INTEREFERENCE FIT SETUP USING

HYPERMESH & LS-DYNA

A Skill Advanced Course

(FINITE ELEMENT ANALYSIS USING HYPERMESH & LS-DYNA)

report submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, KAKINADA

In partial fulfillment for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by

K.LEELA BHARATH
21761A0315
Under the guidance of

Mr. K.V.VISWANADH
Sr. Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING (AUTONOMOUS)
(Approved by AICTE, Affiliated to JNTUK, KAKINADA, Accredited by NBA (Tier-I),
NAAC and an ISO 9001-2015 certified Institution) L. B. REDDY NAGAR, MYLAVARAM,
KRISHNA DIST –521230 ANDHRA PRADESH
November - 2024

i
 LAKIREDDY BALI REDDY COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the Skill Advanced Course (FINITE ELEMENT ANALYSIS USING
HYPERMESH AND LS-DYNA) report entitled “INTERFERENCE FIT SETUP USING
HYPERMESH & LS-DYNA” that is being submitted K.LEELA BHARATH bearing register
number 21761A0315 in partial fulfilment for the award of the degree of Bachelor of Technology
in Mechanical Engineering is a record of Skill Advanced Course- II, work carried out by him
under our guidance and supervision.

Staff In-charge Head of the Department

Mr. K. V.VISWANADH Dr. M. B. S. Sreekar Reddy

Internal Examiner External Examiner

ii
 ACKNOWLEDGEMENT

The Satisfaction that accompanies that the successful completion of any task would be
incomplete without the mention of the people whose cease less co- operation made it possible,
whose constant guidance and encouragement crown all efforts with success.

I humbly express my thanks to our management and Principal Dr. K. Appa Rao for extending
their support for providing us with an environment to complete our internship successfully.

I indebted to our Head of the Department Dr. M. B. S. Sreekar Reddy who modelled us both
technically and morally for achieving greater success in life.

I humbly express my thanks to my guidance of Mr. K. Venkateswara Reddy forgiving timely

valuable suggestions and encouragement that make the completion of the internship
successfully.

I would like to thank all the teaching and non- teaching staff members of Mechanical
Engineering, who have extended their full co-operation during the course of this work.

K.LEELA BHARATH
(21761A0315)

iii
 INDEX

S. No. CHAPTER Pg. No.

1. Introduction to Hypermesh and Ls-Dyna 1-3

2. Introduction to Hypermesh Workspace 4-9

3. Introduction to Fits 10-11

4. Procedure for the analysis 12-21

5. Conclusion 22

6. References 23

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 1. INTRODUCTION TO HYPERMESH AND LS-DYNA
1.1 Hyper Mesh Software
Altair Hyper Mesh is a high-performance finite element pre-processor to prepare even the
largest models, starting from import of CAD geometry to exporting an analysis run for various
disciplines.

• Hyper Works delivers easy-to-learn solution- and domain-specific workflows across a

growing number of engineering applications to increase team productivity and accelerate
the development of today’s increasingly complex, connected products.
• Sim Lab minimizes the time users must spend creating finite element models and
interpreting results through automation. It can accurately analyze the performance
of complex assemblies in multiple physics types, including structural, thermal, and
fluid dynamics.
• Users can learn Inspire in just a few hours. Its intuitive interface provides the dependable
Altair solver power for analysts and designers so they perform what-if studies faster,
easier, and earlier. Inspire encourages collaboration, optimizes product design, and
reduces time to market.
Mesh generation is the premise of finite element analysis, Hyper Mesh as a high-
performance finite element preprocessor, by analyzing the specific example of bearing gear
system, the key problems of geometry cleaning and mesh generation in the process of finite
element preprocessing are studied. The influence of different modeling methods on mesh
generation is analyzed. According to the basic principle of finite element mesh division,
through the good interface between Hyper Mesh and CAD and CAE software, the
geometric model import and modal analysis are realized, and the quality and efficiency of
finite element analysis are improved.

The one-dimensional hyper mesh, referred to as a cluster, forms the basic topology upon
which higher- dimensional hyper mesh structures are formed. The cluster is a hypergraph
consisting of k nodes connected within a single hop. A k-array n-dimensional hyper mesh,
is a regular hypergraph with N=kn nodes, formed by taking the Cartesian n-product of the
cluster topology. This has the effect of imposing the cluster organization in every
dimension, making each node equally a member of n independent.

