MSC.Software Corporation reserves the right to make changes in specifications and other information contained in this document without prior notice. Concepts, methods, and examples presented in this text are for illustrative and educational purposes only.
MSC.Software Corporation reserves the right to make changes in specifications and other information contained in this document without prior notice. Concepts, methods, and examples presented in this text are for illustrative and educational purposes only.
MSC.Software Corporation reserves the right to make changes in specifications and other information contained in this document without prior notice. Concepts, methods, and examples presented in this text are for illustrative and educational purposes only.
Part Number: MDAM*R3*Z*FLEX*Z*SM-ADM710-NT Copyright 2009 MSC.Software Corporation
July 2009 ADM710 Course Notes ADAMS/FLEX MSC.Software Corporation Europe MSC.Software GmbH Am Moosfeld 13 81829 Munich, Germany Telephone: (49) (89) 43 19 87 0 Fax: (49) (89) 43 61 71 6 Corporate MSC.Software Corporation 2 MacArthur Place Santa Ana, CA 92707 USA Telephone: (800) 345-2078 Fax: (714) 784-4056 Asia Pacific MSC.Software Japan Ltd. Shinjuku First West 8F 23-7 Nishi Shinjuku 1-Chome, Shinjuku-Ku Tokyo 160-0023, JAPAN Telephone: (81) (3)-6911-1200 Fax: (81) (3)-6911-1201 MSC Confidential Copyright 2009 MSC.Software Corporation 2 Legal Information MSC.Software Corporation reserves the right to make changes in specifications and other information contained in this document without prior notice. The concepts, methods, and examples presented in this text are for illustrative and educational purposes only, and are not intended to be exhaustive or to apply to any particular engineering problem or design. MSC.Software Corporation assumes no liability or responsibility to any person or company for direct or indirect damages resulting from the use of any information contained herein. Copyright 2009 MSC.Software Corporation. All Rights Reserved. This notice shall be marked on any reproduction of this documentation, in whole or in part. Any reproduction or distribution of this document, in whole or in part, without the prior written consent of MSC.Software Corporation is prohibited. The MSC.Software corporate logo, Adams, Dytran, Easy5, Fatigue, Laminate Modeler, Marc, Mentat, MD Nastran, Patran, MSC, MSC Nastran, Mvision, Patran, SimDesigner, SimEnterprise, SimManager, SimXpert and Sofy are trademarks or registered trademarks of the MSC.Software Corporation in the United States and/or other countries. NASTRAN is a registered trademark of NASA. All other trademarks belong to their respective owners. MSC Confidential Copyright 2009 MSC.Software Corporation 3 CONTENTS Section Page 0.0 Welcome to Adams/Flex Training About MSC.Software ..... 0-3 Course Overview ... 0-4 Getting Help .... 0-5 1.0 Introducing Adams/Flex Virtual Prototyping Process ..... 1-4 How You Benefit from Using Adams/Flex . 1-8 Linear Assumption . 1-12 Flexible Body Linear Limit Check 1-13 Controlling Modal Content 1-14 Inertia Modeling . 1-19 Visualization Attributes . 1-22 Workshop 1: Preparing a Can Crusher Presentation .. WS1-1 2.0 Theoretical Background Modal Superposition ..... 2-4 Craig-Bampton Component Mode Synthesis ... 2-7 Mode Shape Orthonormalization . 2-8 Kinematics of Markers on Flexible Bodies . 2-10 Applied Forces ... 2-14 Flexible Body Equations of Motion ..... 2-19 3.0 Replacing Rigid Bodies (Part I) Renaming Flexible Bodies ....... 3-4 Modeling Attributes ....... 3-5 List Info ........ 3-6 Nodes ... 3-7 Plotting ........ 3-10 Workshop 2: Performing a Simple Swap ....... WS2-1 MSC Confidential Copyright 2009 MSC.Software Corporation 4 CONTENTS (cont.) Section Page 4.0 Replacing Rigid Bodies (Part II) About Joints and Motions ..... 4-4 Joints Connection Limitations ...... 4-5 About Dummy Parts ...... 4-7 About Forces ...... 4-9 Workshop 3: Performing an Advanced Swap ....... WS3-1 5.0 Optimizing MNFs and Exporting Loads Modal Neutral Files .... 5-4 Introducing Adams/Flex Toolkit .. .... 5-5 MNF Browser Application ..... 5-6 Adams/Flex Toolkit Optimization Options .. 5-10 Command Line Flex Toolkit . 5-25 Exporting FEA Loads .... 5-29 FEMDATA 5-32 Workshop 4: Optimizing MNFs and Exporting Loads ..... ..... WS4-1 6.0 Using Flexible Body Statements Data Transfer ... 6-4 Statements Used .... 6-5 Matrix Files ...... 6-6 Workshop 5: Using External Adams/Solver ...... WS5-1 7.0 Contacts and Modal Forces Contact with Flexible Bodies . 7-4 Modal Applied Force and Preloaded Flexible Bodies .. 7-6 Workshop 6: Using Contacts and Modal Force ..... ... WS6-1 MSC Confidential Copyright 2009 MSC.Software Corporation 5 CONTENTS (cont.) Section Page 8.0 Stress Recovery with Adams/Durability Introduction to Adams/Durability . 8-4 Theory of Modal Stress Recovery .. 8-5 MSR Nastran Example 8-13 Improving Graphics Performance in Adams/PostProcessor .. 8-18 Using the Hot Spots Table ... 8-23 Workshop 7: Stress Recovery with Adams/Durability ......... WS7-1 9.0 Fatigue Analysis What is Metal Fatigue? ..... 9-4 Durability Design Process .... 9-5 Determining Loads .... 9-6 Overview of Fatigue Life Analysis ....... 9-7 Stress Life (S-N) Approach .. 9-8 Strain Life (E-N) Approach 9-9 MSC.Fatigue .. 9-10 Workshop 8: Fatigue Analysis using Adams and Fatigue ........................ WS8-1 10.0 MNF Generation in Nastran Modal Neutral Files 10-3 Superelement Definition ... 10-4 Selecting Attachment Points 10-9 What is a Spider Web? .. 10-10 ADAMSMNF Case Control .. 10-11 Units . 10-16 ADMOUT = YES 10-18 FLEXONLY = NO .. 10-19 Residual Vectors ....... 10-20 Releasing DOF ...... 10-25 Common MD DB 10-26 MSC Confidential Copyright 2009 MSC.Software Corporation 6 CONTENTS (cont.) Section Page 11.0 Modeling Considerations First Thoughts .... 11-4 FE Modeling Considerations ... 11-5 Special Adams Modeling Considerations ..... 11-12 Concluding Thoughts .... 11-15 12.0 Validating and Debugging Validating Your Flexible Body ...... 12-4 Workshop 9: Validating and Debugging ........ WS9-1 13.0 Appendix A Application Examples Industrial Robot ...... A-4 Low-Voltage Circuit Breaker .... A-6 Flexible Go-Kart ........ A-11 Comfort Tire Model ....... A-13 Satellite with Flexible Panels and Antennas ..... A-15 Flexible Vehicle Suspension .... A-17 Shell Panels for Missile Separation ........ A-18 Landing Aircraft ...... A-20 Flexible Vehicle Frame and Chassis ..... A-22 Flexible Car Body in Passing Maneuver .... A-23 Pothole Passing with a Truck ...... A-25 Rail Vehicle Comfort Calculations ... A-33 14.0 Appendix B Making an MNF Using FEM Software ABAQUS ...... B-4 ANSYS ........ B-5 I-DEAS ......... B-6 Nastran ........ B-7 Marc ...... B-10 Other MSC Products ...... B-12 MSC Confidential Copyright 2009 MSC.Software Corporation 7 CONTENTS (cont.) Section Page 15.0 Appendix C Adams/View Command Language Syntax Flex Body ..... C-4 Establish the Selected Modes .. C-5 Modifying/Disabling Modes ... C-6 Visualization Attributes ......... C-7 Auto-generated Matrix ... C-8 Flex Body Markers ..... C-9 16.0 Appendix D Adams/Vibration Frequency Domain Analyses Adams to Nastran for NVH D-4 Nastran Modal Export for Frequency Domain Stress Recovery . D-5 Frequency Response Function Plots for Stress and Strain . D-6 17.0 Appendix E Answer Key Answer Key for Workshop 1 .... E-4 Answer Key for Workshop 2 .... E-6 Answer Key for Workshop 3 .... E-7 Answer Key for Workshop 4 .... E-9 Answer Key for Workshop 5 .... E-14 Answer Key for Workshop 6 .... E-17 Answer Key for Workshop 9 .... E-18 MSC Confidential Copyright 2009 MSC.Software Corporation 8 S0-1 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation SECTION 0 WELCOME TO ADAMS/FLEX TRAINING S0-2 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation S0-3 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation ABOUT MSC.SOFTWARE Find a list of MSC.Software products at: http://www.mscsoftware.com/products/products.cfm Find a list of Adams products at: http://www.mscsoftware.com/products/products_detail.cfm? PI=413 Find additional training at: http://store.mscsoftware.com/training/ Or your local support center Run through verification problems at: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB9587 S0-4 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation COURSE OVERVIEW Lecture Hands-on workshops Theory S0-5 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation GETTING HELP Online Help To access the Online Help, do either of the following: While working in any Adams/Flex dialog box, press F1 to display Online Help specific to that dialog box. From the Help menu, select Adams/View Help. Once the Online Help is displayed, you can browse through the table of contents or the index, or search for any terms. S0-6 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation GETTING HELP (CONT.) Contents of selected tab Table of Contents for selected tag Index/search for entire Adams/Flex S0-7 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation GETTING HELP (CONT.) Technical support To find your local support center, go to: http://www.mscsoftware.com/support/contacts/index.cfm To read the Standard Enhancement & Technical Support Usage Guide, do one of the following: If in the United States, go to http://www.mscsoftware.com/support/Tech_Spt_Guide_Americas. cfm If outside the United States, go to: http://www.mscsoftware.com/support/contacts/, and then select your region S0-8 ADM710, Section 0, July 2008 Copyright 2008 MSC.Software Corporation GETTING HELP (CONT.) Knowledge base Go to http://support.mscsoftware.com/kb Consulting services: Go to http://www.mscsoftware.com/services/esg/ Adams News and Users Forums To join the community of Adams users, go to: http://forums.mscsoftware.com/news/ubbthreads.php S1-1 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation SECTION 1 INTRODUCING ADAMS/FLEX S1-2 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation S1-3 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation INTRODUCING ADAMS/FLEX Whats in this section: Virtual Prototyping Process How You Benefit from Using Adams/Flex Linear Assumption Flexible Body Linear Limit Check Controlling Modal Content Inertia Modeling Visualization Attributes S1-4 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VIRTUAL PROTOTYPING PROCESS Build a model of your design using: Bodies Forces Contacts Joints Motion generators Build Test Review Improve DESIGN PROBLEM Cut time and costs Increase quality Increase efficiency IMPROVED PRODUCT S1-5 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VIRTUAL PROTOTYPING PROCESS (CONT.) Test your design using: Measures Simulations Animations Plots Validate your model by: Importing test data Superimposing test data Build Test Review Improve DESIGN PROBLEM Cut time and costs Increase quality Increase efficiency IMPROVED PRODUCT S1-6 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VIRTUAL PROTOTYPING PROCESS (CONT.) Review your model by adding: Friction Flexible Parts Forcing functions Control Systems Iterate your design through variations using: Parametrics Design Variables Build Test Review Improve DESIGN PROBLEM Cut time and costs Increase quality Increase efficiency IMPROVED PRODUCT S1-7 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VIRTUAL PROTOTYPING PROCESS (CONT.) Improve your design using: DOEs Optimization Automate your design process using: Custom menus Macros Custom dialog boxes Build Test Review Improve DESIGN PROBLEM Cut time and costs Increase quality Increase efficiency IMPROVED PRODUCT S1-8 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation HOW YOU BENEFIT FROM USING ADAMS/FLEX Better loading prediction for durability analysis Improved system performance Additional benefits Adams/Flex provides valuable insight for the analyst, balancing strength and flexibility design factors with the cost and weight of a mechanism. S1-9 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation HOW YOU BENEFIT FROM USING ADAMS/FLEX (CONT.) Better loading prediction for durability analyses The flexible component is the focus of your attention. What is the system doing to my flexible component? Examples: Connecting rod Automotive jack stand S1-10 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation HOW YOU BENEFIT FROM USING ADAMS/FLEX (CONT.) Improved system performance The model fidelity is the focus of your attention. Component flexibility is just another parameter of the system design. What is the flexible component doing to my system? Examples: Handling characteristics of a vehicle with a flexible frame Robot manipulator path Manipulator S1-11 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation HOW YOU BENEFIT FROM USING ADAMS/FLEX (CONT.) Contrasting MSS and FEA Finite element analysis (FEA) offers excellent modeling capabilities for individual components in isolation. Estimating loads is an art. FEA is too inefficient for system level modeling and is incapable of analyzing large motion. Rigid body mechanical system simulation (MSS) efficiently analyzes large motions of complex systems and can be used to generate component loads for FEA. However, failure to account for component flexibility can dramatically reduce modeling fidelity. Flexible body MSS gives you the best of both worlds. S1-12 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation LINEAR ASSUMPTION Modal flexible bodies are linear modeling elements. Deformations are assumed to be small and within the linear range. With large deformations (> 10% of its characteristic length), the assumptions of modal superposition are violated and results will be inaccurate. Sometimes, a flexible body can be deformed beyond its linear limit. S1-13 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY LINEAR LIMIT CHECK Linear limit check (C++ Solver Only): Settings > Solver > Flex Bodies Limit Check Skin: Solver will check the deformation of all the surface nodes on the skin of the flexible body to see whether they violate the linear limit. Selnod: Solver will only check the nodes specified in the SELNOD section of the mtx file. Limit Action Halt: Terminates execution of Solver. Return: Stops the simulation and returns to the command level. Message Only (Default): Only issues a warning message. S1-14 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation CONTROLLING MODAL CONTENT Mode enabling and disabling Disabling a mode prevents Adams/Flex from considering that shape when generating the overall deformed shape of the component. Manual Table (modal ICs) Range By strain energy (auto) If a mode does not contribute to the response of the flexible component during a simulation, consider disabling it. Your control over modal degrees of freedom (DOFs) can greatly affect the success of your analysis: Too many DOFs can mean unacceptably long computation time Too few DOFs can prevent Adams from converging to an acceptable solution S1-15 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation CONTROLLING MODAL CONTENT (CONT.) S1-16 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation CONTROLLING MODAL CONTENT (CONT.) Modal damping Default: 1% damping for all modes with frequency lower than 100 Hz. 10% damping for modes with frequency between 100 and 1000 Hz. 100% critical damping for modes with a frequency higher than 1000 Hz. Single scalar damping value applied to all the modes Function expressions: Damping ratio can be defined by any generic function expression Two special functions can be used to define the damping ratio: FXMODE: Returns the mode number of the current mode of the flexible body FXFREQ: Returns the modal frequency (Hz) of the current mode of the flexible body. S1-17 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation CONTROLLING MODAL CONTENT (CONT.) Example: FLEX_BODY/1 CRATIO = IF(FXFREQ-100:0.01,0.1,if(FXFREQ- 1000:0.1,1.0,1.0)) This example recreates the default modal damping scheme using nested IF function expressions. Cycles/user time Control the damping using a DMPSUB user-written subroutine: If you want to specify the modal damping using more complicated expressions, consider a DMPSUB user-written subroutine. For more information, see Knowledge Base Article 9000 at: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB9000. S1-18 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation CONTROLLING MODAL CONTENT (CONT.) S1-19 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation INERTIA MODELING Inertia modeling There are four preset options and one custom option: Rigid body - approximates rigid body behavior but uses flexible body formulation (INVAR6 disabled). Constant - deformations dont affect the inertial properties. Partial coupling - the default. Full coupling - uses all nine invariants and, therefore, is the most computationally intensive choice. Custom - allows you to set your own or view a preset option, as shown next. Note that check mark indicates on (or true). S1-20 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation INERTIA MODELING (CONT.) Preset options S1-21 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation INERTIA MODELING (CONT.) Custom S1-22 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES Plot type Deformation scale factor Datum node S1-23 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) Plot type Enable color contour or vector plots for a flexible body Options include: Contour - Sets Adams/Flex so it displays color contour plots Vector - Sets Adams/Flex so it displays vector plots None - Displays neither the color contours or vector plots Both - Displays both the color contours and vector plots S1-24 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) Deformation scale factor Used to exaggerate deformation for viewing purposes only Can scale up or down The deformation scale does not affect the position of marker icons Constraints can appear violated when the scale is >1. This is merely visual: the analysis will, of course, maintain the constraints youve defined. When the scale is equal to 0, only the rigid body motion of the flexible body will be animated. This produces faster animations for flexible bodies. S1-25 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) S1-26 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) Datum node Deformation is a relative term and should be expressed with respect to a node: You select which node Adams/Flex considers as the undeformed (datum) node and then color contour plots reveal deformation relative to it. LBRF (local body reference frame, the default) is in the same location as the reference frame used in FEA. S1-27 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) S1-28 ADM710, Section 1, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES (CONT.) Example of using different datum nodes Here, node 1000 is the datum node. In this case, node 1001 is the datum node. The color red denotes maximum deformation relative to the datum node. Node 1000 Node 1001 Node 1000 Node 1001 WS1-1 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 PREPARING A CAN-CRUSHER PRESENTATION WS1-2 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WS1-3 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 PREPARING A CAN-CRUSHER PRESENTATION Problem statement You have just been promoted to a high-profile project. Your supervisor is responsible for the dynamic analysis of a can- crushing mechanism. He wants you to prepare a presentation that includes: Table of eigenvalues from Adams/Linear Screen snapshot (.jpg) of system mode 8 A plot of the y-component of the torque in a revolute joint versus the distance the can has been compressed Animation movie files (.avi) of the flexible body model alongside the rigid body model A Web page with the presentation. For example: WS1-4 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) WS1-5 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Mechanism information This model represents a can-crushing mechanism, as shown in Figure 1: Can Base Coupler Plunger Node 2505 Node 2502 Node 2498 flx_lever WS1-6 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) The mechanism includes the following parts: WS1-7 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) An input force is applied to the end of FLX_LEVER with a STEP function and turns off after 0.55 seconds. F o r c e WS1-8 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Setting up the model To set up the model: 1. Start Adams/View from the directory exercise_dir/mod_01_cancrusher. Where exercise_dir is the directory where the workshop subdirectories reside. 2. From the same directory, import the model command file cancrusher_start.cmd. ADAMS/View displays the model named cancrusher. Inspecting the flexible lever You can quickly inspect the flexible lever to see how each mode would contribute to its deformation. WS1-9 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) To inspect the flexible lever: 1. From the Main Toolbox, select the Isometric tool , and then select Render. 2. Turn off icon (v) and grid visibility (g). You can turn on and off the icon and grid visibility as needed throughout the course. 3. If the strip chart is blocking the view, you can move it aside. 4. Right-click FLX_LEVER, point to Flexible_Body: FLX_LEVER, and then select Modify. 5. In the Mode Number text box, enter 10, and then press Enter. ADAMS/View displays mode 10 superimposed on the undeformed body: Mode 10 WS1-10 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 6. In the Flexible Body Modify dialog box, select the Animate tool . Adams/View animates mode 10 for three cycles. 7. To see how Adams/View displays the deformation mode and the undeformed body, toggle the Superimpose option a few times. 8. Set Plot Type to Contour. The resulting contours show deformation, not stress. 9. To exaggerate the results, set Deformation Scale Factor to 2.0, and then press Enter. WS1-11 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 10. Animate mode 10 once again and note the difference caused by the increased deformation scale factor. 11. Review modes 7 - 28. The first six modes are rigid body modes and are automatically disabled because Adams/Flex already handles the dynamics for those modal degrees of freedom. 12. Set Deformation Scale Factor back to 1.0. WS1-12 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Simulating the rigid lever Make the lever temporarily rigid, and then simulate it to observe the can-crushing operation. To simulate the rigid lever: 1. Set Inertia modeling to Rigid body. 2. Select OK. 3. Confirm that the flexible body is not selected. From the Main Toolbox, select the Select tool to clear the Select List. You should do this whenever you want to stop seeing the model in a dimmed appearance. 4. From the Simulate menu, select Scripted Controls. WS1-13 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 5. Run scripted simulation using the script .cancrusher.RIGID_SCRIPT. The script uses the following Adams/Solver commands: SIM/STATICS INTEGRATOR/GSTIFF, HMAX=.01 SIM/TRANSIENT, END=0.75, STEPS=50 The strip chart CAN_COMPRESSION_MEA displays the deformation of the can versus time. WS1-14 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 6. From the Simulation Control dialog box, select the Save Simulation Results tool . 7. Save the results with the name rigid. You will use these results later in your presentation material. 8. Animate the results of the simulation. The lever arm stays blue because its not deforming. It is not deforming because you set Inertia Modeling to Rigid Body. 9. Close the Animation Controls dialog box or reset the model to the modeling view by other means. WS1-15 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Simulating the flexible lever Make the lever flexible again, and then simulate it to observe its motion. To simulate the flexible lever: 1. Right-click FLX_LEVER, point to Flexible_Body: FLX_LEVER, and then select Modify. 2. In the Flexible Body Modify dialog box, set Damping Ratio to default. Deformations of the flexible body are displayed relative to the datum node. You'll choose node 2505 because it is at the opposite end of the applied load, as shown in Figure 1. The colors indicate the magnitude of the deformation: red indicates the most deformation, blue the least. 2. Clear the selection of LBRF. 3. In the Datum Node text box, enter 2505. 4. Set Inertia modeling to Partial coupling. Partial coupling is the default flexible body representation of the inertia invariants. 5. Select OK. 6. Clear the selection of the lever. WS1-16 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 7. Perform another scripted simulation using .cancrusher.FLEX_SCRIPT. The script uses the following Adams/Solver commands: SIM/STATICS LINEAR/EIGENSOL INTEGRATOR/GSTIFF, SI2, HMAX=0.01 SIM/TRANSIENT, END=0.75, STEPS=50 8. Save the simulation results as flexible. 9. Animate the results of the simulation. By animating the results you've seen how the flexible lever deforms as the load is applied. You may have noticed in the script that an Adams/Linear eigenvalue solution was performed at the static position. In the next section you will learn how to export a table of eigenvalues and create an image of one of the eigenmodes which will be used in your presentation. WS1-17 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Preparing the eigenvalue data table For your presentation, generate a table of system eigenvalues from Adams/Linear and export it to a text file. To prepare the data table: 1. From the Review menu, select Postprocessing or press the F8 key. 2. Right-click the viewport, and then select Load Mode Shape Animation. 3. From the Database Navigator, under flexible, double-click the Eigen results (for example, EIG_1). Adams/PostProcessor displays the model and updates the dashboard with mode shape animation controls. 4. From the dashboard, select Table of Eigenvalues. The Information window displays the table. 5. Select Save to File, and save the file as system_modes.txt. 6. Close the Information window. WS1-18 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Creating an image of the lever For your presentation, create a color image of system mode 8 and name it mode_8.jpg. Figure 2. System Mode 8 WS1-19 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) To create the image: 1. To display the triad, from the dashboard, select the View tab, and then select Display Triad. 2. For optimal viewing, fit the model in the viewport by using the view control keyboard shortcuts, rotate, zoom, and translate so that you have a view of the model similar to the view in Figure 2. 3. From the dashboard, select the Mode Shape Animation tab. 4. Set Mode Number to 8, to display mode 8 and its frequency. Note its frequency: _____(hz). 5. Change the Scale Factor to 0.1. 6. To animate mode 8, select the Play tool . WS1-20 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 7. Observe the mode shape animation, and when youve finished animating, press the Pause tool . Why do you think that mode 8 is important? ________________________________________________________ ________________________________________________________ ________________________________________________________ 8. Select the Reset tool . 9. From the File menu, select Print. 10. Set Print to File. 11. In the File Name text box, enter mode_8.jpg. 12. Set the pull-down menu, directly under File Name, to JPG. 13. Select OK. Adams/PostProcessor creates the image file. WS1-21 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Comparing animations You use Adams/PostProcessor to compare the animations of the rigid and the flexible levers. You compare animations using the overlay feature. Figure 3 shows how your window looks after youve completed the steps in this section. WS1-22 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Figure 3. Overlaying Animation Results WS1-23 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) To compare animations: 1. Delete the current page to remove the mode shape animation. 2. From Adams/PostProcessors Main toolbar, from the Page layout tool stack, select the 2 Views, side by side tool . 3. Right-click the viewport on the right, and then select Load Animation. 4. Double-click rigid. 5. For optimal viewing, fit the model in the viewport. 6. As shown in Figure 3, overlay the simulation named flexible: From the dashboard, select the Overlay tab. In the Offset text box, enter -10, 0, 0. In the Colors text box, enter blue. Hold down the Control key and multiple-select .cancrusher.rigid and .cancrusher.flexible. Move the pointer out of the dashboard area, to execute the command (which can take a while). 7. Fit the models in the viewport and then animate by selecting the Play tool. 8. After you finish viewing the animation, pause it. WS1-24 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Observing deformations Deformations of the flexible body are displayed relative to the datum node you assigned earlier, in Simulating the flexible lever. Increase the deformation scale so that you can better visualize the deformation in the movie file you will be creating soon. To exaggerate deformations: 1. Right-click the flexible body, point to Flexible_Body: FLX_LEVER, and then select Select. 2. In the Flex Props tab, set Scale to 20, and then press Enter. 3. To clear the selection of the flexible body, select the Select tool . 4. Animate again. Notice how increasing the scale factor has exaggerated the flexible lever deformations. WS1-25 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) WS1-26 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Comparing joint torque plots As the lever crushes the can, you can see the combined twisting and bending of the lever. The twisting and bending produces force components that act as a torsional load on the revolute joint (at the coupler). The torque climbs until the can finally collapses from the crushing operation. At the end of the duty cycle, the load in the lever is relieved and the joint torque drops back to zero. The measure for the joint torque is named LVR_CPLR_REV_MEA_TY and you will plot it versus the deformation of the can, CAN_COMPRESSION_MEA. WS1-27 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) To compare plots: 1. Right-click the viewport on the left and select Load Plot. If an alert box appears, select OK to dismiss it. 2. In the dashboard, set Source to Measures. 3. Set Independent Axis to Data, and then select CAN_COMPRESSION_MEA as the independent data measure. 