Autodesk Simulation Workshop

Section 3: Nonlinear Analysis

This section presents the theory and methods used to

perform nonlinear analyses using Autodesk Simulation
Multiphysics. Nonlinear phenomena can be due to non- Modules Contained in Section 3
linear material behavior, large displacements, stress
dependency, and intermittent contact. Each of these 1. Overview of Nonlinear
nonlinear phenomena will be treated separately or jointly in Analysis
the six modules in this section. 2. Elastic-Plastic Material
Analysis
The first module provides an overview of nonlinear analysis 3. Hyperelastic Material Analysis
features found in Autodesk Simulation Multiphysics and 4. Viscoelastic Material Analysis
other nonlinear finite element programs. Modules 2 through 5. Riks Analysis
4 cover three of the more common non-linear materials 6. Impact
models: elastic-plastic, hyperelastic, and viscoelastic. Some
of the problems used to demonstrate how to setup and
perform analyses containing these materials also contain other nonlinear phenomena such
as large displacements. The Riks method covered in Module 5 is a type of analysis used to
determine the load-deflection response of systems that become unstable during the solution
process. Finally, Module 6 addresses contact and related modeling issues.

The intent is to present the material in such a way that a senior level undergraduate
engineering student or a practicing engineer could use the modules as a learning resource.
Standard matrix notation is used instead of the more concise indicial notation taught in
graduate school. The content is presented at a depth that an interested student can work
through the mathematics and obtain insight into the methods and workings of a commercial
program. Each subsequent module contains just enough theory to teach a student or
practicing engineer how to set up and perform each analysis type.
 Section 3: Nonlinear Analysis

Important Note on Archived Datasets

The datasets associated with each module in Section 3 have been Archived to facilitate
downloading. An Archived dataset is a compressed file created by Autodesk Simulation
Multiphysics to reduce the overall size of the file. The Archived files do not contain solution
results, and it will be necessary to execute the analysis in order to obtain the results. In most
cases there is a Begin and an End dataset file. The Begin file contains the problem data
prior to setting the analysis parameters, and will not run properly. It provides a starting point
for the module. The videos show how to change the analysis parameters in the Begin
datasets to those in the End datasets. The End dataset can be executed to obtain the
analysis results.

Note that Module 1 only has one archive file, and does not require a Begin and End file.

An Archived dataset can be retrieved by selecting the Autodesk Simulation Icon in the upper
left corner of the screen, selecting Archive in the drop down menu, and then selecting
Retrieve.

Autodesk Inventor Files

The Inventor part or assembly files are also included as part of the datasets. In some cases
the Inventor files are used as in the videos or PowerPoint presentations. For example, the
intent of the video may be to show how to go from Autodesk Inventor into Autodesk
Simulation Multiphysics. In other cases the Inventor files are not part of the videos or
PowerPoint presentations, but having them available will enable instructors or students to
develop additional problems or exercises.
 Section 3: Nonlinear Analysis

Table of Contents
Click below to jump to the current Module:

1. Module 1: Overview of Nonlinear Analysis Methods .............................................. 4

2. Module 2: Elastic-Plastic Material Analysis ........................................................... 6
3. Module 3: Hyperelastic Material Analysis .............................................................. 8
4. Module 4: Viscoelastic Material Analysis ........................................................ 11
5. Module 5: Riks Analysis ...................................................................................... 13
6. Module 6: Impact ................................................................................................ 15
 Section 3: Nonlinear Analysis

1. Module 1: Overview of Nonlinear Analysis Methods

Introduction

This module presents an overview of the nonlinear analysis capabilities found in Autodesk
Simulation. The PowerPoint slides provide an introduction to the types of things that can
cause a problem to be nonlinear. These four things are: 1) material behavior, 2) large
displacements and/or rotations, 3) stress stiffening or softening, and 4) intermittent boundary
conditions. The correlation between these four phenomena and the other modules in this
section is also explained (Table 1). The video shows where the nonlinear analysis types are
found, and where nonlinear material models are selected. Subsequent modules provide
additional detail on nonlinear analysis types and material models.