Altair Hyper Mesh is a high-performance finite element pre-processor to prepare even the
largest models, starting from import of CAD geometry to exporting an analysis run for
various disciplines.

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1.2 LS-DYNA SOFTWARE

Ansys LS-DYNA is a general-purpose finite element software solution capable of simulating

complex, real-world problems such as impact and crash related problems in automotive
industries, as well as blade containment, bird strike, metal forming, fluid splashing, metal
cutting, blast and biomechanics in other industries.
It is a post processing soft ware

The key features of the software: -

• Understand the keyword structure of LS-DYNA

• Understand key concepts of penalty and kinematic contacts
• Have awareness of unit consistency while setting up your units for materials,
element length and time
• Distinguish between an acceptable "Normal Termination" and incorrect results

• ANSYSAUTODYN-Explicit dynamic solver for transient non‐ linear simulations

involving large deformations and strains, non‐ linear material behavior, non‐linear
buckling, complex contact, fragmentation, and shock wave propagation.
• ANSYS LS ‐DYNA–LSTC’s LS‐DYNA explicit dynamic solver technology with the
pre/postprocessing power of ANSYS software. This powerful pairing can be used to
simulate crash tests, metal forging, stamping, and catastrophic failures.

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1.3 STEPS INVOLVED IN THE ANALYSIS OF A COMPONENT

PRE-PROCESSING

SOLVER

POST-PROCESSING

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 2. INTRODUCTION HYPERMESH WORKSPACE
Hyper Mesh Introduction: The User Interface

Fig 2.1

• Graphics area – displays the model

• Toolbar – Gives access to commonly used tools via icons
• Pull Down Menu – places functionality into groups, accessible via pull downs
• Menu Pages – divides the main menu into groups based on function
• Main Menu – contains “panels” grouped in columns
• Panels – menu items / functions for interacting with Hyper Mesh
• Sub-panels – divides panel into similar tasks related to panel’s main function
• Command Window – lets the user type in and execute tcl commands
• Available through the View drop down menu (turned off by default)

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 Tab Area – contains the following tabs:
• Solver, Model, Utility, Include, Import, Export, Connector, Entity State, etc.
• Status Bar – shows status of operations being performed
• Indicates the “current” Include file, Component Collector, and Load Collector

2.1 FILE OPERATIONS

General terminology:
▪ Open: Loads a file into Hyper Mesh replacing the current session
▪ Save: Saves the current session contents to the file name specified
▪ Import: Loads a file into Hyper Mesh, merging with the current contents
▪ Export: Saves data to the file name specified
• Generally, refers to file types other than a Hyper Mesh binary file

2.2 IMPORTING GEOMETRY

2.2.1 Import geometry data via:

2.2.2 File > Import > Geometry drop-down menu

2.2.3 Toolbar > > Geometry

2.2.4 Common types of geometry files supported:
2.2.5 Unigraphics (NX2, NX3, NX4, NX5, NX6)
2.2.6 CATIA (V4 & V5)
2.2.7 IGES
2.2.8 STEP

2.3 MODEL ORGANIZATION:

• The Hyper Mesh model is organized using “collectors”

• There are many types of collectors
• Most entities in Hyper Mesh must be placed in a collector
• Each collector type holds a specific type of entity

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 Collector Types Table – 2.1
Component Elements, Points, Lines, Surfaces, Connectors
Multibody Ellipsoids, Mb joints, Mb planes, Sensors
Assembly Components, Multi bodies, Assemblies
Load Collector Loads, Equations
Material
Property none (materials and properties don’t contain other entities but
are still treated as collectors)
System Collector Systems
Vector Collector Vectors
Beam Section Beam Sections
Collector

2.1 MODEL ORGANIZATION

Model browser
Create, delete, and rename collectors Edit

collector attributes Organize collectors

into assemblies Drag and drop

Fig 2.2

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 Right-Click onCollector for advanced
options

Fig 2.3
2.2 MODEL ORGANIZATIONS: Tools

• Panels

• Collectors – create new collectors

• Model Browser – Set the current collector for various entity types

• Organize – Move entities into a different collector than the one they are currently contained

in

• Rename – Change the name of an existing collector

• Recorder - allows the order the collectors appear in to be changed

• Collectors - appear in a certain order when presented in a list to pick from

• Delete – Delete entities or collectors

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2.3 STATIC STRUCTURAL

A static structural analysis calculates the effect of steady (or static) loading conditions on a
structure, while ignoring inertia and damping effects, such as those caused by time varying
loads. Static structural analyses are used for simple linear calculations as well as complex
material, geometric and contact nonlinear calculations. The analysis results help to identify
weak areas with low strength and durability.

