent. And ultimately my design will be reviewed by an honest-to-goodness engineer for peace of mind and a building permit, so I am trying my best to set myself up for success.)

 

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Message 7 of 10

bwalker145
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It mates to a flat face, but I did not constrain the face as I assumed it is only truly constrained at the bolt holes (and a small surrounding area corresponding to the bolt head/washer.)


With fixed constraints applied to only the fastener thru holes & the location of the load, it's trying to bend the part around the x-axis at the bottom fastener hole. In reality, the mating component on the rear face will help resist the moment, and may change the stress you see reported at the curved transition.

Your pattern of bolt holes constrain translation/rotation in X-Z (plus Y rotation) , and the fastener heads/washers + mating piece work together to constrain Y translation.

@henderh  can answer this better than I can, but adding a frictionless constraint on that back surface may be adequate to simulate the backing plate for your needs, or you might need to use Contacts with the backing plate modeled.

 

[Edit: Based on your last comment, looks like this might be a DIY project as well. In that case, you can probably get away with a less-than-perfect simulation & sizable safety factor, and don't have to iterate your life away trying to optimize the design and shave pennies.]

bwalker145_0-1757621899067.png

 

Message 8 of 10

henderh
Community Manager
Community Manager
  • @henderh  can answer this better than I can, but adding a frictionless constraint on that back surface may be adequate to simulate the backing plate for your needs, or you might need to use Contacts with the backing plate modeled.

I had a similar idea @bwalker145, and gave it a whirl. The reason there's only 1/2 the model showing is to take advantage of symmetry, and we can add a 'frictionless constraint' to the faces created by the cut (and the face in contact with the bolt sleeves). I didn't model that portion and used a Bearing load instead, which will only push down on the hole in a parabolic load profile, but will also not pull down from the top portion of the hole (not reality) as a conventional Force load would. The dummy mount also doesn't take into account the same compliance of the real structure, which likely has a bit more deflection.

Contacts setup - DOF View - Potentially Fixed bracket group.png  Above 50 MPa Equivalent stress.png

 

I enabled Adaptive Mesh Refinement that will automatically detect the area(s) of highest stress, then automatically refine the mesh in the local area, and does a wash, rinse, repeat iteration until it converges upon a stable value. i.e. it's one way to check the numerical result is likely not mesh-size dependent.

Max stress - convergence plot.pngHalf symmetry model - Von Mises.png5x super exaggerated Deformation - side view.png

(view in My Videos)

 

I hope this helps illustrate a few approach options in the setup. In my example (F3z Fusion archive attached below) I could have made a major blunder and offer no guarantee it is correct for the real-life loading conditions, etc. <caveat emptor 🙏>

 

 

Best regards,

 

 



Hugh Henderson
QA Engineer (Fusion Simulation)
Message 9 of 10

ericjkortAW8CL
Explorer
Explorer

Thanks very much for these additional ideas. A frictionless constraint on the back plane resulted in what seemed like reasonable results. I also like the idea of modeling the backing plate--the bracket will be attached to wood studs, which I cannot model in Fusion, but I can try metal as you did @henderh (bearing in mind reality will be a little more bendy than the model). With no constraints other than the holes vs. frictionless constraint vs. metal backing plate I should have a pretty good triangulation on reality. 

 

And @bwalker145, I think I will put "Don't iterate your life away" on a T-shirt.

Message 10 of 10

henderh
Community Manager
Community Manager

No worries @ericjkortAW8CL! We're here to help as best we can, and it's a pleasure being involved in your "stressful" thread topic 😉

At risk of being Captain Obvious, I'll toss in another three cents...although the Frictionless constraint is a very handy tool for say non-planar faces, it may introduce an unintended limitation due to the way it constrains the nodal DOFs:

By using the backing plate and a Separation contact, the video & screenshots illustrate how it allows the bracket to 'peel away' from the backing plate to be consistent with real-life. I found it's sometimes deceptively tricky to set up just enough constraints that will allow the natural free movement (as close as possible to actual with the 'tools provided') versus a falsely over-constrained setup. Worst case it could lead to generating the correct results for a different problem.

For a single body study, Frictionless may be the appropriate choice. However, a Separation contact in an Assembly context would be the way to approach the setup IMO. Reason being is Frictionless allows only sliding (tangential movement of the nodes with respect to the face normal at that point). As such, it locks out not only the penetration effect (good) but simultaneously locks out the separation effect, which may become a factor to consider if the load magnitude reached triggers the effect.

 

Here's a chart from the OLH that explains the contact DOFs in case you're eager to dive down another rabbit hole:

I'm now wearing @bwalker145's advice on a fresh new t-shirt, selfishly combined with my own from a SimQA perspective, of course:

  • "Don't iterate your life away" <front> "Fine tuning results for a different problem" <back> 😇

 

Happy Friday, and we wish y'all (or yinz, for you western Penn folks) an excellent weekend!



Hugh Henderson
QA Engineer (Fusion Simulation)