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Introduction
The structural response of the pump assembly shown in Figure W31 will be determined. The assembly components include the pump housing (imported as an orphan mesh), a gasket, a cover, and eight bolts (all imported as CAD geometry). The analysis involves application of pre-tensioning loads in the bolts followed by internal pressure.
pump housing
bolts
gasket
cover
Figure W31. Pump assembly In this workshop, you will create the parts of the model. Use the Part module of ABAQUS/CAE to import the mesh of a pump housing. Some modifications of its geometric features follow. The other components of the pump assembly (cover, gasket, and bolts) will be imported as CAD geometry. All of the parts will be halved to take advantage of symmetry.
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Note: The parts created in this workshop will be used in subsequent workshops to build the complete model and to perform the analysis. It is important that you use the dimensions stated and not deviate from the workshop instructions; otherwise, you may find it difficult to complete the subsequent workshops.
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Figure W33. Top view of pump housing 2. From the main menu bar, select Tools Datum. The Create Datum dialog box appears (see Figure W34). Select CSYS as the datum type. Select the 3 points method, and click OK. When prompted for the type of coordinate system, choose Cylindrical. Place the coordinate system at the origin (0.0, 0.0, 0.0) and click Create Datum. A cylindrical datum coordinate system is created. The origin of the coordinate system coincides with the position of the center of the hole.
Figure W34. Create Datum dialog box 3. You will now modify the inner diameter of the hole. From the main menu bar, select Tools Edit Mesh. In the Edit Mesh dialog box, select Node as the category and Edit as the method, as shown in Figure W35. Click OK to close the dialog box and proceed.
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Figure W35. Edit Mesh dialog box 4. You will be prompted to select the nodes to be modified. Begin by setting the selection filters as shown in Figure W36 by clicking the Show/Hide Selection Options tool, in the prompt area.
Toggle off the selection of entities closest to the screen Circular drag shape Select entities inside the drag shape
Figure W36. Selection filters 5. The nodes can be selected in one of two ways: Try selecting the nodes individually (the default selection technique) using a Circular Drag Shape. The center of the drag shape should be the center of the cylindrical coordinate system defined earlier (see step 2). Select a perimeter point for the drag shape such that you include all the nodes on the inside surface of the hole. The selected nodes will be highlighted in red after the selection, as shown in Figure W37. You may wish to rotate your model to check whether all the nodes have been selected properly. You may also select the nodes using the face angle method (i.e., by specifying the maximum deviation in the angle between adjacent element faces). This technique is generally more efficient than selecting the nodes individually: all nodes that pertain to the element faces that satisfy the face angle criterion are automatically selected. In the prompt area, choose by face angle as the method by which the nodes will be selected. Then, click on any element face located on the inner surface of the hole. The nodes on the inner surface are
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highlighted in red after the selection. As before, rotate your model to make sure all the nodes have been selected properly. Once you are satisfied with the selection (using either method), click Done in the prompt area.
Figure W37. Modified nodes 6. The Edit Nodes dialog box appears, as shown in Figure W38. This dialog box will be used to change the diameter of the hole. Click Select in the upper right corner of the dialog box, and choose the cylindrical coordinate system defined in step 2 by clicking on it in the viewport when prompted to choose a local coordinate system. 7. Using the Coordinates specification method, change the 1coordinate (i.e., the radial coordinate) by selecting Specify from the pull down list and entering 0.65. Click OK to close the dialog box and then Done in the prompt area to complete the operation.
Deleting elements
You will now remove the ribs on the pump housing and then you will remove half of the part. Begin by removing some of the elements in the rib located near the front of the housing, as shown in Figure W39. Use the 13 view from the Views Toolbox, and rotate the pump to view one of the front ribs, as shown in Figure W39.
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1. 2.
3. 4.
5.