Fig 2.4

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 3 INTRODUCTION TO FITS

In mechanical engineering, fits refer to the relationship between two mating parts that are assembled
together. The fit defines the degree of tightness or looseness between the parts, depending on their
dimensions and tolerances. This concept is critical in ensuring that components function as intended,
whether they are meant to move relative to each other or remain stationary.

Classification of Fits

Fits are categorized based on the interaction between the mating parts:

1. Clearance Fit

• A clearance fit occurs when the shaft diameter is smaller than the hole diameter, allowing
free movement between the parts.
• Example: Bearings and shafts in rotating machinery.
• Applications: Systems requiring relative motion, like sliding or rotating components.

2. Interference Fit

• An interference fit occurs when the shaft diameter is slightly larger than the hole diameter,
creating a tight, press-fit connection.
• The assembly requires force, and the fit relies on compressive stresses to hold the parts
together.
• Example: Gears pressed onto shafts, bushings in housings.
• Applications: High-strength connections where relative motion is undesirable.

3. Transition Fit

• A transition fit is a compromise between clearance and interference fits. Depending on

tolerances, the parts may have either a slight clearance or a slight interference.
• Example: Couplings or parts that require precise alignment.
• Applications: Assemblies that need accurate positioning but allow for some assembly ease.

Importance of Fits

• Functional Performance: Ensures parts assemble correctly and perform their intended
function.
• Load Transfer: Determines how forces and loads are distributed between parts.
• Ease of Assembly: Balances tightness with manufacturability and ease of assembly.
• Durability: Prevents wear, slippage, or failure due to improper fitment.

Factors Affecting Fit

1. Material Properties:
o Elasticity, strength, and thermal expansion can influence how fits behave under
operational conditions.
2. Manufacturing Tolerances:
o Accurate machining ensures the required fit is achieved.
3. Environmental Conditions:
o Temperature variations, lubrication, and corrosion can affect fit performance.
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 4. Assembly Methods:
o Interference fits may require tools like presses, while clearance fits might be
assembled manually.

Applications of Fits

• Automotive: Engine components, such as piston-cylinder assemblies.

• Aerospace: Precision fits in turbine shafts and rotors.
• Industrial Machinery: Bearings, bushings, and couplings.
• Consumer Goods: Fasteners and mechanical joints in household appliances.

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 4 PROCEDURES FOR THE ANALYSIS
This structural analysis consists of three steps

➢ Pre-processing
➢ Solving
➢ Post-processing

Step1 :-
After the 3D modeling is completed in the CATIA software and save the file. The saved file is
converted into STEP file. Now open the Hyper mesh software and import the geometry from the
import panel and save it with the proper name.

Fig 4.1

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 Step2:-
The geometry is appeared on the hyper mesh workspace. Now delete the solids if any present by
clicking (f2) and delete the entities.

Step3:-

After deletion of solids if any duplicate surfaces are appeared in the geometry now delete the
duplicate surfaces. Go to the

Geometry – defeature—duplicates – select all – delete.

Step4:-

Meshing operation is performed, because it helps the infinite degree of freedom is converted
into finite degree of freedom. Generate the 2D mesh, go to the

2D – auto mesh – select all surfaces – set the element length – generate.

Fig 4.2

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Step5:-

After 2D meshing is completed now check the total geometry and find the free edges if in
case any free edges are appeared delete the free edges. The component must enclose.

Step6:-

Generate the 3D mesh in 3D panel

3D – Tetra mesh – select all component – mesh – generate

Fig 4.3

Step7:-

Now Delete the 2D Mesh.

Delete – By config – quad 4 – displayed – select entities – delete entity

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Step8:-

Now create the both material (steel) and property and assign them with the component.

Fig 4.4

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Step9:-

After assigning the material properties apply boundary conditions to the fit.

First create a load collector and fix the one end of the fit.

Analysis – constraints – by face – create

Fig 4.5

15
Create another load collector opposite to the fixed one.

Analysis – forces – by face – create

Fig 4.6

Create another stress concentration in intereference fit of the structure to get the final results

Step10:-

Now create load step and name it as the linear static and give the subcase definition and do
the same steps for the buckling forces and define them and create

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Step11:-

For solving the component

Analysis – select optimization – click optimization – yes – results

Fig 4.7

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 Step12:-
Final Results
After clicking the results HyperView window open in that window, we can see the different
types of results.

