Torsional Loading: Introduction

As part of the unit MEC3455 a study needs to be done comparing the elastic
deformation of bars of different geometries under torsional loading conditions.
As part of this practical assignment different analytical methods are compared,
in the past weeks the torsional stiffness has been found using experimental
apparatus and empirical calculations. This tutorial is here to demonstrate how
to set up and run Finite Element Analysis (FEA) to simulate the torsional
loading and resulting deformation. As well as provide a brief introduction into
FEA.

Instructions will be given on how to construct simplified Computer Aided

Design (CAD) models of the geometry, to be used as a base for further analysis
of other geometries. The model has been simplified to ease the analysis of the
apparatus, this does come at the cost of some accuracy with the solutions but
on this occasion it was deemed suitable to consider the system as the bar
being analysed with an additional boss on each end to simulate fixtures.

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 How to Use This Tutorial

Title
The page title defines the
overall step being completed.

Explanation
This section
contains a more
detailed explanation
about what is being
done and why. It will
also sometimes
contain additional
definitions as well as
extra images.

Instructions
The silver callout
boxes contain
numbered tutorial
instructions. The
specific action (e.g.
CLICK) for each
instruction is
BOLDED.

Action Box & Cursor

The red action boxes and Page Number
cursors draw attention to
what needs to be clicked on
each page.

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 Torsional Loading: Expected Outcomes
Aim:
To gain a basic understanding in Finite Element Analysis using SolidWorks.

Upon completion of this tutorial, you will be able to:

• Set up a 3D CAD representation of the different geometries
• Understand and use Mesh Controls
• Apply Boundary Conditions in the form of fixtures and loadings
• Find and interpret results

It is expected that you apply the techniques and understanding from this
tutorial to the different loading cases and geometries.

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 Contents
Page
Computer Aided Design
Sketching 5
Extruding 8
Adding Bosses 9
Finite Element Analysis
Initial Steps 11
Constraints 13
Applying Torque 17
Applying Material 19
Meshing 21
Solving 22
Post-Processing 23
Duplication of Study 26
Redefining Mesh 27
Conclusion
Conclusion 28

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 Computer Aided Design: Initial steps
Before starting any
analysis, we must first
develop the model of the
geometry. This is done
using SolidWorks 2012 x64
CLICK ‘Part’ to create a standalone
Edition, found under the 1 part.
SolidWorks 2012 tab in the
start menu.
Create a new document by
using the shortcut Crtl+N,
or selecting
File > New.
Under the features panel, select the Extruded Boss/Base button, this feature
will be used multiple times to construct the geometry. CLICK ‘OK’ to confirm
2 selection.
CLICK ‘Extruded Boss/Base’
3 to begin creating the
geometry

4 CLICK ‘Front Plane’ This is

the plane from which the
extrude will come from.

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 Computer Aided Design: Sketching
Before beginning the sketch, we need
to determine which Unit System will
be used. This can be done by either;
Options > Document Properties >
Units. Or by the steps shown to the CLICK Unit System . This may appear
right. 1 as: ‘MKS’, ‘CGS’, ‘MMGS’ or ‘IPS’.
Depending on which system is default.
For these models either ‘MKS’ (meter,
kilogram, second) or ‘MMGS’
(millimeter, gram, second) are
suggested to be used. This tutorial will
use ‘MMGS’.

The first part to sketch is the profile of

the bar, the bar in this tutorial is the
Closed Aluminium Bar. This is a simple
sketch of two concentric circles based
at the origin of the sketch plane. CLICK ‘MMGS’ to set the units to
2 millimeters, grams and seconds.

CLICK ‘Circle’ from the Sketch

3 tab.

CLICK the Origin of the sketch plane,

4 denoted by the perpendicular
Red Arrows.
CLICK Anywhere in the Sketch Plane.
5 The dimensions of this circle are not
important at this point of sketching.

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 Computer Aided Design: Sketching
As this model being created is the
closed aluminium tube, it is
necessary to create a concentric
circle, this is done using the same
steps as previously.

The circles will now be

dimensioned, this is done using the
Smart Dimension feature, which
can be used for dimensioning of all
types of sketches as it recognises
Create a concentric circle,
radii and straight edges. follow the steps on previous
1 page, click the centre of the
first circle.