4. Select Surf. The Surf feature lets you quickly browse or surf through multiple results. Using it can eliminate mouse clicks and other operations, such as delete, undo, and so on. 5. Select both the rigid and the flexible analyses, and plot LVR_CPLR_REV_MEA_TY. 6. If the legend obscures the plot, select it and move it up slightly. 7. Clear the selection of the legend. 8. Select the viewport on the right, and then animate. WS1-28 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Preparing the movie file To prepare the movie file: 1. Click on the viewport on the right. 2. From the dashboard, select the Animation tab. 3. Choose a frame range of 1 to 50, and then press Enter. 4. Reset the animation so it displays the first frame. 5. For optimal viewing, fit the models in the viewport. 6. To prepare for recording the .avi file, select the Record tab. 7. Clear the File Name text box. 8. In the File Name text box, enter the name movie. 9. Verify that Format is set to AVI. 10. Select the Record tool. 11. Select Play. Note: Do not change windows during the record phase. 12. After the animation goes through one pass, or 50 frames, select Pause. Note: Do not return to Adams/View because you will complete the next steps in Adams/PostProcessor. WS1-29 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Publishing to the Web For publishing to the Web, you export data in the current session of Adams/PostProcessor as HTML pages for viewing by others in your organization. Adams/PostProcessor also creates: Plots and animations as .png, .jpg, .bmp, .xpm, or .tiff images. Movies of animations as .avi or .mpg. Information about the parts, constraints, forces, and more in the selected models. This is the same information that appears when you select Info. WS1-30 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) To publish to the Web: 1. From the treeview in Adams/PostProcessor, select page_1. 2. From the Edit menu, select Rename, and then rename the page to movie. 3. From the main toolbar, select the Create a new page tool . 4. Rename this page to system_modes. 5. From the Page Layout tool stack , select the 1 View tool . 6. Right-click the viewport, and then select Load Report. 7. Double-click system_modes.txt. 8. From the main toolbar, select the Create a new page tool. 9. Rename this page to can_compression. 10. Right-click the viewport, and then select Load Plot. 11. Set Source to Measures. 12. Plot the CAN_COMPRESSION_MEA for both the rigid and flexible bodies. WS1-31 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) 13. From the File menu, point to Export, and then select HTML Report. 14. Select OK. Note: Do not change windows because the movie will be re-recorded. Adams/PostProcessor creates a folder, named html_export, in your working directory. 15. From the Adams/PostProcessor Main toolbar, select to return to the modeling environment. 16. Save the database using the default name. 17. Exit Adams/View. 18. Open the html_export folder. 19. In a browser, open index.html. 20. To view the results, expand the pages folder. 21. Expand the cancrusher folder to browse information on the parts, constraints, and forces in the selected model. WS1-32 ADM710, Workshop 1, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 1 CAN-CRUSHER PRESENTATION (CONT.) Module review 1. How does the system mode 8 compare with the flexible body mode that is near the same frequency? ________________________________________________ ________________________________________________ ________________________________________________ 2. Can you suggest a better reference frame in which to express the measure LVR_CPLR_REV_MEA_TY? ________________________________________________ ________________________________________________ ________________________________________________ S2-1 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation SECTION 2 THEORETICAL BACKGROUND S2-2 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation S2-3 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation THEORETICAL BACKGROUND Whats in this section: Modal superposition Craig-Bampton Component Mode Synthesis Mode Shape Orthonormalization Kinematics of Markers on Flexible Bodies Applied Forces Flexible Body Equations of Motion S2-4 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation MODAL SUPERPOSITION Represent deformation as a linear combination of mode shapes Simple example Craig-Bampton modes distinguishes boundary nodes from interior nodes S2-5 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation MODAL SUPERPOSITION (CONT.) Fixed boundary normal modes Obtained by fixing the boundary DOF and computing an eigensolution. There are as many fixed-boundary normal modes as the user desires. These modes define the modal expansion of the interior DOF. The quality of this modal expansion is proportional to the number of modes retained by the user. Two fixed-boundary normal modes for a beam that has attachment points at the two ends. S2-6 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation MODAL SUPERPOSITION (CONT.) Constraint modes Static shapes obtained by giving each boundary DOF a unit displacement while holding all other boundary DOF fixed. The basis of constraint modes completely spans all possible motions of the boundary DOFs, with a one-to-one correspondence between the modal coordinates of the constraint modes and the displacement in the corresponding boundary DOF. Two constraint modes for the left end of a beam that has attachment points at the two ends. The figure on the left shows the constraint mode corresponding to a unit translation. The figure on the right corresponds to a unit rotation. S2-7 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation CRAIG-BAMPTON COMPONENT MODE SYNTHESIS Deformations are represented in Craig-Bampton modal basis Transform stiffness and mass matrices to Craig- Bampton basis Generalized stiffness Generalized mass S2-8 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation MODE SHAPE ORTHONORMALIZATION Problems using raw Craig-Bampton modes Constraint modes embed rigid body motion. Constraint modes do not advertise the high-frequency dynamics that they add Constraint modes cannot be disabled in Adams Solve a second eigenvalue problem Eigenvalue problem yields coordinate transformation Transformation orthonormalizes modes S2-9 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation MODE SHAPE ORTHONORMALIZATION (CONT.) Physical interpretation of orthonormalized modes Approximate free body modes Boundary eigenvectors Before: After: Problem solved Rigid body modes drop out All modes have natural frequency Disabling high-frequency boundary eigenvectors is benign S2-10 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation KINEMATICS OF MARKERS ON FLEXIBLE BODIES Why are marker kinematics needed? Joints Generalized forces Expressions Position Velocity Orientation S2-11 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation KINEMATICS OF MARKERS ON FLEXIBLE BODIES (CONT.) Position Use slice of modal matrix corresponding to translations of P Generalized coordinates S2-12 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation KINEMATICS OF MARKERS ON FLEXIBLE BODIES (CONT.) Velocity Differentiate position with respect to time Simplify using the relationship further simplify where S2-13 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation KINEMATICS OF MARKERS ON FLEXIBLE BODIES (CONT.) Orientation Use slice of modal matrix corresponding to rotations of P Orientation of marker at P is the product of three Euler transformation matrices Reorientation due to deformation builds on the small rotation assumption S2-14 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation APPLIED FORCES Point forces and torques Distributed loads Residual forces and residual vectors Preloads S2-15 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation APPLIED FORCES (CONT.) Point forces and torques Generalized forces Generalized force on the translations Generalized torque on the Euler angles Generalized modal load S2-16 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation Distributed loads New Adams element, the MFORCE FEM equation of motion Transform to modal coordinates Modal load Assume that time varying load may be represented as a time varying linear combination of static load cases Pre-project the static load cases on the modes In Adams, scale factors can be a function of time and state APPLIED FORCES (CONT.) S2-17 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation APPLIED FORCES (CONT.) Residual forces and residual vectors When load is projected on the modes, not all the load may make it The residual force gives us an additional mode (the residual vector) which enhances the Craig-Bampton basis. S2-18 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation APPLIED FORCES (CONT.) Preloads An Adams flexible body can contain a preload. This allows Adams to support flexible bodies linearized in a non-linearly deformed state. S2-19 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION Lagrange's equation S2-20 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) Mass matrix Velocity represented as a product of a matrix and the time derivative of the state vector Kinetic energy The flexible body mass matrix. We study it in block form S2-21 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) The blocks are conveniently represented as products of inertia invariants S2-22 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) where the invariants are computed in a preprocessor S2-23 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) Gravity and stiffness Potential energy includes stiffness effects and gravity The stiffness matrix is very simple because it has no rigid body contribution Generalized forces due to gravity S2-24 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) Damping Damping is assumed to be derivable from a quadratic form The equation of a simple harmonic oscillator leads to a characteristic equation S2-25 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) which yields the eigenvalues Critical damping occurs when the harmonic term vanishes Modal damping in Adams is represented as a fraction of critical damping S2-26 ADM710, Section 2, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE BODY EQUATIONS OF MOTION (CONT.) Equations of motionfinal form The final form of the equation of motion S3-1 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation SECTION 3 REPLACING RIGID BODIES (PART I) S3-2 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation S3-3 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation REPLACING RIGID BODIES (PART I) Whats in this section: Renaming Flexible Bodies Modeling Attributes List Info Nodes Plotting S3-4 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation RENAMING FLEXIBLE BODIES Uses the same method as rigid bodies When you rename a flexible body: Adams/View writes a new matrix (.mtx) file when you issue the next simulation command or export an .adm file The original matrix file is now redundant and since you dont need it, you may delete it Adams/View creates a redundant matrix file when you export the dataset (.adm). The .adm uses this new matrix file. Keep in mind that matrix names do not update until the next time you solve or export a dataset S3-5 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation MODELING ATTRIBUTES Color Use the same method as you would for rigid bodies Doesnt affect deformation colors Active/inactive Use the same method as you would for rigid bodies S3-6 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation LIST INFO Use it to view flexible body parameters We suggest using the Verbose option because it includes the mode enabled/disabled status S3-7 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation NODES The following options are available for locating markers on flexible bodies: 1. Coincident to a node Default option Compatible with Adams/Solver (FORTRAN) 2. Offset from a node Must first create the marker at a node, then modify it to the desired offset distance Adams/Flex will apply forces to the node Compatible with Adams/Solver (C++) Adams/Solver (FORTRAN) automatically adds an interface part 3. Attached to multiple nodes Must first create the marker attached to one node, then modify the marker to attach it to multiple nodes Allows the user to distribute loads to multiple nodes to avoid unrealistic stress concentrations. Compatible with Adams/Solver (C++) ONLY Adams/Solver (FORTRAN) does not support this option Note: Option 1 is the only option available before MSC.ADAMS 2003. S3-8 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation NODES (CONT.) Nodes are shown on mesh You can pick nodes based on FEM ID in the modeling environment S3-9 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation NODES (CONT.) Joints and forces may be applied at any location on a flexible body. The applied forces or reaction forces, however, will only be applied at node locations. For markers that are attached to one node with no offset, the force will be applied directly to that node. For markers that are attached to one node with an offset, the force will be transferred to the node and applied to the flexible body at this nodes location. This behavior is similar to creating a massless- rigid link between the marker (where the force is located) and the node (where the force is being applied to the flexible body). For markers that are attached to multiple nodes, the weighted force is transferred to each node and then applied to the flexible body at the node locations. For more information, in the online help for Adams/Solver (C++), follow the link: Statements Marker. Measures may reference any marker on a flexible body. You can designate any single node as a datum node for deformation color contours. S3-10 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING Result set components Standard measures User-written measures Output requests S3-11 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) Result set components You can plot the modal displacements and their derivatives (Q, DQ, DDQ) S3-12 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) Standard measures Available object characteristics: Center of mass (CM) position CM velocity (translational and angular) CM acceleration (translational and angular) Potential energy delta Kinetic energy (total, angular, and translational) Strain energy (due to deformation) Momentum (translational and angular) CM position relative to LBRF Available results data: Modal coordinates, velocities, and accelerations Part displacements, velocities, and accelerations (just like rigid bodies) S3-13 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) S3-14 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) User-written measures Point-to-point measures Object measures Markers on flexible bodies also support all standard marker measures and additional deformation measures (relative to LBRF). S3-15 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) Point-to-point measures Object measures Adams/PostProcessor dashboard S3-16 ADM710, Section 3, July 2008 Copyright 2008 MSC.Software Corporation PLOTTING (CONT.) Output requests Define using type and markers Displacement, velocity, acceleration, and force Define using subroutine (REQSUB) Define using function expression You can create output requests by using markers on the flexible body. Limitation: Because there is no center of mass (cm) marker for a flexible body, you cannot make a request from a cm marker. WS2-1 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP WS2-2 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WS2-3 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP Problem statement The design team is concerned about how component flexibility may influence the system performance of a robot. You need to modify the rigid-body model so it contains a flexible part, and then investigate the effects of that change. Mechanism information The model represents a robotic welding mechanism, as shown below: Hand Wrist Forearm Arm Level Shoulder Base Figure 4. Robotic Welding Mechanism WS2-4 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) The following table lists the robotic welding mechanism parts, their associated geometry, and characteristics. Note that the dummy parts listed in the table only exist for graphical reasons. They could be easily deleted from the model without affecting the functionality. Deleting these parts would decrease the number of equations in Adams/Solver, therefore, solving more efficiently. WS2-5 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) The following table lists the robotic welding mechanism joints, their type, and associated input motions. The motions are applied to the joints and control the angular displacements for the operational sequence. WS2-6 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) WS2-7 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Setting up the model To set up the model: 1. Run ADAMS/View from the directory exercise_dir/mod_03_robot. 2. From the same directory, import the model command file robot_rigid_start.cmd. 3. Adams/View displays the model named robot. 4. Set the render mode to shaded (type an uppercase S). 5. Turn off icon and grid visibility. WS2-8 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Simulating the model Before you simulate the model, set the specifications for the analysis files that Adams/View outputs. You may want to use these files later to compare the rigid analysis with the flexible one. To simulate the model: 1. From the Settings menu, point to Solver, and then select Output. 2. Set Save Files to Yes. 3. In the File Prefix text box, enter robot_rigid. 4. Close the Solver Settings dialog box. 5. Run a scripted simulation using .robot.RIGID_SCRIPT. The script uses the following Adams/Solver commands: SIM/STATICS KINEMATIC/ERROR = 1e - 4 SIMULATE/KINEMATIC, DURATION=1.7, DTOUT=1.0E-02 WS2-9 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) 6. Animate the results. 7. Save the simulation results as rigid. 8. To return to the model view, from the View menu, select Model. Swapping in the flexible forearm You now import a flexible forearm. You use the rigid-to-flex utility to replace the rigid forearm with a flexible one. To import the flexible forearm: 1. From the Build menu, point to Flexible Bodies, and then select Rigid to Flex. 2. Right-click the Current Part text box, point to Part, point to Browse, and then select the part FOREARM. WS2-10 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) 3. Right-click the MNF File text box, point to Browse, and then select robot_arm_easy.mnf. 4. Set Flex Body Positioning to Align Flex Body CM with CM of Current Part. Note: Do not select Apply or OK yet. The dialog box should look as follows: Flexible Body Rigid Body WS2-11 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) The model now includes the flexible forearm, as shown next: WS2-12 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Establishing flex body connections To establish connections: 1. Select the Connections tab. 2. Hold down the Ctrl key and select the rows for MK13 and MK14. 3. Select Preserve location. The dialog box should look as follows: 4. Select Apply or OK. WS2-13 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Switching to Adams/Solver (C++) To switch to Adams/Solver (C++): 1. From the Settings menu, point to Solver, and then select Executable. 2. Set Choice to C++. 3. Close the Solver Settings dialog box. 4. From the Tools menu, select Model Verify, and then check that youve established the correct connections and the model is ready to run. 5. Close the Information window. 6. Before continuing, save the model in binary format. WS2-14 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Preparing the flexible forearm To prepare the flexible forearm for analysis, you set parameters for inertia, disable modes that we dont want to include in this analysis, and set deformation display parameters. To prepare the flexible forearm: 1. In the Flexible Body Modify dialog box, verify that Inertia modeling is set to Partial coupling. 2. In the Mode Number text box, enter 12. 3. Select Disable . 4. In the Mode Number text box, enter 16. 5. Select Disable. 6. Clear the selection of LBRF and make node 3000 the datum node. 7. Ensure that Plot Type is set to Contour. 8. Select Apply or OK. 9. Clear the selection of the forearm. WS2-15 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Building a measure You build a measure of the lateral deflection of the flexible forearm. Later, you will use the measure to see how much the forearm deforms as the robot moves through its prescribed path. To build a measure: 1. From the Build menu, point to Measure, point to Point-to-Point, select New, and then use the following specifications: Create Strip Chart: clear its selection (uncheck) Measure Name: FOREARM_LATERAL_DEFL To Point: ARM_PIN.MK21 From Point: WRIST_PIN.MK23 Characteristic: Translational displacement Component: Z Represent coords in: ARM_PIN.MK21 2. Select OK. WS2-16 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Simulating the flexible forearm To simulate the flexible forearm: 1. From the Simulate menu, point to Simulation Script, and then select New. 2. In the Script text box, enter .robot.FLEX_SCRIPT. 3. Set Script Type to Adams/Solver Commands. 4. In the Adams/Solver Commands text area, enter: SIM/STATICS INTEGRATOR/SI2, GSTIFF, HMAX=1E-3 SIMULATE/TRANSIENT, DURATION=1.7, DTOUT=1.0E-02 5. Select OK. 6. Set simulation settings to Save Files, and assign it the file prefix robot_module3. Tip: See Step 1 - Step 4 under Simulating the model. WS2-17 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) 7. Perform a simulation using FLEX_SCRIPT. As the simulation runs, the screen updates with the robot motion. The deformation contours represent the relative deformations for the given animation frame. 8. To see how much the flexible forearm has deflected laterally (or end to end), display the strip chart for the measure you created earlier in Building a measure: from the Build menu, point to Measure, select Display, and then double-click FOREARM_LATERAL_DEFL. 9. Save the last simulation results as flex (in the Simulation Control dialog box, select ) . 10. From the Main Toolbox, animate the model with the Loop and the Contour Plots options selected. WS2-18 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Inspecting the results To inspect the results: 1. Launch Adams/PostProcessor. 2. Display a horizontal, 2-page layout ( ). 3. In the upper viewport, for the flexible run, plot the measure FOREARM_LATERAL_DEFL versus time. 4. In the lower viewport, load the animation of the analysis. 5. Choose HAND.TIP as the trace marker. Tip: To see this marker in your model, turn on the visibility of icons. Hand Tip WS2-19 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) 6. Animate the model. 7. Rotate the model so you can see the trace from different perspectives. 8. To see the hand tip vibrate as it momentarily comes to rest, zoom in on the part of the trace where the plot shows the vibration at the first dwell point. Note: If you're having trouble seeing the trace because its obscured by the HAND.CYLINDER geometry, you can set its transparency to 25 or remove its endcap. To remove the endcap: from the Edit menu, point to Preferences, and then clear the selection of Graphics Endcaps, which is located under the Geometry tab. 9. Return to Adams/View. 10. Save the model as robot.bin. Now you've learned how to run flexible body simulations with the integrated solver in Adams/View. WS2-20 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Exporting the model An easy way to export all model files in a single operation is to use a script mode known as Write Files Only. This is a good way to archive your .adm and .acf files for future reference. Exporting the model in this way gives you the minimal file set required to re-run the simulation with stand-alone Adams/Solver. To export the model: 1. From the Settings menu, point to Solver, and then select Executable. 2. Set Executable to Write Files Only. 3. Close the dialog box. 4. Run another scripted simulation using FLEX_SCRIPT. This will finish very quickly because it doesnt really run a simulation: it only wrote the files. 5. Check that ADAMS/View wrote the following files to your disk: robot_module3.acf robot_module3.adm robot_module3_FOREARM_flex.mtx 7. You will use these files again in Workshop 5 Using External Adams/Solver. Exit Adams/View. WS2-21 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Optional tasks 1. Use xdiff (or equivalent) to compare your dataset with the one in the directory completed/robot_module3.adm. Do the differences make sense?_______Yes _______No. Consider discussing the differences that you cannot explain. 2. To see the effect of the MNF path by inspecting the file robot.bin: Rename the working directory of this module: change it from mod_03_robot to mod_03_robot_renamed. Start Adams/View in mod_03_robot_renamed and open the database, robot.bin. Is the flexible body in the model? _______Yes _______No. What prevents it from being displayed? ______________________________________________________ To fix the display problem: Tools Command Navigator part modify flexible_body name_and_position. Browse for the flexible body and then fix the path for Modal Neutral File Name. WS2-22 ADM710, Workshop 2, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 2 PERFORMING A SIMPLE SWAP (CONT.) Module review The motions in this module used STEP5 functions. This plot shows a comparison of the rigid forearm acceleration using STEP and STEP5 functionslist some reasons why STEP5 is preferable in this application. ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ S4-1 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation SECTION 4 REPLACING RIGID BODIES (PART II) S4-2 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation S4-3 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation REPLACING RIGID BODIES (PART II) Whats in this section: About Joints and Motions Joint Connection Limitations About Dummy Parts About Forces S4-4 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation ABOUT JOINTS AND MOTIONS Using joints After you bring a flexible body into Adams/View, you can connect it to your rigid model using the Adams/View library of constraints. Joint locations Joints attached to a flexible body must originally be located at an existing node or marker on the flexible body. Note: The marker defining the joint can then be offset from this location or attached to multiple nodes by modifying it. It is not required that the joint be located on an attachment point in FEM. It is good modeling practice, however, to connect joints at attachment points. You can avoid nodal mismatch by: Using consistent numbering Paying attention to alignment issues S4-5 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation JOINT CONNECTION LIMITATIONS S4-6 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation JOINT CONNECTION LIMITATIONS (CONT.) Workaround: Attach the joint to an intermediate dummy part that is fixed to the flexible body at a node. Note: The C++ options were introduced in Adams/Flex 2003. Only the FORTRAN options were available before the 2003 release. * Starting with the 2005 release, Adams/Solver (FORTRAN) will automatically introduce a dummy part between the joint and the flexible body. S4-7 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation ABOUT DUMMY PARTS Dummy parts Starting with the 2005 release, dummy parts are automatically created for Adams/Solver (FORTRAN) Only necessary if you are using Adams/Solver (FORTRAN) 2003 or a previous version of ADAMS/Flex. Rigid parts with zero (or an insignificant amount of) mass and inertia, and are also referred to as massless links or phantom parts. Not physical parts of your model. Must be constrained in all six DOF (commonly accomplished with a fixed joint). Although they do not increase the DOF count of your model, they do increase the number of system equations you are solving. The dynamic behavior is not negatively affected by dummy parts. The use of some modeling elements is only possible through the use of dummy parts. S4-8 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation ABOUT DUMMY PARTS (CONT.) Flex body connects to dummy part through fixed joint Motion is applied to the WRIST_PIN dummy part S4-9 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation ABOUT FORCES S4-10 ADM710, Section 4, July 2008 Copyright 2008 MSC.Software Corporation ABOUT FORCES (CONT.) * The floating marker cannot be on a flexible body. The reaction force cannot act on a flexible body. ** The joint's J marker cannot be on a flexible body. ***Starting with the 2005 release, Adams/Solver (FORTRAN) will automatically introduce a dummy part between the force and the flexible body. Workaround: Attach the joint to an intermediate dummy part that is fixed to the flexible body at a node. Modal force (MFORCE) Allows you to apply forces in the modal domain (covered in Modal Applied Force and Preloaded Flexible Bodies). WS3-1 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP WS3-2 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WS3-3 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP Problem statement The product engineering department is investigating ways of reducing the cost of the robot. One designer suggested hollowing out a portion of the forearm (a lightening hole). The FEA expert meshed the proposed design change, and now you have to incorporate it into your robot model. You must redefine the properties of the current flexible body by referencing a different MNF, and then simulate the new design. Mechanism information This model is the flexible robot model you completed in Workshop 2Performing a Simple Swap. The FOREARM is modeled as flexible (robot_arm_easy.mnf) and you must replace it with a different flexible body (robot_arm_hard.mnf). Input motions haven't changed. WS3-4 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Existing flexible body New flexible body Lightening hole WS3-5 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Setting up the model To set up the model: 1. Run Adams/View from the directory, exercise_dir/mod_04_robot. 