Fig 4.8
ARRANGEMENT

Fig 4.8.1

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STRESS GENERATED IN INTEREFERENCE FIT

Fig 4.8.2

Fig 4.9

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Fig 4.10

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 5. CONCLUSION

The interference fit analysis conducted using Hypermesh provided a detailed understanding of the
mechanical behavior of a shaft and hub assembly under operational conditions. Combining a
structured methodology with advanced simulation techniques, the study effectively evaluated contact
pressure distribution, stress patterns, and deformation characteristics, confirming the fit’s reliability
and robustness.

The methodology involved several key steps. First, the geometry of the shaft and hub was prepared
as concentric cylinders, with the shaft diameter slightly larger than the hub’s inner diameter (50.02
mm and 50.00 mm, respectively). These models were created using CAD software like SolidWorks
and imported into Hypermesh for pre-processing. Material properties for both components were
defined as steel, with a Young’s Modulus of 210 GPa, Poisson’s ratio of 0.3, yield strength of 250
MPa, and a thermal expansion coefficient of 12×10−6 °C−112 \times 10^{-6} \, \text{°C}^{-
1}12×10−6°C−1. High-quality tetrahedral meshing was employed, with finer meshes in the contact
zones to capture stress gradients accurately and coarser meshes elsewhere to optimize computational
efficiency. Frictional contact was defined between the shaft and hub, with a coefficient of friction of
0.2, and an interference clearance of 0.02 mm was introduced to simulate the dimensional mismatch.
Boundary conditions included applying a displacement to the shaft to simulate insertion, fixing the
hub’s outer surface to replicate rigid support, and leveraging symmetry conditions to reduce
computational load. A nonlinear static analysis was conducted using solver integration with Abaqus
or OptiStruct, accounting for material nonlinearity and large deformations.

In conclusion, this study demonstrated the reliability and robustness of the interference fit, while
Hypermesh’s advanced capabilities proved instrumental in achieving accurate modeling and
simulation. The findings offer actionable insights for further optimization of the fit design, ensuring
enhanced performance and durability in real-world applications. This work highlights the critical role
of finite element analysis in addressing complex mechanical challenges and underscores the
effectiveness of a structured methodology for achieving reliable engineering solutions.

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 5.REFERENCES

• Altair HyperWorks Help Center

Comprehensive guides for using HyperMesh, including contact analysis and interference fit
setups.
https://altairhyperworks.com
• Altair OptiStruct User Guide
Detailed explanation of contact parameters and solver-specific setup for interference fits.
OptiStruct Documentation

• Practical Finite Element Analysis" by Nitin S. Gokhale et al.

This book provides insights into contact modeling and FEA techniques, which are applicable
for interference fits.
• "Finite Element Simulations with ANSYS Workbench 2021" by Huei-Huang Lee
Though ANSYS-specific, the principles of interference fit and nonlinear contact modeling
are broadly applicable.

• "Finite Element Analysis of Interference Fits in Shrink-Fit Assemblies"

Author: S. S. Nimbalkar, et al.
This paper discusses the theoretical and practical aspects of interference fit simulations.
Available on platforms like ScienceDirect or ResearchGate.
• "Contact Mechanics in Press Fits"
Author: K.L. Johnson
A classic paper providing the theoretical foundation of contact mechanics in interference
fits.
• Altair University
Offers free eBooks, tutorials, and webinars on HyperMesh and related simulations.
https://altairuniversity.com

• Altair Community Forum

A platform for solving specific issues related to HyperMesh and OptiStruct setups.
https://community.altair.com
• SimScale Blog
Articles on contact analysis, interference fits, and other FEA concepts.
https://www.simscale.com/blog
• Altair Knowledge Base
Access case studies and tutorials for interference fit and contact analysis setups.
Altair Knowledge Base

• YouTube Channels
o Altair Engineering: https://www.youtube.com/user/HyperWorks
o Independent creators also provide step-by-step guides for interference fit simulations

• "Mechanical Engineering Design" by Shigley and Mischke

Discusses interference fits from a design perspective, including stresses and contact
pressures.
• ASME Standards
Refer to ASME B1.1 for standards related to interference fits and tolerances.
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