CLICK ‘Smart Dimension’

2

CLICK the input box in ‘Modify’

and enter ‘25’, this is the outside
4 diameter of the tube.
CLICK the outer circle, MOVE the CLICK the green tick to confirm
3 mouse to desired dimension
position and CLICK.
CLICK the inner circle, instead enter the
value of 21 into the modify box. This
dimension is found from the outside
5 dimension, 25mm, minus two of the wall
thicknesses, each at 2mm.
NOTE: The sketch lines should turn black to
21

indicate the sketch is ‘Fully Defined’.

CLICK ‘Exit Sketch’ When finished, this is

6 found on the right of ‘Smart Dimension’

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 Computer Aided Design: Extruding Sketches
Upon exiting the sketch the ‘Boss-Extrude’ menu should appear, with a
preview of the extrusion. If this is not the case, click the ‘Extruded
Boss/Base’ feature and select either of the circles of the sketch.

The default setting for a Boss-Extrude is ‘Blind’ ending, this means extrude
a set distance, this is the desired setting.
In this case the length of the bar is 520mm, therefore the dimension ‘D1’
should enter 520. No other options need to be selected or changed.

CHECK set to ‘Blind’ For this

1 assignment no other options needed.

CLICK and ENTER ‘520’ This is the

2 length of the bar which we want to
test, other bars may have different
lengths.

CLICK the Green Tick, to confirm.

CLICK ‘View Orientation’ CLICK ‘Back’ this will change the view
3 Alternatively press SPACEBAR to get 4 to the back face of the extrude, from
view Orientation Menu this face a boss will be attached.

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 Computer Aided Design: Adding Bosses
To add a Boss to the end of our tube
select ‘Extruded Boss/Base’ feature
from earlier, now select the face
which the boss will come from. This
face is the back face of the tube that
was rotated to be viewed previously.
Upon clicking the end of the tube,
the sketch menu will appear. In this
sketch create a circle, with its centre
at the origin, and then ‘Smart
Dimension’ this circle to diameter CLICK ‘Extruded Boss/Base’
50mm. Exit the sketch and input the 1 CLICK the face of the tube.
distance of the extrude. Dimension
‘D1’ should be 10mm for these
bosses.

Using Pg. 6 & 7 as a guide.

Create another concentric circle
based at the origin.
2 ‘Smart Dimension’ this circle to
50mm
CLICK ‘Exit Sketch’ when done

Using Pg. 8 as a guide to complete

this extrude.
Modify ‘D1’ to 10mm
3 The ‘Middle Mouse Button’ can be
used for free rotating the model to
see the boss is in correct direction.
CLICK the Green Tick when done

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 Computer Aided Design: 2nd End Boss
The final step in creating the
model of this tube is to add a
Boss to the other end of the
tube. Using ‘View
Orientation’ to select the
front view. This will allow easy
selection of the front face of
the tube.

Following the instructions

CLICK ‘Extruded Boss/Base’
from pg. 9 to create another 1 CLICK the face of the tube not the
boss on this end. This boss face of the end boss just added.
should only be 40mm in
diameter, unlike the first boss.
Create another concentric circle based at the
This smaller diameter is so it
origin.
is easy to determine which ‘Smart Dimension’ this circle to 40mm
end is fixed and which end is CLICK ‘Exit Sketch’ when done
rotated in later steps.
To Create the extrude,
Ensure ‘D1’ is set to 10mm, the
CLICK the Green Tick when done

This is what the completed CAD model should look like, the next part of the
tutorial is setting up and performing Finite Element Analysis (FEA) on the
model.

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 Finite Element Analysis (FEA): Initial steps

SolidWorks comes with a

basic Finite Element
Analysis package called
“SolidWorks Simulation”.
To make sure that the
SolidWorks Simulation CLICK the arrow button next to the options
toolbar is active on your 1 button shown and select “Add-Ins”
computer you need to
activate the Add-In from
the Add-Ins toolbox.

Check the SolidWorks

2 Simulation checkbox.

3 CLICK “OK”
The SolidWorks Simulation tab will now be active.

4 SELECT the ‘Simulation’ tab

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 Finite Element Analysis: Creating a New Study

SELECT ‘New Study’ from the drop down

menu from the ‘Study Advisor’ button.