Execution

1) The types of nonlinear analyses available in Autodesk Simulation are found by

selecting the analysis type tab in the browser. The nonlinear tab in the popup menu
shows four types of analyses.
a. MES with nonlinear material models
b. Static analysis with nonlinear material models
c. Natural frequency with nonlinear material models, and
d. Riks analysis.
2) An MES analysis with nonlinear material models is the most general analysis type. It
can be used to model real world events containing any combination of the four
nonlinear phenomena. An MES analysis is dynamic in nature and must be used
when time dependent material models are used.
3) A Static analysis with nonlinear models is limited to non-dynamic events and cannot
be used with time dependent materials.
4) A Natural frequency analysis with nonlinear material models allows the natural
frequencies of a deformed or stressed system to be computed. This would be used
for example to determine the natural frequencies of suspension lines whose stiffness
is very dependent on the tension in the cables.
5) A Riks analysis is used to determine the buckling load. It differs from a linear load
factor analysis in that it can handle components with nonlinear materials. This is
important for metal compression members that yield prior to buckling.
6) The various modules contained in this section provide examples of all of these
analysis types except Natural frequency with nonlinear material models (Table 1).
However, a similar analysis with linear materials is included as part of Section II.
7) The various nonlinear material models available in Autodesk Simulation can be seen
by selecting an element definition tab in the browser. Different elements have
different material models available, so the list may differ depending on the element
type that was selected. A 2D element type is used in the video.
8) The nonlinear material models are organized within two main categories: 1) Elasticity,
and 2) Plasticity.
9) Elasticity is associated with materials that return to their original configuration when
unloaded. They exhibit no residual stress and retain their original shape. The
Elasticity material models are organized into four subgroups: a) elastic, 2)
hyperelastic, 3) foam, and 4) viscoelastic.
 Section 3: Nonlinear Analysis

a. Elastic materials contain isotropic and orthotropic linear elastic materials.

b. Hyperelastic material models are typically used to model elastomers
(rubbers) and biological material (ligaments and tendons).
c. Foam material models have similarities with hyperelastic material models in
the way they are formulated. The major difference is that hyperelastic
materials are incompressible or nearly so, while foam undergoes large
volumetric deformation.
d. Viscoelastic material models allow the several of the other elastic materials
to have time dependent responses such as creep or relaxation.
10) Plasticity is associated with materials that do not return to their original shape when
deformed. Their final shape is not the same as the original shape and residual
stresses are often present. The most common examples of plasticity are metals that
have been loaded beyond their yield stress and soils that compact.
11) All of the things that can make a problem nonlinear can be present in a single
analysis.
12) Nonlinear problems require iterative solution methods. In most cases they also
require that the load be applied in increments with equilibrium iterations at the end of
each increment.

Table 1: Nonlinear Phenomena included in Subsequent Modules

Nonlinear Module Material Large Stress Intermittent

Analysis Behavior Displacements Stiffening Boundary
Type and/or or Conditions
Rotations Softening
Static Module 2
stress with Elastic- X
nonlinear Plastic
material Material
models Analysis
MES with Module 3 -
nonlinear Hyperelastic X X X
material Material
models Analysis
MES with Module 4
nonlinear Viscoelastic X X
material Material
models Analysis
Riks Module 5
Analysis Riks X X X
Analysis

MES with Module 6

nonlinear Impact X X X
material
models
 Section 3: Nonlinear Analysis

2. Module 2: Elastic-Plastic Material Analysis

Introduction

This module presents an overview of the issues encountered in performing a nonlinear

analysis that includes an elastic-plastic material model. The PowerPoint slides provide an
introduction to concepts associated with monotonic and cyclic stress-strain curves, the
Bauschinger effect, the von Mises yield criterion, and isotropic and kinematic hardening. The
PowerPoint slides also show how these concepts relate to setting up an analysis. The video
shows how to perform an analysis in which yielding occurs at a stress concentration point.
The redistribution of stresses around the yielded material can easily be seen in the contour
plots. Localized yielding around stress concentrations and the associated redistribution of
stresses is a very common problem found in industry.