Figure W39. Rib elements From the main menu bar, select Tools Edit Mesh. In the Edit Mesh dialog box, select Element as the category and Delete as the method. Click OK. When prompted to select the elements to be deleted, use the Show/Hide Selection Options tool to change the drag shape to a Polygon. Select some of the elements located near the 90 bend of the rib, as shown in Figure W39. In the prompt area, toggle on Delete associated unreferenced nodes. Zoom out and rotate the view to confirm that only elements pertaining to the ribs have been selected. If any other elements are highlighted, deselect them using [Control]+Click. When you are satisfied with the selection, click Done to delete the elements and their associated nodes. The remaining ribs on the pump housing can be removed by carefully selecting them in a similar fashion. This can be a tedious and time-consuming process for large, complicated models. To facilitate such tasks, elements may also be deleted using sets. A. From the main menu bar, select Tools Edit Mesh. In the Edit Mesh dialog box, click OK to continue deleting elements. B. In the prompt area toggle on Delete associated unreferenced nodes. C. In the prompt area, click Sets to open the Region Selection dialog box. In this dialog box, select the set RIBS and toggle on Highlight selections in viewport to highlight the elements belonging to this set. D. Click Continue to delete the remaining rib elements. E. Click Cancel to close the dialog box. You will now halve the pump housing. Use the 12 view from the Views Toolbox to facilitate element selection.
6. From the main menu bar, select Tools Edit Mesh. In the Edit Mesh dialog box, click OK to continue deleting elements. 7. In the prompt area, toggle on Delete associated unreferenced nodes.
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Tip: If the Region Selection dialog box appears, click Select in Viewport on the right side of the prompt area so you can select elements in the viewport. 8. Select the upper half of the pump housing for deletion, as shown in W310. When you are satisfied with the selection, click Done to delete the elements and their associated nodes. The half pump housing without the ribs is shown in Figure W311. 9. Save the model database. Name the model database file PumpAssy.cae.
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selected elements
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(a) cover
(b) gasket
(c) bolts
3. 4. 5. 6. 7.
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sketch plane
datum axis
Figure W313. Sketch plane and datum axis 8. Select the datum axis as the edge that will appear vertical and on the right of the sketch. 9. From the main menu bar, select Add Line Rectangle. Sketch a rectangle enclosing the upper half of the cover, as shown in Figure W314.
cut rectangle
Figure W314. Cut profile 10. Click mouse button 2 to continue, and click Done in the prompt area. 11. In the Edit Cut Extrusion dialog box, choose the end condition Through All. The direction of extrusion is into the cover. Click OK. The final cover geometry is shown in Figure W315.
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Similarly, halve the gasket and bolt parts. 12. From the Part list located under the tool bar, select gasket to access the gasket geometry. Use the 12 view from the Views Toolbox. 13. As before, define the datum axis to orient the part. From the main menu bar, select Tools Datum. 14. In the Create Datum dialog box, click OK to create another Axis using the Principal axis method. Choose the principal Y-Axis as the datum axis. 15. From the main menu bar, select Shape Cut Extrude. 16. Select the top surface of the gasket as the plane on which to sketch, as shown in Figure W316. Select the datum axis as the edge that will appear vertical and on the right of the sketch. 17. From the main menu bar, select Add Line Rectangle. Sketch a rectangle enclosing the upper half of the gasket, as shown in Figure W316. surfaces selected as sketch planes
(a) gasket
(b) bolts
18. Click mouse button 2 to continue, and click Done in the prompt area. 19. In the Edit Cut Extrusion dialog box, choose the end condition Through All. The direction of extrusion is into the gasket. Click OK. 20. Repeat steps 12 through 19 to remove four of the bolts from the part named n_bolts. Note that the top surface of any of the bolts to the left of the datum axis may be used as the sketch plane for the extruded cut. The final gasket and bolt parts are shown in Figure W317. 21. Save the model database as PumpAssy.cae.
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(a) gasket
(b) bolts
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2. 3.
4. 5.
6.
The Run Script dialog box appears. Select the file named gasket_material.py. Click OK in the dialog box. From the main menu bar, select Material Manager to open the Material Manager. Notice that the material named Gasket has been added to the model database. Select Gasket, and click Edit. Review the gasket material properties. Note the gasket has membrane elasticity of 12155 psi, shear stiffness of 6435 psi, and a coefficient of thermal expansion of 1.67 E5 /F. Select Gasket Thickness Behavior from the list of available Material Options in the dialog box, and notice the tabular specification of the loading and unloading curves for the gasket (see Figure W51).
