The lever arm in the industries is being described as a “simple machine” due to it
containing only two parts which is the handle or arms and the fulcrum. In this report,
a Finite Element Analysis (FEA) was done to the simple arm part while applying a lot
of primary analysis conditions including properties and materials, load, constraints,
and contacts that including the linear static stress analysis and an advance
constraints techniques. The analysis of using different mesh size was also done to
refining the mesh for realistic representation of the model. The main objective is to
understand the and improve the skill in FEA. The AutoCAD Inventor Nastran was
used for the analysis.
Contents
1.0 INTRDUCTION ................................................................................................................................................. 3
1.1 Introduction ................................................................................................................................................ 3
1.2 Objective ..................................................................................................................................................... 3
1.3 Problem Statements ................................................................................................................................... 3
2.0 LITERATURE REVIEW ....................................................................................................................................... 4
2.1 Introduction ................................................................................................................................................ 4
2.2 The training section .................................................................................................................................... 4
2.2.1 Section 5 Cast Lever Exercise ............................................................................................................... 4
2.2.2 Section 6 Modify Boundary Conditions Exercise ................................................................................. 5
2.2.3 Section 7 Meshing................................................................................................................................ 5
2.2.4 Section 8 Refine the Mesh Exercise ..................................................................................................... 5
2.2.5 Section 9 Contact Modelling ................................................................................................................ 5
2.2.6 Section 10 Add Contact and Symmetry Exercise ................................................................................. 6
2.2.7 Section 11 Analysis Setting .................................................................................................................. 6
2.2.8 Section 12 Results Visualization (Post-Processing) .............................................................................. 6
2.2.9 Section 13 Compare the Iteration Exercise ......................................................................................... 6
3.0 METRODOLOGY .............................................................................................................................................. 7
3.1 Introduction ................................................................................................................................................ 7
3.2 Section 5 Cast Lever Exercise ...................................................................................................................... 7
3.3 Section 6 Modify Boundary Conditions Exercise ........................................................................................ 8
3.4 Section 8 Refine the Mesh Exercise ............................................................................................................ 8
3.5 Section 10 Add Contact and Symmetry Exercise ........................................................................................ 9
4.0 Results........................................................................................................................................................... 10
4.1 Introduction .............................................................................................................................................. 10
4.2 Section 5 Cast Lever Exercise .................................................................................................................... 10
4.3 Section 6 Modify Boundary Conditions Exercise ...................................................................................... 13
4.4 Section 8 Refine the Mesh Exercise .......................................................................................................... 15
4.5 Section 10 Add Contact and Symmetry Exercise ...................................................................................... 18
5.0 CONCLUSION ................................................................................................................................................ 21
1.0 INTRDUCTION
1.1 Introduction
The Finite element analysis or FEA is a simulation or computerized method for
predicting on the how an items or products react to the real-world physical effect,
vibration, heat, fluid flow and other forces. The FEA shows the after effect of the
product if it will break, wear out or work the way it was designed to be. The software
use to analyse the finite elements is the Autodesk Inventor with the Inventor Nastran
Add-on.
The self-pace training is the training that teach and cover the basic need and
information that will help when using the Autodesk Inventor Nastran. The self-pace
training is focus on the basic operation of Autodesk Inventor Nastran. It helps the user
familiarize with the setup of the Autodesk Inventor Nastran and help with the skill and
knowledge of conducting commonly used analysis types.
1.2 Objective
The objective of the repot on the self-pace training is to study and Familiarize
the Autodesk Inventor Nastran setup and learn the basic skill on conducting a finite
element analysis. The other objective is to perform and understand Finite Element
Analysis on a simple lever arm part.
1.3 Problem Statements
The problem statements in this self-pace training is to learn the basic of the
process of analysing the material to perform the analysis need for getting the result
that was wanted. The other problem is by using the software there might be inaccurate
in the result of the training.
2.0 LITERATURE REVIEW
2.1 Introduction
This chapter is to provide a review on the training done throughout the selfpace
training from section 5 to section 13. The section that was done through the training is
the self-pace trainings section 5 the Cast Lever Exercise, Section 6 the Modify
Boundary Condition Exercise, Section 7 Meshing, Section 8 Refine the Mesh
Exercise, Section 9 Contact Modelling, Section 10 Add Contact and Symmetry
Exercise, Section 11 Analysis Setting, Section 12 Results Visualization
(postprocessing) and lastly Section 13 The compare the Iterations Exercise.
The objective of the self-pace training is to familiarize self with the process of
analysis using the Autodesk Inventor Nastran. The training help understanding the
process of analysis the design fully until the result are achieved. The training also can
be done multiple time to get a better understand of the procedure that was done during
the training.