Execution

1) The analysis type must be set to Static Stress with Nonlinear Material Models. If
one of the nonlinear material analysis types is not selected the user will not be able to
select any of the nonlinear material models. The analysis type can be selected
during the startup process or by selecting it under Analysis Parameters in the FE
Editor browser.
2) Elastic-plastic material models can be used with several element types. In the
analysis being performed, the 3D brick element is used. The analysis could also be
done with a 2D plane stress element since the plate is very thin and there is little
stress variation through the thickness.
3) The type of nonlinear material model that will be used is selected when defining the
element definition data. Either of the kinematic or isotropic hardening models could
be used. The top two shown in the selection table are bilinear models that use a
constant strain hardening modulus. The bottom two use stress-strain curves that can
entered into a table manually or imported from an Excel spreadsheet. Since a
monotonic type load will be applied either of the isotropic or kinematic hardening
models can be used. Both will give the same results. The only time a distinction has
to be made between isotropic and kinematic hardening is when cyclic loads are being
used. Isotropic hardening will not compute a Bauschinger effect, while the kinematic
hardening model will.
4) There are two methods that can be used to capture steep stress gradients: 1) use
many lower order elements and/or 2) increase the order of the interpolation functions
used in the elements. A combination of these two approaches is used in the
example problem. Refinement points are used to increase the number of brick
elements in the area of the high stress gradients. In addition, mid-side nodes are
included when defining the element data. Mid-side nodes add quadratic
displacement terms that provide linear strain results. The mesh density used in the
analysis is based on preliminary runs made to investigate convergence of the stress
results.
5) The explicit material used in the analysis is cold rolled 1020 steel. This material has
a yield strength of 50.8 ksi. The work hardening modulus is automatically returned
from the material database by Simulation because the bilinear kinematic hardening
model was selected. If the curve kinematic hardening model had been selected, a
 Section 3: Nonlinear Analysis

table of stress-strain values describing the true stress-strain curve for the material
would have been returned. It is important that true stress-strain curves be used when
performing plasticity calculations. The theory is based on true stress and strain
measures.
6) The default analysis parameters can be used for this analysis. The load curve
defaults to a 0 to 100% linear increase in load. Loads should be applied
incrementally when performing this type of analysis. For simplicity purposes, the load
was applied in 20 increments (5% of total each increment). Simulation will
automatically decrease the load increment if it is not converging quickly enough. In
this problem, the load increment is automatically decreased as the load approaches
100%. This is when the material has reached the point in which yielding is occurring
across the total cross section and the displacements are increasing rapidly.
7) An alternative method of performing this analysis that may require less computer time
would be to break the problem into two load cases. The first load case would apply
the load necessary to reach the onset of yielding in one load increment. The next
load case would increase the load through the elastic-plastic portion of the loading.
The first load case would be used as a restart file for the second load case.
8) When elastic analyses of parts or systems having stress concentrations are
performed it is not uncommon for large stresses that significantly exceed the yield
stress to be computed. These elastic stresses are not realistic and an elastic-plastic
analysis must be performed if more accurate stress values are required. As this
example problem demonstrates, the stresses in the vicinity of the stress
concentration will spread out over a larger area as yielding progresses. This
redistribution of stress around stress concentrations will generally not affect the
overall strength of a large complex system. However, the stress concentrations do
provide locations where fatigue cracks can initiate and can decrease the life of the
system.
 Section 3: Nonlinear Analysis

3. Module 3: Hyperelastic Material Analysis

Introduction

This module presents an overview of issues associated with performing an analysis using
hyperelastic material models found in Simulation. Hyperelastic materials are routinely used
in applications involving larger deformations, and the strain energy density functions used to
define the material models are based on finite deformation quantities. Therefore, an
introduction to finite deformation quantities used with hyperelastic materials is provided. The
PowerPoint slides show how to set up an analysis of an o-ring. There are two videos
associated with this module. The first video shows how to set up an axisymmetric model,
define the hyperelastic material properties for a 2-parameter Mooney-Rivlin material, and
then how to setup the analysis parameters. The portion of the video associated with setting
up an axisymmetric model is not peculiar to a hyperelastic material and the process can be
used with any of the other material types.