Figure W51. Edit Material dialog box You can use the plotting capabilities within ABAQUS/CAE to plot the loading and unloading curves. This may help you obtain a better understanding of the material behavior. 7. Open the Loading tabbed page. Right-click your mouse over the column headings of the table, and select Create XY Data from the list of options that appears. Name the curve loading when prompted for a name in the Create XY
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Data dialog box. Repeat the same operation for the unloading curve to create a curve named unloading. 8. Switch to the Visualization module. 9. From the main menu bar, select Tools XY Data Manager. The XY Data Manager appears. 10. Select both the curves (using the shift key), and click Plot. You should see a similar plot in the viewport as that shown in Figure W52.
Figure W52. Loading and unloading gasket behavior 11. Click Dismiss in the XY Data Manager, and switch back to the Property module to continue with the gasket section property specification. 12. From the main menu bar, select Section Create to create a gasket section. 13. In the Create Section dialog box, select Other as the category and Gasket as the type. Name the section gasketSection (see Figure W53) and click Continue.
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Figure W53. Create Section and Edit Section dialog boxes 14. In the Edit Section dialog box (see Figure W53), select Gasket as the material and accept all other defaults. 15. Assign the section named gasketSection to the part named gasket. 16. Save your model database as PumpAssy.cae.
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gasket
pump housing
Figure W61. Housing and gasket arrows initially point in opposite directions The pump housing will be moved so that its arrow points in the same direction as that of the gasket. 5. Click Flip in the prompt area to reverse the direction of the arrow on the pump housing so that both arrows point in the same direction. When both arrows point in the same direction, click OK in the prompt area. 6. Accept 0.0 as the default distance from the fixed plane along its normal. 7. Use the assembly display options to restore the visibility of the pump housing. 8. Verify that the pump housing is now exactly on top of the gasket. Tip: Use the Query tools to calculate the distance between a point on the lower surface of the pump housing and a point on the top surface of the gasket. If the pump is exactly on top of the gasket, the third component of the distance vector should be zero.
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Figure W62. Gasket and cover 6. The cover also needs to be positioned so that its top touches the bottom of the gasket. Use the Contact constraint to position the top of the cover with respect to the bottom of the gasket. Alternatively, you could also use the Face to Face constraint. 7. From the main menu bar, select Constraint Contact. 8. Select the top face of the cover (shown in Figure W63) when prompted for the face of the movable part instance.
Figure W63. Positioning of cover relative to the gasket 9. Select the bottom face of the gasket (shown in Figure W63) when prompted for the face of the fixed part instance. 10. Pick a point on the top surface of the cover as a start point for the direction of contact, as shown in Figure W64
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end point
start point
Figure W64. Contact positioning constraint 11. Select a point on the bottom surface of the gasket as the end point for the direction of contact, as shown in Figure W64. 12. When prompted for a clearance between the surfaces, enter a value of 0.0. 13. Verify that the gasket is now just in contact with the cover.
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Figure W91. Selected element attributes 8. Click Cancel in the Query dialog box to close it. 9. The element type for the pump housing is the linear tetrahedron (C3D4), which is not suited for an analysis involving contact. Thus, change the element type assigned to the pump housing to modified second order tetrahedrons (C3D10M). 10. From the main menu bar, select Mesh Element Type. 11. When prompted for the type of region, click Sets on the right side of the prompt area.
Copyright 2003 ABAQUS, Inc. http://www.SciEi.com
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12. The Region Selection dialog box appears. Select the set pump-mesh and click Continue. 13. The Element Type dialog box appears. Review the current settings. Toggle on Quadratic under Geometric Order. Notice that the element type message changes to C3D10M. Click OK. 14. Use the Query tools to confirm that the element type associated with the mesh has been updated.
