FEA Academy Workshop

FEA ACADEMY WORKSHOP
MODELING A HIGHLY
Modeling a Highly Nonlinear Problem
NONLINEAR
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UNLOCK THE
SECRETS OF PROB LE M
NONLINEAR
ANALYSIS BY
FEA
GEOMETRIC – MATERIAL -
CONTACT
© 2024 FEA Academy 1
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Modeling aa Highly
Modeling Highly Nonlinear
Nonlinear Problem
Problem
AGENDA
👉 Part #1: Reminders about Nonlinear Analysis
by FEA
👉 Part #2: Workshop - Modeling a Highly

Nonlinear Problem - Metal Forming

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Modeling aa Highly
Modeling Highly Nonlinear
Nonlinear Problem
Problem
Reminders about
Nonlinear Analysis by
FEA

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Reminders about Nonlinear Analysis by FEA
The Types of
Nonlinearity

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The Types of Nonlinearity
• Geometric Nonlinearity
• Material Nonlinearity
• Boundary Nonlinearity

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Geometric nonlinearity
 If a body undergoes large deformations:
• The strain-displacement relations become
nonlinear.
• The stiffness of the system will change with
deformation
 Stress stiffening (tension-bending coupling). The

bending stiffness of an element increases because of
the tension transferred in the membrane.

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Material nonlinearity
 If a material does not follow Hooke’s law,
nonlinear material models must be used.

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Boundary nonlinearity
 The most frequent boundary nonlinearities
are encountered in contact problems.

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Remindersabout
Reminders about Nonlinear
Nonlinear Analysis
Analysis by FEA
by FEA
The Types of Contact

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Types of Contact
Normal Direction Tangential Direction
Contact
Contact Name Remark
Type Behavior Behavior Resistance
Bonded or Weld Contact Contact Pair CANNOT Separate Out Contact Pair CANNOT Slide N/A Defined geometry acts like one body.
GLUED
Bodies cannot translate or rotate between each
Rough Contact Contact Pair CAN Separate Out Contact Pair CANNOT Slide N/A other.
NO Once the contact is detected, then the surfaces
No Separation Contact Contact Pair CANNOT Separate Out Contact Pair CAN Slide
m=0 are tied up for the rest of the analysis.
NO
Frictionless Contact Contact Pair CAN Separate Out Contact Pair CAN Slide The contact pair can slide and separate.
TOUCHING m=0
YES The contact pair can slide and separate.
Frictional Contact Contact Pair CAN Separate Out Contact Pair CAN Slide If Fsliding > Ffriction Coefficient of friction m affects the tangential
m = constant motion.
Normal Direction Tangential Direction
Can or Cannot Separate Can Slide With or Without Resistance

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Computational Methods in Nonlinear Analysis

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For a structural problem, the nonlinear static equilibrium matrix equation becomes:
{F(u)} = [K(u)]*{u}
Functions of {u} Unknown
Not Constant
• The structural stiffness matrix [K] and possibly the load vector {F} become functions of the displacement
vector {u}.
• It is not possible to solve for {u} immediately, as [K] and {F} are not known in advance.
• The classic LDLT decomposition method is not applicable to solve the problem directly.
• An iterative and incremental process is needed to obtain {u} and the associated [K] matrix and {F} vector,
satisfying the equations of equilibrium.
• Unlike linear problems, which always have a single solution, nonlinear problems do not.
• Even when a solution is found by a nonlinear algorithm, it may not be the solution that is sought.
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F To solve nonlinear problems, an iterative

process based on the modified Newton-Raphson
F
method is needed.
l 4F
So, instead of solving {F} = [K]{u}, we must
Solution
solve a set of nonlinear algebraic equations:
l 3F FINT(u) = {F}
l 2F
FINT(u4, l4)
FINT(u3, l3) The sum of The sum of

internal nodal externally applied
FINT(u2, l2)
forces loads
l 1F
FINT(u1, l1)
u1 u2 u3 u4 u

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Basic operations:
 Gradual loading
 Iterations with convergence tests for equilibrium
 Stiffness matrix updates
Iterative process is based on:

• Newton’s methods: nonlinear static
• Arc-Length methods: nonlinear buckling
Gradual
Stiffness matrix updates performed occasionally:
Loading
 Improve the computational efficiency
 May be overridden at the user’s discretion
The loading sequence and load increments will strongly

influence the solution. Stiffness matrix updates

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The Newton-Raphson method combined with the incremental force method
The loading is applied gradually in increments, and equilibrium iterations

at each load increment are performed to drive the incremental solution to
equilibrium and satisfy the global equilibrium equation of the nonlinear
system.
The incremental process continues until the residual parameters are within
Solution a tolerance defined by the FEA analyst.
Note that the load increments do not have to be uniform, and critical parts
typically require a smaller increment size.
The tangential stiffness matrix is calculated at the beginning of each load

increment and is unchanged for each iteration in the load increment,
unless a potential divergence is detected.
If a divergence is detected by the solver, the tangent stiffness matrix

update can be forced.
Here the Ri are the unbalanced loads.

