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Composites modelling:
Modelling and Finite Elements (continued)
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1.
2.
3.
Nodal damping
4.
Contact treatment
Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
.
Extract from: NAFEMS (National Agency for Finite Element
Methods and Standards) A finite element primer
Clear meshing rules are difficult to define, much depends on experience and instinct.
Carefully study and examine the results check for meshing/analysis errors and look
for possible mesh improvements.
3
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
t, E, .
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Composites modelling:
Modelling and Finite Elements (continued)
Final FE Mesh
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Composites modelling:
Modelling and Finite Elements (continued)
good
poor
Aspect ratio
Avoid poor aspect ratio
elements
Warping
Avoid warped shell elements
ETC.
7
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Composites modelling:
Modelling and Finite Elements (continued)
Grading of FE meshes
Incorrect way of joining meshes
Incompatible displacement fields
between elements due to free nodes
holes will appear in the structure!
A
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
10
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Composites modelling:
Modelling and Finite Elements (continued)
ST RESS
CONT OURS OF SY
0
0.23828
0.47656
0.71484
0.953121
1.1914
1.42968
1.66796
Poor
Better
F 1.90624
2.14452
2.3828
2.62108
2.85936
3.09764
3.33592
3.5742
C
E
M ax 3.632 at Node 1
M in -0.1801 at Node 40
B
A
Good
Note:
E
Z
F
G
H
I
JK
L
X
MN
Local mesh
around the
notch
11
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Composites modelling:
Modelling and Finite Elements (continued)
Explicit: Crash
E.g. buckling:
In buckling problems:
1. Explicit codes for crash and folding/buckling
2. Implicit codes for buckling (Eigenmode) analysis
The mesh must be fine enough to capture the required
physical buckling modes.
Implicit: Eigenmodes
Z
12
True
(physical)
folding
mode
Best folding
mode with
coarse mesh
Necessary element
sizes to capture
the physical folds
MODE
1
EIGENVALUE
53.5783
FREQUENCY
ERROR NORM
1.16497
0.606236E-12
0.458210E-12
57.7202
1.20916
-57.7215
0.000000E+00 0.477816E-12
-62.1734
0.000000E+00 0.404732E-12
62.1760
1.25496
0.926765E-12
63.1296
1.26455
0.190411E-10
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Composites modelling:
Modelling and Finite Elements (continued)
13
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Composites modelling:
Modelling and Finite Elements (continued)
2. Circular symmetry
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Composites modelling:
Modelling and Finite Elements (continued)
Pressure loads are distributed to nodes; note that nodal loads depend on the area they
act over.
Distributed 100N/mm2
50N
100 100
50
50
100
100 75 50 50 50
25
0.5mm
1mm
15
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Composites modelling:
Modelling and Finite Elements (continued)
Dmax =
12.53mm
Y
X
LOAD CASE
RESULTS FILE =
DISPLACEMENT
1
1
CONTOURS OF DY
-1,59696
-1,49715
-1,39734
-1,29753
-1,19772
-1,09791
-0,998098
Loadcase 1
-0,898288
-0,798478
-0,698669
Distributed loadings at
mid span of a beam
Dmax =
1.6mm
-0,598859
-0,499049
-0,399239
-0,299429
-0,19962
-0,0998098
Max 0.0000E+00 at Node 1
Min -1.597 at Node 20
16
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Composites modelling:
Modelling and Finite Elements (continued)
Simplified FE models
A correct model of the part and loadings/BC can be difficult to make and require alot of effort
to get right (+ CPU expensive); but a simplified model can provide quick and valuable
information to help guide a design.
The simplified model can help understand:
Failure mechanisms.
Means to increase performance (even if it does not
accurately predict maximum load).
Or other effects (e.g. points of max stress )
17
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Try to model
supports accurately
Composites modelling:
Modelling and Finite Elements (continued)
18
Maximum
load [kN]
Change in failure
load
Reference model
1,68
2,07
+23%
2,08
+23%
2,55
+51%
2,503
+49%
2,38
+42%
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
10
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Composites modelling:
Modelling and Finite Elements (continued)
Fj(=-Fi)
Fi
u j= 0
ui
ui = 0
uj
Fi EA / L EA / L ui
=
F j EA / L EA / L u j
In matrix form
{F }= [K ]{d }
Fi k
=
F j k
Fj = (EA/L)*(-ui+uj)
21
Spring stiffness
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Fj
Stiffness matrix
k ui
k u j
Composites modelling:
Modelling and Finite Elements (continued)
L2
E1, A1
E2, A2
k1 = E1A1/L1
k2 = E2A2/L2
u2
u1
2 ,
F2
Element 1
k1
k
1
Element 2
k2
k
2
2
F1=- f11
Force equilibrium
f11
u3
u 1 , F1
F1
3,
F3
dof
k1 u1 f
=
k1 u 2 f
1
1
1
2
Internal
nodal forces
dof
k 2 u2 f 22
=
k 2 u3 f 32
22
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Composites modelling:
Modelling and Finite Elements (continued)
u1
u2
u1
u3
u2
u3
d.o.f.