2. From the same directory, import the model command file, robot_mod4_start.cmd. This is the model you completed in Workshop 2 Performing a Simple Swap. Swapping flexible bodies To swap flexible bodies: 1. From the Build menu, point to Flexible Bodies, and then select Flex to Flex. 2. Right-click the Flexible Body text box, point to Flexible_Body, point to Browse, and then select FLEX_FOREARM. 3. Right-click the MNF File text box, point to Browse, and then select robot_arm_hard.mnf. WS3-6 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) 4. Select 3 Point Method. 5. To make it easier to see the nodes, set the render mode to shaded. 6. Follow the instructions in the Status bar to select the following nodes in the order listed: Note: To select the right nodes, zoom and rotate the model as needed. Right-click near the nodes to ensure that you are selecting the correct node. N325 N52 N34 N30 N10 N3 WS3-7 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) 4. Select OK. WS3-8 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Running a flexible body simulation Before you run a simulation, prepare the flexible body by reviewing modes and setting various simulation settings, such as: Turning off execution graphics to prevent Adams/View from trying to animate when it is done solving. Keep in mind that when you run Adams/View interactively, you can turn off the execution display to speed up your simulation. Make sure that you are using Adams/Solver (C++). To prepare the flexible body: 1. Briefly review the mode shapes to see the modal content that will be used in the analysis. (Modes 1 through 6 have been automatically disabled because they are rigid body modes.) 2. Verify that Inertia modeling is set to the default, Partial coupling. WS3-9 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) To prepare for simulation: 1. From the Simulate menu, select Scripted Controls. 2. From the bottom of the dialog box, select Simulation Settings. 3. Verify that Category is set to Executable. Set Executable to External. 4. Set Category to Output. Set Save Files to Yes. In the File Prefix text box, enter robot_mod4. These settings run the simulation externally. 5. To prevent Adams/View from animating while it is solving, set Category to Display. Set Update Graphics to Never. To display the textual output to the Information window, set Show Messages to Yes. 6. Select Close. WS3-10 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) To set the variable to use Adams/Solver (C++): To run Adams/Solver externally using Adams/Solver (C++), you must set an environment variable on your computer. On UNIX, do one of the following: In the Adams Toolbar, set Solver Select to C++. Set the following environment variable using the appropriate shell commands for your version of UNIX: set MDI_SOLVER_SELECT to CXX. On Windows: 1. From the Start menu, point to Settings, and then select Control Panel. 2. Double-click System. 3. Select the Advanced tab. 4. Select Environment Variables. 5. Check to see if an environment variable named MDI_SOLVER_SELECT=CXX already exists on your computer. If it already exists, then skip Step 6. 6. In the Environment Variables dialog box, create a new user variable as follows: Variable Name = MDI_SOLVER_SELECT Variable Value = CXX (for Adams/Solver (C++)) WS3-11 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) To run the simulation: 1. Run a scripted simulation using FLEX_SCRIPT. This script uses the following Adams/Solver commands: SIM/STATICS INTEGRATOR/SI2,GSTIFF, HMAX=1E-3 SIMULATE/TRANSIENT, DURATION=1.7, DTOUT=1.0E-02 The analysis will take a while. 2. When the analysis has finished, write down the CPU time displayed at the bottom of the Information window: Elapsed time = ____________ seconds. After the analysis has finished, Adams/View updates the strip chart, FOREARM_LATERAL_DEFL. WS3-12 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Inspecting the analysis results You now inspect the analysis results and compare them with the results from Workshop 2Performing a Simple Swap. To inspect the analysis results: 1. Launch Adams/PostProcessor. 2. Load the animation in the viewport and animate the simulation of the robot. 3. Select the Contour Plots tab, and verify that Contour Plot Type is set to Deformation. 4. Right-click FLEX_FOREARM, and then select Select. 5. In the Property Editor, select the Flex Props tab and set the Datum Node to 4001. 6. Create a new page and plot the measure FOREARM_LATERAL_DEFL versus time. 7. Import the .res file, robot_module3.res, created in Workshop 2 Performing a Simple Swap: From the File menu, point to Import, and then select Results File. In the File Name text box, browse for mod_03_robot/robot_module3.res. In the Model Name text box, enter .robot. 8. Select OK. WS3-13 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) 9. Create another new page (page_3) to plot the measure again. This allows you to compare results from several runs. 10. Verify that Surf is selected. 11. Plot these results onto page_3 so the curves are overlaid. Simulation: robot_module3, Last_Run Source: Result Sets Result Set: FOREARM_LATERAL_DEFL Component: Q 12. After the curves are displayed, clear the selection of Surf so the plot won't be overwritten later. WS3-14 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Investigating analysis with disabled modes Run the model again with modes disabled based on strain energy contribution. To disable modes: 1. Return to Adams/View. 2. From the Flexible Body Modify dialog box, select auto. 3. In the Analysis Name text box, enter .robot.Last_Run. 4. In the Energy Tolerance text box, enter 1e-3. 5. Select OK. 6. Select Modal ICs to see which modes have been disabled. 7. Review some of the modes that have been disabled. We suggest you review modes 16 through 21. 8. Close the Flexible Body Modify dialog box. WS3-15 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) To prepare and run the model: 1. In the Solver Settings dialog box, name the output file prefix, robot_mod4_se_disabled. 2. Perform a simulation using FLEX_SCRIPT. Again, the analysis will take a while. When it has finished, write down the run time: CPU time used = ____________ seconds. 3. Save the model to a binary file. 4. Launch Adams/PostProcessor. 5. Automatically update the plots on page_2 and page_3: From the File menu, select Replace Simulations. Select Add Simulation. Set Update Pages to All. 6. Look at the plot on page_2 and answer the questions: How has disabling the modes changed the results? ____________________________ _____________________________________________________________________ Based on the CPU times you recorded, was this analysis faster or slower than when the model had all modes enabled? ____________________________________________ _____________________________________________________________________ Consider the repercussions of overzealously disabling modes based on a single simulation. 7. Exit Adams/View. WS3-16 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) Optional tasks 1. Disable some modes that are obviously important and then run another simulation. What effect does it have on the simulation results? ________________________________________________________ ________________________________________________________ ________________________________________________________ 2. In your directory, use xdiff (or equivalent) to difference the .adm files: xdiff robot_module4.adm <completed>/robot_module3.adm. What is different? Do the differences make sense? ________________________________________________________ ________________________________________________________ ________________________________________________________ ________________________________________________________ WS3-17 ADM710, Workshop 3, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 3 PERFORMING AN ADVANCED SWAP (CONT.) 3. Difference the matrix files. Do the differences make sense? _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ 4. See if you can reduce the CPU time by finding the right combination of enabled and disabled modes. Did the results degrade significantly? _____________________________________________________ _____________________________________________________ S5-1 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation SECTION 5 OPTIMIZING MNFS AND EXPORTING LOADS S5-2 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation S5-3 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation OPTIMIZING MNFS AND EXPORTING LOADS Whats in this section: Modal Neutral Files Introducing Adams/Flex Toolkit MNF Browser Application Adams/Flex Toolkit Optimization Options Command Line Flex Toolkit Exporting FEA Loads FEMDATA S5-4 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MODAL NEUTRAL FILES Are: Binary files Platform independent Contain the following information: Generalized mass and stiffness matrices Nodal masses/inertias Nodal coordinates Inertia invariants Eigenvalues Mode shapes File comments and version information Modal loads/preloads Attachment points Element topology Units Stress/strain modes S5-5 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation INTRODUCING ADAMS/FLEX TOOLKIT Adams/Flex Toolkit is a tool that allows you to view the contents of your MNF and translate your MNF into different formats. You can access it through: Adams Toolbar (UNIX) Start menu (Windows) Adams command line It contains the following applications: MNF Browser MNF MTX Translator MSC MNF Translator MNF MNF Optimizer MNFLOAD S5-6 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNF BROWSER APPLICATION Allows you to browse the contents of an MNF or MD DB (MD only) and generate reports Useful for debugging Note: The Index textbox will become active if an MD DB has more than one flexible body. Right-click in the box to select a flexible body. S5-7 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNF MTX TRANSLATOR Translates an MNF or MD DB (MD only) into an ASCII matrix file, which Adams/Solver uses Allows you to manually generate a matrix file without having to run Adams/View Note: We will be talking about and using matrix files directly in the next section. S5-8 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNF MNF OPTIMIZER Allows you to decrease the size of your MNF or MD DB (MD only) by decreasing the amount/type of information stored in it Adams/Solver will not solve the model faster; however, animations in Adams/View will run faster Generates a new MNF or MD DB (MD only) using the options that you choose Several options are available, as shown on the Adams/Flex Toolkit Optimization Options page S5-9 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNF MNF OPTIMIZER (CONT.) S5-10 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation ADAMS/FLEX TOOLKIT OPTIMIZATION OPTIONS The following are the options in the MNF MNF Optimizer: Invariants Units Formatting Precision Stress and Strain Modes Rigid-Only MNF Automatic Manual S5-11 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation INVARIANTS Sets which inertia invariants should be computed and stored in the MNF Fast Set - Corresponds to partial coupling (5 and 9 are not computed) Full Set - Calculates and stores all invariants None - None of the invariants are stored in the MNF. Adams/Solver recalculates the invariants needed each time you write out your matrix files. Notes: The None option is not valid when you are using the automatic or manual optimizing methods. If you select Fast Set, the newly generated MNF will never be able to recover a full set of invariants. S5-12 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation UNITS Adams/View and Adams/Solver use SI units as their internal units. Original - Preserves your current units in your MNF. If your original units differ from SI, Adams/Flex will have to perform unit scaling as it performs different operations. This can degrade performance noticeably. SI - Converts your MNF into SI units. Improves performance if original units differ from SI. S5-13 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation FORMATTING Platform specific Turns off the extra coding needed to make the MNF platform independent. Can be done if the MNF will not be transferred to other platforms. Standard portable Keeps the extra code needed to make the MNF platform independent. S5-14 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation PRECISION Double This is the default option in Adams/Flex. The numerical values stored in the MNF are in double precision. Single Optionally, an MNF can be generated using single-precision. This reduces the MNF size by 50%, and speeds up any process that requires obtaining information from the MNF. For example, animation of flexible bodies and creating MTX files. S5-15 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation STRESS AND STRAIN MODES If stress (strain) recovery was requested from the finite element program when generating the MNF, the MNF contains grid point stresses (strains) for every mode. The collection of grid point stresses (strains) for a given mode is referred to as a stress (strain) mode. Typically, stress (strain) values are requested from the finite element program for a subset of nodes in the MNF. You can specify how the MNF stores stress (strain) modes, particularly for nodes where stress (strain) was not requested from the finite element program: Sparse - The optimized MNF only stores stresses (strains) for nodes that were retained in the optimized MNF and for which stress (strain) values existed in the original MNF. If a node had zero values for stresses (strains) in the original MNF, and that node was retained in the optimized MNF, the zeroes are written to the optimized MNF. S5-16 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation STRESS AND STRAIN MODES (CONT.) Full - The optimized MNF stores nodal stresses and strains for all nodes that were retained in the optimized MNF. For nodes that did not have stress (strain) values, the optimized MNF stores zeroes. Remove zero entries - The MNF only stores non-zero stresses (strains) for nodes that exist in the optimized MNF. If you have an MNF that has several zero entries in the stress (strain) modes, this option can significantly reduce the size of the MNF. S5-17 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation RIGID-ONLY MNF Depending on the component and application, the size of the MNF can be very large, can exceed several gigabytes, and be difficult to manage. If you are in the process of building your Adams/Flex body model, you may consider treating the body as rigid until you are confident in your model assembly process. If temporarily using a rigid body formulation for an Adams/Flex body makes sense, you can drastically reduce the size of the MNF by selecting Rigid-Only MNF. S5-18 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation RIGID-ONLY MNF (CONT.) Rigid-Only MNF creates a reduced MNF that only contains enough information to build a rigidized flexible body. With this MNF, you cannot build an Adams/Flex body with Constant, Partial, or Full modal formulations, but it may be convenient to work with while you are assembling and verifying your model. When you are confident in your model, you can easily replace the reduced MNF with the full MNF. S5-19 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation AUTOMATIC Removes excessive nodal detail from the MNF Note: The invariants must be stored in the MNF to use this option. Removing Internal Solid Element Geometry - Removes all internal node and element graphics for models made with solid elements Graphical performance of Adams/View is greatly enhanced Mesh Coarsening Algorithm: Mesh Resolution - Combines mesh elements that are smaller than a fraction of the total component size: S5-20 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation AUTOMATIC (CONT.) Diagonal dimension of original mesh = 1000*sqrt(2) = 1414.21 mm Mesh coarsening resolution is set to 15% = 1414.21 * .15 = 212.13 mm Therefore, any element whose diagonal is smaller than 212.13 mm is combined with its neighboring element to produce a larger element. Multiple elements are combined to satisfy this parameter. The result is a coarser mesh. For our example, 4 (100 mm * 100 mm) elements were combined to produce a larger element with a diagonal of 282.84. Original mesh Mesh coarsened 15% S5-21 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation AUTOMATIC (CONT.) Mesh Coarsening Algorithm...: Face Smoothing - Controls the angle between adjacent faces, below which Adams/Flex should merge faces: Range: 0 to 45 degrees For example: During the coarsening algorithm, adjacent elements were merged together if the resulting angle, phi, was less than 45 degrees Original face Face smoothed 45 degrees S5-22 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation AUTOMATIC (CONT.) Remove Collinear Points - Controls the removal of intermediate nodes on the straight edge of a face. Retained Node List - Specify a list of nodes that Adams/Flex should not remove during coarsening. Note: Only visible nodes can be used to place markers, joints, and so on, onto the flexible body. Therefore, make sure to include relevant nodes. Original mesh Mesh with colinear points Mesh without colinear points S5-23 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MANUAL Removes excessive nodal detail from the MNF through a user-defined sketch of the mesh Sketch File - Contains a list of surfaces, two-dimensional lines, and specific nodes to define the graphics of the .mnf. Color resolution of the flexible body animation is reduced. Open GL applies color information to each of the nodes present for the flexible body. Then, it interpolates the colors between the nodes. If your flexible body is only represented by a couple of nodes, then the color resolution will be reduced. The invariants must be stored in the MNF to use this option. Useful option when animation speed or file size is more important than the visual representation of the flexible body. Note: Only visible nodes can be used to place markers, joints, and so on, onto the flexible body. Therefore, make sure to include relevant nodes. S5-24 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation SKETCH FILE 2Number of total faces 4 1 11 121 111 4 total nodes defining the face. The face connects nodes 1, 11, 121, and 111. 1 61 1 node defining this face. The face just contains node 61. 11 1 121 111 11 1 121 111 61 61 S5-25 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation COMMAND LINE FLEX TOOLKIT adamsmdr3 -c flextk on UNIX systems or adamsmdr3 flextk on Windows systems. MNFLOAD Apply a distributed load to an MNF. MNFXFORM Translating, rotating, or mirroring an MNF or MD DB. MNFRES Recovering nodal displacement, velocity, or acceleration of a flexible body. S5-26 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNFLOAD APPLICATION Load can be applied to the flexible body using the MFORCE statement. (We will talk about the MFORCE statement in Contacts and Modal Forces.) The MNFLOAD tool can only be accessed through the command-line version of Adams/Flex Toolkit Note: A distributed load can be added to an MNF when the FEA package creates the original MNF. All FEA programs that support Adams/Flex do not support this capability. Therefore, the MNFLOAD tool was created as a workaround. Whenever possible, you should create the distributed load within the FEA package because it will include the residual vector. The MNFLOAD tool cannot calculate the residual vector; therefore, a portion of the load will not be applied to the flexible body. For more information on the residual vector see the Applied Forces section. mnfload existing.mnf new.mnf loadfile S5-27 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNFXFORM MNFs and MD DBs have data defined with respect to the FE origin. MNFXFORM translates, rotates, or mirrors the MNF or MD DB with respect to the FE origin. mnfxform <option> <input_flex_file> <output_flex_file> <parameters> [- offset d] [-id nid n1 n2 n3 ...] <option>: -t for translation, -r for rotation, or -m for mirror. <input_flex_file>: MNF or MD DB <output_flex_file>: Output MNF or MD DB <parameters>: -p px py pz Specify a point P -r rx ry rz Specify a point R -s sx sy sz Specify a point S -v vx vy vz Specify a Vector V -d dist Specify Distance dist -a angle Specify Angle (Anti-clockwise in degrees) [offset inc]: Optional argument to offset the interface node IDs by inc. New interface node id will be old id plus inc. [-id nid n1 n2 ...]: Optional argument to specify new interface node IDs. nid is the number of new IDs will be specified, n1 n2 ... are the new IDs. Example: mnfxform.exe -m input.mnf output.mnf -v 1 0 0 -p 0 0 0 -offset 1 This example mirrors input.mnf about yz plane and increase the ids of the interface nodes by 1. Then the transformed flexible body is saved as output.mnf. S5-28 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation MNFRES mnfres [options] <Adams_result_file> <input_flex_file> [options] -t <time> output results only until specified time. -n <name> specify flexible body when multiple exist. -g include rigid body motion -r also report nodal rotations. Only effective when -g is not specified -s <file> report only on nodes listed in <file> -L <unit> specify length unit used in the Adams model. Abbreviation is accepted. Default value is METER. -T <unit> specify time unit used in the Adams model. Default value is SECOND. Abbreviation is accepted. -i <key> report specific results. <key> values are: d: Nodal displacements v: Nodal velocities a: Nodal accelerations <Adams_result_file>: Adams result file. <input_flex_file>: MNF or MD DB Example: mnfres -i d -n FLEX_BODY_1 example.res foo.mnf Output all the nodal deformation of flexible body FLEX_BODY_1, whose mnf file is foo.mnf and the result file is example.res. S5-29 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation EXPORTING FEA LOADS Allows you to export Adams/View dynamic load information about any rigid or flexible body in your model to a (FEA) program The FEA program uses the load information for a variety of purposes, such as stress and strain analyses You can export load information into the following formats: ANSYS Nastran ABAQUS DAC or RPC III (requires Adams/Durability) The load files contain the following forces per node selected: Joint reaction forces External (applied forces) Gravitational forces Inertial forces S5-30 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation EXPORTING FEA LOADS (CONT.) The load file contains a series of load cases (one per output step) where the body is at an instantaneous dynamic equilibrium Gravitational + external forces + joint reactions = inertial S5-31 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation EXPORTING FEA LOADS (CONT.) Steps: 1. Run a simulation - You must run a simulation so that Adams/View can determine the loads acting on the bodies in the model. 2. Identify the body - Specify which part whose load information you would like to export: Rigid bodies - Load information is calculated relative to the marker that you select. Note: This marker's location must correspond to the origin of the body in the FEA package. Flexible bodies - Load information is calculated relative to the LBRF. 3. Identify the load points - Adams/View will automatically select all points on the body that have external loads applied to them. 4. Assign node ID's to load points - For a rigid body, you can assign node ID's to the load points that correspond to the node ID's on the part in the FEA program (optional step). 5. Specify the output times - Determine the time interval from the specified simulation that you would like included in the load file (optional step). To generate a complete loads history, leave the text box Output at times blank. For DAC and RPC III, you can enter start and end output times. S5-32 ADM710, Section 5, July 2008 Copyright 2008 MSC.Software Corporation FEMDATA You can also set up Adams/View to produce data files of component loads, deformations, stresses, or strains for input to subsequent finite-element or fatigue-life analysis for use in third-party products. Select Settings > Solver > Output > More > Durability to specify the type of file to produce. WS4-1 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS WS4-2 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WS4-3 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Problem statement Now that you have incorporated the hollowed flexible body into your model, the design team has decided that they would like you to do the following: Send a simplified version of your flexible model to a colleague Export the loads at each of your attachment points in Nastran format so that your company's FEA expert can perform a stress recovery calculation Gathering information on the current .mnf To gather information on your current files: 1. In Window's Explorer (or in a shell if you are using UNIX), find the working directory exercise_dir/mod_05_robot. 2. Write down the size of the following files: robot_arm_hard.mnf ____________________ forearm_hollow.mtx ____________________ WS4-4 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To inspect the contents of an .mnf using Adams/Flex Toolkit: Because MNF files are binary, you cannot directly view their contents. You will use Adams/Flex Toolkit to view the contents of the current MNF. 1. Start ADAMS/Flex Toolkit: On Windows, from the Start menu, point to Programs, point to MSC.Software, point to Adams, point to AFlex, and then select Adams - Flex. On UNIX, display the Adams Toolbar, and then select the Adams - Flex Toolkit icon . 2. In the MNF Browser tab, right-click the MNF Input File text box, and then select Select a File. 3. Select the file exercise_dir/mod_05_robot/robot_arm_hard.mnf. WS4-5 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 4. Verify that the following options are selected: MNF File Info: Version code Header Content Summary Units Modal Properties: Eigenvalues FEM Properties: Global Body Properties Adams Properties: Interface Nodes 5. Leave all other options at their defaults. 6. To start the MNF browser, select . The Adams/Flex MNF Browser appears. WS4-6 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 7. At the top of the window, select Content Summary. Answer the following questions: Are the nodal masses included in the MNF? Yes or No Are the generalized K and M included in the MNF? Yes or No Are the invariants included in the MNF? Yes or No Are the nodal coordinates included in the MNF? Yes or No Are the eigenvalues included? Yes or No Note: The generalized K and M matrices were not included directly in this MNF because it has already been orthonormalized. Therefore, the generalized M matrix has become an identity matrix and the generalized K matrix has become a matrix representing the eigenvalues of the flexible body. 8. Use the tabs along the top of the output window to familiarize yourself with the output (version information, units, global body properties, and so on), and then answer the following questions: What is the mass of the new flexible part? _______________ What are the interface node numbers? ___________, ___________, ___________ 9. Close the MNF Browser. WS4-7 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Optimizing the MNF This flexible body model was made with solid elements (parabolic tetrahedral elements). Therefore, you will first attempt to optimize the MNF by removing all internal solid element geometry. To optimize the MNF using the Automatic option: 1. In MNF MNF Optimizer tab, ensure that the MNF Input File is set to robot_arm_hard.mnf. (If the file is not set correctly, right-click the MNF Input File text box, and then browse for the file.) 2. Name your optimized file external_mesh.mnf, and then save it in your current working directory: Right-click the MNF Output File text box, and then browse for your current working directory, exercise_dir/mod_05_robot. After you have selected your working directory, in the File name text box, enter external_mesh.mnf. Select Save to close the browser and store the full name of the file in the MNF Output File text box. 3. In the Automatic tab, ensure that Remove Internal Solid Element Geometry is selected. 4. Ensure that the Invariants are set to Fast Set. WS4-8 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 5. Leave all other options at their defaults. Your dialog box should look like the following: WS4-9 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 6. Select the Begin Optimization tool . A window appears that contains the commands issued to perform the operation, a list of information concerning what is stored in your MNF, and the additional properties of your new optimized MNF. 7. Review the contents of the window and answer the following questions: What information was stored in your MNF? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ How many nodes were in your model? ____________________________ How many modes were in your model? ___________________________ What was the number of element faces in your model? ______________ 8. Press any key to close this window. WS4-10 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Creating a sketch file Now you will optimize the original MNF using the manual optimization method. This method involves representing the MNF as an outline of specific nodes. The graphical information for all nodes that are not specified in the sketch file is permanently removed from the optimized MNF. The outline will be a simple three-dimensional outline of the robot_arm. WS4-11 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To create a sketch file: 1. From your current working directory, open a text editor. 2. Type the following into the text editor: 8 5 3 25 4002 16 4 8 3 25 26 12 11 22 21 10 5 10 21 4003 19 9 8 9 19 20 14 13 15 16 4 4 11 12 13 14 4 3 4 9 10 2 4002 4003 1 4001 3. Save the file as my_sketch.dat in your current working directory. 