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The part is now colored pink, indicating it can be meshed with the free mesh technique. 2. Assign a global mesh seed size (Seed Instance) of 0.35 and local edge seeds (Seed Edge By Number) of 8 to the edges comprising the bolt holes. 3. From the main menu bar, select Mesh Element type. Select the cover geometry as the region to which the element type will be assigned and choose the modified quadratic tetrahedron element type (C3D10M). 4. Generate the cover mesh. The mesh on the cover plate is shown in Figure W92. The Gasket Use the assembly display options to restore the visibility of the gasket and suppress the visibility of the cover. The gasket is colored yellow, indicating it can be readily meshed with hexahedral elements using a swept mesh technique. 1. Assign a global mesh seed size (Seed Instance) of 0.25. 2. Assign the linear hexahedral gasket element type (GK3D8) to the gasket geometry (Mesh Element type). 3. Generate the gasket mesh. The mesh on the gasket is shown in Figure W93.
Figure W93 Gasket mesh 4. Save the model database as PumpAssy.cae, and exit the ABAQUS/CAE session.
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Defining the surfaces In ABAQUS/CAE a surface can be created either on a part that has underlying geometry (such a surface is known as a geometry-based surface) or on a part that does not have underlying geometry (e.g., an orphan mesh; such a surface is known as a mesh-based surface). Since this assembly consists of both imported geometry and an orphan mesh, you will create both types of surfaces. 1. Switch to the Interaction module. 2. Make only the pump housing visible using the Assembly Display Options dialog box (View Assembly Display Options). 3. Create a surface named PumpBot by following the steps given below: A. From the main menu bar, select Tools Surface Manager. B. In the Surface Manager, click Create. C. The Create Surface dialog box appears. Select Mesh as the surface type. Name the surface PumpBot, and click Continue. D. You will be prompted for the regions to define the surface. For a mesh-based surface, you can either select the elements individually or select a group of elements by specifying the maximum deviation in the face angle between adjacent elements. The face angle method is in general a more efficient way of choosing elements to define a surface. Hence, in the prompt area select by angle as the selection method and enter a face angle of 5 degrees. E. Click any element face on the bottom of the pump. All the element faces on the bottom of the pump will then be highlighted in red, as shown in Figure W131. Click Done in the prompt area when you are finished.
Figure W131. Surface PumpBot 4. Similarly, create a surface named PumpBolts that defines a surface in the region of the pump that will come into contact with the heads of the bolts. Select the surface using a face angle of 5 degrees, as shown in Figure W132. 5. Next, define a surface in the region where the internal pressure will be applied to the pump. Name the surface PumpInside. Using the face angle method with a
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maximum deviation of 24.1 degrees, select the element faces shown in Figure W133. Tip: Use [Shift]+Click to select more than one item at a time. Select as many regions as possible using the face angle technique; then select any remaining regions individually. Zoom in as necessary to facilitate your selections. To deselect any unintentionally selected regions, use [Ctrl]+Click.
Figure W133. Surface PumpInside 6. Use the Assembly Display Options dialog box to restore the visibility of the cover and to suppress the visibility of the pump housing. 7. Define a geometry-based surface named CoverTop on the region of the cover where it contacts the gasket. 8. Define a surface named CoverInside that defines the region where the pressure load will be applied as shown in Figure W134. 9. Create a surface for each of the four holes in the cover as shown in Figure W135. Name these surfaces BoltHole-1 through BoltHole-4.
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Note: Keep track of the order in which you define the bolt hole surfaces since later you will have to create corresponding surfaces on the bolt shanks. You should save your current view (View Save User 1) to make it easier when defining the bolts surfaces later. 10. Restore the visibility of the gasket and suppress the visibility of the cover using the Assembly Display Options dialog box. Define surfaces on the top and bottom regions of the gasket. Name these surfaces GasketTop and GasketBot, respectively. 11. Suppress the visibility of the gasket, and restore the visibility of the bolts. Set the view to the user-defined view (View Views Toolbox and click 1 in the Views dialog box). 12. Create a surface for each bolt thread corresponding to each bolt hole surface in the cover, as shown in Figure W135. Name the surfaces BoltThread-1 through BoltThread-4. 13. Create a single surface that includes the regions directly under the heads of all the bolts as shown in Figure W135. Name this surface BoltHeads. 14. Save your model database as PumpAssy.cae.