0
0 0
0
k
2
k 2
Element 2 only
0 k 2 k 2
k 1 k 1 0
Element 1 only k 1 k 1 0
0
0 0
ASSEMBLY
Global stiffness matrix of the assembly
[K ]{U } = {F }
1
k1
k1
k k + k
1
2
1
k2
0
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dof
= F1
0 u1 F1
k 2 u2 = F2
k 2 u3 F3
= F3
External loads
Composites modelling:
Modelling and Finite Elements (continued)
k1
k1
k k + k
1
2
1
0 0 k 20
Operations done
to enforce u3 =0
= -P
0 0 u1 F1
k 20 u2 = F2
=0
0
k 2 1 u3 F3
u2 = - P / k2
1
P
2
1
3 dof
2
u1 = -P / k1 - P / k2
u3 = 0
24
Ditto for 2
Exercise: Impose the constraint at d.o.f 2; what are the expressions for displacement
and strain? (hopefully 2 = 0).
12
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Composites modelling:
Modelling and Finite Elements (continued)
[k2]
[k1]
[k3]
[K]
25
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Composites modelling:
Modelling and Finite Elements (continued)
{P}
{P} = [K ]{u}
{u} = [K ]1{P}
{u}
For STATIC linear
problems [K] = constant
{P}
constant
[K ] =requires
a simple
linear solution
[K ]
constant
requires a non-linear
(iterative) solution;
e.g. interative
Newton-Raphson
{u}
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Composites modelling:
Modelling and Finite Elements (continued)
P
P=
24dEI
a (3L2 4a 2 )
Linear FE analysis
Analytical formulae
Point A (limit of
linear assumption)
varies depending
on the problem:
loading
geometry
materials.
Explicit FE analysis
Non-linear FE analysis
Linear analysis
region
Non-linear
analysis region
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Composites modelling:
Modelling and Finite Elements (continued)
14
Composites modelling:
Modelling and Finite Elements (continued)
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Explicit method
Implicit method
{P} = [K ]{ }
Load
Stiffness
Displacements
(3)
Advantages:
Advantages:
Static problems
29
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Composites modelling:
Modelling and Finite Elements (continued)
Main codes
Literature
Industry
Car companies
Applications
30
Explicit FE
1.
2.
3.
4.
5.
6.
90%
1.
2.
3.
4.
5.
6.
DYNA3D
PAMCRASH
PAMSTAMP
PAMFORM
RADIOSS
ABAQUS explicit
Others
1.
2.
3.
4.
5.
6.
CFD codes
Vehicle dynamics
Welding simulation
Casting simulation
Vibro-acoustics
....
10%
90%
10%
50%
Stress Analysis
Stiffness
Eigenvalue (vibrations)
Flow problems; eg
Heat, Magnetism.
Fatigue
.
1.
2.
3.
4.
5.
Crash
Safety
Stamping
Biomechanics
..
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
m&x& + kx = f (t )
k
known
starting
point
&x&(t )
f (t ), x , x&, &x&
m&x&n + kxn = f n (t )
&x&n
&x&n 1
(1)
&x&n = m 1 ( f n kxn )
( 2)
(3)
x& (t )
x&n +1 / 2
x&n 1 / 2
x (t )
tn
tn +1 / 2
xn +1
xn
tn 1
tn 1 / 2
tn
tn +1 / 2
tn +1
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Composites modelling:
Modelling and Finite Elements (continued)
t
k = EA/L
L, E, ,
c= E
bar
spring-mass
L
c
Small elements (small L) are bad for the timestep (small) >> High CPU cost
Similarly, stiff (large E) or light elements (low ) also reduce the timestep
The timestep criteria ensures that the shock wave (information) does not pass more than
one element in one timestep
Note: The worst (smallest timestep) computed for all elements in the structure is
used for analysis! Unless specialised sub-cycling techniques are activated.