4. Close the text editor. WS4-12 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Performing a manual optimization To use the sketch file to optimize the .mnf: 1. In the MNF MNF Optimizer tab, ensure that the MNF Input File is set to robot_arm_hard.mnf. (If the file is not set correctly, right-click the MNF Input File text box, and then browse for the file.) 2. Name your optimized file manual_opt.mnf and save it in your current working directory: Right-click the MNF Output File text box, and then browse for your current working directory, exercise_dir/mod_05_robot. After you have selected your working directory, in the File name text box, enter manual_opt.mnf as the file name. Select Save to close the browser and store the full name of the file in the MNF Output File text box. 3. In the Automatic tab, make sure that the Remove Internal Solid Element Geometry is not selected. 4. Select the Manual tab. WS4-13 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 5. Right-click the Apply Sketch File text box, select Select a File, and then browse for the sketch file my_sketch.dat. 6. Ensure that the Invariants are set to Fast Set. 7. Leave all other options at their defaults. 8. Select the Begin Optimization tool . 9. Review the contents of the window that appears and answer the following questions: What information was stored in your .mnf? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ How many nodes were in your model? ____________________________ How many modes were in your model? ____________________________ What was the number of element faces in your model? _______________ WS4-14 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 10. Press any key to close the window. 11. Select Quit to exit Adams/Flex Toolkit. Note: When you use the manual or automatic optimization methods you selected the invariants to be computed and stored in the MNF. Optimizing your MNF involves discarding nodal information. All of the information, however, associated with each node is needed to compute the invariants. Therefore, you must store the inertia invariant information in the MNF when you perform a manual or automatic optimization. If you try to optimize your MNF, but do not store the invariants, the optimization will be void and will not be completed. WS4-15 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Swapping in the first MNF, external_mesh.mnf During the last two workshops, you learned how to swap in two different MNFs to replace the robot arm in the rigid-body model. During the last workshop, you specifically dealt with replacing the simple robot_arm with the hollowed-out version of the robot arm. In that workshop, you had to translate/rotate the flexible body, modify the constraints, and fix nodal mismatch. To swap in the optimized versions of the .mnfs, the process is greatly simplified. The optimized version of the robot arm has the same node numbering and locations as the original MNF. The only difference is that most of the extraneous geometrical information is gone. You will use the Flex to Flex option to swap in the optimized MNFs. Note: When optimizing an MNF, ensure that the nodes that you are attaching features to (joints, forces, and so on) have not been removed from the MNF. In this model, these nodes are your attachment points. WS4-16 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To import the model: 1. Start Adams/View from the directory exercise_dir/mod_05_robot. 2. From the same directory, import the model command file robot_mod_05_start.cmd. 3. This is the model you completed in Workshop 3 - Performing an Advanced Swap. To swap in the first MNF, external_mesh.mnf: 1. From the Build menu, point to Flexible Bodies, and then select Flex to Flex. 2. Right-click the Flexible Body text box, point to Flexible_Body, point to Guesses, and then select FOREARM_HOLLOW. 3. Right-click the MNF File text box, point to Browse, and then select external_mesh.mnf. 4. Select Align Flex Body CM with CM of Current Part. 5. Select OK. WS4-17 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) WS4-18 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To run a simulation: 1. Change the Solver Settings: From the Settings menu, point to Solver, and then select Display. Set the following: Show Messages to Yes. Update Graphics to Never. Set Category to Output. Save Files to Yes. In the File Prefix text box, enter external_mesh. Set Category to Executable. Set Executable to External. Set Choice to C++. Select Close. WS4-19 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 2. Run a simulation using the script FLEX_SCRIPT. 3. When the simulation is finished, write down the CPU time displayed at the bottom of the Information window: CPU time used = __________ seconds. 4. Animate the model. 5. Do the graphics look correct? Do they look similar to the graphics from the original model? __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ WS4-20 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Swapping in the second .mnf, manual_opt.mnf To swap in the second .mnf, manual_opt.mnf: 1. Right-click the Flexible Body text box, point to Flexible_Body, point to Guesses, and then select FOREARM_HOLLOW. 2. Right-click the MNF File text box, point to Browse, and then select manual_opt. 3. Select Align Flex Body CM with CM of Current Part. 4. Select OK. WS4-21 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To run a simulation: 1. From the Settings menu, point to Solver, and then select Output. 2. In the File Prefix text box, enter manual_opt. 3. Run a simulation using the script FLEX_SCRIPT. 4. When the simulation is finished, write down the CPU time displayed at the bottom of the Information window: CPU time used = __________ seconds. 5. Animate the model. 6. Do the graphics look correct? Do they look similar to the graphics from the original model? ________________________________________________________ ________________________________________________________ ________________________________________________________ ________________________________________________________ WS4-22 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Comparing the MNFs Now that you have optimized your MNF using two different methods, and run simulations with them, you are now going to compare these two new files with the original file. To compare the MNFs: Using your answers from the sections listed below, fill in Table 1: Gathering information on the current MNF. Performing a manual optimization. Swapping in the first MNF, external_mesh.mnf WorkshopOptimizing MNFs and Exporting Loads WS4-23 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To compare the graphics of the .mnfs: 1. Create a new model: From the Build menu, point to Model, and then select New. In the dialog box that appears, select OK. 2. Import the flexible body external_mesh: From the Build menu, point to Flexible Bodies, and then select Adams/Flex. Import the flexible body external_mesh.mnf. Use default damping. 3. Using the Flexible Body Modify dialog box, animate the modes of the flexible body. 4. Do the modes look the same as the modes for the unoptimized flexible body robot_arm_hard.mnf? ________________________________________________________ ________________________________________________________ ________________________________________________________ WS4-24 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 5. Close the Flexible Body Modify dialog box. 6. Delete this flexible body from your model. 7. Using Steps 1 through 3, perform the same operations on the flexible body manual_opt.mnf. 8. Do the modes look the same as the modes for the unoptimized flexible body robot_arm_hard.mnf? ________________________________________________________ ________________________________________________________ ________________________________________________________ 9. With the information youve gathered, answer Question 1 in Module review. 10. From the Build menu, point to Model, and then select Delete. 11. Use the Database Navigator to delete MODEL_2. 12. From the View menu, select Model. WS4-25 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Exporting the FEA loads of the attachment points Now you will focus on your second task, which is to export the loads at the attachment points. You will export the loads at the times when the flexible body is undergoing large lateral deflections (times = .45, 1.3). To export the loads at the attachment points: 1. From the File menu, select Export. 2. Set the following: File Type to FEA Loads. Format to NASTRAN. In the File Name text box, enter lateral_def.lod. Set Analysis to Last_Run. Select Loads on a Flexible Body. In the Flex Body Name text box, select FOREARM_HOLLOW. Select Add Load Points to Nodes Table. This transfers the node IDs for the locations where loads were applied to the flexible body. For this model, these are your attachment points. Set Output at times to .45, 1.3 with a +/- tolerance of .015. WS4-26 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) The dialog box should look like the following: 3. Select OK. 4. In the Question dialog box that appears, select Continue. WS4-27 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) To examine the loads on the flexible body: 1. In a text editor, open the file lateral_def.lod, which should be located in your working directory. 2. Look for the following items: 6 SUBCASE statements in the CASE CONTROL DECK - Each of these subcase statements corresponds to a time step in the model. 6 LOAD CASE statements in the BULK DATA DECK - Each of these load cases is associated with a subcase statement. Each load case consists of a gravity load (GRAV), a force and moment applied at each of the specified nodes in your model (FORCE and MOMENT), and sometimes an inertial force (RFORCE). The directions of these loads are with respect to the LBRF. WS4-28 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) For example: $ $ LOAD CASE = 2 $ GRAV,10004,,-1.0,-1.40346e+004,3.86003e+004,1.23043e+004 RFORCE,10005,,,-1.0,-7.31611e-004,1.07812e-001,1.88179e-001,2 RFORCE,10006,,,0.0,-4.33138e-001,3.74316e+000,7.02479e+000,2,+RF10006 +RF10006,-1.0 FORCE,10005,4001,,1.0,5.27564e+006,5.63896e+006,2.12884e+006 MOMENT,10006,4001,,1.0,-1.70519e+009,1.97445e+008,4.68934e+009 FORCE,10005,4002,,1.0,-1.58588e+006,-1.61227e+007,1.85232e+006 MOMENT,10006,4002,,1.0,4.75092e+008,3.06770e+007,2.22593e+008 FORCE,10005,4003,,1.0,-1.65535e+006,1.40517e+007,-2.99013e+006 MOMENT,10006,4003,,1.0,-1.37822e+005,-2.86234e+006,2.11043e+008 LOAD,2,1.0,1.0,10004,1.0,10005,1.0,10006 $ WS4-29 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) This file is now ready to be added to the original Nastran data deck. Running this model in Nastran with these forces applied allows you to perform stress recovery calculations at the times when the flex body lateral deformations were at their peaks. 3. Exit Adams/View. 4. If time permits and Nastran and/or Adams/Durability is available, continue with the next section. WS4-30 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Optional tasks Running a Nastran analysis using your FEA loads: If Nastran is available, follow these steps to incorporate your FEA loads with your data deck and perform a stress recovery analysis in Nastran. 1. Copy your file lateral_def.lod into the directory /completed/optional. 2. Open the file lateral_def.lod in a text editor. After the line "$ B U L K D A T A D E C K E C H O" add the following command: OUTPUT(POST) SET 100 = 4001,4002,4003,150,246,1223,464,417 DISP=100 SET 200 = 26,51,58,133,868 VOLUME 400 SET 200 BEGIN BULK Save the file and close the text editor. 3. Run the file lateral_def.dat in Nastran. WS4-31 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) 4. To view the stresses, open the file lateral_def.f06 in a text editor and scroll down to the end. You should see the following: All of the reaction forces should be negligible compared to your loads applied to the model at each time step. For example, if your applied loads are in the range of 106, then negligible reaction forces should be less than about 104. For example, for Load Case 2, the applied forces are in the range of 106 and the applied moments are in the range of 109. We see from the following table, that the largest reaction force is in the range of 104, therefore the reaction forces are less than 1% of the applied forces. Here is part of the table for Load Case 2: F O R C E S O F S I N G L E - P O I N T C O N S T R A I N T POINT ID. TYPE T1 T2 T3 R1 R2 R3 150 G 2.863195E+03 -6.973841E+04 0.0 0.0 0.0 0.0 246 G 0.0 0.0 -2.947010E+030.0 0.0 0.0 1223 G -5.078449E+03 6.746709E+04 3.213485E+03 0.0 0.0 0.0 ROBOT ARM STRESS RECOVERY USING FEA LOAD EXPORT ADAMS SIMULATION TIME = 4.50000E-001 SUBCASE 2 WS4-32 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Note: A solid element node one has three translational degrees of freedom. Therefore, the rotational forces should all be 0 for this model since the model is defined by solid elements. Compare the values of the stresses for each time step for the grid points listed. Do they agree with the physical model? Adams/Durability indicates that the largest Von Mises stress occurs at time .880 seconds at the node 464. Generate a new load file for this time step and confirm that the stress at this grid point is ~7.09E4 kPa. WS4-33 ADM710, Workshop 4, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 4 OPTIMIZING MNFS AND EXPORTING LOADS (CONT.) Performing stress recovery in Adams/View: Swap in the flexible body robot_stress.mnf found in the directory /completed/optional. The .mnf has stress information stored in it. Run a simulation and use Adams/Durability to view the stresses in your model. Module review Which of the three MNFs (robot_arm_hard.mnf, external_mesh.mnf, or manual_opt.mnf) would you prefer to send to your vendor? ________________________________________________ Why?___________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ S6-1 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation SECTION 6 USING FLEXIBLE BODY STATEMENTS S6-2 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation S6-3 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation USING FLEXIBLE BODY STATEMENTS Whats in this module: Data Transfer Statements Used Matrix Files S6-4 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation DATA TRANSFER S6-5 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation STATEMENTS USED Statements: FLEX_BODY - Describes a flexible body and associates it with matrix elements. MARKER - Defined at any nodal locations where you want to attach modeling elements, measure deformations, and more. MATRIX - Correspond to the matrices contained within the matrix file. For syntax and extended definitions, see the Adams/Flex and the Adams/Solver (C++) online help. S6-6 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation MATRIX FILES Matrix files Save modal information corresponding to any node that has a marker on it. Used by Adams/Solver to describe the properties of a flexible body. Structure The matrix file for a flexible body contains matrices (currently between 12 and 17), which list the selected modes, selected nodes, and invariants. See the sample in the Adams/Flex online help. S6-7 ADM710, Section 6, July 2008 Copyright 2008 MSC.Software Corporation MATRIX FILES (CONT.) Generating from MNF file To manually generate a matrix file, use the MNF2MTX translator in Adams/Flex Toolkit. The matrix file is in ADAMSMAT format, and you should only create it using the translator. Note that when using Adams/View, it automatically translates the MNF for you (done transparently in workshops 1 through 3). WS5-1 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER WS5-2 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WS5-3 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER Problem statement The FEA group created a new representation of the flexible body modal neutral file (MNF) that also happens to have a different node-numbering scheme. Since your colleague has checked out your Adams/View license and you have a deadline, you must hand-edit the necessary files and perform a stand-alone Adams/Solver simulation. Mechanism information This model is the flexible robot model you completed in Workshop 2Performing a Simple Swap. The FOREARM is modeled as flexible (robot_arm_easy.mnf), and you must replace it with a different flexible body (robot_arm.mnf). WS5-4 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Inspecting the MNF Inspect the new MNF to find its node-numbering scheme. To inspect the MNF: 1. From the directory, exercise_dir/mod_06_robot, start Adams - Flex Toolkit. 2. In MNF Browser, right-click the MNF Input File text box, and then browse for robot_arm.mnf. 3. Select . 4. Look in the output window for the node numbers of the attachment points: _________, _________. 5. Write down the units: ________, ________, ________, ________. 6. Exit Adams/Flex Toolkit. WS5-5 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Inspecting the Adams/Solver dataset Inspect the Adams/Solver dataset to familiarize yourself with its organization. To inspect the dataset: 1. In a text editor, open the file robot_module3.adm. 2. Save it with a new name, robot_module6.adm. 3. Review the contents of the dataset and find the following statements and character strings: FLEX_BODY statement - What is the Adams ID for the current flexible body? _____. UNITS statement - Write the units: _______, _______, _______, _______. String NODE_ID - List statement(s) where this argument is used ________________. String FILE - List statement(s) where this argument is used ____________________. Do the units agree with the previous page? ______ Yes ______ No. WS5-6 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Modifying the dataset Update the model to incorporate the new representation of the flexible body. To modify the dataset: 1. Change the FLEX_BODY id to 2. 2. Change the MNF_FILE reference to robot_arm.mnf. 3. Use an exclamation mark to comment out the 12 MATRIX statements from the DATA STRUCTURES section, as shown next: !MATRIX/1 !, FILE = robot_module3_flex_forearm.mtx !, NAME = GENSTIFF ... 4. Save the file. WS5-7 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Running an interactive simulation To run an interactive simulation: 1. Do one of the following: For Windows: From the Start menu, select Run and open a command window by typing in cmd. Change directories to your working directory, exercise_dir/mod_06_robot. WS5-8 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) To select Adams/Solver (C++), type set MDI_SOLVER_SELECT = CXX. Run an interactive simulation with stand-alone Adams/Solver (note that within the string, adamsxx, xx indicates the version number): adamsxx ru-s n Note: The n means that you are not using an .acf. For UNIX: Open a UNIX shell and change directories to your working directory, exercise_dir/mod_06_robot. Using the appropriate shell commands for your version of UNIX, set the MDI_SOLVER_SELECT environment variable to CXX. For example, for a C shell, use setenv MDI_SOLVER_SELECT CXX Use the command: adamsxx -c ru-s -n WS5-9 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 2. At the prompt, enter the Adams model file name, FILE/MODEL = robot_module6.adm, and then press Enter. 3. Notice the two types of errors, MATRIX ID and FLEX_BODY ID: .... ERROR: The MATRIX referenced by id number does not exist. ERROR: Value : 1 ERROR: Value number : 1 ERROR: Argument : MATRICES ERROR: Statement : FLEX_BODY/2 ERROR: Line number : 327 ERROR: The FLEX_BODY referenced by id number does not exist. ERROR: Value : 1 ERROR: Argument : FLEX_BODY ERROR: Statement : MARKER/13 ERROR: Line number : 334 .... WS5-10 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) These errors indicate that merely changing the FLEX_BODY ID and deleting the MATRIX statements is not enough. There are other dependencies you will have to address. Unlike Adams/View, Adams/Solver will not automatically generate the matrix files (MTX) for the flexible body from the MNF file you referenced. Instead, you will have to run the mnf2mtx translator by hand, which you will do in the next section. 4. To stop Adams/Solver, type Stop. Note: Leave this window open, because you will use it again later. WS5-11 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Generating the matrix file Use the mnf2mtx translator, from Adams/Flex Toolkit, to create a new MTX file representing the new flexible body. Create the MTX file with these parameters: Include nodes _________ and _________ (see Step 4). Exclude the rigid-body modes (1-6). Set the units to match the .adm file (see Step 3). Select the option for fast translate (Fast Invar). WS5-12 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) To generate the MTX file: 1. From the directory, exercise_dir/mod_06_robot, start Adams - Flex Toolkit. 2. Select the MNFMTX Translator tab. 3. Right-click the MNF Input File text box, and then browse for: exercise_dir/mod_06_robot/ robot_arm.mnf. 4. Right-click the Matrix Output File text box, and then browse for the MTX file located in exercise_dir/mod_06_robot. 5. Change the name of the MTX file to be robot_module6.mtx. Note: You browse for the existing MTX file to ensure that the path is correct. You then rename the mtx file to create a new one. 6. Change the default units as follows: Length: MILLIMETER Force: MILLINEWTON 7. Change the modes/nodes as follows: Node ID List: make sure Include is selected, and then, in the text box, enter 2000 3000 Mode Number List: first select Exclude and then, in the text box, enter 1 2 3 4 5 6 WS5-13 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 8. Make sure that Fast Invar is selected. 9. Select the Begin Translation tool . 10. Follow the prompts and when the translation is done, exit Adams/Flex Toolkit. 11. In a text editor, review the robot_module6.mtx file to see if it makes sense. Are the units the same as in the .adm file? Are the correct nodes and modes included? Do the node locations match the locations of the markers that reference them (see QPs in dataset)? ________________________________________________________ ________________________________________________________ ________________________________________________________ ________________________________________________________ WS5-14 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Adding matrix statements to the dataset To add matrix statements: 1. In a text editor, open data_structures.txt from the working directory. 2. Copy the 14 MATRIX statements and paste them into robot_module6.adm within the DATA STRUCTURES section: !------------------------------------- DATA STRUCTURES -------------------------------------! MATRIX/1, FILE = myfile.mtx, NAME = GENSTIFF MATRIX/2, FILE = myfile.mtx, NAME = INVAR1 --etc.--- Note: If the data_structures.txt file is not available, you can obtain this data structure by searching for example dataset in the Adams/Flex online help. WS5-15 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 3. Search and replace the string myfile.mtx with robot_module6.mtx. 4. Save the file. 5. Run another simulation (as you did earlier in the workshop) and notice the errors: ERROR: The FLEX_BODY referenced by id number does not exist. ERROR: Value : 1 ERROR: Argument : FLEX_BODY ERROR: Statement : MARKER/13 ERROR: Line number : 334 .... This error indicates that the code cant find a FLEX_BODY in the model that has an ID of 1. This is because in Step 1 you had assigned the FLEX_BODY an ID of 2 and there are markers that depend on the flexible body ID. Therefore, you need to update MARKER/13 (and others) to reference the correct FLEX_BODY ID. WS5-16 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Updating FLEX_BODY ID references Change the FLEX_BODY ID for all the markers that reference it. To update flexible body ID references: 1. In a text editor, search for MARKER/13 (or, if your text editor allows, go directly to line 334). 2. On the marker statement, modify FLEX_BODY argument to be 2 instead of 1. This will fix the first error. 3. To fix the other errors, make a global change to update all FLEX_BODY = <id number>. 4. Save changes and run another simulation. 5. Notice the warnings and the error: WARNING: Matrix 'INVAR5' not found in file 'robot_module6.mtx'. WARNING: Matrix 'INVAR9' not found in file 'robot_module6.mtx'. ERROR: The node ID on MARKER .model.FLEX_FOREARM.MK13 is not one of the nodes selected on its parent FLEX_BODY. ---- START: ERROR ---- Attempt to read in model into AMD was unsuccessful WS5-17 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Investigating the warnings and error To investigate: 1. Think through the following: Can you explain the two warnings? ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Were the warnings there before? ___ Yes ___ No Can you find either INVAR5 or INVAR9 in the .mtx file? ___ Yes ___ No 2. Think back through the changes you made: How many matrices did you paste into the robot_module6.adm? ______ Is that number equal to the number of matrices declared in the MATRICES argument of FLEX_BODY/2? Yes ____ No ____, there are _________ matrices listed. Which particular matrices are missing? _______________, _______________ WS5-18 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Making final changes to the dataset To make final changes: 1. Comment out the MATRIX/6 and MATRIX/10 lines, as shown next: !MATRIX/6 ... ... !MATRIX/10 ... 2. Update the MATRICES argument by appending 13 and 14, and removing 6 and 10. MATRICES = 1, 2, 3, 4, 5, 7, 8, 9, 11, 12, 13, 14 3. Change NODE_IDs for MARKER/14 and MARKER/11012 to _______, which is the first node number you listed in Step 4 under Inspecting the MNF. 4. Save the changes that you made to the file robot_module6.adm. WS5-19 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Creating and running an ACF Create an Adams command file (ACF) that issues simulation commands for stand-alone Adams/Solver, and then simulate using the command line. To create and run an ACF: 1. Using a text editor, write an ACF for the simulation, named robot_module6.acf: robot_module6.adm robot_module6 SIMULATE/STATICS INTEGRATOR/SI2,GSTIFF, HMAX=1E-3 SIMULATE/TRANSIENT, DURATION=1.7, DTOUT=1.0E-02 STOP 2. Simulate using the ACF file: On Windows, use the command: adamsxx ru-s robot_module6.acf exit Note: exit is optional. On UNIX use the command: adamsxx -c ru-s i robot_module6.acf exit 3. The model solves successfully. WS5-20 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Importing analysis results Because your colleague still has your Adams/View license, use stand-alone Adams/PostProcessor for post processing your analysis results. You import the results from Workshop 2 Performing a Simple Swap and compare them with the results of the simulation you just performed. To import results: 1. From the command line, start stand-alone Adams/PostProcessor in your working directory: On Windows, use the command: adamsxx appt On UNIX, use the command: adamsxx -c appt WS5-21 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 2. From the File menu, point to Import, and then select Solver Dataset. 3. In the File to Read text box, browse for robot_module6.adm. 4. In the Model to Create text box, enter robot_module6. 5. Select OK. 6. Ignore any warnings. 7. From the File menu, point to Import, and then select Analysis Files. 8. In the File Name text box, browse for robot_module6.res. 9. In the Model Name text box, browse for robot_module6. 10. Select Apply. 11. In the File Name text box, browse for robot_module3.res. Tip: The file robot_module3.res is not in your current directory. You will have to browse back to find the file in the directory mod_03_robot. 12. Select OK. If Adams/View displays an alert dialog box, dismiss it by selecting OK. WS5-22 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Inspecting results You compare measure results from two analyses, import shells to visualize the model, and then modify the visual representation parameters of the flexible body. To inspect results: 1. Change the pull-down menu at the top of Adams/PostProcessor to Plotting. 2. Simultaneously plot the FOREARM_LATERAL_DEFL measure for each run: Simulation list: robot_module6 and robot_module3 Results set: FOREARM_LATERAL_DEFL Component: Q Can you describe the differences in a general sense? ________________________________________________________ ________________________________________________________ ________________________________________________________ WS5-23 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 3. Choose the vertical 2-view layout. 4. Right-click in the right-hand viewport, select Load Animation, and then select robot_module6. 5. Animate the model at different viewing angles. Do you know why certain geometries are missing? ________________________________________________________ ________________________________________________________ 6. From the File menu, point to Import, and then select Shell. 7. Import the file with the following specifications: File Name: cad/base.shl Shell Name: .robot_module6.base.base_shell Reference Marker: .robot_module6.BASE.Origin Verify that Wireframe Only is not selected. 8. Select OK. Now you can see the base shell geometry. Note: If the screen hasn't updated with base shell graphics: Right-click the viewport on the right, and then select Clear View. Right-click the viewport again, and then select Load Animation. WS5-24 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) 9. Import the rest of the shells using the command file, mod_06_robot/misc/load_shells.cmd. To modify the visual representation of the flexible body: 1. From the View menu, select Command Window. 2. In the command window, enter: part modify flex visual flexible=.robot_module6.FLEX_FOREARM datum=2000 3. Right-click FLEX_FOREARM, and then select Select. 4. In the Property Editor, under the Flex Props tab, set Plot Type to Contour. 5. Set Scale to 500. 6. In the Contour Plots tab, change Contour Plot Type to Deformation. To view the animation and finish up: 1. Animate the model, and then save it. 2. Exit Adams/PostProcessor. WS5-25 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Optional tasks 1. Perform an FFT analysis on the measure that you plotted. Examine the results. Notice that the frequency at the dwell point wasnt captured. Modify the .acf script so the DTOUT = 1.0E-03. Replot and perform another FFT analysis on that signal. What is the frequency of the vibration at the first dwell point? _______________________________. Tip: Try hanning window of .3-.4 seconds. 2. Create a measure or request between two markers on the flexible body. Run a simulation and plot the results. WS5-26 ADM710, Workshop 5, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 5 USING EXTERNAL ADAMS/SOLVER (CONT.) Module review Would it have been easier to work through this workshop using Adams/View? ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ List some advantages to using external Adams/Solver. ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ S7-1 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation SECTION 7 CONTACTS AND MODAL FORCES S7-2 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation S7-3 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation CONTACTS AND MODAL FORCES Whats in this section: Contact with Flexible Bodies Modal Applied Force and Preloaded Flexible Bodies S7-4 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation CONTACT WITH FLEXIBLE BODIES Adams 2005r2 began supporting points on flexible bodies Point to plane Point to curve The point can exist on the flexible body, but the plane or curve cannot. Adams/Solver (C++) supports several points defined in a contact. Adams/Solver (FORTAN) supports only one point in a contact. For other contact pairs, you must use your own modeling tricks or the built-in contact primitives. Use dummy parts and the Adams/View built-in contact pairs: Curve to plane Curve to curve (for example, circle to circle) Sphere to plane (see Creating the contact forces) Solid to solid Note: Spheres will solve faster than other solids. Write your own user-written forces. Dont forget that the flexible body must be the action body. S7-5 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation CONTACT WITH FLEXIBLE BODIES (CONT.) Flexible body contact using modal formulation (C++ Solver only) Flex body to solid (flex body must be the action body) Flex body to flex body Setup just like rigid body contact Main Toolbox > Force Pallette > Contact The Contact Create dialog will show the Flex Body to Solid and Flex Body to Flex Body options. Geometry used for contact detection is extracted from the mnf. Additional Limitations Only solid elements, no shell elements No lists of flexible bodies or geometry (JGEOM) Restitution method not supported, use IMPACT method instead Parasolid contact library only, no support for the RAPID geometry library S7-6 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation MODAL APPLIED FORCE AND PRELOADED FLEXIBLE BODIES In Adams/Flex you can accept exported finite element load cases as part of your flexible body definition and optionally apply them in Adams using the MFORCE element Possibilities: Easily define distributed loads using FEM facilities and efficiently apply them in Adams Combine multiple load cases, scaling them with functions of time and response Thermal loads Flutter analysis S7-7 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation MODAL APPLIED FORCE AND PRELOADED FLEXIBLE BODIES (CONT.) Adams/PostProcessor features: When you define MFORCEs for your flexible bodies, you can display the force magnitudes in Adams/PostProcessor The force magnitudes are displayed in Cartesian coordinates Color contour and vector plots: Let you determine the scale of the MFORCEs Allow you to verify that the MFORCE is set up correctly Help you in debugging your models Note: These options must be selected for each flexible body in either the Modify Flexible Body dialog box in Adams/View or in the property editor in Adams/PostProcessor. Modal forces of the various modes are denoted by FQ. The sum of FQ on all the modes equals the applied force. S7-8 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation MODAL APPLIED FORCE AND PRELOADED FLEXIBLE BODIES (CONT.) Additionally, Adams/Flex lets you define preloaded flexible bodies Possibilities: Simplify modeling by defining flexible bodies that have a natural deformed shape. Example: assemble valve springs or other assemblies. Account for stress stiffening, for example in spinning systems or taut strings. Linearize non-linear finite element models about a deformed state. Example: finite element tire models. Notes: A preload cannot contain a global resultant force. No body should have a tendency to accelerate itself. A preloaded flexible body pushes or pulls on its surroundings and recoils unless the preload is maintained. S7-9 ADM710, Section 7, July 2008 Copyright 2008 MSC.Software Corporation MODAL APPLIED FORCE AND PRELOADED FLEXIBLE BODIES (CONT.) Availability Currently not all FEA programs that support Adams/Flex have added support for modal loads and preloads. The following table lists the FEA vendors and available MNF functionality. For the most current version of this chart, see Knowledge Base article 9474 at: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB9474. Workaround: Add applied loads and preloads to existing mnf files using the MNFLOAD tool in Adams/Flex Toolkit. WS6-1 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE WS6-2 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WS6-3 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE Problem statement For the following manufacturing material transfer device, determine if a maximum vacuum force of 1/2 atmosphere is adequate to move the flexible sheet. Mechanism information The model represents a material transfer mechanism, as shown in Figure 5: VACUUM FLEX_SHEET TABLE Sphere (dummy part) Figure 5. Material Transfer Mechanism WS6-4 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Setting up the model Import the model, set its viewing attributes, and then simulate it. To set up the model: 1. Run Adams/View from the directory, exercise_dir/mod_07_contact. 2. From the same directory, import the model command file, mod_07_start.cmd. 3. Set the view mode to isometric. 4. Set the render mode to shaded. 5. Run a scripted simulation using SIM_SCRIPT_1. 6. To better understand the mechanism, animate from different viewpoints. WS6-5 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Importing the flexible body Import the flexible body and set its color to blue. To import the flexible body: 1. Create a flexible body (Build Flexible Bodies Adams/Flex): Flexible Body Name: FLEX_SHEET Modal Neutral File Name: sheet_load.mnf Use default damping 2. Select OK. 3. Select FLEX_SHEET. 4. From the Main Toolbox, from the Color tool stack, select the tool for the color blue . 5. Clear the selection of FLEX_SHEET. WS6-6 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Connecting the flexible body The spheres act as dummy parts and are attached to ground with fixed joints. Attach the spheres to the flexible body by modifying the joints. Later you will use the spheres to create sphere-to-plane contact forces. After you connect the flexible body, perform a static equilibrium simulation. To connect the flexible body: 1. To see the fixed joints, turn on the icons. Adams/View displays the icons as shown next: WS6-7 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 2. Modify the five fixed joints (named using the convention FX_JOINT_#) so the First Body is always the FLEX_SHEET. To perform a static equilibrium simulation: 1. From the Main Toolbox, select the Simulate tool , and then select the Static Equilibrium tool . WS6-8 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Creating the vacuum force Create a parabolic vacuum distribution using a modal force. This modal force forms a negative pressure causing lift on FLEX_SHEET. To create the vacuum force: 1. From the Main Toolbox, from the Create Forces tool stack, select the Modal Force tool . 2. Create the modal force as follows: Force Name: .model_1.MFORCE_1 Flexible Body: .model_1.FLEX_SHEET Reaction Part: .model_1.VACUUM Define Using: Function Load Case: parabolic one atu overpressure Scale Function: -STEP5(TIME, T1-0.1, 0.0, T1+DW1-0.1, 0.5) +STEP5(TIME, 1.55, 0.0, 1.60, 0.5) WS6-9 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 3. Select OK. Adams/View displays the icon for the modal force: Modal Force Icon WS6-10 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Changing render mode of VACUUM To be able to see the contact planes, and to see the deformation of FLEX_SHEET, make the VACUUM extrusion visible as wireframe geometry. To make VACUUM wireframe: 1. Right-click VACUUM, and then select Appearance. 2. Set Render to Wireframe. 3. Select OK. Now youll have an unobstructed view of the flexible sheet when the model is rendered shaded. WS6-11 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Creating the contact forces Create sphere-to-plane contact forces between the ellipsoids attached at the corners of the FLEX_SHEET and the VACUUM surface planes. These forces prevent the FLEX_SHEET from passing through the VACUUM block as it is lifted. To transport the FLEX_SHEET, you need to enable coulomb friction forces. The arrows in Figure 6 show the pairing of the contact forces between the right and the left sides. WS6-12 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Notice that the surfaces, denoted by the markers, are inclined at 45 angles, as a self-centering feature of the vacuum design. PLANE_0 PLANE_1 ELLIPSOID_4 ELLIPSOID_3 ELLIPSOID_2 ELLIPSOID_1 Figure 6. Contact Forces WS6-13 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) To create the contact forces: 1. From the Create Forces tool stack, select the Contact Force tool . 2. Create the sphere-to-plane contact forces as follows: Tip: Select the appropriate plane markers, as shown in Figure 6. Contact Name: .model_1.Contact_1 Contact Type: Sphere to Plane Sphere: .model_1.PART_5.ELLIPSOID_1 Plane: .model_1.VACUUM.PLANE_1 Force Display: on Normal Force: Impact Stiffness: (1.0E+04(newton/mm)) Force Exponent: 1.5 Damping: (100.0(newton-sec/mm)) Penetration Depth: (0.1mm) Friction Force: Coulomb Coulomb Friction: On Static Coefficient: 0.6 Dynamic Coefficient: 0.5 Stiction Transition Vel.: (100(mm/sec)) Friction Transition Vel.: (200(mm/sec)) WS6-14 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 3. Select OK. You have created contact for one corner of the flexible sheet. Now you must create similar contacts for the remaining three corners. It is easiest to create the others by copying the one you've just created and modifying the sphere and plane. You will use a method of copy- rename-modify so that the same contact impact and friction parameters are used without your having to re-type them every time. 4. Select .model_1.CONTACT_1, and from the Edit menu, select Copy. 5. From the Edit menu, select Rename. 6. Change the name of the copy to .model_1.CONTACT_2. WS6-15 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 7. Modify .model_1.CONTACT_2 and change its sphere from ELLIPSOID_1 to ELLIPSOID_2. 8. Repeat Steps 4 through 7 to create the other two contacts, as shown next: Why do you think there is no contact at the center (ELLIPSOID_5)? ________________________________________________________ ________________________________________________________ ________________________________________________________ ________________________________________________________ WS6-16 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Simulating the flexible body when rigid The sphere radii were artificially enlarged so you could easily select them when creating the forces. Before you run another scripted simulation, reduce the sphere radii to make the model more realistic. To reduce the sphere radii: 1. From the Build menu, point to Design Variable, and then select Modify. 2. Double-click sphere_rad1. 3. In the Standard Value text box, enter (5mm). 4. Select OK. Because the spheres are parameterized, Adams/View reduces the radii of all the spheres. WS6-17 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) WS6-18 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) To simulate: 1. Make the FLEX_SHEET rigid by setting Inertia modeling to Rigid body. 2. Before simulating, save the model in its current configuration: From the File menu, select Save Database As. Save the database as rigid_model. 3. From the Simulate menu, point to Scripted Controls, and then browse for .model_1.RIGID_SCRIPT. The script uses the following Adams/Solver commands: SIMULATE/STATIC SIMULATE/TRANSIENT, END=1.61, DTOUT=1.0E-02 MARKER/555,QP = -1675, -1290, 2200 SIMULATE/TRANSIENT, END=2.6, DTOUT=1.0E-02 The MARKER command instantaneously repositions a plane marker for contact with the table that the sheet is being dropped on. 4. In your Adams/Solver setting, change your Solver Executable to use Adams/Solver (FORTRAN). 5. Run the simulation. WS6-19 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Adams/Solver may issue a warning indicating that it has had difficulty solving portions of the simulation. For example: WARNING: The symbolic refactorization failed. The matrix is structurally singular at time = 1.6101. WARNING: The corrector has not converged after 3 attempts. No. of iterations = 10. Investigate what modeling decisions could possibly be causing trouble for Adams/Solver. You may have seen similar warning in your own models. Based on your experiences can you suggest alternate modeling choices that would minimize this problem? ________________________________________________________ ________________________________________________________ ________________________________________________________ 6. Save the simulation results as rigid. WS6-20 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 7. Perform a looped animation and select the best answer. When the sheet falls on the TABLE, it: _____ Bounces high _____ Bounces a little _____ Doesnt bounce at all Running a flexible body simulation Before you run another simulation, make the FLEX_SHEET flexible, turn deformation on, and disable unnecessary modes. To prepare the flexible body: 1. Set Inertia modeling to Partial coupling and set Plot Type to Contour. 2. Disable the following modes: 8, 15, 19, 24, 27-28, 33-35, 40-48. To run the simulation: 1. From the Simulate menu, point to Simulation Script, and then select Import ACF. 2. Name the script SIM_SCRIPT_2. WS6-21 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 3. Import the ADAMS/Solver commands from script_commands.acf: SIMULATE/STATIC SIMULATE/TRANSIENT, END=1.61, DTOUT=1.0E-02 MARKER/555,QP = -1675, -1290, 2200 INTE/GSTIFF,ERR=1E-3,ADAPT=1.0e-05, HINIT=1.0E-06,HMAX=1e-3 SIMULATE/TRANSIENT, END=2.6, DTOUT=1.0E-02 The MARKER command instantaneously repositions a plane marker for contact with the table that the sheet is being dropped on. 4. Run another simulation using SIM_SCRIPT_2. You can ignore the convergence warnings that Adams/Solver issues. Was the parabolic vacuum force strong enough to transfer the FLEX_SHEET to the TABLE? _______ Yes _______ No. WS6-22 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) 5. After the simulation has completed, rename the analysis. By doing this, you can save disk space because you are not retaining a duplicate copy of the analysis (for example, when you save, not only do you have the saved copy, but you also have Last_Run). From the Edit menu, select Select List, and then select Clear All. From the Edit menu, select Rename. Select .model_1.Last_Run with a single click. Select OK. Rename the analysis Last_Run to flexible. 6. Save the database as flexible_model. WS6-23 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Comparing simulation results In Adams/PostProcessor, perform two animations using different contour options. Notice how the sheet deforms as it is being lifted and how much it bounces when it is dropped. To view the MFORCE: 1. Launch Adams/PostProcessor. 2. In the upper left corner, change the pull-down menu to Animation. 3. In the dashboard, under the Animation tab, select Include Contacts. 4. In the viewport, load the animation flexible. 5. Select the Contour Plots tab. 6. Set Contour Plot Type to MFORCE FMAG. 7. Make sure that Display Legend is selected. 8. Animate the model. A parabolic vacuum distribution defines the MFORCE. Turning the contour plot on, allows you to view the MFORCE and ensure that it was defined correctly. WS6-24 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) To compare results: 1. Reset the model. 2. Set Contour Plot Type to Deformation. 3. Zoom in on the flexible sheet such that it is centered on the screen. 4. Select the Camera tab. 5. Right-click the Follow Object text box, select Marker, and then browse for the marker FLEX_SHEET.INT_NODE_1. 6. Select the Play tool. 7. Now compare the behavior of the sheets, rigid versus flexible. See Step 7 and select the best answer (you may have to animate the flexible sheet again): When the flexible sheet falls on the TABLE, it rebounds: _____ Less than the rigid sheet _____ Same as the rigid sheet _____ Higher than the rigid sheet 8. If you chose the last option, can you explain why it rebounds that way? ________________________________________________________ ________________________________________________________ WS6-25 ADM710, Workshop 6, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 6 USING CONTACTS AND MODAL FORCE (CONT.) Optional tasks 1. Plot the modal force results components. 2. Try different pressure distributions or use a smaller magnitude (0.1 atm). Does the sheet come loose? ________________________________________________ 3. Try to limit the spring-back effect by adding contact at the center sphere, between the sheet and the vacuum. S8-1 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation SECTION 8 STRESS RECOVERY WITH ADAMS/DURABILITY S8-2 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation S8-3 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation STRESS RECOVERY WITH ADAMS/DURABILITY Whats in this section: Introduction to Adams/Durability Theory of Modal Stress Recovery MSR Nastran Example Improving Graphics Performance in Adams/PostProcessor Using the Hot Spots Table S8-4 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation INTRODUCTION TO ADAMS/DURABILITY With Adams/Durability, you can recover stresses on flexible or rigid bodies. Recovering stresses on flexible bodies is called Modal Stress Recovery (MSR). Adams/Durability lets you easily interface with: FEA programs for stress recovery Durability test machines or experimental data using the RPC III file format Fatigue life calculation programs using DAC file format Adams/Durability benefits: Shortens your development cycle, reducing costly durability testing. Provides access to the system-level simulation capabilities of ADAMS/View, or vertical products, such as Adams/Aircraft, Adams/Car, Adams/Engine, and Adams/Rail. Provides access to dynamic stress recovery methods using Nastran or ANSYS. Performs modal stress recovery of flexible bodies. Provides access to component life prediction using Fatigue or FE-Fatigue. Note: Adams/Aircraft and Adams/Rail are now products of VI-grade. S8-5 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY Adams uses a modal synthesis method to calculate the flexibility effect of complex machine members. This method drastically reduces the total number of DOFs of an FE component, while preserving its local deformations with high level of accuracy. Flexible structural component motion with N DOF and defined boundaries is described by a combination of P normal modes (normal constrained modes) and S constraint modes (static correction modes). Flexible body motion equation with I internal DOFs and B boundary ones (equal to S) becomes: S8-6 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY From a static equilibrium analysis, assuming that interior forces are set to zero, equation above becomes: After extraction of the constraint modes matrix and the normal modes matrix, physical coordinates are calculated as a linear combination of the mode shapes. S8-7 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY where: {x} is the vector of physical displacements {q} is the vector of modal coordinates []=[{}1,...,{}P+S] is the modal matrix that includes both P normal and S constraint modes An ortho-normalization of the reduced system is performed while translating from each FE output file into the Adams modal neutral file (MNF). The effect is to obtain a diagonal model and to associate frequency content to the static correction modes as well. Adams assembles and solves fully inertial coupled equations of motion of the mechanical system including the flexible part(s). It also adds the generalized modal coordinates as unknowns. S8-8 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY Adams/Solver manages the full set of equations giving the parts rigid body coordinates and modal coordinates as a result. During the modal basis generation phase, the FE code can also pre- compute additional information for lately combining the modal coordinates to the FE stresses in Adams. We know and where: is the strain vector is the stress vector is a function matrix of the FE geometry relating strains to displacements is the stress-strain relationship S8-9 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY Hence we have Where: and: Here, is the ortho-normalized modal stress matrix that identifies the stress component associated with each orthogonalized mode shape. If the modal stress matrix has been computed by the FE code and stored in the MNF for the flexible body, it is possible to perform MSR in Adams. It is also possible to perform MSR in the FE code or in the fatigue code, such as Fatigue, with the modal coordinates from Adams and the modal stress matrix from the FE code's database. S8-10 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY Likewise, for strains we have: and where: is the ortho-normalized modal strain matrix identifying the strain component associated with each orthogonalized mode shape Based on the theory of modal superposition What is done for displacements: Can be done for stresses: Where The are mode shapes or stresses from FEA The q(t)s are modal responses from Adams { } | | { } ) ( ) ( t q t u u = { } | | { } ) ( ) ( t q t u = o o S8-11 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY THEORY OF MODAL STRESS RECOVERY repeat for each node or element Stress Mode Shapes Point A Stress Histories Modal Deformations (Responses) o A q 1 Mode 2 | A1 * q 1 (t) + | A2 * q 2 (t) + ... = o A (t) q 2 Mode 1 | o @ pt A S8-12 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation THEORY OF MODAL STRESS RECOVERY (Nastran) THEORY OF MODAL STRESS RECOVERY (Nastran) SOL 111 and SOL 112 PARAM,ADMPOST=m; m=0 (default-no MSR),1(no rigid motion), or 2 (rigid motion) ASSIGN INPUTT2=name.mdf UNIT=ni DLOAD=n in the appropriate subcase Caution: In order to obtain consistent results, the Adams results, when brought back into Nastran SOL 111 or SOL 112, MUST be restarted off the original Nastran database that produced the original MNF which was the basis of the Adams run. S8-13 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation MSR Nastran Example SOL 103 ADAMSMNF FLEXBODY=YES etc. SCR=NO Produce MNF Run ADAMS RESTART into SOL 111 S8-14 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation MSR Nastran Example (Cont.) File Management Section (FMS) ASSIGN PRIMARY='e1_msr.MASTER' RESTART LOGICAL=PRIMARY version=1 keep ASSIGN INPUTT2='e1_111_ascii.mdf' UNIT=31 ASSIGN INPUTT2='e1_x_111_ascii.mdf' UNIT=32 . SOL 111 . CEND S8-15 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation MSR Nastran Example (Cont.) 1 Subcase SET 10 = 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 $ MODESELECT = 10 METHOD = 1 $ <- from SOL 103 run $ SUBCASE 1 SUPER = 1 DISP(PLOT,PRINT,PUNCH) = ALL SET 21 = 1 THRU 9, 10, 11 $ STRESS(PLOT,PRINT,PUNCH) = 21 STRAIN(PLOT,PRINT,PUNCH) = 21 S8-16 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation MSR Nastran Example (Cont.) 2 nd and 3 rd Subcase SUBCASE 21 SET 11 = 1.0, 2.0, 3.0, 4.0 OFREQ = 11 DLOAD = 31 $ <- points to UNIT 31 $ SUBCASE 22 SET 12 = 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 OFREQ = 12 DLOAD = 32 $ <- points to UNIT 32 S8-17 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation MSR Nastran Example (Cont.) Bulk . BEGIN BULK . PARAM, POST, -1 PARAM, ADMPOST, 2 . ENDDATA S8-18 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation IMPROVING GRAPHICS PERFORMACE IN ADAMS/POSTPROCESSOR You can use various techniques to configure animations of flexible bodies for optimal performance. File caching versus memory caching By default, cached information necessary for animations containing flexible bodies is maintained on disk in files with an .fcf extension. Adams/PostProcessor can also maintain this information in physical memory, which can result in significantly less disk input/output, higher CPU use, and, consequently, faster performance. If you work in an environment with remote disk servers (accessed across a network), you should see a dramatic improvement in performance if you select to maintain the cache in memory. Users using local disk will see improvements on a smaller scale. The disadvantage of memory caching is the increased process size and the risk that it will exceed your computer's physical memory. If your computer has enough physical memory, then this approach is more efficient. If your computer doesn't have enough physical memory, then its operating system will begin swapping and the animation performance may be worse than when using the .fcf file. Adams/PostProcessors Preferences dialog box is used to modify the cache settings for flexible bodies during animation (Edit Preferences). S8-19 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation IMPROVING GRAPHICS PERFORMACE IN ADAMS/POSTPROCESSOR (CONT.) Mode filtering By default, all enabled modes are used to generate nodal displacements for each flexible body during animations. To increase animation performance, Adams/PostProcessor has three filters that let you remove graphically insignificant modes for animations. A mode that is filtered out is excluded from the modal superposition and any contribution to the deformation of the body is ignored. Frequency - Excludes any mode that is activated above the specified frequency. Min. Displacement - Excludes any mode that does not contribute the minimum displacement specified for at least one vertex of the flexible body. Percentage - Determines the maximum displacement contributed by all modes, and excludes any mode that doesn't contribute displacement of one vertex at least as significant as a percentage of the maximum. S8-20 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation IMPROVING GRAPHICS PERFORMACE IN ADAMS/POSTPROCESSOR (CONT.) Flexible body cache compression Three levels of data compression are available for controlling the size of a flexible body animation cache. Each level implements a higher level of data compression applied to nodal deformation data in the cache. Each higher level comes with a higher risk of data loss and may lead to slightly incorrect geometric representations. The accuracy of cached contour plot information is maintained. S8-21 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation IMPROVING GRAPHICS PERFORMACE IN ADAMS/POSTPROCESSOR (CONT.) Rendering options The rendering method used for flexible bodies can impact animation performance. Three rendering methods are available: Flat - Renders flexible bodies more simply, with flat edges. Uses face normals to produce a faceted rendition of the body. This is the fastest of the rendering options but can produce some incorrect light intensity for bodies with large nodal deformations. Smooth - Renders the flexible body with smooth, rounded edges. Uses vertex normals to produce a smooth rendition of the body. This method is appropriate for presentations, but slows down the animation compared to flat rendering. Precision - Renders the highest quality image for the flexible body. Uses vertex normals to produce a smooth rendition of the body. We recommend that you use this option only when producing movie files or hardcopy images for presentation purposes. S8-22 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation IMPROVING GRAPHICS PERFORMACE IN ADAMS/POSTPROCESSOR (CONT.) Nodal displacements To represent flexibility of bodies during animations, the nodal deformations of the bodies are displayed at each frame of the animation. Calculation of the nodal deformations can cause a delay in the initial display of an animation as the results of the calculations are cached. You can avoid this delay by choosing to display the flexible bodies in their undeformed shapes. This is accomplished by setting the scale of the flexible body to 0. S8-23 ADM710, Section 8, July 2008 Copyright 2008 MSC.Software Corporation USING THE HOT SPOTS TABLE Identifying regions of high stress is a critical task in component analysis and design. Several design-time functions are now available in Adams/Durability to interrogate a flexible body for useful stress, strain, or life data. You can easily find all nodal locations that exceed a prescribed stress threshold using the Hot Spots Table. Starting with Adams v2005r2, a new Hot Spots tab is available in the Animation dashboard when the Adams/Durability plugin is loaded. This tab allows you to control the definition, display, and labeling of hot-spot data. WS7-1 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION WS7-2 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WS7-3 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION Problem statement You want to run a dynamic simulation of the vehicle to produce loads (modal coordinates) for the flexible lower control arm in the left, front suspension. The modal coordinates will be used for stress calculation and are exported to Fatigue. Importing the model into Adams 1. Run Adams/View from the directory, exercise_dir/<mod_08_atv>. 2. From the same directory, import the model command file, mod_08_atv.cmd. This model contains the all-terrain vehicle standing on a four-poster rig. All parts are rigid. Importing and replacing the flexible suspension arm 1. Zoom in on the left Lower Control Arm (LCA) in the front suspension. 2. To replace the rigid LCA with a flexible LCA, from the Build menu, point to Flexible Bodies, and then select Rigid To Flex. 3. In the Current Part text box, enter RB2_left_lca_59. WS7-4 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 4. Browse the MNF File text box for left_lca.mnf. The flexible body defined in the MNF is already positioned correctly. Note: Do not select Apply or OK, because you will continue working in this dialog box. WS7-5 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Establishing connections The table in the Connections tab compares the connection points on the flexible body with the connection points on the rigid body. As shown in the Distance column, there is a small offset for the four bushing connection points. You should keep the bushings at the points where they were originally defined in the rigid model. WS7-6 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) To establish connections: 1. Select the Connections tab. 2. Click on the first table row and then click Preserve location. 