Execution

1) The analysis type must be set to Static with nonlinear material models. This can be
done either when Simulation is started or it can be changed by Editing the Analysis
Type in the FEA editor.
2) The modeling plane used for an axisymmetric model is the y-z plane. The orientation
of the part in the coordinate system is very important in this case. The part must be
set up so that the z-direction is the axis of symmetry (longitudinal direction) and the y-
direction is the radial direction. The x-direction is in the circumferential direction. It is
easiest if the CAD model has a cut surface lying on the y-z plane. There are
commands in Simulation that can be used to rotate and/or project a surface to make
it correspond to the y-z surface. The project command is used in this analysis.
3) It is customary to define the element type as one of the first steps in creating an FE
model. When setting up an axisymmetric model is easier to first generate the mesh
and then define the element types. Unless the x-coordinate for all vertices lying on
the y-z plane is identically equal to zero, Simulation will not let 2D elements be
defined.
4) The wedge model used in this analysis has surfaces that are not needed in the
axisymmetric model. All surfaces are initially set to have a mesh generated on them.
The surfaces for each part can be seen by expanding the surfaces in the FEA
Editor. Each of the surfaces has an option that will allow it to be excluded from the
meshing process. Each surface not lying on the y-z plane must have this option
deselected.
5) The default meshing process is set to mesh a solid part Plane/Shell option must be
selected on the 3D Mesh Settings screen to create a 2D or axisymmetric model .
6) The Automatic Mesh Geometry Function is turned off under the Model button on the
3D Mesh Settings screen. This will allow a uniform mesh to be created using an
absolute mesh size.
7) The Absolute Mesh size specified for the model is set to 0.01 on the Surface screen
of the 3D Meshing settings. This mesh size was found based on trial-and-error to
give adequate results for the shaft and housing. A finer mesh is used for the o-ring.
 Section 3: Nonlinear Analysis

8) The o-ring mesh size is selected by editing the CAD Mesh parameters for the o-ring
in the FEA Editor browser. An absolute mesh size of 0.0075 inch was found to give
acceptable results. Although the runtimes for non-linear analyses can be significant,
it is important to verify that final results are not sensitive to the size of the mesh used
in the analyses.
9) Once the mesh has been generated, all of the vertices can be forced to lie exactly on
the y-z plane by: 1) selecting all vertices, and 2) right clicking and selecting the
Project command. The x-value should be set equal to zero. Even if an x-value is
1.0e-15, Simulation wont allow 2D elements to be defined. The Project command
is the easiest way to ensure that this condition is met.
10) Now, that the mesh is defined the element types can be set. All parts use the 2D
element type. 2D elements can be used to model plane strain, plane stress, and
axisymmetric problems.
11) The Element Definition data allows the type of 2D element and the specific class of
material to be specified. The 2D element geometry parameter for each of the parts
should be set to axisymmetric.
12) The material class for the shaft and housing are set to Linear Isotropic.
13) The material class for the o-ring is set to Hyperelastic, Mooney-Rivlin. The other
hyperelastic material types can be seen in the list used to select the Mooney-Rivlin.
The Mooney-Rivlin material is selected for this problem because the stretches are
expected to be moderate (i.e. less than 200%).
14) The material constants for each part are defined by editing the material properties for
each part. A two-parameter Mooney-Rivlin model is used in this analysis. Higher
order Mooney-Rivlin material models are available in Simulation. The material library
values for the two parameters are used in the analysis. These parameters are
associated with the deviatoric or distortional deformation of the material.
15) The Bulk Modulus is also required and is associated with the volumetric deformation.
A truly incompressible material will have an infinite bulk modulus. A method for
estimating the bulk modulus for a nearly incompressible material is contained in the
PowerPoint slides. A value of 400,000 psi is used in the analysis. This corresponds
to a Poissons ratio of 0.4988.
16) The vertices at the compression end of the shaft and housing are set to zero in the z-
direction. There is no need to define a displacement constraint in the y-direction
because of the strain constraints inherent to an axisymmetric model.
17) There is contact between the o-ring and the shaft, and the o-ring and the housing.
The contact is defined by: 1) selecting each pair of parts involved in the contact, 2)
right clicking and selecting contact. Surface contact is defined for each pair of parts.
18) By selecting the contact pairs in the browser, and right clicking on the Settings, the
parameters for each contact pair can be edited. In this analysis, the frictional contact
option is used. The coefficients of friction (static and dynamic) are set to 0.25. The
tangential stiffness ratio parameter is set to 0.01. The addition of friction often adds
stability to an analysis. The absence of friction is not realistic unless significant
lubrication is used. The coefficients of friction were chosen to simulate rubber to
metal contact with light lubrication.
19) The element edges where the pressure load is to be applied to the o-ring are
classified as lines. They must be converted to surfaces so that the pressure load can
be applied to one side of the o-ring. All of the lines associated with the element
pressure loads should be selected. By right clicking and selecting Edit Attributes,
 Section 3: Nonlinear Analysis