34
17
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Composites modelling:
Modelling and Finite Elements (continued)
m&x& + kx = f (t )
Known at n
m&x&n+1 + kxn+1 = f n+1 (t )
To find
( x& x& )
&x&n+1 = n+1 n
tn
f (t ), x, x&, x&&
&x&(t )
x&n+1 =
( xn+1 xn )
(x x )
x&n = n n1
tn
tn
&x&n+1 =
&x&n +1
known
&x&n
x& (t )
x&n +1
x&n
m
(2xn xn1 )
tn2
m
2 + k
tn
f n+1 +
x (t )
tn
xn +1
xn
tn 1
tn
tn +1
xn+1 =
t
k is function a function of xn+1
(iterative solution required)
35
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Composites modelling:
Modelling and Finite Elements (continued)
x n+1 =
f(
x n+1 =
36
f(
18
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Composites modelling:
Modelling and Finite Elements (continued)
Explicit analysis requires a small time step. This leads to many, but
CPU cheap solutions: Contact, material and geometrical nonlinearities
are easily handled.
Equations to be solved:
Static problems:
37
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Composites modelling:
Modelling and Finite Elements (continued)
2
2M
3
2M
L o , F int = 0
4
M
L o , Fint = 0
L o , Fint = 0
Pext
A n = (Pext- Fint)/M
V n+ =V n-+A n * T
X n+1=X n + V n+ * T
n=0
An = 0
V n+ =0
X n+1= 0
An = 0
V n+ =0
X n+1= 0
F int = (Fn+1)
A n = (Pext- Fint)/M
V n+ =V n-+A n * T
X n+1= Xn+ V n+ * T
F int = 0
=0
A n =(Pext - Fint)/ 2M
V n+ =V n- +A n * T
X n+1= Xn +V n+ * T
An = 0
V n+ =0
X n+1= 0
n=1
L n+1 = Ln - X n+1
Fn+1 = K *X n+1
Pext
F int = (Fn+1)
L n+1 = Ln - X n+1
Fn+1 = K *X n+1
Fint = (Fn+1)
Fint = 0
ETC
38
19
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Composites modelling:
Modelling and Finite Elements (continued)
Axial force
Bar 3
Bar 2
Bar 1
Node 2
acceleration
velocity
Timestep
displacement
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T=0
T=1
T=2
Composites modelling:
Modelling and Finite Elements (continued)
20
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Composites modelling:
Modelling and Finite Elements (continued)
Length = 100mm
E = 70 kN/mm2
Area = 100 mm2
Fixed end
Consistent units used: kg, mm, msec, kN
41
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Composites modelling:
Modelling and Finite Elements (continued)
21
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Composites modelling:
Modelling and Finite Elements (continued)
Exercises
There are seven simple Excel VBA codes I have prepared:
Ex 1. Explicit_SimpleSpring.xlsm
43
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Composites modelling:
Modelling and Finite Elements (continued)
Study and understand it (see next slide for hints on using VBA Excel)
Compile, run and study the results (see additional handout notes)
Try to use this (Ex. 1) as a basis to do the other examples on the following pages:
1. Apply Force loading (Ex. 2)
2. Study timestep stability criteria for the explicit method (Ex. 3)
3. Apply nodal damping to get a quasi-static solution (Ex. 4)
Modifying Example 1 to do Examples 2,3,4; if you get stuck I have also supplied the
Excel VBA codes for all of these.
Try example 5, 6 and 7 yourself which cover contact analysis and energy balance for
stable and unstable solutions. Hints on doing these are given in the following slides.
44
22
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Composites modelling:
Modelling and Finite Elements (continued)
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Composites modelling:
Modelling and Finite Elements (continued)
46
23
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Composites modelling:
Modelling and Finite Elements (continued)
101,5
101
100,5
100
99,5
99
98,5
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0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
0,11
0,12
0,13
0,14
0,15
0,16
0,17
0,18
0,19
0,2
0,21
0,22
0,23
0,24
0,25
0,26
0,27
0,28
0,29
0
0,3
Bar length
99,975
99,9500088
99,925035
99,9000875
99,8751749
99,8503061
99,8254896
99,8007342
99,7760486
99,7514413
99,7269211
99,7024964
99,6781758
99,6539679
99,6298811
99,6059238
99,5821045
99,5584314
99,5349129
99,5115571
99,4883723
99,4653666
99,442548
99,4199245
99,397504
99,3752944
99,3533035
99,3315389
99,3100082
2
99,2887191
Time
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
0,11
0,12
0,13
0,14
0,15
0,16
Bar length
0,17
0,18
0,19
0,2
0,21
0,22
0,23
0,24
0,25
0,26
0,27
0,28
0,29
6
0,3
Res. Force
0
1,75
3,4993875
5,24755021
6,99387629
8,7377545
150
10,4785745
12,215727
100
13,948604
50
15,676599
17,3991072
19,11552560
20,8252537 0
-50
22,5276929
24,2222474
-100
25,9083242
27,585333
-150
29,2526869
30,9098025
32,5560995
34,191002
35,8139376
37,4243383
39,0216405
40,6052851
42,1747179
43,7293895
45,2687559
846,7922782
10
48,2994231
Bar (nodal
force) versus
time
Res. Force
10
12
Mass = 50kg
Bar length
versus time
12
Composites modelling:
Modelling and Finite Elements (continued)
Force = 1000kN
Mass = 50kg
Mean
length ca.