3. Repeat step 2 for the next three rows of the table. The table should look as shown next: 4. Select OK. The rigid part is now replaced by the flexible body as defined in the MNF. The flexible body is connected to the frame, knuckle, and damper in the same way as the rigid body. WS7-7 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Checking connections To verify that the flexible LCA is correctly connected to the rest of the model, check the graphical topology. To check connections: 1. From the Tools menu, select Database Navigator. 2. Set the option menu at the top of the Database Navigator to Graphical Topology. Tip: The Graphical Topology option in the Database Navigator is a very useful tool in Adams/View. It helps you to debug your model without having all the geometry in the way. Here it is used to verify that the imported flexible body is connected as expected. WS7-8 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 3. Select the flexible LCA: .mod_08_atv.RB2_left_lca_59_flex. The LCA should be connected to the frame through two bushings, and to the damper and knuckle with one bushing each, as shown next. WS7-9 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Animating modes You can animate the 40 modes calculated by Nastran, imported from the MNF. In the dynamic simulation results, you should see 36 modal coordinates: one coordinate for each enabled mode. The first mode of interest is mode 7. Note that modes 1 - 6 are rigid body modes and are automatically disabled. The first modes are very similar to the free-free modes of the component. The high-frequency modes are usually a bit strange looking, but useful for describing local deformations and stress around the attachment points. WS7-10 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) To animate modes: 1. Right-click the flexible LCA, RB2_left_lca_59_flex, and then select Modify. 2. Animate the modes. The following figure shows modes 7 - 10. 3. Do not close the dialog box. WS7-11 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Modifying damping The high-frequency modes are normally not very active in a dynamic simulation. There are two strategies to avoid the high-frequency modes: Disable them. This may cause simulation difficulties if any of the disabled modes are necessary to describe, for example, a static position with local deformation around an attachment point. Modify damping so high-frequency modes are critically damped. This way, the modes are enabled but don't participate in the dynamics because of the high damping applied to them. Here you use the method of setting critical damping on the very high-frequency modes. A STEP function defines the damping. The higher the frequency, the higher the damping. WS7-12 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) To modify damping: 1. In the Flexible Body Modify dialog box, clear the selection of default for Damping Ratio, and then enter the following function: STEP(FXFREQ,1000,0.005,10000,1). The function means: Modes with a frequency below 1000 Hz will have a damping ratio of 0.5% Modes with a frequency above 10,000 Hz will have a damping ratio of 100% Modes in the range 1000 10,000 Hz will be increasing with respect to their frequency according to the STEP function Tip: The default damping usually is not useful, especially in this case. If using default damping here, you would get 10% damping ratio for mode 7, which is too much, considering that the component is made of steel. 2. Select OK. WS7-13 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Running a dynamic simulation Before you run a dynamic simulation, you change your Adams/Solver settings and then modify the Adams/Solver Dynamics parameters. Note that the Stabilized Index-2 (SI2) formulation enables the integrator to monitor the integration error of velocity variables, and therefore, renders highly accurate simulations. A positive side effect of the SI2 formulation is that the Jacobian matrix remains stable at small step sizes, which, in turn, increases the stability and robustness of the corrector at small step sizes. High accuracy of the inputs to the fatigue analysis is crucial; therefore, you use the SI2 formulation here. To run a dynamic simulation: 1. From the Settings menu, point to Solver, and then select Executable. 2. Set Choice to C++. 3. Change the Category to Dynamics. WS7-14 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 4. Set Formulation to SI2. 5. Set Error to 0.01. 6. Click Close. 7. From the Simulate menu, select Interactive Controls. 8. Set End Time to 10 seconds. 9. Change Steps to Step Size. 10. Set Step Size to 0.01 seconds. 11. To avoid having the screen updated at every output time step taken by the solver, clear the selection of Update graphics display. 12. Select Play. Each plate that the vehicle is standing on moves in the vertical direction to simulate the vehicle running in rough terrain. This could also have been done by defining tire forces and a road profile. Note that the simulation will take a few minutes. WS7-15 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Reviewing the results To review the results: 1. From the Review menu, select Postprocessing. 2. Verify that the option menu in the top left corner of Adams/PostProcessor is set to Plotting. WS7-16 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 3. From the dashboard (the lower section of the Adams/PostProcessor window) select the following: Source: Objects Filter: force Object: BUSHING_9. This is the bushing connecting the LCA with the spring/damper. Characteristic: Element_Force Component: Mag Add Curves WS7-17 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Reviewing stress results You can perform a modal stress recovery directly in Adams/PostProcessor. Before you can review the stress results, you must load Adams/Durability. To load Adams/Durability: 1. From the Tools menu, select Plugin Manager. 2. Select to load Adams/Durability. To review stress results: 1. Set the option menu in the top left corner of Adams/PostProcessor to Animation. You will be notified that the plot will be deleted. Select OK. 2. Right-click the viewport, and then select Load Animation. 3. Select the Contour Plots tab. 4. Set Contour Plot Type to Max Prin. Stress. 5. Select the Camera tab. 6. Right-click the Follow Object text box, point to Part, point to Guesses, and then select RB1_frame_57. WS7-18 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 7. Select Lock Rotations. 8. Zoom in on the flexible LCA and look, for example, on the bottom surface of the LCA. 9. Select Play. Note: When you later export the results to Fatigue, it is actually not the stresses as calculated in Adams that you export. It is only the modal coordinates that are exported. The stress shapes are already calculated and stored in the XDB file. The stress shapes in the XDB file will be combined with the modal coordinates from Adams. Stress recovery is performed in Patran for later use in Fatigue. WS7-19 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Creating a Hot Spots Table To create a hot spots table: Now you create a table that lists the three most critical areas of the LCA. 1. From the Durability menu, select Hot Spots Table. 2. Fill in the bottom of the dialog box as shown next: WS7-20 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) 3. Select Report. When the calculation is done, a table is displayed. The hottest spot is located around node 2990, which is located on the bottom surface of the LCA, close to the cross beam connection. WS7-21 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Plotting Nodal Stress Here you will generate a plot of the stress at a particular node over time: 1. In the upper left corner of Adams/PostProcessor, use the pull-down menu to select Plotting. 2. In Adams/Durability, from the Durability menu, select Nodal Plots. 3. Set Analysis to Last_Run. 4. Set Flexible Body to RB2_left_lca_59_flex. 5. In the Select Node List text box, enter 2990. 6. Check Maximum Principal stress. 7. Select OK to close the Compute Nodal Plot Components A new result set named RB2_left_lca_59_STRESS will be generated for the nodal stress component. 8. Set Source to Results Sets. 9. Set Result Set to RB2_left_lca_59_flex_STRESS. 10. Select the node_2990_MAX_PRIN component. 11. Select Add Curves. WS7-22 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Note that the peak stress value corresponds to the Hot Spots Table WS7-23 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Visualizing Hot Spots A new Hot Spots tab is available in the Animation dashboard beginning with Adams 2005r2: 1. Select the Animation tab. 2. In the Component text box, select RB2_left_lca_59_flex. 3. Select the Hot Spots tab. 4. Check Display Hot Spots. 5. Verify that the filter is set to Count. 6. Change the count Value to 3. 7. Enter a value for Radius. 8. Turn the Graphics Label contents to display Rank, Value and Node ID. 9. You can now visualize the Hot Spots. WS7-24 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) WS7-25 ADM710, Workshop 7, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 7 SYSTEM-LEVEL SIMULATION (CONT.) Exporting results to Fatigue To export results: 1. From the Durability menu, point to FE-Fatigue, and then select Export. 2. Browse the Flexible Body text box for RB2_left_lca_59_flex. 3. In the Job Name text box, enter mod_08_atv. 4. Select Modal Coordinates. 5. Set Analysis to Last_Run. 6. Select OK. Adams/View exports the modal coordinates for the flexible LCA in DAC-format (40 files with prefix mod_08_atv) suitable for import to Fatigue. One file is produced for each modal coordinate. Note These files will be used in an upcoming workshop. S9-1 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation SECTION 9 FATIGUE ANALYSIS S9-2 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation S9-3 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS Whats in this section: What is Metal Fatigue? Durability Design Process Determining Loads Overview of Fatigue Life Analysis Stress Life (S-N) Approach Strain Life (E-N) Approach MSC.Fatigue S9-4 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation WHAT IS METAL FATIGUE? Strain S t r e s s Monotonic: Failure when stress exceeds UTS in a single pass Stress Vs Strain Plot time S t r e s s Apply cyclic load at low stress level Cyclic: Failure occurs after a period of time even though stress is low. The component seems to get Tired, hence the name FATIGUE S9-5 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation DURABILITY DESIGN PROCESS COMPUTER AIDED DESIGN Loads analysis Loads Data Manipulation FE Model Analytical Prediction Durability OK? Materials and Manufacturing OPTIMIZE DESIGN SERVICE LOADS ARCHIVE YES NO Correlation COMMIT PRODUCTION TOOLING Physical Lab. or PG Testing Data collection BUILD PHYSICAL PROTOTYPE Durability OK? NO YES S9-6 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation DETERMINING LOADS Experimental - using wheel force transducers, load cells and strain measurements from instrumented prototype. Semi-analytical - using wheel forces and accelerations from prototype or from earlier model (adjusted for weight etc.) and calculating component forces using Multi-Body Simulation software (Adams). Fully analytical - using Multi-Body Simulation software (Adams), including tire models, and knowing the road surface profile S9-7 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation OVERVIEW OF FATIGUE LIFE ANALYSIS Fatigue is the process where repeated variations in loading cause failure even when the nominal stresses are below the material yield strength. Two main approaches Stress Life (S-N) Crack Initiation (E-N) S9-8 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation Stress Life (S-N) Approach The S-N approach uses the (assumed elastic) nominal stress range (S) as a measure of the severity of fatigue loading Tests at several levels of stress range characterize the S-N Curve Such a curve can be derived from smooth specimens for individual components, for sub-assemblies, or for complete structures. S9-9 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation Strain Life (E-N) Approach Practically, crack initiation means that a crack of around 1-2 mm has developed. This is often a high proportion of the component life. Many automotive components are designed to survive some significant plastic strains in use. The E-N Method will handle these better because the S-N method ignores plasticity. E-N Method is not very suitable for structural joints such as welds, spot welds etc. S9-10 ADM710, Section 9, July 2008 Copyright 2008 MSC.Software Corporation MSC.Fatigue Cycle&Damage Cycle&Damage Materials prop Materials prop FEA Results FEA Results Loading info Loading info Analysis Options Analysis Options Stress (total) Life Stress (total) Life Strain (initiation) Life Strain (initiation) Life Crack Propagation Crack Propagation Vibration Fatigue Vibration Fatigue Spot Weld Analyzer Spot Weld Analyzer Seam Weld Analyzer Seam Weld Analyzer Software Strain Software Strain Gauge Gauge Utilities Utilities Multi Multi- -axial Fatigue axial Fatigue Fatigue Life Fatigue Life 1500 -1500 12 0 S t r a i n ( u E ) Time (seconds) DISPLAY OF SIGNAL: TEST101.DAC Strain Life Plot 605M30 Sf': 857 b: -0.067 Ef': 0.636 c: -0.579 1E-3 1E-2 1E-1 S t r a i n A m p l i t u d e ( M / M ) 1E0 1E1 1E2 1E3 1E4 1E5 1E6 1E7 1E8 Life (Reversals) 1E3 1E4 1E5 1E6 1 2 3 4 5 6 7 Cross Plot of Data : S61STRAIN1KT Life(Miles) K t ( ) 0 1574.7 -750.4 808.7 0 4.8548 Range uE X-Axis Mean uE Y-Axis Damage Z-Axis DAMAGE HISTOGRAM DISTRIBUTION FOR : TRACK05.DHH Maximum height : 4.8548Z Units : % WS8-1 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation WORKSHOP 8 FATIGUE ANALYSIS USING ADAMS & FATIGUE WS8-2 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Patran Life/Damage Calculation Load histories Component Mode Synthesis System-level Simulation Mode shapes Stress shapes Nastran Fatigue Adams Geometry and Mesh WS8-3 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Problem statement Perform an integrated virtual durability process and use the modal coordinates (response) time histories exported from Adams in the DAC file format. The modal coordinates along with FEA results will be used in Fatigue for Fatigue Analysis. In this workshop, you will use Nastran Patran Adams Fatigue WS8-4 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Run a Nastran Simulation First step is to run Nastran to obtain the reduced flexible modes in MNF (Modal Neutral File) format and modal stresses in XDB (Nastran Binary attachable) format. The provided input file (left_lca.dat) is set up for MNF generation via the ADAMSMNF statement ADAMSMNF FLEXBODY=YES, FLEXONLY=YES, MINVAR=PARTIAL,PSETID=2, OUTGSTRS=YES,OUTGSTRN=NO The output of grid point stresses are requested with the OUTGSTRS option. No output of strains are requested with the OUTGSTRN option. Partial mass invariant calculation is requested with the MINVAR option. Note: Details of the ADAMSMNF card are covered later. WS8-5 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Since version 2005, Nastran has supported the output of ortho- normal modal stress or strain resulting from MNF generation in XDB format. This data can be combined with the modal coordinate results from Adams in a very efficient way for subsequent fatigue evaluations in Patran and Fatigue. To take advantage of this feature, the following statement as been added to the Nastran input file: PARAM POST 0 Run Nastran to obtain the reduced flexible modes in MNF format (Modal Neutral File): 1. Locate and launch Nastran. 2. Browse to left_lca.dat from the mod_09_fatigue folder and select Open. 3. Add any relevant runtime command, e.g. scr=yes can be used in this case because, having chosen the XDB file to store results, you dont need the database information for subsequent usage. WS8-6 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Hint: Depending on your computer resources it may take 5-10 minutes to run the job. Upon successful completion of the Nastran job, you will note at least two files will be created in the run directory: left_lca_0.mnf and left_lca.xdb. These two files are important in completing the rest of the tutorial. WS8-7 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Importing the model in Patran: 1. To have Patran default to your current working directory, right-click the Patran shortcut and edit the properties so that the start directory will be your current working directory. 2. Launch Patran 2005 (or later) and open a New database (from the File Menu select New). 3. In the Filename textbox, enter tutorial and Select OK. WS8-8 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE 4. From the File menu, select Import, and then specify the following: Set Object to Model. Set Source to Nastran Input. Set File name to *.dat. Browse to left_lca.dat, select it, and then select Apply to import the model. The Nastran Input File Import Summary dialog box displays. 5. Select OK to close the dialog box. WS8-9 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Separating Shells from Solids: 1. From the Group menu, select Create. 2. Set Method to Property Type. 3. Set Create to Multiple Groups. 4. Select Apply. Patran creates two new groups named Membrane and Solid. You will reference the Membrane group later in this tutorial. Note: Fatigue is a phenomena that normally originates on the surface. It is, therefore, a common practice to skin any solid model with a thin shell membrane. This allows you to obtain a true two-dimensional stress tensor (which should always be the case on free surfaces) and also avoids uninteresting computation on internal nodes. WS8-10 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Attaching Results in Patran: 1. Select Analysis toggle, and then specify the following: Action: Access Results Object: Attach XDB Method: Result Entities 2. Select Select Results File. 3. In the Select File dialog box, browse to the left_lca.xdb file, and then select OK. 4. Select Apply. WS8-11 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE To view the results in Patran: 1. Select Results. A list of 40 mode cases in the result selection window appears. These represent the orthonormalized modes that were computed by Nastran and imported into Adams using the MNF. 2. Perform some simple plotting as follows: Set Action to Create. Set Object to Quick Plot. Highlight one mode case with a frequency higher than zero (that is, a non-rigid body mode). For example, highlight mode 7. Select Stress Tensor as the Fringe Result. 3. Select Apply, and then view the results. Note: The stresses you are viewing are not actual stress values sustained by the component, but modal stress shapes. Later in this tutorial, these stress shapes will be combined with results from Adams to obtain actual stress values. Note: Do not close Patran. WS8-12 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE System-Level Simulation Next step is to run a dynamic simulation of the vehicle to produce loads (modal coordinates) for the flexible lower control arm (LCA) in the left-front suspension. In the last workshop, modal coordinates for the flexible LCA were exported in DAC format (40 files with prefix ATV_4poster) suitable for import to Fatigue. One file was produced for each modal coordinate. Note: Copy the 40 DAC files into the directory mod_09_fatigue since we will use these files in this workshop. WS8-13 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Set up Stress-Life Analysis in Fatigue: 1. From the Tools menu, select MSC.Fatigue. 2. Select Main interface. 3. Complete the dialog box as shown next, being sure to set Analysis to S-N. WS8-14 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE 4. Enter fat_left_lca for the jobname for the fatigue jobs in Patran. All fatigue related files will have this prefix. The bottom section of the Fatigue dialog box contains the five steps to complete your fatigue job: Three inputs - Solution Parameters, Material, and Loading Job control - Used to submit and monitor fatigue jobs Results - Used to postprocess fatigue results Solution Parameters Select Solution Params and complete the dialog box as shown. Note - The Certainty of survival is set to 99%, indicating the highest conservatism in material properties scatter. WS8-15 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Note - The design life is the number of repetitions this part is expected to withstand without failure. Fatigue will perform an additional analysis to assess the load scaling factor to reach a given target life. A design life of 60000 is derived from a simple assumption that under the given loading condition, the target life is around 10,000 km, and that the 10-second repetition was performed at an average speed of 60 km/h. Select OK to close the Solution Parameters dialog box. WS8-16 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Material Info Select Material Info. Note - Fatigue offers a built-in library with more than 200 predefined materials. You can select multiple materials for the same run and access advanced material options, such as temperature dependency. Click in the first cell of the spreadsheet (Material) and scroll through the available material list below it. Select MANTEN_SN (carbon wrought steel). Select No Finish and No Treatment. Set Region to Membrane. Note - The region is the part of your model that will be analyzed. As mentioned previously, you are only interested in the surface element and you will use the previously created Membrane group as the target region. Keep the defaults for all remaining fields, and then select OK. WS8-17 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Importing and Combining Modal Coordinates from Adams WS8-18 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Note - The Loading Information dialog box is the spreadsheet that displays the association between modal stresses (Nastran output) and modal coordinates (from Adams). This is the key in recreating the stress history at each node that will be used for rainflow cycle counting (central to fatigue analysis algorithm). Select Loading Info. To access the modal variables, Fatigue needs to load the relative *.dac files (the output from Adams created in Part 2 - System-Level Simulation) into the local time database (ptime.tdb). Select Time History Manager to open the local time database. Then, perform the following: Select Load files. Select OK. In the PTIME Load Time History dialog box, enter the following: Source and target Filename: mod_08_atv* Description 1: modal coordinates Load Type: Scalar Units: none Select OK. WS8-19 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE The 40 files start loading. Select More enough times to make sure all load channels are loaded. Select End. The PTIME dialog box shows that you have 40 .dac files. Select exit, and then select OK to close the PTIME-Database Options dialog box. In the Loading Information dialog box, perform the following: Set Number of Static Load Cases to 40. Be sure to select Enter on your keyborard after setting this value. Doing so will update the number of rows in the spreadsheet from 1 to 40. Select Fill Down OFF and the option changes to Fill Down ON. Select the first cell in the Load Case ID column. Select Get/Filter Results to open the Results Filter dialog box. To access all available results in the database in the Results Filter dialog box, select Select All Results Cases, and then select Apply. Select the first available results loadcase ( Mode 1) in the Select a Results Load Case list. Make sure the first cell in the Time History column is selected to populate column 2. Select MOD_08_ATV_01.DAC from the Select a Time History list. Your spreadsheet should look similar to the image shown. Leave the remaining default values, and then select OK. WS8-20 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Running S-N Fatigue and Factor of Safety (FOS) Analysis From the MSC.Fatigue Main Interface, select Job Control. To start the analysis, select Apply. Wait a minute or two until the fat_left_lca fatigue job has been submitted. You can check the status by accessing Job Control Action Monitor Job, and then periodically selecting Apply. When completed, the status window displays the following message: Safety factor analysis completed successfully. WS8-21 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE Importing and Reviewing Results in Patran Select the MSC.Fatigue tab near the bottom right corner of the Patran window. Select Results. Select Apply to read in the results. Fatigue automatically accesses the results based on the current job name. The results are now stored in the Patran database as the Total Life and Factor of Safety sub cases for postprocessing. To view a quick plot of the factor of safety in Patran, select Results on the main Patran form (not in Fatigue). In the results window, scroll through the list of Result Cases, and then select Factor of Safety, fat_left. Select Safety Factor as the fringe result, and then select Apply. You can create a damage plot to improve the visualization of the critical areas. WS8-22 PAT301, Workshop 8, July 2008 Copyright 2008 MSC.Software Corporation FATIGUE ANALYSIS USING ADAMS & FATIGUE To see a damage plot: Select Total Life from the Result Cases list. Select Damage from the Fringe Result list. Select Apply. Note that the highest damage occurs at three critical regions of the LCA. Optional Task - Importing and Reviewing Results in Adams From the Durability menu, point to MSC.Fatigue, and then select Import. Browse to the Fatigue results file (*.fef), for example, ...