the lines can changed to a single surface. The selection option must now be
switched from Lines to Surfaces so that the new surface can be selected.
20) Select the new surface, right click and select Add, then select Pressure/Traction.
The magnitude of the pressure to be applied is 500 psi. The analysis is now ready to
be submitted.
21) Once complete the results can be reviewed in the results section. Of particular
importance are the two zones of deformation seen in the results. The top zone has
very little deformation and is experiencing principally volumetric type deformation due
to hyrdrostatic loading. This causes the von Mises stress levels in this area to be
low. The von Mises strain and shear stress are also low because of the hydrostatic
loading. The lower zone has significant deformation since it is not constrained by the
pressure loading. The distortion causes the von Mises stresses and strains, and the
shear stresses to be much higher than in the lower zone.
22) The Penetration Probe showing the amount of penetration at the contact surface
between the o-ring and gland may appear on the screen during the solution. This
can be turned off by going into the Results Inquire tab, and clicking on the move
button under Probes, and then choosing Contact Diagnostic Probes
 Section 3: Nonlinear Analysis

4. Module 4: Viscoelastic Material Analysis

Introduction

This module presents an overview of issues associated with performing an analysis using
viscoelastic material models found in Simulation. Viscoelastic materials demonstrate time-
dependent stress-strain relationships that lead to creep, relaxation, and hysteresis
phenomena. The difference between linear and nonlinear viscoelastic material behavior is
discussed in the PowerPoint presentation. In Simulation, linear viscoelastic data can be
coupled with linear or nonlinear instantaneous material models. In the PowerPoint
presentation and the video an example of a cantilevered sandwich beam is presented that
uses linear viscoelastic relaxation data in conjunction with a nonlinear hyperelastic material
model.

Execution

1) The analysis type must be set to MES with Nonlinear Material Models when
Simulation is started. This is one of the nonlinear analysis types. The analysis type
can be selected during the start-up process or selected under Analysis Parameters in
the FE Editor browser.
2) Viscoelastic material models can be used with several element types. In the analysis
used in the example, a 2D plane strain element is used. The width of the beam is
relatively large compared to its thickness and a plane strain formulation is
appropriate.
3) Module 3 shows how to create a 2D axisymmetric model from a 3D CAD file. The
method used to create a 2D plane strain model is very similar. The basic steps are to
include only those surfaces that lie on the yz-plane in the meshing operation. Once
the yz-plane surfaces are meshed using the plate/shell option in the 3D Meshing
Options tab, the vertices are projected onto the yz-plane by setting the x-coordinate
to zero using the project command. The element types can then be set to 2D.
4) The top and bottom plates are made of aluminum and a linear isotropic material is
selected in the element definition dialog box. Mid-side nodes should also be
selected on the element definition dialog box. Mid-side nodes increase the order of
the interpolation functions used in the element formulation and will ensure that the
stress variation through the thickness of the beam is captured correctly.
5) The adhesive is a commercial adhesive known as ISR 70-03. This adhesive was
selected because detailed relaxation data is contained in the reference given in the
PowerPoint presentation. Hyperelastic and viscoelastic data for specific polymers
can be difficult to find, and independent testing programs are often required to
support analysis activities. The relaxation data presented in the reference was
obtained using a Dynamic Material Analyzer technique in conjunction with a shift
function.
6) The adhesive is modeled as a Mooney-Rivlin hyperelastic viscoelastic material. The
Mooney-Rivlin constants define the instantaneous shear modulus of the material.
The reference for ISR 70-03 gives the instantaneous tension modulus and the
PowerPoint presentation shows how to convert this to the instantaneous shear
modulus. The relationship between the shear modulus and the Mooney-Rivlin
constants is G=2(C10+C01). This equation and the assumption that the ratio of the
 Section 3: Nonlinear Analysis

