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Multi-Body Dynamic Transient Simulation for a Spray Mechanism Satheesh C. Kaviraj Shinde Raviteja S. Design Engineer Team Leader Project Manger Infotech Enterprises Ltd. Infotech Enterprises Ltd. Infotech Enterprises Ltd. Manikonda Manikonda Manikonda Hyderabad-500072,India Hyderabad-500072,India Hyderabad-500072,India Abbreviations : FMBD : Flexible Multi Body Dynamics DSTIFF : Differential/algebraic equations (DAE) integrator code h3D : Hyper 3D Keywords : Rigid-to-rigid, Point to deformable contact, Flexprep AbstractThe paper deals with a study of kinematic motion of a spray mechanism. MotionView tool is used in constraining multiple bodies withtheir respective joints and also contacts at the interfaces. Compression & torsion springs are modeled to support the kinematic motionin the mechanism.The simulation is performed in two stage process:Rigid body simulation:Transient load is applied, and the load transferred and displacement in each body is calculated.Flexible body simulation:FE model is created in HyperMesh and imported into MotionView. Transient analysis is carried out in MotionSolve to observe the stress& strains developed in the bodies.IntroductionDifferent types of spraying mechanisms to spray the fluid generated are the integrated part of some of thecurrent home appliances. The spray mechanism involves number of joints, springs and contacts. Thefunctionality of these joints is to provide the required amount of fluid while in operation. Accessing theFailure modes and stresses in the mechanism due to the applied force by end user is the main objective ofthe project.A linear transient 3D MBD simulation with rigid bodies and flexible body is carried out by considering thegeneric material and inertia properties using MotionSolve. HyperMesh and MotionView softwares are usedfor pre-processing. HyperView and HyperGraph are used for post-processing. Ansys software is used tocompare the flexible body results.Process Methodology (details with figures)For Rigid Body Simulation: After importing the CAD model into MotionView, mass and inertia properties ofeach components are applied. Joints are modeled for the respective components to achieve the requiredmechanical function. Please refer the table 1. TABLE 1Simulation Driven Innovation 1
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JOINTS WITH RESPECTIVE DOFSThe calculation method for contacts is selected as poisson contact with coulomb friction on. Contact relatedproperties viz., penalty, restitution coefficient, static and dynamic frictional coefficients are obtained byiterative method starting with the default values defined in MotionView. Stiffness, damping coefficients,preload properties are defined as given. Rigid-to-rigid body contacts are used for rigid body simulation.The frictional force is modeled as a viscous (dynamic) force according to the following law: .....cnt01In the above equations:• is the current slip speed at the point of contact.• is the coefficient of static friction.• is the coefficient of dynamic friction. is the stiction (static friction) transition slip speed at which the full value of is used for the• coefficient of friction.• is the dynamic friction slip speed at which the full value of is used for the coefficient of friction.• is the friction force that is to be applied. The friction force opposes the direction of the slip velocity.Simulation Driven Innovation 2
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Figure 1 Spray Mechanism with Joints and Contacts 1:The springs are modeled at the required joints. Force and displacement output are requested for therequired components/ joints/ springs. Solution run is given as transient with provided end time. Theintegrator type is defined as DSTIFF. Integration tolerance, maximum step size are defined by carrying out ypenumber of iterations.The transient analysis is carried out to calculate the response of a multi body system to time multi-body time-dependentloads and motions. The results obtained of a transient analysis are displacements, velocities, accelerations, obtainedforces. The responses are usually time time-dependent. Figure 2: Force vs. Time curve (Force is applied gradually at the location as shown in figure 1) :The equation of motion is given in the following form: iven .....em01The matrix M is the mass matrix, the vector P is the vector of external forces, and the vector q represents the generalized coordinates. Stiffness, damping, constraint forces, external loads, and gravity are allincluded in the external force vector P. An initial and maximum integration time step, an end time, andintegrator tolerance is defined.Simulation Driven Innovation 3