1
LEFT-CLICK the green ‘TICK’ in
4 the top left corner
To start the Finite Element Analysis
first we must select which type of
analysis that is to be conducted. CHANGE the name of
Since the experiment involves 2 the study to reflect the
statically loading a beam resulting analysis that you are
undertaking.
in pure torsion, select ‘Static’

When conducting a Finite Element

Analysis it is very important to get
the fixtures as close as possible to
the real situation in order to obtain SELECT ‘Static’
useful results. This is generally the 3 under ‘Type’
hardest part. However since the
simulation being conducted is
relatively simple the application of
the fixtures is also quite simple.

It is important to think about which

constraints can used to create a
realistic simulation of a simplified
torsional rig. A new tab will now be open at the
bottom left hand side of the window
with the name of the study

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 Finite Element Analysis: Constraints
The next step is setting up the constraints for the simulation. The torsional rig
that the experiments were conducted on applies a torque to one end of the
beam, the opposite end is fixed in position and not free to rotate or translate.
There was also a bearing at the end that the torque was applied to which
allowed only rotational motion of the beam but restricted the translation.

For useful results it is important to apply these constraints to the geometry

correctly.

LEFT-CLICK the ‘end face’ of

1 the 50mm diameter boss

RIGHT-CLICK ‘Fixtures’ and

2 SELECT ‘Fixed Geometry’

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 Finite Element Analysis: Constraints

LEFT-CLICK the green ‘TICK’ in

3 the top left corner of the
property manager

SELECT ‘Fixed Geometry’ if it is

1 not already selected by default

MAKE SURE that the name of

2 the face you selected is now in
the fixtures list

Now the ‘end face‘ of the 50mm diameter boss is the fixed end of the beam.
Next the bearing fixture will be applied to the other end.

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 Finite Element Analysis: Constraints

Applying the ‘Bearing Fixture’ will allow the beam to rotate freely at the end
where the torque is going to be applied but restrict any translational motion.
By applying this fixture the bearing on the rig is taken into account.

LEFT-CLICK the outside

1 cylindrical face of the 40mm
diameter boss

RIGHT-CLICK ‘Fixtures’ and

2 then SELECT ‘Bearing Fixture’

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 Finite Element Analysis: Constraints

LEFT-CLICK the green ‘TICK’ in

4 the top left corner of the
property manager

MAKE SURE that the face that

1 was selected is now in the
selection list

MAKE SURE that the ‘self-

2 alignment’ option is selected

MAKE SURE that the ‘Rigid’

3 option is selected

Once the ‘Bearing Fixture’ has been applied then the constraints for this
particular study are complete. This simplified model of the experiment is now
accurately constrained to mimic the rotation and translation of the real
experiment.

The next step is to apply the loading

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 Finite Element Analysis: Applying the Torque

The torque will be applied to the same face the bearing fixture was applied to.
When applying a torque you need to select a face that the force will be directly
applied to and also a central axis for the torque to be centred on which in this
case can be found by choosing any one of the cylindrical faces due to the
symmetry of the geometry

LEFT-CLICK the outside

RIGHT-CLICK ‘External Loads’ cylindrical face of the 40mm
2 and then SELECT ‘Torque’ 1 diameter boss (same face that
the bearing fixture was
applied)

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 Finite Element Analysis: Applying the Torque

When applying the torques make sure that you are applying the same torques
that you applied during the experiment. This will ensure that you have good
comparable data.

LEFT-CLICK the green ‘TICK’ in

6 the top left corner of the
property manager

MAKE SURE that the ‘Torque’

1 option is selected SELECT the same face that the
4 torque is being applied to

MAKE SURE that the face you

2 selected is in the list shown

LEFT-CLICK in the axis selection

3 box

ENTER the torque that is to be

5 applied. For this tutorial use
5N.m.

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 Finite Element Analysis: Applying the Material

For this experiment the material used was Aluminium Alloy 2024. SolidWorks
has a vast library of materials and all their physical properties already defined.
To change the material follow the instructions below.

