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SolidWorks Lesson Template for Teachers to Contribute

Cover Sheet for Exemplary Lessons/Units Project

Faculty Member Name: Dr. Jeff Brown Date: 17 August, 2006

School District: Olympic College

Teacher’s School email address: [email protected]

Title of Lesson/Unit: Cantilever Beam Design

Science, Technology, Engineering and Math) STEM Concepts Addressed:1. Design a cantilevered I-beam to carry a distributed load of 30 kN.2. Conduct a stress analysis of the original

beam. The original cross section is shown tothe right.

3. Optimize the beam by determining the lowest

cross sectional area subject to two designcriteria: the lowest factor of safety can be 5and the maximum deflection of the beam canbe 75 mm. The student may vary the flangewidth and/or height. However, the width anddepth of the upper and lower flanges MUSTbe equal in each design. The student mayalso vary the web width and/or height.

4. The student will also develop a PowerPointpresentation of the results.

Length of instruction period: 50 min

How many periods needed to implementlesson unit:

1. ½ period - (optional) lecture activity onstress, stress calculations, factor ofsafety, ultimate stress, failuremechanisms.

2. 1 period - develop the model of the I-beam and conduct the stress analysis3. 1 period – optimize the design4. 1 period – prepare 5 minute presentations5. 1 period – present 5 minute presentations

Grade Level(s) for use: All

Objectives:1. Create a SolidWorks model of an I-beam.2. Conduct a stress and deflection analysis using COSMOSXpress.3. Optimize the design to obtain the smallest cross section subject to two design

constraints.4. Prepare a 5 minute oral presentation of results.

Materials:SolidWorks software with COSMOSXpress, calculator, PowerPoint software for thepresentation.

Flange

Web



Procedures:Step 1—model baseline I-beam

1. Open New Part2. Sketch – Front Plane3. Line – sketch the object around

the origin making sure that allhorizontal and vertical lines areconstrained as you sketch them.

4. Add Relations – make the upperand lower edges equal in length.Also make the upper flangeheight equal to the lower flangeheight.

5. Smart Dimension all lines asshown at the right. Setdimension between edges andthe origin first—simply set

dimensions, you will addequations in the next step. Setthe edge dimensions second—make these dimensions equal tothose shown in the figure.

6. Add equations – open the equation editor.Add equations to make the dimensions

between the left edges of the upper andlower flanges equal to ½ the flange width.Then make the dimension between theleft hand edge of the web and the originequal to ½ of the flange width. Finallymake the dimension between the upperedge of the lower flange and the originequal to the dimension between the loweredge of the upper flange and the origin. This will maintain the design intent when thecross section is modified in step 3.

7. (optional) discuss alternate ways to maintain the design intent.8. Feature: Extruded Boss/Base – extrude the cross section 6 meters (6000 mm).

9. Save the Part as Baseline I Beam.



Step 2—Cosmos Stress analysis1. Open COSMOSXpress.

2. In the welcome window,click Options.

3. Confirm that SI units is

selected and browse to thefolder in which you wish tokeep the results. Click Next>to choose the material.



4. Choose Alloy Steel for thematerial. Click Next> to setrestraints.

5. Click Next> again.Then click on the

forward facesection as shown.Click Next> twiceto define theloads.

6. Click Next> again.Confirm that force isselected. ClickNext>.



7. Chose the upper face to define where the force will act. Click Next>.



8. Confirm that Normal to each selected face is selected and input the magnitude of theforce. Click Next> twice.

9. Confirm that Yes isselected. (Youmay experimentwith No andchangingparameters but itwill probably onlyconfuse thestudents.) ClickNext>.



10. Click Run—the first piece of information returned is the factor of safety. If youskipped the optional discussion on factor of safety, you should discuss it here. Toget the picture shown, I entered 11 in the box and clicked Show me to determinewhere the lowest FOS is located. Click Next>.

11. Click on Show me thedisplacement distributionin the model. Click Next>.



12. The displacement distribution is shown.

13. You now know the FOS and maximum displacement.

Step 3—Optimize the DesignThe students will now work in teams of two to modify the geometry to obtain the I-beamwith the smallest cross sectional area that meets the design criteria. The students are

free to modify the flange width and/or height. They are also free to modify the flangeheight and/or width. The design must have a minimum FOS greater than 5 and amaximum deflection less than 75 mm. NOTE: it is unlikely that a design will exactlymeet either criterion. In other words, if the design has a FOS of exactly 5, then themaximum deflection will be less than 75 mm—it will not, in general, be possible to find adesign with FOS exactly equal to 5 and deflection exactly equal to 75 mm.

Step 4—the teams prepare an oral presentation using PowerPoint.

Assessment:o Students will demonstrate skill in creating solid model

o Students will demonstrate skill in conducting stress analysiso Students will optimize an engineering design subject to two constraints

Resources Used:NoneCopyrighted Materials:None

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