\fat_left_lca.fef. Select RB2_left_lca_59_flx as the flex body, and then select OK. Select the Contour Plots tab. S10-1 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SECTION 10 MNF GENERATION IN NASTRAN S10-2 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation MNF GENERATION IN NASTRAN Whats in this section MNF Generation in Nastran Modal Neutral Files Superelement Definitions Selecting Attachment Points What is a Spider-Web? ADAMSMNF Case Control Units ADMOUT = YES FLEXONLY = NO Residual Vectors Releasing DOF Common MD DB S10-3 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation MODAL NEUTRAL FILES Are: Binary files Platform independent Contain the following information: Generalized mass and stiffness matrices Nodal masses/inertias Nodal coordinates Inertia invariants Eigenvalues Mode shapes File comments and version information Modal loads/preloads Attachment points Element topology Units Stress/strain modes S10-4 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SUPERELEMENT DEFINITIONS What is a Superelement? Physical and mathematical representation Physical - substructure: a finite element model of a portion of a structure Mathematical - boundary matrices: loads, mass, damping, and stiffness reduced from the interior points to the exterior or boundary points Nastran allows the use of a residual structure only or any superelement or any part super element to be used as a component for an Adams/Flex flexible body. The user can define the attachment points in Nastran by either defining the component as a superelement, in which case, the physical external (a-set) grids become the attachment points; or for a residual only type model, using standard Nastran ASET Bulk entries to define the attachment points. S10-5 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SUPERELEMENT DEFINITIONS Three small examples are discussed below that are intended to show salient features of the Nastran/Adams interface. In all, the examples GRID_1, GRID_11, GRID_111, and GRID_121 are to be used as the attachment points for Adams. S10-6 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SUPERELEMENT DEFINITIONS 1. Flexible body component as a superelement The SPOINT and SEQSET1 bulk entries are used to define the component modes. These entries must specify enough degrees of freedom or modal amplitudes to capture the shape of the component and residual flexibility for any loading conditions. $ The corner grids 1, 11, 111, 121 are the exterior or attachment point grids $ SESET,200,2,THRU,10 SESET,200,12,THRU,110 SESET,200,112,THRU,120 $ $ $ SCALAR Point and SEQSET1 to define DOFs to use for component Modes $ SPOINT,80001,THRU,80010 SEQSET1,200,0,80001,THRU,80010 $ S10-7 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SUPERELEMENT DEFINITIONS 2. Flexible body component as a residual only run This example represents a Nastran/Adams interface run with the component modeled residual only structure. This is accomplished by use of the ASET1 bulk entry. $ The corner grids 1, 11, 111, 121 are the exterior or attachment point grids $ ASET1,123456,1,11,111,121 $ $$ $ SCALAR Point and QSET1 to define DOFs to use for component modes $ Include enough for structure shape and capture of residual flexiblity $ SPOINT,80001,THRU,80050 QSET1,0,80001,THRU,80050 S10-8 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SUPERELEMENT DEFINITIONS 3. Flexible body component as a part superelement This example represents a Nastran/Adams interface run with the component modeled as part super element 200 as defined by the BEGIN BULK SUPER = 200 entry. Grids listed in this section represent the complete component as a substructure. $ $ The corner grids 1, 11, 111, 121 are the exterior or attachment point grids $ GRID 1 0.0 0.0 0.0 GRID 11 0.0 1.0 0.0 GRID 111 1.0 0.0 0.0 GRID 121 1.0 1.0 0.0 $$ $ SENQSET to define DOFs to use for component modes - must be in main Bulk Data Section. Include enough for structure shape and capture of residual Flexiblity $ SENQSET 200 50 $ BEGIN BULK SUPER = 200 $ $ This PART defines interior grids as superelement 200 $ The corner grids 1, 11, 111, 121 are the exterior or attachment point grids S10-9 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation SELECTING ATTACHMENT POINTS Attachment points are idealized for attachment by preserving all six DOFs. An attachment point is equivalent to a superelement exterior grid point. Each attachment point normally contributes six modal DOF. A large number of attachment points can result in a large MNF. Example: If you have 50 attachment points you would have 300 additional modes (6 modes/attachment point) in your MNF. If you have 50,000 nodes in your model, the resulting MNF would be approximately 720 MB. 8bytes/DOF * 6 DOFs/node * 50,000 nodes/mode * 300 modes = 720 MB You can always apply joints and forces to any node without it having been identified as an attachment point during the FEA. The nodes with the greatest force interaction should be chosen as attachment points. S10-10 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation WHAT IS A SPIDER WEB? Elements surrounding the attachment point. Solid elements require a spider web that connects at least three nodes of the mesh because solid elements have no rotational DOFS. Use spider webs to give the attachment point a full set of stiffnesses. Think of a cylinder with the nodes on the circumference at one end all connected to a single centerline node. RBE3 spider-web" - The independent nodes are the circumference nodes and are free to move elastically while the centerline dependent node is the average of all of the motions of the circumference. RBE2 spider-web - The independent node is the centerline node and the dependent circumference nodes are fixed to it with the same motions. The RBE3 retains the circumferential wave modes at the end whereas the RBE2 will not. RBE3 vs RBE2 http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB9960&requestTimeout=2000 S10-11 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADAMSMNF CASE CONTROL Starting with v2004 of Nastran, a new ADAMSMNF Case Control command is now available for requesting the MNF file directly in Nastran for Adams/Flex. The Nastran/Adams integration provides an easy method to move from a FE analysis to a system analysis study by providing the direct generation within Nastran of the Adams Modal Neutral File (MNF) required for the Adams/Flex solver. The interface is initiated by the simple Nastran Case Control command ADAMSMNF FLEXBODY=YES and the addition of a Bulk Data entry, DTI,UNITS. DTI,UNITS used to specify the unit system to be used by Adams/Flex. S10-12 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADAMSMNF CASE CONTROL ADAMSMNF Note: The underlined text indicates default values {FLEXBODY = [NO/YES]} Requests that the Nastran/Adams interface be run. {FLEXONLY = [YES/NO]} Requests data recovery be run or not run after standard DMAP solution. {ADMCHECK = [NO/YES]} Requests diagnostics print {ADMOUT = [NO/YES]} Requests that the FLEXBODY run outputs Nastran OP2 files. {OUTGSTR = [YES/NO]} Controls grid point stress output to OP2 file or MNF or both. S10-13 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADAMSMNF CASE CONTROL {OUTGSTRN = [YES/NO]} Controls grid point strain output to OP2 file or MNF or both. {OUTSTRS = [NO/YES]} Controls element stress output to OP2 file. {OUTSTRN = [NO/YES]} Controls element strain output to OP2 file. {V1ORTHO = [-1.0/value1]} Lower frequency bound of the Craig-Bampton modes (cycles/unit time) value1 = User specified value of lower bound. {V2ORTHO = [1.0e8/value2]} Higher frequency bound of the Craig-Bampton modes (cycles/unit time) value2 = User specified value of upper bound. S10-14 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADAMSMNF CASE CONTROL {MINVAR = [FULL/CONSTANT/PARTIAL/NONE]} Requests the type of mass invariants to be computed. FULL : all nine mass invariants will be calculated. CONSTANT : mass invariants 1, 2, , 6, and 7 will be calculated. PARTIAL : mass invariants 5 and 9 will NOT be calculated. NONE : the ADAMSMNF module outputs ONLY modal data. {PSETID = [NONE, setidplotel, ALL]} Selects a set of elements (including PLOTEL) whose grids are retained in the MNF. Setidplotel : specified in the OUTPUT(PLOT) section of Nastran. ALL : select all the sets defined in the OUTPUT(PLOT) section. S10-15 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADAMSMNF CASE CONTROL S10-16 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation UNITS Units must be defined using the DTI entry when generating the MNF file. Adams/View and Solver require units Example: S10-17 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation UNITS S10-18 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation ADMOUT = YES The ADMOUT=YES option is intended for users who plan to import ADAMS results into MSC.Fatigue. ASSIGN OUTPUT2=name.out STATUS=UNKNOWN UNIT=20 FORM=UNFORM. To insure compatibility with the Adams OP2-to-MNF translator the Nastran SYSTEM word OP2NEW is automatically set to OP2NEW = 0. This means that any OP2 files generated will have a pre- MSC.Nastran 2004 format. S10-19 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation FLEXONLY = NO For PARAM,POST,0 Orthonormalized modes used by Adams available for display in PATRAN and SimXpert. Solution modes computed by Nastran available for display in PATRAN and SimXpert. S10-20 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RESIDUAL VECTORS Concept of Modal approach Assume response can be represented as a linear combination of calculated modes { U } = [ ] { } Number of possible modes = number of degrees of freedom with mass on them Same results as direct if all modes are retained Not practical Defeats purpose of modal approach S10-21 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RESIDUAL VECTORS { U } = [ ] { } = [ ] r { } r + [ ] n { } n where [ ] r = modes that are retained [ ] n = modes not retained [ ] r is usually a small subset of [ ] Quality of modal solution depends on how well a linear combination of [ ] r can represent the actual solution due to the applied loads. To compensate for the missing modal content the method of Residual Vectors is recommended and is turned ON by default for most modal solutions S10-22 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RESIDUAL VECTORS Augment modes with static vectors obtained from static loading The response of the neglected modes tends to be static if these frequencies are high as compared to the excitation frequency As (/ n ) << 1 Excellent approximation of missing modes if the above condition is satisfied Improves modal solutions in all cases Recommended to be included for all response analysis using the modal approach (the default) Supports Superelement Analysis Two eigenvalue tables printed Original eigenvalue table Second eigenvalue table with the additional eigenvalues appended at the endone for each additional residual vector. S10-23 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RESIDUAL VECTORS Re-orthogonalization is performed to ensure that linearly dependent vectors are removed Residual vectors can come from the following sources Inertial forces due to rigid body motion Applied loads Structural, viscous, and inertial forces due to enforced motion Forces at user specified discrete degrees of freedom Discrete damping forces due to viscous elements S10-24 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RESIDUAL VECTORS Residual Vectors can be requested with RESVEC Case Control command Note: By default RESVEC is turned ON S10-25 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation RELEASING DOF Using the RELEASE card in the Bulk Data section you can define degrees-of-freedom for superelement exterior grid points that are not connected to the superelement. SEID Superelement identification number. (Integer > 0) C Component number. (Any unique combination of Integers 1 through 6) Gi Grid point identification numbers. Example: The following statement will remove rotational DOF of attachment grid point 1 $ SESET,200,2,thru,8 RELEASE,200,456,1 $ S10-26 ADM710, Section 10, July 2008 Copyright 2008 MSC.Software Corporation COMMON MD DB Flexible bodies can now be imported directly from an MD Nastran database without creating an MNF. Advantages: Create several flexible bodies from one MD DB. Read access time for mode data is quicker than from an MNF. No need for MNF creation. ADAMSMNF case control command is still required. S11-1 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation SECTION 11 MODELING CONSIDERATIONS S11-2 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation S11-3 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation Whats in this section: First Thoughts FE Modeling Considerations Special Adams Modeling Considerations Concluding Thoughts MODELING CONSIDERATIONS S11-4 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FIRST THOUGHTS Do I care about flexibility? Gauging the importance of flexibility is difficult without actually trying to add a flexible component. Perhaps you could build a very rough simplified version of your component as a first iteration. Do I create a rigid body model first? Veteran users advise avoiding the complexity of flexible bodies during initial modeling, but recognize that unsupported connections (joints, forces) may result from this practice. You may consider using a rigidized FLEX_BODY or a simplified surrogate FLEX_BODY instead. S11-5 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS Can I use an existing FE model? Yes. Although chances are that the existing model was built for stress analysis and is, consequently, excessively detailed for an Adams dynamics analysis. With some FEM software you will have to make minor modifications to your model, while others require no modifications. What kind of elements can I use? Since Adams does not work at the element level, element support is not a concern. Element information is only used for visualization purposes. In the worst case, graphics information is missing. S11-6 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) Must I define Craig-Bampton attachment points? This depends on the FEM program you are using. Adams can work with any kind of modes, including the eigenvectors of an unconstrained body. Which nodes should be attachment points? In general, you should promote to attachment-point status any node that you expect to make connections to. When this leads to an excessive number of modes, you can consider nominating a representative attachment point for a region of the structure and remove neighboring attachment points. You can also consider using only normal modes. Do all six of the attachment point DOFs need to be included? No, some software programs allow you to select a subset. This is useful, for instance, if you know that you will never apply a torque to the node. S11-7 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) How do I apply a connection in Adams where there is no node or where a point force would be unrealistic? It is common practice to create a stiffening spider-web of elements to a new or existing node for this purpose. This can be accomplished by introducing an element spider web in the finite element model (FEM) or by introducing a marker that is attached to multiple nodes in your Adams model. How many normal modes should I add? You need to keep a sufficient number of normal modes to allow your flexible body to have dynamic resolution in the frequency range of interest. Also, if you plan to make attachments to nodes that have not been promoted to Craig-Bampton attachment-point status, you will need additional modal DOFs that you can get by adding more normal modes. S11-8 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) Is it appropriate to use constraints in the FEM model? This is very rarely advisable. There is a danger of creating artificial constraints in the flexible body. How about units? Adams supports a large number of units and all of these can be used in your FEM analysis. All we require is that you properly register the units used in the MNF. Do I need additional information to use for validation? As a minimum you should know the mass, center-of-mass location, and moments of inertia of your component to compare it with the information in Adams. You should also know the natural frequencies of the unconstrained body. Further validation of the right choice of modes can be achieved by extracting the natural frequencies from the FEM program for some given set of boundary conditions, which can be replicated in Adams. S11-9 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) Why am I getting more modes in Adams than I asked for in the FEA? Suppose you had 25 attachment points in your FEM and you asked for 10 normal modes. You would end up with 160 modes in Adams/View. Here are the calculation details: Constraint modes: 6 DOF x 25 attachment points = 150 modes S11-10 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) How much data will I get from my FEM analysis? Heres how you can approximate the size of your MNF in bytes: Total # of mode types is: 1 when no stress or strain 2 if stress or strain 3 if both stress and strain All other data in the MNF file is negligible compared to what weve calculated above. S11-11 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation FE MODELING CONSIDERATIONS (CONT.) Can I receive wrong answers to problems by constraining parts incorrectly to my flexible body nodes? Yes, you must pay close attention to how you constrain parts to a node. Different types of elements can only support specific types of loads. For example, you have a cantilever beam that was created using brick elements. Brick elements only support translational DOFs. If you used a fixed joint to constrain a dummy part to a random node (one that was not spider-webbed to its neighbors), then the dummy part would be over-constrained. Possible solutions to this problem would be: use a different type of element, create a spider-web of elements near the node and promote the node to an attachment point in the FEM software, or attach this node to multiple neighbor nodes in Adams. The basic rule is to not do something to your model in Adams that you would not do to your model in your FEM software. S11-12 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation SPECIAL ADAMS MODELING CONSIDERATIONS The connection forces in my model don't have a fixed point of application. I have something sliding or bouncing on the flexible body. What can I do? There are two solutions to this problem: Create multiple nodal forces and turn them on or off as needed. Add dummy parts along the path of the load and attach joints or floating markers to the dummy parts. Keep in mind that the dummy part will act like a rigid lever giving rise to torque at the dummy part location. Can I use markers that are located directly on the flexible bodies in function expressions? Yes, but when you have a large number of active modes, you may find that performance suffers compared to using a marker on a dummy part. This has to do with how Adams uses finite differencing to generate a system Jacobian matrix. S11-13 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation SPECIAL ADAMS MODELING CONSIDERATIONS (CONT.) How do I measure deformation of a flexible marker? Decide which node you consider the undeformed node (what you might call a datum node). Attach a massless dummy part to this node. Create a marker on the dummy part coincident with the other flexible body marker, whose deformation you want to measure. The change in distance between the rigid and flexible markers is the deformation. Do I need to worry about the initial values of the modal coordinates in my model? Occasionally, Adams will deform the flexible body as it assembles the system (displacement/velocity ICs). This can lead to large transients during the dynamic solution. You can prevent or lessen this by setting modal ICs for the flexible body. Normally, there is no need to worry about the initial values of modal coordinates. S11-14 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation SPECIAL ADAMS MODELING CONSIDERATIONS (CONT.) I think my model may have nonlinear behavior. Can I use a FLEX_BODY? Some users have successfully used flexible bodies to model large displacements and spinning systems by breaking the body into multiple flexible bodies. Adams/Flex uses the principle of linear superposition to combine mode shapes to reproduce the total deformation of the flexible body. Therefore, a single flexible body cannot model nonlinear phenomena. However, you can piece together several flexible bodies to represent nonlinear deformations, as shown in this excerpt from the Adams/Flex online help. A twist-beam suspension is an application of nonlinear deformation. An example of a twist beam suspension modeled as an assembly of linear flexible bodies is shown in the Flexible Vehicle Suspension section of Appendix A. S11-15 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation CONCLUDING THOUGHTS This MNF file is huge. What can I do? Mode shape information is the bulk of the MNF content. Much of this mode shape information concerns nodes that you don't care about and if the inertia invariants have been pre-computed, you can discard this information. For instance: If your MNF uses solid elements, then you can automatically remove interior geometry without losing any nodes on the surface. If this is not enough, you can ask for automatic removal of surface nodes. Visual representation will suffer, and you must be careful not to discard any nodes you might need. You could use single precision instead of double precision when optimizing your MNF. Combining single precision with the removal of interior geometry will dramatically reduce the size of your MNF. Finally, if you don't care how your graphics look, you can replace the geometry in the MNF with a manually generated geometry, usually a stick figure through a subset of nodes. For example, consider the change in size when going from 100,000 nodes to 100 nodes. My MNF does not contain the invariants. What can I do? The MNF2MNF optimizer can compute invariants for existing MNFs. S11-16 ADM710, Section 11, July 2009 Copyright 2009 MSC.Software Corporation CONCLUDING THOUGHTS (CONT.) How do I get information about the stress in my components? You can use either of these two methods: Export your Adams loads: You can export the loads Adams generates and perform a static analysis in FEM software. Currently, you can export your loads to the following FEM packages: ANSYS, ABAQUS, and Nastran. Stress recovery in Adams You can include stress/strain information directly in your MNF. After running an analysis, you can use Adams/Durability along with Adams/PostProcessor to do the following: Animate dynamic stress or strain on flexible bodies Plot time histories of nodal stress or strain measures This capability is available in the following FEM packages: Nastran, Marc, ANSYS, ABAQUS, IDEAS, or Adams/AutoFlex during the creation of the MNF. For current information on our FEA vendors involvement in implementing this feature, see Knowledge Base article 9474, at: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB9474. S12-1 ADM710, Section 12, July 2008 Copyright 2008 MSC.Software Corporation SECTION 12 VALIDATING AND DEBUGGING S12-2 ADM710, Section 12, July 2008 Copyright 2008 MSC.Software Corporation S12-3 ADM710, Section 12, July 2008 Copyright 2008 MSC.Software Corporation VALIDATING AND DEBUGGING Whats in this section: Validating Your Flexible Body S12-4 ADM710, Section 12, July 2008 Copyright 2008 MSC.Software Corporation VALIDATING YOUR FLEXIBLE BODY Consider performing a quality test by validating your flexible body with FEA results: Check that mass, center-of-mass location, and inertia properties are correct. Compare FEA modes with undamped Adams/Linear results (free-free analysis). Compare maximum static deflection under various end conditions, such as pinned, cantilever, and so on. WS9-1 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING WS9-2 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WS9-3 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING Problem statement You've been simulating your models and have been noticing some difficulty with convergence and behavior that doesn't match test data or reality. You suspect that one or more of the four MNFs provided to you is erroneous. Determine whether or not the four MNF files are sources of error by comparing and validating against the results from an FEA package. FEA model description and results Solid cylindrical rod: Length: 600 mm Diameter: 20 mm Density: 2710.0 kg/m 3 (aluminum) The rod is meshed with 144 parabolic CPENTA solid elements. Static deflection with a gravity load and pinned-end conditions. WS9-4 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Notes: Gravity is -9.80665 m/s 2 in the global y direction. Deflection is measured at mid-span (node 420) in the global y direction. The reaction force is the magnitude of force (at either of the pinned ends). WS9-5 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Figure 7 shows the results from a Nastran normal modes analysis for the free-free structure. Figure 7. Nastran Free-Free Modes Rigid-body modes First free-free mode WS9-6 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Results table In the directory exercise_dir/mod_09_debugging, there are four MNF files: rod1.mnf rod2.mnf rod3.mnf rod4.mnf For each MNF file, you will perform several tasks. Everyone on the team completes Task 1: Estimating mass and deflection. For Tasks 2 through 7, divide the work among the members of your team, assigning one column of the table to each team member. For example, one person handles all tasks for rod1, another handles all tasks for rod2, and so on. If you encounter problems, work them out as a team. WS9-7 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 1. Perform all the steps in Task 1: Estimating mass and deflection and write the answers here: Mass __________________ Cantilever with gravity load Y1max __________________ Cantilever with applied torque Y2max __________________ Estimate of total Ymax __________________ 2. Follow the directions in the following table and fill it out using Y (yes), N (no), and entering numerical values on the lines, as needed. WS9-8 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation Tip deflection due to combined loading: does the Adams value match Nastrans (-0.5098 mm) within 1%? Complete Task 7: Performing a cantilever analysis (3) and then answer: Tip deflection due to moment: does the Adams value match Nastrans (2.877E-01 mm) within 1%? Complete Task 6: Performing a cantilever analysis (2) and then answer: Was static equilibrium for the cantilever analysis found without you having to alter the modal content? Did the flexible body model always solve without an error stating that MTX translation failed? Tip deflection due to uniform load: does the Adams value match Nastrans (-0.2221 mm) within 1%? Complete Task 5: Performing a cantilever analysis (1) and then answer: Do the free-free Nastran modes generally agree with the values from an undamped Adams/Linear analysis? Complete Task 4: Performing a free-free analysis and then answer: Does the mid-span global-y deflection (at node 420) agree with the Nastran results (-0.02185mm) within 1%? Does the global-y force in the spherical joint agree with Nastran results (2.499N)? Can you find static equilibrium for the flexible body? (If you encountered MTX translation failure, disable offending modes and rerun static.) Complete Task 3: Performing a pinned-end analysis and then answer: Is the total mass equal to the hand calculation (rounded at the second decimal place)? Y Is the flexible body center of mass located halfway between the ends (that is, z = 300mm)? Complete Task 2: Browsing the MNF, and then answer: Rod4 Rod3 Rod2 Rod1 WS9-9 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 3. Now that youve completed the entire table, you should have enough information to determine which MNF is the error-free one. The following three modal neutral files are sources of error. Identify the MNFs and state why you think they are in error: rod__.mnf: ___________________________________________________________ rod__.mnf: ___________________________________________________________ rod__.mnf: ___________________________________________________________ The error-free MNF is rod__.mnf. WS9-10 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 1: Estimating mass and deflection Estimate the mass and total tip deflection you would expect by using standard engineering calculations. To perform calculations: 1. Approximate the expected mass of the rod and fill in the blanks to complete the calculation: Now that youve calculated the mass, continue with calculating tip deflections. WS9-11 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 2. Approximate the tip deflection of the rod by using two standard beam theory calculations: Calculation A: Cantilever beam with uniformly distributed load WS9-12 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Calculation B: Cantilever beam with end moment WS9-13 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 3. Combine the deflections from calculations A and B for an estimate of the total tip deflection. 4. Summarize all the values youve calculated by recording them in the results table. WS9-14 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 2: Browsing the MNF Browse the MNF to determine total mass and the center of mass location. To browse the MNF: 1. Use the MNF Browser to open the MNF file. 2. Generate a report using the default settings. 3. Inspect blocks 6 and 11 of the report. 4. Go back to the results table and answer the questions for this task. WS9-15 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 3: Performing a pinned-end analysis You create a model in Adams that is equivalent to the Nastran pinned-end model. You then analyze it to see how it compares to the Nastran results. JOINT_2 JOINT_1 WS9-16 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) To build a model and perform an analysis: 1. Start a new Adams/View session, creating a new model using the defaults. 2. To create the design points, import the file create_points.cmd. 3. Depending on the column you are working on, import the appropriate flexible body (rod1.mnf, and so on), name it rod, and set Damping Ratio to use default. 4. Constrain the rod to ground by creating spherical joints at POINT_1 and POINT_2. 5. Place a marker on the rod at POINT_3. 6. Use that marker to build a measure for the global-y displacement at mid- span. 7. Build a measure at either JOINT_1 or JOINT_2 for global-y force. 8. Change your simulation settings for Adams/Solver (FORTRAN). 9. From the Main Toolbox, run a static equilibrium simulation. Notes: If the MTX translation fails, then disable the modes that cause the problem and solve again. The strip chart legends update with the static equilibrium values. WS9-17 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 10. Record these values in the results table. 11. Save the database so you can reuse this model in Task 4: Performing a free-free analysis. Task 4: Performing a free-free analysis You modify the model so it is equivalent to the Nastran free-free model. You then analyze it with Adams/Linear to see how it compares to the Nastran results. To perform the analysis: 1. Delete the strip charts. 2. Turn off gravity. 3. Delete the joints (select Delete All if given the option). The rod is now unconstrained and ready for the eigenvalue analysis. 4. Simulate using SIM_SCRIPT_1. The SIM_SCRIPT_1 script uses the following Adams/Solver commands: SIMULATE/STATIC LINEAR/EIGENSOL, NODAMPING WS9-18 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) 5. Save the eigenvalues to a file: In the Simulation Controls dialog box, select switch to linear controls. In the Linear Modes Controls dialog box, select Table. At the top of the Information Window, select Save to File to save the eigenvalues to a file. Tip: You can also save the eigenvalues to a file by using the Command Window. Open the Command Window and then use the command line to list the eigenvalues by entering: list_info eigen_values eigen_solution_name =... (Press the Esc key to complete the command, so it finds the correct eigensolution name). When the Information Window appears, select Save to File to save the eigenvalues to a file. 6. Compare the Adams/Linear results with the results in Figure 7: Nastran Free-Free Modes and answer the question in the results table. WS9-19 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 5: Performing a cantilever analysis (1) Validate your Adams model by comparing its results to the Nastran results. The following is the first of three cantilever analyses. It is an Adams analysis of the cantilever under a gravity-induced load; it is equivalent to the loading condition you calculated in Calculation A: Cantilever beam with uniformly distributed load. You are interested in the deflection of the tip. WS9-20 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) To perform the analysis: 1. Turn on gravity, using -9806.65 in the y direction. 2. Create a fixed joint at POINT_1. 3. Create a marker measure of global-y displacement of the tip at POINT_2. 4. From the Main Toolbox, run a static equilibrium simulation. Note: If the static simulation fails, review the modal content of the flexible body; see if any modes are strange, and if so, disable them. 5. Record the value in the results table. WS9-21 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 6: Performing a cantilever analysis (2) It is an Adams analysis of the cantilever under an end torque; it is equivalent to a loading condition you calculated in Calculation B: Cantilever beam with end moment. Again, you are interested in the deflection of the tip. WS9-22 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) To perform the analysis: 1. Turn off the gravity. 2. From the Create Forces tool stack, select the Three-Component Torque tool : Construction: 2 Bod-1 Loc, Normal to Grid Characteristic: Custom. First Body: rod Second body: ground Location: POINT_2. Set AZ Torque to 1000. 3. Perform a static equilibrium simulation. The strip chart legend updates. 4. Record the value in the results table. WS9-23 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Task 7: Performing a cantilever analysis (3) It is an Adams analysis of the cantilever under a combined loading condition; the resulting deflection is equivalent to the Total Ymax you calculated in Step 3. WS9-24 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) To perform the analysis: 1. Turn on the gravity and use -Y. 2. Perform a static equilibrium simulation. The strip chart legend updates. 