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For this project, FEA simulations were carried out using the ANSYS Discovery AIM 2020 R2 software. This software can be used to run many different types of simulations, such as: structural, fluid flow, thermal, and electromagnetic. The necessary steps that must be completed in order to set up and run a structural simulation, as well as properly interpret the simulation results, are described in detail below. The pictures shown throughout correspond to an example structural simulation run on an armchair geometry. There are three main sections to the simulation workflow: "Geometry", "Physics", and "Results".
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| Typical View of Simulation Workflow in the Discovery Aim 2020 R2 Client |
Geometry
The first step in creating a simulation in Discovery Aim is to import the geometry of the part or assembly that is being studied. This can be done using the following steps:
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Note: Under the current student version of the software, any geometry imported is subject to a limit of 50 bodies and 300 faces.
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| Example of Imported Armchair Geometry |
Physics
Material Assignments
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- Under the "Physics" tab, select the "Material Assignments" option
- Click the "Body selection" tool on the top right side of the workspace
- Select a body and press the "Replace with selected entities" button that will have become blue
- If any other bodies in the geometry are the same material as the previously selected body, select those bodies and press the "Add selected entities" button
- Once all bodies of a common material have been added, click the "Material" drop-down menu and select the desired material (if the desired material is not a pre-defined material, select the "Create New" option and specify known properties)
- Return to the "Physics" tab. For any other sets of bodies that share a common material, select the "Add" option besides "Material Assignments" and repeat the above steps
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| Define Example Material | Use Defined Material to Create a Material Assignment |
Structural Conditions
The next step in setting up the simulation is the most important. The structural conditions section is where you will define all of the conditions that the geometry will face during the simulations. This tool can be used to define structural conditions such as forces, supports, temperatures, pressures, and many more. Structural conditions can be defined using the following steps:
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Note: A support can either be defined as the faces of the geometry that would be resting on the "ground" in reality, or by adding a body to the geometry that serves as the ground (flat slab of concrete for example), and defining that body as a support.
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| Example Loading Conditions | Example Support Definition |
Advanced Setting: Interface Conditions
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When viewing a result, the value and location of the maximum and minimum calculated values are automatically displayed. Appearance settings such as "variable range", "coloring", and "color distribution" can be varied under the "Appearance" tab to fit the needs of the user. Changing these settings can make it easier to view and understand the results for specific areas of the geometry.
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| Equivalent Stress Contour Plot Result (Automatic Appearance Settings) | Equivalent Stress Contour Plot Result (Optimized Appearance Settings) |
For geometries with more than one body, the "Location" option under the "Definition" tab can be used to specify which bodies the results are evaluated for. By default, results are generated for all bodies in the assembly. However, choosing only specific bodies can make it easier to determine the maximum and minimum result values in these bodies (especially when those values are not the maximum and minimum values of the overall geometry).
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| Fatigue Life Contour Plot Result Generated for Only the Chair Arms |
