Upright FEA Report - 06/04/2023
- Mackenzie Lui
Model Used
Loading
Load Case | FX | FY | FZ | MX | MY | MZ |
|---|---|---|---|---|---|---|
1 | 0 | 2096.57 | 0 | 0 | 0 | 87.3221405 |
2 | -1080.4 | 2160.8 | 1080.4 | 0 | -48.261468 | -211.65036 |
3 | 759.92 | 1519.85 | 759.92 | 0 | -29.3557096 | 275.4714165 |
4 | -1381.27 | 2762.55 | -1381.27 | 0 | 53.3584601 | -270.5903765 |
5 | 971.55 | 1943.1 | -971.55 | 0 | 43.3991385 | 352.186875 |
Fixtures
For all 5 loading cases, the UCA and LCA bearing enclosures were fixed radially and rotationally using a Cylindrical Faces fixture. Two Reference Geometry fixtures were also used to constrain the upright in the axial direction. The Reference Geometry fixtures were applied to split line features with the same shape and area as the bearing caps to simulate the restraining effect of the caps on the upright. Lastly, a Flat Face advanced fixture was used to simulate the contact between the recessed faces of the bearing enclosure and the bearings.
Mesh Convergence
Notes:
Using blended curvature-based mesh, node size is max node size.
Material yield strength: 505 MPa
Coarsest/finest meshes:
Loading Case 1
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 7.624 | (Max: inside edge of spindle hole) |
15 | 6.971 |
|
10 | 8.953 | |
5 | 10.51 |
|
2 | 15.51 |
|
Loading Case 2
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 148.1 |
|
15 | 138.8 |
|
10 | 142.7 |
|
5 | 200.1 |
|
2 | 463.1 | (Max: bottom of upright above LCA bearing enclosure) |
Loading Case 3
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 57.59 | (Max: inside LCA bearing cap screw holes) |
15 | 58.72 |
|
10 | 57.35 |
|
5 | 60.33 |
|
2 | 70.47 | (Max: inside of spindle hole)
|
Loading Case 4
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 79.33 | (Max: inside LCA bearing cap screw holes) |
15 | 82.79 |
|
10 | 81.36 |
|
5 | 99.44 | (Max: above LCA bearing enclosure) |
2 | 178.8 |
|
Loading Case 5
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 161.1 |
|
15 | 150.1 |
|
10 | 154.2 |
|
5 | 212.9 |
|
2 | 491.8 |
|
Results
Loading Case 1: Results are converging. Stress increases as the mesh is refined. Max stress is not concerning.
Loading Case 2: Results are generally converging. Stress increases overall as mesh is refined but there was a dip between node sizes of 20mm and 5mm. Highest stress found using the finest mesh is concerningly high, might have to reinforce the bottom of the upright or look into possible simulation errors/inaccuracies.
Loading Case 3: Results are converging. Stress seems to increase as the mesh is refined. Max stress is not concerning.
Loading Case 4: Results are converging. Stress increases as the mesh is refined. Max stress is not very concerning, but there was a significant jump in max stress when changing from a 5mm max node size to 2mm.
Loading Case 5: Results are converging. Stress increases as the mesh is refined. As the mesh is refined, the stresses get very high, approaching the yield strength. Like loading case 2, simulation setup will have to be checked and reinforcement might need to be added.
Recommendations/Next Steps
Review forces and fixtures.
Reinforce high stress areas as required.
Run topology studies to determine areas where material can be removed.
Design new model based on the results of the topology studies.
Limit test my computer with finer meshes?
Feedback is always welcome!