115mm
1,20E+02
length
1,00E+02
8,00E+01
Date
6,00E+01
4,00E+01
2,00E+01
0,00E+00
0,00E+00 2,00E+00 4,00E+00 6,00E+00 8,00E+00 1,00E+01 1,20E+01
time
48
24
IFB
Composites modelling:
Modelling and Finite Elements (continued)
Modify example 2.
1. Tfac = 0.001
1,40E+02
T = Tfac * Tnodal
1,20E+02
1,00E+02
Tfac =
Dat
0.001 e
8,00E+01
Tfac = 1.0
6,00E+01
4,00E+01
2,00E+01
1,20E+02
1,00E+02
0,00E+00
0,00E+00 2,00E+00 4,00E+00
8,00E+016,00E+00 8,00E+00 1,00E+01 1,20E+01
Tfac = 1.1
6,00E+01
4,00E+01
2,00E+01
0,00E+00
0,00E+00
49
IFB
5,00E+00
1,00E+01
1,50E+01
Composites modelling:
Modelling and Finite Elements (continued)
1,18E+02
1,16E+02
1,14E+02
1,12E+02
1,10E+02
IMPLICIT solution:
1,08E+02
Date
F=k
1,06E+02
1000 = (EA/L)
1,04E+02
= 14.2mm
1,02E+02
1,00E+02
9,80E+01
0,00E+00
2,00E+00
4,00E+00
6,00E+00
8,00E+00
1,00E+01
1,20E+01
25
IFB
Composites modelling:
Modelling and Finite Elements (continued)
Critical damping
Undamped solution
Overdamping
IFB
Composites modelling:
Modelling and Finite Elements (continued)
Ex 5. Contact: This considers the simple spring problem with a penalty contact force
(temporary spring) to stop displacements on one side on the
oscillations (see next slide).
52
26
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Composites modelling:
Modelling and Finite Elements (continued)
Ca. 1mm
0.5mm
Mass = 10 kg
Ca. 1mm
Ex 5. Contact: You could try this with the simple spring example (Ex.1 is easiest).
Impose penalty force treatment at Unew = say 0.5mm. This is simply
an extra (stiff) spring that is only active when the displacement of the
free node is greater than 0.5mm.
53
IFB
Composites modelling:
Modelling and Finite Elements (continued)
Materials laws
1
4
.
2
5
1.
2.
3.
4.
5.
54
27
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Composites modelling:
Modelling and Finite Elements (continued)
Energy computations
Numerical stability in the explicit method must be checked: check the general results and
especially from the energy balance.
55
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Composites modelling:
Modelling and Finite Elements (continued)
Energy computations
For a simple impact problem; such as car crash the initial Kinetic energy is converted to
Internal (plastic or damage) energy.
Indication of numerical instability
KE =
*Mass*
vel^2
For problems where energy is fed into the system e.g. Application of external loading the
constant energy check is more difficult; but still look for sudden energy increases.
Contact can be responsible for such numerical instability.
Ex 6. Energy balance:
Compute and check energy balance for the contact example (Ex 5.). You will have to
compute energies for the bar (internal), contact spring and kinetic energy. Then add these
together to check the total is constant.
28
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Composites modelling:
Modelling and Finite Elements (continued)
IFB
mx
my
mz
0
Ix
Iy
Iz
Composites modelling:
Modelling and Finite Elements (continued)
Fixed end
E = 70 kN/mm2
Area = 100 mm2
Consistent units used:
kg, mm, msec, kN
58
29
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Composites modelling:
Modelling and Finite Elements (continued)
59
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Composites modelling:
Modelling and Finite Elements (continued)
..
..
60
30
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Composites modelling:
Modelling and Finite Elements (continued)
..
Still set but not used
..
61
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Composites modelling:
Modelling and Finite Elements (continued)
..
..
62
31
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Composites modelling:
Modelling and Finite Elements (continued)
..
Reduced to lower mass effect
..
63
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Composites modelling:
Modelling and Finite Elements (continued)
..
New code at the top for
output of headers
..
..
64
..
32