surface CoverInside
surface BoltHole
Defining the contact interaction Now that you have defined the surfaces that will be involved in contact, you can define the contact interactions between the different components. Defining contact interactions in ABAQUS/CAE involves choosing the surfaces involved contact and defining contact
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properties (friction, etc.) for each interaction. Follow the steps given below to define the contact interactions for this model. 1. From the main menu bar, select Interaction Property Create to create a contact property named Friction. 2. In the Edit Contact Property dialog box, select Mechanical Tangential Behavior. Choose the Penalty friction formulation, and define a coefficient of friction of 0.2. Click OK to close the dialog box. 3. From the main menu bar, select Interaction Create to create an ABAQUS/Standard surface-to-surface contact interaction in the Initial step. Name the interaction Pump-Bolts. 4. Click Surfaces in the prompt area to select the regions involved in contact using the surfaces defined earlier. In the Region Selection dialog box, choose the surface PumpBolts as the master surface (since it is continuous) and the surface BoltHeads as the slave surface (since it has a relatively finer mesh and is discontinuous). Use the Small sliding formulation, adjust slave nodes within 1.e-5 in. of the master surface to ensure that the surfaces are initially in contact, and accept Friction as the contact property. 5. Create another ABAQUS/Standard surface-to-surface contact interaction in the Initial step between the bottom of the gasket and the top of the cover. Name the interaction named Cover-Gasket. Choose the surface CoverTop as the master surface (since the underlying elements are much stiffer) and GasketBot as the slave surface. Use the Small sliding formulation, adjust slave nodes within 1.e-5 in. of the master surface to ensure that the surfaces are initially in contact, and accept Friction as the contact property. Defining tie constraints Tie constraints will be used to tie the gasket to the pump. You will also define tie constraints to simulate the effect of the bolt threads when fastened to the bolt holes. 1. From the main menu bar, select Constraint Create. Name the constraint PumpGasket. Select Tie as the constraint type and click Continue. 2. The list of previously defined surfaces appears in the Region Selection dialog box; select the surface PumpBot as the master surface and the surface GasketTop as the slave surface. Accept all the default settings in the Edit Constraint dialog box, and click OK to close the dialog box. 3. In a similar fashion, define tie constraints between each bolt thread and its corresponding bolt hole. In each case, select the bolt hole to be the master surface and the bolt thread to be the slave surface. Name the constraints Tie-1 through Tie-4. In the Edit Constraint dialog box, specify a distance of 0.07 as the position tolerance and toggle off Adjust slave node initial position for each constraint. Tip: After creating the first tie constraint between the bolt and the bolt holes, copy the constraint and edit the region selections.
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Figure W136. Create Load dialog box 9. In the prompt area, click Geometry as the region type. 10. Select the internal surface of any bolt (e.g., as shown in Figure W137). This surface defines the pre-tension section.