Mooney-Rivlin constants (C10/C01) is equal to four are used to determine C10 and C01
in the example. This assumption would not be required if a Mooney plot for the
adhesive material were available.
7) The bulk modulus is estimated by assuming that Poissons ratio is 0.499. An
incompressible material has a Poissons ratio of 0.5 and an infinite bulk modulus. A
Poissons ratio of 0.499 makes this material nearly incompressible.
8) The Prony series data can be entered using two forms. One form uses the
instantaneous shear modulus, G0, as the multiplier, while the other uses the relaxed
modulus, G , as the multiplier. In the example problem, the first form is used and
this form must be selected prior to entering the Prony series relaxation data.
9) Simulation allows the relaxation data to either be applied to both the volumetric and
deviatoric properties. One option allows the same relaxation data to be applied to
both. Another option allows different relaxation data to be applied to the volumetric
and deviatoric components. In the example, it is assumed that volumetric response
is nearly incompressible and remains so throughout the analysis. Therefore, there is
no relaxation of the bulk modulus. The volumetric Prony series data is set to zero.
The deviatoric or shear Prony series is entered into the table. Note that the
Relaxation Modulus column contains relaxation moduli that have been normalized
by the instantaneous shear modulus. They are non-dimensional and the sum must
not exceed a value of one. When their sum is equal to one, the material will relax to
a value of zero at infinite time.
10) The only analysis parameters that must be edited prior to submitting the simulation is
to set all of the multipliers in the load curve table to ones. This will result in a step
input. The capture rate is set to 500 which results in a time step of 0.002 seconds. If
too large of a time step is selected, Simulation will automatically decrease the time
step size if the number of iterations becomes excessive.
11) Simulation has the ability to embed a graph in the results screen that is updated as
the analysis progresses. The video shows how this is done. This is a very useful
feature that allows any variable that is computed (e.g. stress of displacement) to be
viewed as a function of time during the analysis. The video shows only one graph
being embedded. However, multiple graphs could have been added to show the
history of more than one parameter.
12) The damping observed in the results is a result of the viscoelastic material. The
relaxation data completely defines the viscoelastic properties of the material and
phenomena such as creep, dynamic damping (hysteresis), or relaxation can be
simulated. In the example problem, the dynamic damping properties of the adhesive
were demonstrated. The storage modulus and loss factor as a function of frequency
can be determined using the relaxation data. The selection of the best damping
material (adhesive) for a particular application is one that has a high loss factor at the
particular frequency or frequencies of interest.
13) There will also be damping of high frequency modes due to the numerical integration
of the equations of motion. Since the response shown in example is due to lower
order modes, the damping from numerical integration should be small for this
example.
14) The results are also consistent with the step response of a linear spring-mass
system. The peak amplitude ratio for such a system is two. The cantilevered beam
results are close to this.
 Section 3: Nonlinear Analysis

5. Module 5: Riks Analysis

Introduction

This module presents an overview of the Riks Analysis option in Autodesk Simulation and
shows how to apply the method to determine the buckling load of an elastic-plastic arch. The
PowerPoint slides provide an overview of how a Riks Analysis is different than standard static
analysis methods. The concept of a load factor is presented. The load factor changes in
magnitude throughout the analysis as equilibrium at each load increment is pursued. The
load factor can increase, decrease and even go negative as the analysis progresses. The
maximum value of the load factor determines the buckling capacity of the system being
analyzed. There are two videos associated with this module. The first video shows how to
set up a Riks Analysis, while the second shows how to process and interpret the results.