RIGHT-CLICK on ‘Part1’ and

1 SELECT ‘Apply/Edit Material’

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 Finite Element Analysis: Applying the Material

SELECT ‘2024 Alloy’ under the

1 ‘Aluminium’ folder

CLICK ‘Apply’ and then CLICK

2 ‘Close’

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 Finite Element Analysis: Mesh

Correct meshing is one of the most important aspects of FEA, however in this
simulation, due to the simple nature of the geometry, constraints and applied
forces a very simple mesh is all that is required and SolidWorks simulation can
create a simple mesh very easily.
SolidWorks has a simple mesh
creation tool which will make a
basic mesh and allow you to
refine the mesh density with a
simple slider. To change more
details about the mesh click on
the ‘Mesh Parameters’
checkbox.

Below the final mesh is shown.

RIGHT-CLICK ‘Mesh’ and select

1 ‘Create Mesh’

LEFT-CLICK the green ‘TICK’ in

3 the top left corner

LEAVE the slider in the default

position for this tutorial. For
each cross-section quantify
2 the influence of mesh
resolution on the angle of
twist.

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 Finite Element Analysis: Run the Simulation
The final step in the simulation process is to run the solver. The SolidWorks
Simulation Solver is generally very quick but is highly dependant on the mesh
that was used. Obviously, a very dense mesh will take a long time to solve
compared to a simple low density mesh.

1 LEFT-CLICK the ‘Run’ icon

2 WAIT for the solver to finish

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 Finite Element Analysis: Post Processing
By default SolidWorks Simulation has a very large ‘Deformation Scale’ to
emphasise the deformation that is taking place in the geometry. Follow the
instructions below to change the scale to a ‘True Scale’. You will need to repeat
this for different plots.

DOUBLE-CLICK in this area to

1 open the plot display options

LEFT-CLICK the green ‘TICK’ in

3 the top left corner

2 SELECT ‘True scale’ option

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 Finite Element Analysis: Post Processing
The main result that is of interest is the displacement which can be used to
determine the angle of twist. It can be assumed that the maximum
displacement will be at the end of the beam where the torque was applied on
the outside diameter.

To measure the displacement at this location use the ‘Displacement Probe‘. The
probe can be accessed by right clicking on the ‘Displacement1 (-Res disp-)’ in
the property manager. Using the probe click on the outside edge of the beam to
find the displacement.

1 DOUBLE-CLICK ‘Displacement1’

RIGHT-CLICK ‘Displacement1’
2 and SELECT ‘Probe’

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 Finite Element Analysis: Post Processing

The displacement that is being measured is the direct displacement and not the
angle of rotation. It can be assumed that the angle of rotation is sufficiently
small to use small angle approximations in order to get useful data from these
results.

LEFT-CLICK on the edge where

the 40mm diameter boss
1 meets the beam and read off
the displacement

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 Finite Element Analysis: Duplication of Study
One simple thing to save time and retain all results for all iterations is to
duplicate the study. Once you duplicate the study SolidWorks will create a
new study tab at the bottom of the screen which you can rename as
appropriate. Everything within the study will remain the same but it allows
you to change the torque for the next iteration, meanwhile retaining all solved
data for each previous solve.

CHANGE the name of this new

2 study to reflect the next
iteration

3 CLICK ‘OK’

RIGHT-CLICK on the current

1 study’s tab and SELECT
‘Duplicate’

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 Finite Element Analysis: Redefining the Mesh
An important part of this tutorial is to explore what influence the mesh
density has on the result. For each cross-section re-run the highest torque
simulation with a coarse mesh and then again with a fine mesh. Quantify the
difference in the final result and discuss in the report.

CHANGE the ‘Mesh Density’ to

- ‘Coarse’ by moving the slider
to the left

CHANGE the ‘Mesh Density’ to

- ‘Fine’ by moving the slider to
the right

RESET the ‘Mesh Density’ to

- the default position by
CLICKING ‘Reset’

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 Conclusion

Using these steps it is possible to create a simplified yet reasonable

representation of the torsional loading apparatus. Using Computer Aided Design
to model the test rig and Finite Element Analysis to determine the
displacements of the sample.

From this tutorial it is possible to model and solve the other bar geometries
using the same techniques and principals. Once the range of input torques have
been solved for each geometry it will be possible to compare the results
obtained from Computer Aided Engineering, to those from the experimental
test rigs and the theoretical data.

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