Objective

Structural analysis of a rocker arm.

Modeling

Model the following part using NX (Unit: Inch)

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Finite Element Analysis

Material properties:

• Young’s modulus: 3.0 × 10⁷ psi
• Poisson’s ratio: 0.29
• Mass density: 7.35 × 10^-4 slug/in3 (unit conversion may be needed)

Mesh the rocker arm using the following attributes as four different cases:

1. Tetra 4 elements, element size – 0.2
2. Tetra 4 elements, element size – 0.05
3. Tetra 10 elements, element size – 0.2
4. Tetra 10 elements, element size – 0.05

Boundary conditions:

Fix both the counter bore hole and the counter sunk hole (i.e. fix the cylindrical faces) as shown in the figure below

Apply a pressure load of magnitude 600 psi normal to the face shown

For each of the four cases, obtain the (nodal) deflection and (elemental) Von-Mises stress

Drafting

Recreate the drawing above through the drafting application in NX.

What to submit?

Part file, drawing of the part similar to the one shown above, and a written report containing the four cases below. Do not submit the simulation files. The reports do not need to be formal and should be as concise as possible. At the beginning of your document, please tabulate the results of the four cases including the maximum deflections and Von-Mises (elemental) stresses.

• Meshed solid (screenshots of the four mesh cases)
• Magnitude of deflection contour (magnitude of displacement)
• Von-Mises stress contour (elemental stress)
• Brief answers to the following questions:
  • What are the maximum deflection and the maximum stress for each of the four cases?
  • Which of the four cases provides the most accurate results?
  • How are the FEA results affected by the type element and the element size?

How to submit?

• Submit your project report to the corresponding module on Canvas (use your last name to name the file, such as Lastname_Project1. Do not use generic names like project1).