2.2 The training section
2.2.1 Section 5 Cast Lever Exercise
In Section 5 Cast Lever Exercise, a linear static stress analysis exercise was
done on a simple lever arm part. The boundary conditions were used in the training.
In the training, the model was physical property, loads and constraints was defined to
fine the model for finding the result. The model uses a 1000N load that was applied to
the top-most hole and the lever is pinned at the centre.
2.2.2 Section 6 Modify Boundary Conditions Exercise
In Section 6 Modify Boundary Conditions Exercise, the model from the previous
exercise was modify by applying advanced constraint techniques. The process was
done to make sure a more realistic simulation on the pin that was not modelled. The
process was removing incorrect boundary conditions and added a ball joint constraint.
The “ball joint” constraint are a commonly used technique in FEA to control
Rotations. The ball joint constraint uses rigid elements to control the reference point
2.2.3 Section 7 Meshing
In Section 7 Meshing, the mesh was the composed of small pieces called elements.
Meshing setting including the control over the element size, element order, and local
refinement. Due to the accuracy of the solution depend on the mesh, it was important
to define the mesh precisely during the simulation training.
There are 3 element types which are Solid Elements, Shell Elements and Line
Elements. The important of the mesh are it was used to get a greater accuracy solution
because more node can be calculated smaller element will cause less error.
2.2.4 Section 8 Refine the Mesh Exercise
In Section 8 Refine the Mesh Exercise, the model mesh was examined to determine
if mesh distribution was a strong influence on the results.
2.2.5 Section 9 Contact Modelling
In Section 9 Contact Modelling, there were two primary ways to outline or define the
contacts which is automatically and manually. The tolerance defines the separation
between two surfaces to be in contact. Max activation distance also define the
separation between the two surfaces to be in contact. The stiffness of the contact joint
was called the stiffness factor.
2.2.6 Section 10 Add Contact and Symmetry Exercise
In section 10 Add Contact and Symmetry Exercise, the process of defining a more
realistic representation of the physical body was done to the model. In the section 10
exercise, the model design was added contact using the Automatic contact
assignment. The use of contacts was done instead of boundary conditions during the
process because the lever and pins need to have a similar stiffness values to the
model.
2.2.7 Section 11 Analysis Setting
In section 11 Analysis Setting, the model analysis was defined. The commonly used
settings were explored. There are a lot of type menu that can be use for analysis.
Example of analysis types that was available are Linear Static, Normal Modes,
Nonlinear Buckling and Nonlinear Static. The Nodal Output Control and Elemental
Output Control can be used to control the quantities written for the conclusion of the
analysis.
2.2.8 Section 12 Results Visualization (Post-Processing)
In Section 12 Results Visualization (Post-Processing), The post-processing process
was done by visualizing the result that was important to the analysis report. Autodesk
Inventor Nastran provides a multiple option on the results setting. The tool that was
cover in the section are results appearance options, showing deformation and contour
results option and Animating result option.
2.2.9 Section 13 Compare the Iteration Exercise
In Section 13 Compare the Iteration Exercise, the result needs to be checked the fordesign changes and need to compare it stress results. It is important to use boundary
condition and contacts correctly throughout the analysis process.
3.0 METRODOLOGY
3.1 Introduction
Throughout the training, the self-pace training there are a lot of work that was done to
complete all the tutorial and there are a lot of basic need was taught on the self-pace training. The
Autodesk Inventor Nastran have all the setting needed to perform the Analysis of Finite Elements.
3.2 Section 5 Cast Lever Exercise
The process of Cast lever exercise is firstly to open the model and start the Autodesk
Inventor Nastran environment. The model was downloaded from the Autodesk help website.
Secondly, is to define the physical property of the model. To define the physical property, the
idealizations node was used. Thirdly is to constrain the lever of the model and define the load of the
model. Fourthly, is the generate the mesh of the model and run the analysis. Finally, the results are
reviewed, and specific value was prode.
3.3 Section 6 Modify Boundary Conditions Exercise
The process of modify boundary conditions exercise was is firstly needed to remove the incorrect
boundary conditions from the model. Secondly, create a ball joint constraint at the model. Thirdly is
to Run the model and review the displacement results. Lastly, Review the stress results of the model.
3.4 Section 8 Refine the Mesh Exercise
Continue with the model. The first step for the exercise is to refine the mesh locally using the
add mesh control from the menu. Next, the global mesh setting was changed to fit the model. Lastly
is to run the analysis and do a review on the result of the new mesh.