3. Record the value in the results table. WS9-25 ADM710, Workshop 9, July 2009 Copyright 2008 MSC.Software Corporation WORKSHOP 9 VALIDATING AND DEBUGGING (CONT.) Module review 1. Is it sufficient to just compare the free-free modes? Why or why not? ______________________________________________________ ______________________________________________________ ______________________________________________________ 2. Would performing only the pinned analysis have been a sufficient validation test? Why or why not? ______________________________________________________ ______________________________________________________ ______________________________________________________ 3. What characteristic(s) of the results suggest when there might be a units mistake? Do you think youll be able to identify unit mistakes in your own models or the MNFs provided to you by others? ______________________________________________________ ______________________________________________________ ______________________________________________________ A-1 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation APPENDIX A EXAMPLES A-2 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation A-3 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation EXAMPLES Whats in this appendix: Industrial Robot Low-Voltage Circuit Breaker Flexible Go-Kart Comfort Tire Model Satellite with Flexible Panels and Antennas Flexible Vehicle Suspension Shell Panels for Missile Separation Landing Aircraft Flexible Vehicle Frame and Chassis Flexible Car Body in Passing Maneuver Pothole Passing with a Truck Rail Vehicle Comfort Calculations A-4 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation INDUSTRIAL ROBOT Effects of flexibility on joint forces Rigid versus flexible graphic results Rigid Flexible A-5 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation INDUSTRIAL ROBOT (CONT.) A-6 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LOW-VOLTAGE CIRCUIT BREAKER Simple geometry Structural springs including mass Very rapid dynamics Rigid versus flexible results A-7 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LOW-VOLTAGE CIRCUIT BREAKER (CONT.) Rigid Flexible Courtesy of ABB Research A-8 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LOW-VOLTAGE CIRCUIT BREAKER (CONT.) Courtesy of ABB Research A-9 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LOW-VOLTAGE CIRCUIT BREAKER (CONT.) Structural springs, including mass, become one- dimensional FE Where: K = Spring stiffness M = Spring mass A = Area of internal spring helicoid L = Spring length A-10 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LOW-VOLTAGE CIRCUIT BREAKER (CONT.) Courtesy of ABB Research A-11 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE GO-KART Account for frame flexibility to accurately simulate full-vehicle dynamics Model data: Weight: kart=55 Kg, driver=70 Kg About 7000 Nastran shell elements Dynamic data: Initial velocity: 100 Km/h Steering step maneuver: 30 deg at time = 1 A-12 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE GO-KART A-13 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation COMFORT TIRE MODEL Full ABAQUS nonlinear tire model translated into a flexible body ABAQUS model Material nonlinearities Inflation pressure Rim contact and friction Road contact interaction 120,000 DOFs Adams model Nonlinear multiple contact impacts 3D Linearized tire forces at the hub Nonlinear global displacements No spinning Speed-dependent tread forces < 50 active DOFs for 15 contact points A-14 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation COMFORT TIRE MODEL (CONT.) Courtesy of Pirelli Tires A-15 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation SATELLITE WITH FLEXIBLE PANELS AND ANTENNAS Stabilizing the satellites orientation during deployment of flexible solar panels Control system equation integrated with mechanical equations Six flexible bodies are present in the system Original Nastran meshes made with CQUADR and CTRIAR element types A-16 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation SATELLITE WITH FLEXIBLE PANELS AND ANTENNAS (CONT.) A-17 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE VEHICLE SUSPENSION Nonlinear deformation as an assembly of linear flexible bodies Courtesy of VW A-18 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation SHELL PANELS FOR MISSILE SEPARATION Two flexible bodies are present in the system Sudden explosion of the connecting bolts is simulated Contact forces on the structure supports have been defined Radial distance is dependent on internal pressure distribution A-19 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation SHELL PANELS FOR MISSILE SEPARATION (CONT.) Internal pressure fourbar A-20 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LANDING AIRCRAFT Airframe flexibility affects loading at control-surface hinges and landing-gear points Aeroelasticity effects could be included A-21 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation LANDING AIRCRAFT (CONT.) A-22 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE VEHICLE FRAME AND CHASSIS Courtesy of Fiat Research A-23 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE CAR BODY IN PASSING MANEUVER Obstacle-passing maneuver of a full-vehicle model including a flexible body Handling maneuvers on a vehicle with flexible chassis A-24 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation FLEXIBLE CAR BODY IN PASSING MANEUVER (CONT.) Courtesy of Leyland Trucks A-25 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK Pothole-passing maneuver of a full-vehicle truck model including a flexible frame Rigid versus flexible frame comparison of vertical accelerations at the drivers seat Calculation of automatic stress distribution for the most critical dynamic loading condition A-26 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Courtesy of Leyland Trucks A-27 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Model characteristics Multibody model Leaf springs - five-beam element per spring Bushing mounts (cab, engine, spring-dampers) modeled, including frequency- dependent data Tires modeled using University of Arizona Tire Model with Michelin data Dampers modeled with nonlinear cubic spline characteristics Steering system driven by simple closed-loop control algorithm Total of 123 DOFs Courtesy of Leyland Trucks A-28 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Flexible frame About 45,000 nodes and 260,000 DOFs About 45,000 CQUAD4 and TRIA3; about 5,000 CBAR element used 158 originally retained modes, of which 25 normal constrained and 133 static correction 18 modes after energy model reduction algorithm application Simulation 1.8 s run at 50 Km/h with right-sided 75 mm pothole 385 s CPU time on 250 MHz SGI Octane 1 GB Ram Courtesy of Leyland Trucks A-29 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Simulation results in Adams Vertical acceleration at drivers seat. Different response between rigid and flexible frame representation. The most significant feature of the different response in terms of acceleration plot is the vertical component shown here. With a rigid frame, the front wheel strike creates a shock, which dies away progressively. With a flexible frame, the initial shock begins to diminish, but then increases once more as the rear wheel impact shock propagates along the frame. The driver can feel the impact shock when he drives the vehicle over such a disturbance. Rigid body models fail to predict this effect. A-30 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Single-sided 75 mm pothole: 50 km/h impact Driver vertical acceleration Courtesy of Leyland Trucks A-31 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Simulation results transferred to Nastran Once the Adams run is completed, it is possible to automatically create a Loadcase file for Nastran which contains a selection of time steps from the original load history. Equivalent static analysis with inertia-relief technique is then submitted in Nastran. Von Mises stress distribution after the right wheel has struck the trailing edge of the pothole are shown. Little stress over-estimation due to tire enveloping effect and absence of bumpstops. Impact occurs on the right-end side, but the highest stresses appear on the left of the frame due to the steering linkage forces. A-32 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation POTHOLE PASSING WITH A TRUCK (CONT.) Courtesy of De Dietrich A-33 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation RAIL VEHICLE COMFORT CALCULATIONS The purpose of this work is to evaluate coach flexibility influence on vehicle comfort Vehicle design ANSYS coach model Adams/Rail vehicle model with flexible coach A-34 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation RAIL VEHICLE COMFORT CALCULATIONS (CONT.) Analysis on a Straight Track with Vertical, Transversal and Cant angle excitation Train Velocity = 38.9 m/s Vertical Transversal Cant A-35 ADM710, Appendix A, July 2008 Copyright 2008 MSC.Software Corporation RAIL VEHICLE COMFORT CALCULATIONS (CONT.) ANSYS coach model Human factor filters Weighted Vertical Acceleration RMS Value Flexible coach RMS = 0.0448 m/s 2 Rigid coach RMS = 0.0362 m/s 2 UIC 513 acceleration weighting criteria Frequency weighting transfer functions Vertical acceleration time history Weighting curve Weighted vertical acceleration PSD B-1 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation APPENDIX B MAKING AN MNF USING FEM SOFTWARE B-2 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation B-3 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation MAKING AN MNF USING FEM SOFTWARE Whats in this appendix: ABAQUS ANSYS I-DEAS Nastran Marc Other MSC Products B-4 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation ABAQUS ABAQUS by ABAQUS, Inc. ABAQUS, Inc. sells a program for directly creating MNF files called ABAQUS/ADAMS. ABAQUS/ADAMS Product Description: http://www.simulia.com/products/complementary_tools.html? analInter?im01#adams For more information about ABAQUS, go to: http://www.simulia.com/ For more information, see the ABAQUS documentation in the ABAQUS/ADAMS User's Manual and the example ABAQUS input files in the directory install_dir/flex/examples/ABAQUS. For detailed information, see the Translate tab in the Adams/Flex online help. B-5 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation ANSYS ANSYS by ANSYS, Inc. The ANSYS (5.6 and later) program has a macro (ADAMS.mac) that will export an MNF file directly. The macro orthonormalizes the modes. All support for the ADAMS.mac is handled directly through ANSYS' support channels. Macro syntax is straightforward. To give you a general idea, the following command will export an MNF with 10 normal modes: ADAMS,10,1 For more information about ANSYS, go to: http://www.ansys.com/ You can find example ANSYS input files in the directory install_dir/flex/examples/ANSYS. For detailed information, see the Translate tab in the Adams/Flex online help. B-6 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation I-DEAS I-DEAS by UGS You can obtain an MNF of a flexible component in I-DEAS by performing a Superelement Creation analysis of the component's finite element (FE) model. This will directly export an MNF from I-DEAS Master Series (MS). For information on whats available in MS9 and MS10, contact your UGS sales representative. Technical support for using the program files is handled directly by UGS support: http://support.ugs.com/. For more information about I-DEAS, go to: http://www.ugs.com/products/nx/ideas/ For detailed information, see the Translate tab in the Adams/Flex online help. B-7 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation NASTRAN Nastran 69.x, 70.x, or 2001 Requires special DMAP alter and deck preparation procedure. The deck preparation procedure is documented in several places: Adams/Flex online help Within header of DMAP README file within installation directory DMAPs and example data deck files are shipped with Adams (/install_dir/flex/examples/MSCNASTRAN). B-8 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation NASTRAN (CONT.) Nastran 2004 Nastran 2004 provides an improved interface for generating MNFs. The new Nastran-Adams Interface allows you to generate an MNF directly from Nastran without generating an OUTPUT2 file. The Nastran-Adams Interface does not require a DMAP alter or a translator to convert Nastran output files to MNFs. The advanced functionality of the Nastran-Adams Interface is a licensed feature of Nastran. For more information, contact your local sales representative. If you already have the Nastran-Adams Interface license, see the Nastran Quick Reference Guide and Reference Manual for information. B-9 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation NASTRAN (CONT.) Nastran 2004 continued For more information about MSC.Nastran, go to: http://www.mscsoftware.com/products/nastran.cfm?Q=396& Z=401 For detailed information, see the Translate tab in the Adams/Flex online help. B-10 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation MARC You can generate MNF's using Marc 2003. This process is divided into two steps: 1. Generate a results file (either T19 or T16) from Marc. 2. Translate the Marc results file into an MNF by using the marctoadams executable. This executable is located in the following directory: <Marc v2003 install dir>/bin. Documentation on the commands that should be used to generate an MNF file can be found in the following documentation for Marc 2003: Program Input Manual, Volume C, pages 3-106 and 3-107 Theory and User Information, Volume A, pages 12-29 and 12-30 B-11 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation MARC (CONT.) Marc 2004 eliminates the need for the marctoadams translator and allows the MNF to be written directly by Marc. It will also support modal preloads, modal loads, and stress and strain modes. For more information on this process, contact the Marc technical support team: Email: mscmarc.support@mscsoftware.com Phone: 1-800-732-7284 You can find example files in the following KBA: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB10640 B-12 ADM710, Appendix B, July 2008 Copyright 2008 MSC.Software Corporation OTHER MSC PRODUCTS You can also use Patran and SimDesigner (for CATIA v5 and v5i) to create MNFs. Detailed steps on how to generate MNFs from these products can be found in the following KBAs: Patran: http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB10471 Dynamic Designer (for CATIA v5 and v5i): http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- KB10434 C-1 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation APPENDIX C ADAMS/VIEW COMMAND LANGUAGE SYNTAX C-2 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation C-3 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation ADAMS/VIEWCOMMAND LANGUAGE SYNTAX Whats in this appendix: Flex Body Establish the Selected Modes Modifying/Disabling Modes Visualization Attributes Auto-generated Matrix Flex Body Markers C-4 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation FLEX BODY part create flexible_body name_and_position & flexible_body_name = FLX_87 & adams_id = 87 & modal_neutral_file_name = ../my.mnf & matrices = .m1.FLX_87_GENSTIFF, ...& damping_ratio = (none) & location = 10, 40, 300 & orientation = 90d, 20d, 0d & invariants = yes, yes, yes, yes, no, yes, yes, yes, no C-5 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation ESTABLISH THE SELECTED MODES part create flexible_body modal_ics & flexible_body_name = FLX_87 & selected_modes = 7, 8, 9, ... & initial_modal_velocities = 30, 0, ... & <more ...> C-6 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation MODIFYING/DISABLING MODES part modify flexible_body modal_content & flexible_body_name = .robot.FLEX_FOREARM & operation = "disable" & by = "mode_number" & above = 11 C-7 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation VISUALIZATION ATTRIBUTES part modify flexible_body visual_representation & flexible_body_name = FLX_87 & scale_factor = 2.0 & contour_plots = yes & vector_plots = no & mnf_graphics = yes & outline_graphics = no & datum_node_for_deformation = 1024 C-8 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation AUTO-GENERATED MATRIX data_element create matrix file & matrix_name =.m1.FLX_87_GENSTIFF & adams_id = 1 & comments = & ***MATRIX AUTOMATICALLY GENERATED BY ADAMS/VIEWDO NOT EDIT***, & ***Generalized Stiffness & file_name = Adams_FLX_87.mtx & name_of_matrix_in_file = GENSTIFF Note: This matrix file dependency is not exported to command files in Adams/View 2003 and above. C-9 ADM710, Appendix C, July 2008 Copyright 2008 MSC.Software Corporation FLEX BODY MARKERS marker create & marker_name = .m1.FLX_87.MARKER_34 & adams_id = 34 & node_id = 4377 & location = 0, 50, 0 & orientation = 0d, 90d, 0d D-1 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation APPENDIX D ADAMS/VIBRATION FREQUENCY DOMAIN ANALYSES D-2 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation D-3 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation ADAMS/VIBRATION FREQUENCY DOMAIN ANALYSES Whats in this appendix: Adams to Nastran for NVH Nastran Modal Export for Frequency Domain Stress Recovery Frequency Response Function Plots for Stress and Strain D-4 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation ADAMS TO NASTRAN FOR NVH Adams2Nastran Allows you to easily export the linearized model directly from within the Adams/Vibration environment Export to MD Nastran SOL 107 Direct Complex Eigenvalues SOL 108 Direct Frequency Response Example http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- 43125311 D-5 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation NASTRAN MODAL EXPORT FOR FREQUENCY DOMAIN STRESS RECOVERY Modal Stress Recovery (MSR) Recovering stresses on flexible bodies Nastran modal export feature allows you to export modal coordinates and further recover stresses (and/or strains) using MD Nastran. Example http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- 43125354 D-6 ADM710, Appendix D, July 2008 Copyright 2008 MSC.Software Corporation FREQUENCY RESPONSE FUNCTION PLOTS FOR STRESS AND STRAIN New Nodal Info menu item Vibration menu > Build MNF must contain stress and/or strain modes Stress and strain Frequency Response Function (FRF) at grid locations on a flexible body can be plotted in Adams/PostProcessor Example http://support.mscsoftware.com/kb/results_kb.cfm?S_ID=1- 43084321 E-1 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation APPENDIX E ANSWER KEY E-2 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation E-3 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY Whats in this appendix: Answer Key for Workshop 1 Answer Key for Workshop 2 Answer Key for Workshop 3 Answer Key for Workshop 4 Answer Key for Workshop 5 Answer Key for Workshop 6 Answer Key for Workshop 8 E-4 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 1 Step 4: The frequency of system mode 8 is 256.7 Hz. Step 7: Mode 8 is important because it looks like a bending mode that would cause the lever arm to buckle or break when you are crushing a can. Module review: 1. Both component mode 8 and system mode 8 look similar because they are bending modes. The system mode has a frequency that is slightly lower. Design changes that affect this component mode would be expected to directly affect the system mode. E-5 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 1 (CONT.) 2. It would probably make more sense to measure the Y-torque in the revolute joint using a moving reference frame, FLX_LEVER.MARKER_5, on the flex-body itself. This could be accomplished by modifying the measure to be as follows: measure modify object & measure_name=.cancrusher.LVR_CPLR_REV_MEA_TY & object=.cancrusher.LVR_CPLR_REV & characteristic = "element_torque"& component = "y_component" & from_first = no & coordinate_rframe = .cancrusher.FLX_LEVER.MARKER_5 E-6 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 2 Optional tasks: 1. Yes. 2. No. The Adams/View .bin file has stored the path to the MNF file that was there when you created it. If this path has changed, then Adams/View wont be able to find the MNF, and therefore, cannot display the mesh geometry or create the .mtx files. Module review: STEP5 is preferable in this application because it does not introduce instantaneous accelerations like STEP would. Notice how STEP5 is smooth and differentiable throughout. STEP, on the other hand, has some sharp changes in curvature and peaks with undefined derivatives, all of which are unrealistic. E-7 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 3 Step 2: The CPU time used is ~130 seconds. Step 2: The elapsed time is ~40 seconds. Step 6: Disabling the modes hasnt changed the measure results too drastically. The oscillatory behavior has been captured and the peaks are only slightly diminished. The simulation is faster due to disabling modes. The run times will improve with an energy tolerance of 1e-5. The misc/modes_comparison.txt file shows a table of different run times. E-8 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 3 (CONT.) Optional Tasks 1. In some cases, the CPU time will increase. This can be due to disabling required modes. You may also see less deflection. 2. You should see additional markers in robot_module4.adm. These were created when use the 3 point method to align the flexible body. 3. There should be a number of differences, but the most important differences are the different interface nodes and the additional modes in robut_module4.adm. 4. The results should not degrade significantly. E-9 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 4 Step 2: robot_arm_hard.mnf 7011 KB forearm_hollow.mtx 26 KB Step 7: Are the nodal masses included in the MNF? Yes Are the generalized K and M included in the MNF? No Are the invariants included in the MNF? No Are the nodal coordinates included in the MNF? Yes Are the eigenvalues included? Yes Step 8: Mass = 82.1347 kg Interface node numbers: 4001, 4002, 4003 Step 7: The information stored in the MNF was: nodal coordinates, element faces, eigenvalues, mode shapes, global mass properties, nodal masses, mode transformation, interface nodes, and inertia invariants. There are 530 nodes in the model. There are 42 modes in the model. The number of element faces in the model was 1104. E-10 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 4 (CONT.) Step 9: The information stored in the MNF was: nodal coordinates, element faces, eigenvalues, mode shapes, global mass properties, nodal masses, mode transformation, interface nodes, and inertia invariants. There were 19 nodes in the model. There were 42 modes in the model. The number of element faces in the model was 8. Step 4: The CPU time was approximately 25 seconds (times may vary). Step 6: The graphics look very similar, if not identical to the original flexible body model. E-11 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 4 (CONT.) Step 4: The CPU time used was approximately 25 seconds (times may vary). Step 6: The graphics look similar, but display more relative bending near the middle of the robot arm. The middle of the robot arm was blue, but now it is green. This is due to the interpolation of the deformation colors being smeared between the two far ends of the robot arm. E-12 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 4 (CONT.) Table 1: ~25 seconds ~25 seconds ~40 seconds CPU time 36 KB 36 KB 26 KB Size of MTX 69 KB 1114 KB 7011 KB Size of MNF Yes Yes No Invariants included? Yes Yes Yes Nodal coordinates included? No No Yes Nodal masses included? manual_opt.mnf external_mesh. mnf robot_arm_hard. mnf Table 1. Comparison of MNFs E-13 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 4 (CONT.) Step 4: Yes, the modes look the same. Step 8: The modes do not look the same. They appear very different. For example, the first bending mode (Mode 7) causes the robot arm to appear to be not bending at all. Module review: external_mesh.mnf This MNF has the best graphical resolution of the mode shapes, and is a lot smaller than the original MNF (16% of the original size). Therefore, no important graphical information is lost, but the file is small enough to be easily sent to a vendor. E-14 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 5 Step 4: The node numbers of the attachment points are 2000 and 3000. Step 5: The units are: kg, m, s, and N. Step 3: The ADAMS ID for the current flexible body is 1. The units are: mN, kg, mm, sec. NODE_ID is used for markers on flexible body. FILE is used in matrix and FLEX_BODY MNF argument. No, the units do not agree. Generating the matrix file: Include nodes 2000 and 3000. E-15 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 5 (CONT.) Step 11: All should be Yes. Investigating the warnings and error: 1. Think through the following: We used Fast Invar to skip INVAR5 and 9, but the MATRIX statements we pasted into the adm still have references to these matrices, which arent really there. No. No. 2. Think back through the changes you made: 14 No, there are 12 INVAR5 and INVAR9 Step 3: Change NODE_ID for MARKER/11012 to 2000. E-16 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 5 (CONT.) Inspecting results: 2. The amplitudes of vibration are smaller for module6. In this case, its probably due to the use of linear tetrahedron, rather than parabolic, elements. 5. Because shells aren't contained in the .adm file. Optional Tasks 1. 50 Hz. Module review 1. Yes, it would have been easier to use Adams/View because most of the information covered in this workshop is done behind the scenes in Adams/View. 2. Some of the advantages of using external Adams/Solver are: No need to check out an Adams/View license. Greater control over making quick and subtle changes. Useful when you want to run in batch mode. E-17 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 6 Step 8: Because the vacuum structure is unable to support a load at that location. Step 7: When the sheet falls on the TABLE, it bounces a little. Step 4: Yes Step 7: When the sheet falls on the TABLE, it rebounds higher than the rigid sheet. Step 8: Reason: The vacuum force has drawn the sheet inward, deforming it and storing potential energy like a spring. When the vacuum force is removed, the sheet springs back, ejecting itself from the vacuum surfaces. E-18 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 For table in Step 1: E-19 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) For the table in Step 2: Y Y Y N Do the free-free Nastran modes generally agree with the values from an undamped Adams/Linear analysis? Complete Task 4: Performing a free-free analysis and then answer: Y -0.02182 Y -0.02184 Y -0.02185 N -2.185E-05 Does the mid-span global-y deflection (at node 420) agree with Nastran results (-0.02185mm) within 1%? Y 2.499 Y 2.499 Y 2.499 N 0.002499 Does the global-y force in the spherical joint agree with Nastran results (2.499N)? Y Y Y Y Can you find static equilibrium for the flexible body? (If you encountered MTX translation failure, disable offending modes and rerun static.) Complete Task 3: Performing a pinned-end analysis and then answer: Y Y Y N Is the total mass equal to the hand calculation (rounded at the second decimal place)? Y Y Y Y Is the flexible body center of mass located halfway between the ends (that is, z = 300mm)? Complete Task 2: Browsing the MNF, and then answer: Rod4 Rod3 Rod2 Rod1 E-20 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) For the table in Step 2: N -0.003950 N -0.4341 Y -0.5098 N -0.2879 Tip deflection due to combined loading: does the Adams value match Nastrans (-0.5098 mm) within 1%? Complete Task 7: Performing a cantilever analysis (3) and then answer: N 0.0000 N -0.2575 Y -0.2877 Y -0.2877 Tip deflection due to moment: does the Adams value match Nastrans (2.877E-01 mm) within 1%? Complete Task 6: Performing a cantilever analysis (2) and then answer: N Y Y Y Was static equilibrium for the cantilever analysis found without you having to alter the modal content? Y Y Y Y Did the flexible body model always solve without an error stating that MTX translation failed? N -0.003950 N -0.1766 Y -0.2221 N -2.221E-04 Tip deflection due to uniform load: does the Adams value match Nastrans (-0.2221 mm) within 1%? Complete Task 5: Performing a cantilever analysis (1) and then answer: Rod4 Rod3 Rod2 Rod1 E-21 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) For Step 3: The following three modal neutral files are sources of error. Identify the MNFs and state why you think they are in error: rod1.mnf: The wrong units were used (misleading DTI entry). rod3.mnf: No attachment points were used, cant capture end- condition behavior of cantilever. rod4.mnf: Rotational DOF exists at attachment point. The error-free MNF is rod2.mnf. For Calculation A: Cantilever beam with uniformly distributed load: 1. Approximate the expected mass of the rod and fill in the blanks to complete the calculation: MASS = VOLUME * DENSITY MASS = 0.5108 kg E-22 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) 2. Approximate the tip deflection of the rod by using two standard beam theory calculations: W = m*g = (0.5108kg) * (9.80665m/s2) = 5 N (rounded off) Y 1 max = range of -0.2083 to -0.2087 mm E-23 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) For Calculation B: Cantilever beam with end moment: Assumption: cantilever attachment with a 1000 N-mm applied torque at the free end. Y 2 max = -0.2778 mm Combine the deflections from calculations A and B for an estimate of the total tip deflection. Total Ymax = Y 1 max + Y 2 max = (-0.2083 mm) + (-0.2778 mm) Total Ymax = range of -0.4861 to -0.4865 mm Step 1: No, the free-free modes did not capture the MNFs that had problems with attachment points. E-24 ADM710, Section E, July 2008 Copyright 2008 MSC.Software Corporation ANSWER KEY FOR WORKSHOP 9 (CONT.) Step 2: No, the pinned analysis only pointed out the MNF with unit problems. The other three MNFs results were almost identical. Step 3: The first clue that a unit mistake had occurred was during the verification of the mass. This clearly showed that the units were not correct for rod1.mnf because the mass was incorrect.