Mechanical Nonlin 13.0 WS 09A Diagnostics

Customer Training Material
W k h 9A Workshop Contact Diagnostics g
ANSYS Mechanical Structural Nonlinearities

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved. Release 13.0 December 2010
WS9A-1
Workshop 9A: Diagnostics

Goal
Diagnose convergence trouble with surface body contact model
Model Description
3D Spring plate Surface Body 3D Rigid Target Body Linear steel material Meshed with 3D SHELL elements Spring Fixed support at one end, A Rigid Body displaced into Spring 19mm
ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.
WS9A-2
Release 13.0 December 2010

Steps to Follow:
Restore Archive browse for file W9a-diagnostics.wbpz
Save as
File name: W9a-diagnostics Save as type: Workbench Project Files (*.wbpj) ( .wbpj)
WS9A-3

The project Schematic should look like the picture to the right.
From this Schematic, , you y can see that the Engineering (material) Data and Geometry have already been defined (green check marks). It remains to set up and run the FE model in M h i l Mechanical Highlight the Engineering Data Cell and open by clicking on the Right Mouse Button (RMB)=>Edit to verify the linear material properties. Verify y that the units are in Metric(Tonne,mm,..) ( , , ) system. If not, fix this by clicking on Utility Menu=>Units=>Metric(Tonne, mm,..)
WS9A-4

Return to Project Schematic
Utility Menu > Return to Project
D Double bl click li k on the th Model M d l Cell C ll to t open the th FE Model M d l (Mechanical (M h i l Session) (or RMB=>Edit)
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Unit > Metric (mm,kg,N,s,mV,mA)
Once inside the Mechanical application, verify the working unit system The spring assembly is already set up with frictionless contact pairs, a fixed boundary condition and a displacement load on the rigid component. component Highlight the entities beneath each folder to become familiar with the model and to confirm that it is properly supported and loaded and ready to solve.
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Confirm the Analysis Settings Specifications as shown:
Run the Solution Solution
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The model solves without error.
After solution run is complete, highlight the Solution Information folder and scroll to near the bottom of the output.
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Review the Total Deformation results.
Something is wrong. The contact relationship between the two parts has obviously failed.
WS9A-9
With 25 initial substeps and Auto Time Stepping turned On, the contact should have engaged. In an effort to determine the problem, we will evaluate what the initial condition of the contact pairs are. Highlight the Connections Folder: RMB> Insert> Contact Tool
Highlight the Contact Tool: RMB>Initial Information>Generate Initial Contact Results. This will run a partial solve to establish initial contact parameters (i,e. Initial status, gap, penetration, etc).
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Review the Initial Contact Information. Note the following:
The two active pairs both have an initial status of Far Open Both B th pairs i have h a pinball i b ll radius di of f 4mm. 4 Is I 4mm 4 enough? h?
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By studying a profile of the undeformed geometry we can see that the initial gap is less then 1.50mm. Hence, the Pinball Radius of 4mm should be sufficient for this contact pair to be in an initial status of near-open.
Rigid Target Spring
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Hi Highlight hli ht the th contact t t region i representing ti the th contact t t between b t the th spring i and target.
In order for contact to work properly, the contact element normals must be facing the target g element normals. Recall that surface bodies are meshed with shell elements that have a top and a bottom face. The reason this contact pair is not working is because the contact normals are on the wrong side of the surface body with normals that face away from the target target. This needs to be reversed reversed.
Target element normal direction Contact element normal direction
WS9A-13
From the details window of the contact region, switch the contact shell face from Bottom to Top . The red color highlighting the contact side should switch.
WS9A-14

Highlight the Solution Information Branch
Set Newton-Raphson Residuals = 3 This will save force imbalance data for the last 3 3 Newton Newton-Raphson Raphson iterations. iterations This is especially helpful information for troubleshooting troubling contact convergence problems.
Rerun the solution
WS9A-15
From the Solution Information Branch, the contact is now engaging, but the solution fails to converge after several iterations.
WS9A-16
These first two converged substeps likely represent the trivial solutions that occur as the small gap between the two parts is being closed and no contact has been made yet. This first Thi fi t spike ik in i the th Newton-Raphson N t R h residual id l (measure ( of imbalance) likely occurs at the point when contact first engages. From there on out, the solution struggles and fails after two bisections and many y iterations to find a balance.
WS9A-17
A plot of Newton-Raphson Residual (measure of force imbalance in the model) confirms that the point where contact is engaged is the source of the highest imbalance .
WS9A-18

Highlight both Contact Regions and change the contact specifications in the details window.
Augmented Lagrange is recommended for general contact Reducing the contact stiffness factor will reduce the calculated force generated at the contact surface and thereby reduce the imbalance
Re-run the solution

WS9A-19

The solution now converges very nicely with no bisections
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Review R i th Total the T t l Deformation D f ti results. lt
Although this solution is now converged, notice the excessive penetration. This is because, by default the shell contact detection points are at the midplane of the shells.
This can be remedied by adding a command object to the contact elements with the following command: KEYOPT,cid,11,1 (refer to Element manual documentation on CONTA174 and the KEYOPT command) This command will include an adjustment for the shell thickness.
WS9A-21

EXTRA CREDIT !! Highlight each Contact Region and d RMB > I Insert t > Commands C d
Inside the command object and type the command as shown
* * Refer to Element Reference documentation on CONTA174 along with Command Manual documentation on KEYOPT
Re-run the solution

WS9A-22

Review the Total Deformation results as before.
Shell thickness is now properly accounted for.
WS9A-23

Mechanical Nonlin 13.0 WS 09A Diagnostics

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Customer Training Material

W k h 9A Workshop Contact Diagnostics g

ANSYS Mechanical Structural Nonlinearities

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

Diagnose convergence trouble with surface body contact model

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

Run the Solution Solution

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material

Rigid Target Spring

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 9A: Diagnostics

Customer Training Material