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For Flexible Body Simulation: The flexible body is modelled with tetramesh and contact elements arecreated using rigid elements connected to its center of gravity and joints in the Hyper HyperMesh with OptiStructinterface. The material properties are applied as provided. The *.h3D file is created using *.fem file of Theflexible body using Flexprep option in Flextool toolbar. The flex body is overlapped on corresponding rigidbody and contact connectivity and contact parameters are defined for the respective interfaces. Thecorresponding deformable contact surfaces are interpreted as Markers as shown in figure 3. responding Figure 3: Deformable surfaceThe further procedure for loads, boundary conditions and solution run is carried same as for Rigid bodysimulation. Only the contact is used Point to deformable contact The FMBD is carried out for Comp1.Linear static analysis is carried out using the maximum force observed at certain time using ANSYSsoftware. The FMBD results with Motion MotionSolve are compared with the results obtained using ANSYS. inedResults & DiscussionsWith reference to the figure4, the force experienced by the comp2 is similar as the applied force. Thevariation in the displacement shows the effect of forces and damping factors develope by contact developedparameters, torsion spring and compression spring. Figure 4: Force, displacement Vs Time plot of Comp2.Simulation Driven Innovation 4
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The comp1 is considered for the both rigid body dynamics and flexible body dynamics. The force diagramfor the comp1 is as shown in figure 5. Figure 5: Force diagram for Comp1The von-mises stress in the Comp1 is observed less than the allowable limit. Refer figure 6. by ANSYS by FMBD using MotionSolve olve Figure 6: Von-mises stress contours.The active force generated for torsion spring is given by the equation .....ts01where, Tj, Tk are the torque developed in the respective bodies and an partial angular velocitymatrices for respective bodies.The maximum torque developed (refer figure 7) in the torsion spring is well below maximum permissibletorque as per the designed criteria. Refer the formulae ts01, ts02. Figure 7: Torque developed in torsion springSimulation Driven Innovation 5
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The maximum permissible torque for the spring is given by the equation, .....ts02The maximum allowable bending stress is calculated by .....ts03The generalized active force on compression spring is given by the equation .....cs01Where, Vw is partial velocity matrix, fj=fk is forces acting on the respective bodies.The force developed (refer figure 8) in compression spring during operation is observed less than theallowable maximum force of the coil spring. Refer the formulae cs01, cs02, cs03 Figure 8: Force developed in compression springThe maximum force the spring can take when the spring is deformed all the way to its solid height, ......cs02The maximum shear stress is calculated in the spring associated with the maximum force is calculated by, ......cs03Where W is the Wahl correction factor (accounting for spring curvature stress) and C is the spring index(essentially an aspect ratio of the spring cross-section), , .....cs04The torsion and compression spring designs are verified with the above formulae. The designs areestimated further for fatigue calculations.Simulation Driven Innovation 6
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Benefits SummaryThe process reduces the time for meshing for rigid body. It meshes automatically the rigid body components withmeshing parameters provided by user.The process for the rigid body simulation is user friendly and cost-effective.The results can be post-processed directly using single GUI of MotionView.Simulation set-up time is more at the initial stage. The process time reduces drastically once the stabilization occurs.The designs of the components, joints, springs, etc. can be verified accurately.Challenges1. Number of iterations for contact parameters are more to stabilize the transient model.2. Need to change some of the contact parameters in flexible body dynamics which is used for rigid bodydynamic analysis to stabilize the model.Future Plans1. To carry out the FMBD analysis by considering 2-4 flexible bodies.2. To carry out the fatigue analysis.3. To carry out the wear analysis.ConclusionsThe results obtained from the analysis are comparable in majority of the required aspects. MotionView andMotionSolve softwares will be used for the future plans as well as future projects.Simulation Driven Innovation 7
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ACKNOWLEDGEMENTSWe would like to acknowledge and extend my heartfelt gratitude to the following persons who have madethe completion of this paper possible:From Infotech enterprises Ltd.,For vital encouragement and support,Anand Parameswaran - Sr. VP & Head of HTH BUSujeet kumar - General Manager & PDU HeadRahman Shaikh - AGMFrom Altair Engineering Inc.,For extensive technical support,Ramesha BS - Technical ManagerVarun Raj - Technical Support (MBD) REFERENCES[1] Altair Engineering Inc., "Introduction To MBD," for overview of MBD implementation using MotionView and MotionSolve software.[2] Farid M. L. Amirouche, " Fundamentals of Multibody Dynamics: Theory and Applications", ebook for Modelling springs and dampers at the Joints.[3] S. Timoshenko, D.H. Young, JV Rao, " Engineering Mechanics", for Rotation of a Rigid Body about a Fixed Axis.[4] Peter Childs, "Mechanical design", for Spring design.[5] Altair Engineering Inc., "Help for HWSolvers-MBD simulations".Simulation Driven Innovation 8
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