Execution

1) The analysis type must be set to Riks Analysis when Simulation is started. This is
one of the non-linear analysis types. The analysis type can be selected during the
startup process or by selecting it under Analysis Parameters in the FE Editor
browser.
2) Elastic-plastic material models can be used with several element types. In the
analysis being performed, the 3D brick element is used. One of the issues with brick
elements is that they lock up when they get too thin. Precautions will be taken to
avoid this problem during the mesh generation phase.
3) An elastic-plastic material with kinematic hardening will be used to define the
nonlinear material type. Since strain cycling will not be encountered during the
analysis, either the isotropic or kinematic hardening model can be used. The
kinematic model is selected in the video, but either hardening model should give
similar results.
4) Mid-side nodes are used to increase the flexibility of the brick elements through the
thickness direction of the arch. A bending type stress distribution is expected through
the thickness of the arch. The derivatives of the displacement interpolation functions
used in an eight node brick will not capture this linear strain variation. The
derivatives of the displacement interpolation functions for a brick element having mid-
side nodes will capture this linear strain variation.
5) Post-buckling analysis response typically involves large displacements and a Riks
Analysis uses the large displacement option.
6) The automatic mesh size function is turned off so that an absolute mesh size can be
entered. Specifying an absolute mesh size provides better control over the size and
aspect ratios of the brick elements. The automatic mesh size function tends to create
elements with large aspect ratios and widely varying size. Specifying an absolute
mesh size provides a more uniform mesh. A large aspect ratio (i.e big in area
direction and small in the thickness direction) can lead to lock-up of brick elements.
7) An absolute mesh size of 0.0625 inches will give two elements through the thickness.
The mid-side nodes may be sufficient to permit one element through the thickness,
but two will give more assurance that the stress gradients are properly computed.
8) The intent of the boundary condition specifications at the ends of the arch is to not
restrain rotation about the z-axis. This results in a hinge. Only the nodes along the
 Section 3: Nonlinear Analysis

center row of nodes on the end surfaces are restrained. Fixing nodes on the upper
and lower edges will restrain rotation of the surface.
9) The x-direction displacement restraints at the center of the arch will ensure a
symmetric solution and will also make the analysis converge quicker. Without these
constraints the computed buckled shape may be skewed more to one side than the
other due to small numerical imperfections in the model. These displacement
constraints can be omitted to see what effect they have. The magnitude of the initial
load factor will need to be decreased to obtain convergence.
10) The Embed Graph feature is important in this type of analysis. Because Simulation
lacks the option to create a plot of the load factor versus increment number or display
the load factor on the screen for each load increment, the only place the load factor
can be found is in the log file. The log file data can be pasted into Excel to create a
plot of the kind seen in the second video and in the PowerPoint slides. The
maximum load factor seen in the plot defines the buckling load.
11) The number of time steps (load increments) controls the duration of the analysis.
This number needs to be large enough to capture the desired results. Two numbers
were used while setting up this example problem, 50 and 100. The lower number,
50, was used to obtain some initial results. After it was determined that 50 captured
all of the response of interest, the higher number, 100, was used to determine if the
solution had sufficient resolution and accuracy. There was little difference between
the two sets of results. The wiggle in the post-buckling response region was a little
smaller when 100 load increments were used. The load factor at which buckling
occurs did not change.
12) The initial load factor parameter is used to compute a set of displacements that
establishes the magnitude of the hypersphere constraint. This magnitude is treated
as a constant throughout the analysis. The linear displacement versus load
increment plot shown in the second video is a direct result of keeping the constraint
magnitude constant. Using a lower initial load factor would result in smaller
displacements for each load increment in the analysis.
13) A displacement controlled experiment could be carried out to experimentally
determine a load factor versus load increment curve similar to that computed by the
Riks Analysis method. This might be necessary to maintain a safe experimental
setup. Most real world load phenomena are not displacement controlled and the load
increases remains constant throughout the buckling process. The post-buckling
response is dynamic in nature, and a full MES Nonlinear Dynamic Analysis is
required to capture this dynamic response.
14) The most common example used to demonstrate the Riks method is a shallow elastic
arch. This problem experiences snap through, a phenomenon in which the arch
snaps from a concave down geometry to a concave up geometry. The example
problem covered in this module does not snap through because of the elastic-plastic
material model used.
 Section 3: Nonlinear Analysis

