Mapua University

School of Mechanical and Manufacturing Engineering

ME134L-3

Computer Applications in Mechanical Engineering

Lab Report # 1

Static Stress Simulation

BILLONES, Sebastian Luise M. Date: September 13, 2024

2021106723

ME134L-3/B6

Edward Ang

Instructor
 TABLE OF CONTENTS

Objectives 1

Simulation Setup 1

Simulation Results 4

Test Data Analysis 5

Conclusion 14

References 15

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OBJECTIVES

1. To be able to perform a static stress simulation using Fusion 360 on a 3D modeled

component.

2. To be able to adequately explain the test result concerning the stress and strain applied to

the component.

SIMULATION SET-UP

Figure 1. Component schematic

The model to be tested is a tubular component made out of steel drafted from the

previous weeks using a schematic retrieved from the edang20.com website, in particular,

“exercise 128”. It is a 40 outer diameter and 30 inner diameter cylindrical tube with two 70

diameter flanges with the top flange being 30 millimeters thick and having a 45-degree chamfer,

and the bottom flange is 10 millimeters thick and is offset 5 millimeters from the bottom most

surface. The forementioned flanges would then have eight 6-millimeter diameter holes evenly

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spread surrounding the main cavity on the flanges.

Figure 2. Constrained part of the component

First, the model’s bottom most surface is constrained to the Z-X plane which would act as

the floor.

Figure 3. Topmost surface of the component where the load is applied

Then, the model is subjected to 800 Newtons of axial downward force directly on its

topmost surface using the Static Stress Study Simulation function of Fusion 360. After having

the pre-check icon turn green, the student then clicks the “Solve” button on the tool bar and

initiates the simulation.

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SUMLATION RESULTS

Figure 4. The figure above shows the summary results from the simulation from Fusion 360

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TEST DATA ANALYSIS

Safety Factor

Figure 5. Screenshot of the safety factor simulation study

The safety factor for the component test is rated at 15. This high rating is due to the

small, applied load to this component and body of 800 Newtons or around 81 kilograms worth of

weight compared to the component’s actual material strength that the component can handle. As

the safety factor is 15, this means that the component can handle a load fifty times more than its

current load of 800 Newtons. The student may have used a 12000 Newton axial load, and the

components would still not have failed, assuming it is still applied evenly to the topmost surface

of the component.

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Stress

Figure 6. Screenshot of the Von Mises Stresses simulation study

The results for the Von Mises stress under a load of 800 Newtons netted a maximum and

minimum stress of 05.265 MPa and .08 MPa respectively. The maximum force was experienced

by the inner rim of the main cavity and its neck, and the minimum was experienced by the

flanges of the tube. This means that if more force was applied as the axial load, parts of the

component that experience the maximum stress would be the first to buckle under the sheer and

tensile stress and deform, which would make sense as those parts of the components bear the

entire weight of component in this position as well as not receiving as much support given that

they also have to bear the weight of the flanges.

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 Figure 7. Screenshot of the 1st principal stresses simulation study

As for the principal stresses, the maximum values for the principal amounted to 2.318

MPa of tensile stress at the thinnest parts of the flanges due to the holes and 6.351 MPa worth of

bottom most surface of the component. This is due to how the latitudinal force is translated to

longitudinal force deforming the thinner parts of the component, namely the tube, to deform and

expand.

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 Figure 8. Screenshot of the 3rd principal stresses simulation study

Meanwhile, the bottom surface’s outer rim would experience the most compressive force

due to it being in contact with the floor, bearing the load, and then the weight of the component

causing it to be compressed.

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Displacement

Figure 9. Screenshot of the Total Displacement simulation study

Given the load on the topmost surface of the component, it only makes sense that it

would be compressed downward and the shape to expand perpendicular to the force as the

latitudinal force is translated into perpendicular force. The component is deformed by 0.0001

millimeters (it shrinks downwards) with most of the deformation occurring at the point at which

the force is applied.