Figure W137. Bolt internal surface 11. Select the datum axis defined earlier when prompted for a datum axis parallel to the bolt centerline. 12. Enter a bolt load of 500 lb in the Edit Load dialog box. Accept all other default settings in the dialog box. 13. Repeat steps 8 through 12 for the other bolts. Tip: After creating the first bolt load, copy the load and edit the region selections. 14. Typically, you want to tighten the bolts to a predefined load level (pre-tensioning) and then freeze the deformation in the subsequent load steps (pressure loading, heating up, etc). To do this, proceed as follows:
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A. From the main menu, select Load Manager. The load manager appears in the viewport. B. Select any bolt load in the Pressure step by clicking Propagated and click Edit in the dialog box. C. In the Edit Bolt Load dialog box, select Fix at current length as the method and click OK in the dialog box. D. Repeat steps B and C for the other bolt loads. Applying the pressure load and boundary conditions 1. Display the pump housing using the assembly display options. Switch the render style to shaded . 2. From the main menu bar, select Load Create to define a pressure load named PumpLoad in the step named Pressure. Apply the load to surface PumpInside. Specify a load magnitude of 1000 psi. 3. Similarly, apply a pressure of 1000 psi to the surface CoverInside. Name the load CoverLoad. 4. Assume that the bottom of the cover is welded against a rigid plate. From the main menu bar, select BC Create. 5. In the Create Boundary Condition dialog box, select Symmetry/ Antisymmetry/Encastre as the boundary condition type and the Initial step as the step in which to apply the boundary condition and click Continue. 6. In the prompt area, click Select in Viewport to permit direct selection of the affected region in the viewport. Select the bottom region of the cover and click Done in the prompt area. In the Edit Boundary Condition dialog box, select Encastre as the boundary condition type and click OK to close the dialog box. 7. Apply symmetry boundary conditions to the cover and gasket as follows: A. From the main menu bar, select BC Create. B. In the Create Boundary Condition dialog box, accept Symmetry/ Antisymmetry/Encastre as the boundary condition type and the Initial step as the step in which to apply the boundary condition. Click Continue. C. In the prompt area, select Geometry as the region type. Select the faces on the symmetry planes of the cover and gasket using [Shift]+Click and click Done in the prompt area. In the Edit Boundary Condition dialog box, select YSYMM as the boundary condition type and click OK to close the dialog box. 8. Similarly, apply symmetry boundary conditions to the nodes on the symmetry plane of the pump housing. For this part the region type is Mesh. 9. Save your model database.
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B. The Node list type is selected by default. Click Continue in the dialog box. C. In the Edit Node List Path dialog box, click Add After. D. You will be prompted to select the nodes from the viewport to be inserted into the path. Pick the nodes as shown in Figure W138. Click Done in the prompt area when the selection is complete. Click OK in the Edit Node List Path dialog box.
end of path
beginning of path
Figure W138. Node path E. From the main menu bar, select Tools XY Data Create. Select Path in the Create XY data dialog box and click Continue. F. Browse the settings in the XY Data from Path dialog box. In the Y-values frame, click Step/Frame. G. In the Step/frame dialog box, select the last frame of the step named Pressure. Click OK. H. Make sure that Field output variable is set to S11 in the XY Data from Path dialog box. Click Plot in the dialog box to view the path plot. I. Save the plot as Step-2. J. Similarly, create a path plot of the sealing pressure for the same set of nodes for the PreloadBolts step. Save the plot as Step-1. K. View the saved plots. From the main menu bar, select Tools XY Data Manager. In the XY Data Manager dialog box, select both the saved plots using [Shift] +Click and click Plot in the dialog box. The plot should look similar to the one shown in Figure W139.
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Figure W139. Sealing pressure along the path From this figure it is clear the gasket unloads during the pressurization step. In this exercise, however, nominal bolt and pressure loads were applied. At these load levels, the maximum pressure in the gasket after the bolt load step is approximately 330 psi, which is less than the largest pressure specified in the loading data (6835.4 psi). Thus, during the pressurization step, the gasket unloads elastically; i.e., along the loading curve.
Optional analysis
To observe the distinct loading and unloading behaviors of the gasket, make the following modifications to the model: 1. Apply a load of 12000 lb to each bolt. 2. Apply a pressure load of 10000 psi. Rerun the analysis and postprocess the results. You will notice that in this case the peak pressure in the gasket after the bolt load step is approximately 8000 psi, which is greater than the largest pressure value specified in the loading data. In the pressurization step, then, the gasket unloads along the unloading curve. To see this, create a pressure vs. closure curve as described below: 1. Using field data, create and save XY curves of S11 (i.e., pressure) and E11 (i.e., closure) versus time at the integration points of the element indicated in Figure W1310. Since the element has four integration points, eight curves are created.
Figure W1310. Element used for pressure-closure curve 2. Create a new curve by combining the pressure and closure curves of a given integration point (say integration point 1) into a single curve. The resulting curve is shown in Figure W1311 and clearly illustrates the distinct loading and unloading behaviors of the gasket. The response predicted by ABAQUS follows the material data very closely.