6. Module 6: Impact

Introduction

This module presents an overview of concepts associated with performing a Mechanical

Event Simulation with Nonlinear Materials that includes impact. Impact is contact between
two parts that happens at high speed. Therefore, the PowerPoint slides also address
concepts associated with contact in general. The example problem used in the PowerPoint
slides and in the video uses the same sandwich beam used in Module 4: Viscoelastic
Materials. A steel cylinder is added that drops under the action of gravity and impacts the
beam. The nonlinear response is examined in the video.

Execution

1) The analysis type must be set to MES with Nonlinear Material Models when
Simulation is started. This is one of the nonlinear analysis types. The analysis type
can be selected during the start-up process or selected under Analysis Parameters in
the FE Editor browser.
2) The method used to generate a 2D mesh from a 3D CAD file is shown in Video 3A.
In this problem a plane strain 2D element is used. Plane strain was selected
because the beam is relatively wide compared to its thickness.
3) The mesh uses an absolute element size of 1/64 of an inch. It also uses mid-side
nodes to improve the flexibility of the 2D elements in bending. The problem is
sensitive to the amount of bending experienced by the beam. If the problem is run
without mid-side nodes, it is stiffer and the cylinder will strike the beam at a different
location on the second impact and will not roll off the end. Having students run this
option and discuss the difference between the results would make a good homework
exercise.
4) The method used to specify the viscoelastic properties of the adhesive are discussed
in the Module 4 PowerPoint slides and are illustrated in the Video 4.
5) Two different types of contact are encountered in the model used for this analysis.
The first type is between the common surfaces of the top and bottom plates and the
adhesive. The adhesive doesnt allow relative motion along the shared surface and
the default contact type of Bonded is used. Since it is the default type, no action is
required to define the contact. Simulation will automatically apply this type of contact
when it determines that there two surfaces occupying the same space.
6) The second type of contact is between the perimeter surface of the cylinder and the
free edges of the top plate in the cantilevered beam. Surface contact allows parts to
separate or come into contact and to have sliding motion between the contact
surfaces. This is the most general type of contact found in Simulation.
7) The contact parameters are specified by editing the contact settings. These
parameters specify that the analysis involves impact, that no friction is to be included,
and that surface to surface contact is desired.
8) The analysis parameters are set similarly to those in Module 4 with the exception that
the Event Duration is set to 0.6 seconds. Exploratory analyses showed that this is
long enough to have the cylinder impact the beam twice and then roll of the end.
9) A Capture Rate of 500 steps/second is specified. This results in a time step of 0.002
seconds. This allows seven or eight points per oscillation of the cantilever to be
 Section 3: Nonlinear Analysis

computed. During contact between the beam and cylinder, Simulation will
automatically decrease the time step to obtain quicker convergence.
10) The analysis runs approximately one hour. This should provide an appreciation for
how long it takes to perform a complicated impact problem (e.g. between an
automobile and a rigid obstacle).
11) The time variation of stress or displacement at a particular location can be seen by
embedding a plot on the screen. The method used to do this is shown in detail in
Video 4, and is illustrated quickly in the video for this module.
12) The best way to examine the results visually is to create an animation. The video
contains a good example how much information can be seen using this approach.
The vibration of the cantilever beam due to the impact forces imparted by the cylinder
can be easily seen.
13) Although the cylinder is dropped along the y-axis, it picks up momentum in the z-
direction due to the angle of the surface normal vector caused by the slope of the
beam surface. The contact force and contact stiffness are applied normal to the
master surface. As the beam deflects the surface normal takes on a small z-direction
component.