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 Figure 10. Screenshot of the Z axis Displacement simulation study

Consequently, it’s inner rims expands perpendicular to be force on both the z and x axes

in both directions by around 1.4×10 -8 millimeters as the rest of the components expand ever so

slightly along with it.

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Reaction Force

Figure 11. Screenshot of the Total Reaction Force simulation study

The reaction force of the component under a uniaxial load of 800 N is mostly

experienced and applied by the bottom most surface of the component in total and all the axes.

This is mostly due to the parameters set by the student of having this surface be constrained as

“fixed”, as such, acting as though it is touching the floor as the load is applied, leaving the only

surface in which it is possible to reach equilibrium with the load force.

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Strain

Figure 12 . Screenshot of the Equivalent Strain simulation study

The simulation results for equivalent strain and stress reveal that the thinnest areas of the

components, particularly along the rim of the main cavity, experience the highest levels of strain.

This is because these regions are in direct contact with the applied force and exhibit less rigidity

due to their reduced thickness compared to the flanges, which deform the least. These parts are

then “squashed and stretched” as the load force is applied, reducing its height, but also expands it

horizontally as it deforms. As the inner sections of the component expand significantly, the

more rigid parts are compressed, as they are pressed against these expanding regions. The

number procured are extremely small due to the small load, and the high young’s modulus value

of steel.

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Contact Force

Figure 13. Screenshot of the Contact Force simulation study

The contact force remains to be zero as the component only consists of one body and

would not bump into another physical body as per the simulation parameters. Though one could

argue the z-x axis would be the floor, it was not defined as a physical object in the simulation

and was not modeled as a body. This is true for all axes in the study results.

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CONCLUSION

This experiment, combined with the instructor's lecture and tutorial videos, enabled the

student to successfully conduct a static stress simulation using their own 3D model in Fusion

360. As a result, the student revisited and enhanced their understanding of static stress, strain,

structural analysis, and key concepts related to material strength, which facilitated their ability to

interpret some of the simulation results. Additionally, the experiment demonstrated the practical

applications of Fusion 360 in designing components and assessing their suitability for their

intended use, including evaluating their durability and load-bearing capacity. It also provided a

means to determine the limits of a component under specific conditions, such as a uniaxial load.

Fusion 360 further allows for simulations of various stress types on different surfaces of a

defined body, enabling accurate predictions of a component's performance and durability based

on the material from which it is manufactured.

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 REFERENCES

Admin. (2023, January 3). Modulus of Elasticity - Definition, Young’s Modulus,

Formula, unit, FAQs. BYJUS. https://byjus.com/physics/youngs-modulus-elastic-modulus/

Autodesk Fusion. (2019, January 4). Autodesk Fusion 360 | Defining Simulation Contact

Types in Fusion 360 [Video]. YouTube. https://www.youtube.com/watch?v=3bEkBP5Feh8

Lars Christensen. (2017a, September 20). Simulation for absolute beginners — Fusion

360 — and your comments & questions— #LarsLive 61 [Video]. YouTube.

https://www.youtube.com/watch?v=bZnHQTPP-Ps

Lars Christensen. (2017b, October 11). Fusion 360 — next step for simulation beginners!

Non-Linear — #LarsLive 74 [Video]. YouTube. https://www.youtube.com/watch?

v=Qe_7UR87p-o

Sound, E. Y. (2023, March 22). What Is Von Mises Stress? (And what it actually tells us)

- Loudspeaker & Acoustic Engineering Design. Engineer Your Sound.

https://engineeryoursound.com/what-is-von-mises-stress-and-what-it-actually-tells-us/

Strength of Materials/General State of Stress - Wikibooks, open books for an open world.

(n.d.). https://en.wikibooks.org/wiki/Strength_of_Materials/General_State_of_Stress

Tyler Beck of Tech & Espresso. (2017, June 15). Fusion 360 Simulation - How to setup

and test your part [Video]. YouTube. https://www.youtube.com/watch?v=IE2aQiEbwjQ

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