MET 425 - FEA Applications II

Prof. Dave Johnson, psuprofdj@psu.edu, Penn State - Erie, The Behrend College

IGES File Import and Repair - HW Assignment 3

A steel part (named d_spindle) is shown in the figure above.  The diameter of the largest ring is 29 mm.  The axial thickness of the part is 9.5 mm.  The part is provided to you in IGES format created in 1994 by a designer using I-DEAS Master Series 1.3c software.  Click here to access the IGES File   Use a Right-click on this link, then "Save Target As...", then "Save as type: All Files", and use a file name like: D_spindle.igs  (You can open this IGES file in Pro/E to examine it for problems also)

During a default IGES import into ANSYS, several warnings or errors occur and a volume is not produced (areas are plotted) and the automatic merging is not performed.  You need to repair this model.  You should also notice, there is a "tooth" missing on the spindle's face.  Rebuild it. (ANSYS: Look into copying a good tooth shape in a cylindrical coordinate system, see CSWPLA)

You must work with this model, repair it, and create a meshable volume in ANSYS or Workbench.  It is unacceptable to build a new spindle from scratch.

After the imported geometry is repaired, you are to add a shaft (12 mm. O.D. and 9 mm I.D.) which is 50 mm. long and fits into the socket on the back of the spindle, 3.5 mm. socket depth.  (You may use the area at the base of the socket and extrude it 50 mm to create the shaft volume).

ANSYS: Glue these volumes together after creating the shaft.  
Workbench: A multi-body part should be formed with the spindle and shaft bodies
Assign different material attributes to the spindle and the shaft and mesh the volumes.

 

Turn in:

  1. a solid model plot of ONLY the imported IGES geometry (spindle).  Annotate on that plot any problem faces AND edges that you discovered.  (ANSYS: Try "Numbering" of lines and/or keypoints.)  Document the software and approach (procedure) you used to "heal" the IGES geometry - describe how you repaired the spindle geometry, added the missing tooth, and added the shaft.
  2. an element plot or a geometry plot showing that you have actually assigned different material properties to each volume,
  3. an element plot showing that the mesh at the junction between the shaft and the spindle is connected (if bonded-contact was used, include a plot showing this to explain why the shaft-spindle mesh patterns do not match up),
  4. an element plot showing your "repair" for the missing spindle tooth