3.5 Section 10 Add Contact and Symmetry Exercise
For section 10, Firstly is to Assign the physical property of the lever arm. Next is to assign the
property to the two pins. Continue, the constraints of the pin and the symmetry constraint was
assigned. The load and contacts are then assigned the model. The mesh of the model is set in the
setting of the model. The analysis was then run, and the results was reviewed. The results that was
reviewed was displacement, stress, and safety factor results.
4.0 Results
4.1 Introduction
The lever analysis in this report is given by the Self-Paced Training from the help Autodesk.
The three-dimensional model was downloaded and develop using the Autodesk Inventor Nastran.
The results were taken from the report that was generated from the Autodesk Inventor Nastran. The
report shows the results of the analysis.
4.2 Section 5 Cast Lever Exercise
Table of Materials
Material ID
E
G
NU
RHO
ALPHA
T-REF
1) Steel, Mild
2.2e+5
0
0.275
7.85e-9
1.2e-5
0.0
2) Aluminum
1100-O
68947
0
0.33
2.7e-9
2.4e-5
0.0
3) Aluminum
1100-O
68947
0
0.33
2.7e-9
2.4e-5
0.0
Tables of Loads and magnitude
Load
fx
fy
fz
1
0
-1000
0
2
-687.5
0
0
Table of Results
Subcase
Contour
Max (Mpa)
Min (Mpa)
1
Solid Von Mises Stress
99.385
0.391
1
Displacement
0.314
0
1
Solid Principle C Stress
12.096
-101.627
1
Solid Principle A Stress
105.376
-5.620
4.3 Section 6 Modify Boundary Conditions Exercise
The previous boundary conditions are removed from the cast lever except the Load acting
on the shorter end of the lever. The current constrain was replaced with Ball Joint Constraints which
is a commonly use in Finite Element Analysis (FEA). The ball joint constraint was uses rigid elements
to control a reference point.
Table of Materials
Material ID
1) Aluminum
1100-O
E
G
NU
RHO
ALPHA
T-REF
68947
25511
0.33
2.7e-9
2.4e-5
0.0
Tables of Loads and magnitude
Load
fx
fy
fz
1
0
-1000
0
Table of Results
Subcase
Contour
Max (Mpa)
Min (Mpa)
1
Solid Von Mises Stress
170.948
0.019
1
Displacement
3.967E-01
2.824E-04
1
Solid Principle C Stress
28.760
-106.970
1
Solid Principle A Stress
205.857
-12.253
4.4 Section 8 Refine the Mesh Exercise
The Refine mesh exercise was done by changing the mesh size and refining the mesh of the
Cast Lever. The amount of stresses and displacement acquired will be more accurate and will be able
to pinpoint the exact point of maximum and minimum stresses and displacement
Table of Materials
Material ID
1) Aluminum
1100-O
E
G
NU
RHO
ALPHA
T-REF
68947
25511
0.33
2.7e-9
2.4e-5
0.0
Tables of Loads and magnitude
Load
fx
fy
fz
1
0
-1000
0
2
-687.5
0
0
Table of Results
Subcase
Contour
Max (Mpa)
Min (Mpa)
1
Solid Von Mises Stress
192.629
0.045
1
Displacement
3.996E-01
2.539E-04
1
Solid Principle C Stress
28.006
-105.470
1
Solid Principle A Stress
210.428
-16.700
4.5 Section 10 Add Contact and Symmetry Exercise
Table of Materials
Material ID
E
G
NU
RHO
ALPHA
T-REF
1) Steel. Mild
2.2e+5
0
0.275
7.85e-9
1.2e-5
0.0
3) Aluminum
1100-O
68947
0
0.33
2.7e-9
2.4e-5
0
4) Alloy Steel
2.05e+5
0
0.3
7.73e-9
1.2e-5
0
Tables of Loads and magnitude
Load
fx
fy
fz
1
0
0
-500
Table of Results
Subcase
Contour
Max (Mpa)
Min (Mpa)
1
Solid Von Mises Stress
135.995
0.685
1
Displacement
3.348
0.000
1
Solid Principle C Stress
30.791
-153.386
1
Solid Principle A Stress
148.671
-49.780
5.0 CONCLUSION
FEA analysis of the simple lever arm part, Cast Lever, turned into carried of Autodesk
Inventor Nastran. Ball Joint Constraint has proven to offer extra sensible visual representation of the
Cast Lever applied forces and determine a more realistic maximum and minimum stresses and
displacement. By using contacts, the Cas lever will be able to produce the exact same response at
the interaction as the physical parts. The objective of the reports was achieved, and the methods
shows was proven to be efficient for the future references.