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Workshop: Modeling a Highly Nonlinear Problem
Workshop: Highly Nonlinear Problem (Geometric, Material & Contact)

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Workshop: Modeling a Highly Nonlinear Problem
Simulation steps
👉 Definition of the geometry

👉 Creating the FEM
👉 Defining the material properties
👉 Defining the boundary conditions
👉 Defining the contact conditions
👉 Applying the loading
👉 Set the nonlinear parameters
👉 Post-process the results
Workshop: Highly Nonlinear Problem (Geometric, Material & Contact)

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Workshop: Modeling a Highly Nonlinear Problem Nonlinear Geometric, Material & Contact
GEOMETRY
Free Bending Benchmark Testing of 6111-T4 Aluminum Alloy

John Brem, Frederic Barlat, Joseph Fridy
Alcoa Technical Center, Pennsylvania PUNCH PUNCH
PUNCH
Results presented in the Numisheet 2002 Conference, Korea
DIE DIE DIE
PLATE DIE DIE

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FINITE ELEMENT MODEL

PLATE
• 2D shell quadrilateral elements with linear integration.
Punch • Mesh size = 0.500 mm
(Rigid body) • 14,400 elements in the model (60 elements across the width and 240
Geometry = Surface elements along the length)
Not meshed
• t = 1.0 mm
Plate
(2D mesh)
Die
(Rigid body)
Geometry = Surface
Not meshed
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MATERIAL MODEL
• Isotropic elastic-plastic material properties of Aluminum 6111-T4
• For the ELASTIC properties:

 E = 70,500 Mpa
 n = 0.33
 sty = 194 Mpa
• Hollomon Hardening Model is used to represent the PLASTIC stress-

strain data where:
 s = Ken
 K = 550 Mpa (Strength coefficient)
 n = 0.223 (Strain hardening coefficient)
sty = 194 Mpa

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MATERIAL MODEL
Large strain formulation using additive plasticity
Large strain formulation using additive plasticity is a method

used to model the behavior of materials under large deformation.
It is based on the idea that the deformation of a material can be

divided into elastic and plastic components, with the plastic
component being represented by a set of internal variables.
These internal variables are used to describe the history of plastic

deformation in the material and are updated during the simulation
using a set of constitutive equations.
Additive plasticity is a specific type of large strain formulation in

which the plastic deformation is represented by a sum of
contributions from different mechanisms, such as isotropic and
kinematic hardening. This approach is particularly useful for
simulating the behavior of materials in metal forming.
sty = 194 Mpa

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BOUNDARY CONDITIONS
Punch
To restrict the rigid body motion and stabilize the model during the spring Free along Ty
back (See the loading history next slide), grounded 1D springs with very Fixed along Tx & Tz
small stiffness along the degree of freedom Ty are added at two nodes located
at the free ends
Die
Fixed along 6 DOFs
1D spring grounded
Kty = 10-5 N/mm
Fixed node [Tx, Tz, Rx, Ry, Rz]

Free in [Ty] 1D spring grounded
Kty = 10-5 N/mm

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LOADING
PUNCH IN
• Vertical (dy) enforced displacement
applied to the punch rigid body
y • Cumulative effect:
 the starting state of a subcase
x
PUNCH MAINTAINED
corresponds to the state of the last
converged iteration from the
previous subcase
y
x
PUNCH OUT
upward
y
x
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CONTACT
TOUCHING FRICTIONAL CONTACT
(Bodies can separate & can slide with resistance) Deformable body: all the 2D shell elements of the sheet
Rigid body #1: the surface of the punch
Rigid body #2: the surface of the die
Punch
(Rigid body #1)
Plate
(Deformable Body) Contact Slave Master
Pair Touching Body Touched Body
PUNCH PLATE
#1
Rigid body #1 Deformable body
PLATE DIE
#2
Deformable body Rigid body #2
Friction factor of 0.15 with bilinear Coulomb friction model.

This is a typical friction for lubricated metal-to-metal contact for
a sliding condition between surfaces,
Die
(Rigid body #2)

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SET THE NONLINEAR PARAMETERS

Method: Full Newton-Raphson Method
👉 The solver updates the stiffness matrix at every iteration and on convergence.
Geometric Nonlinear: Large Displacement activated

👉 Updated element coordinates
Material Nonlinear: Activated by the definition of an elastic-plastic material model
Nonlinear Boundary: Activated by the definition of contact pairs
Number of load increments: See table
Convergence criteria: See table

Convergence criteria
No of
Subcases
Maximum number of iterations allowed for each load increment: 500 increments Displacement Residual Load
#1 Punch in 100 10-2 10-2

Maximum number of bisections allowed for each subcase: 10
#2 Punch maintained 10 10-4 10-4
#3 Punch out 200 10-2
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RESULTS The sheet deformation and punch displacement during the forming and
spring back subcases are shown here.
We can see how the sheet deforms, during the forming subcase, as the
Punch punch pushes on the sheet until it enters in contact with the die.
(Rigid body #1)
When the punch goes up again, the spring back of the sheet occurs, but it
does not return to its original position owing to the plastic effect.
The tangential forces due to friction result in a stretching of the sheet,

which, in turn, induces contact between the punch and the sheet during the
complete forming history.
During the unloading, the punch and the sheet move simultaneously in an
upward direction by remaining in contact.
Die
Then, the sheet stops moving, while the punch continues to move upward
(Rigid body #2)
to return to its original position. This release of the sheet from the punch
allows the sheet to spring back to its final position.

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RESULTS The sheet deformation and punch displacement during the forming and
spring back subcases are shown here.
We can see how the sheet deforms, during the forming subcase, as the
Punch punch pushes on the sheet until it enters in contact with the die.
(Rigid body #1)
When the punch goes up again, the spring back of the sheet occurs, but it
does not return to its original position owing to the plastic effect.
The tangential forces due to friction result in a stretching of the sheet,

which, in turn, induces contact between the punch and the sheet during the
complete forming history.
During the unloading, the punch and the sheet move simultaneously in an
upward direction by remaining in contact.
Then, the sheet stops moving, while the punch continues to move upward
to return to its original position. This release of the sheet from the punch
allows the sheet to spring back to its final position.
Die
(Rigid body #2)

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RESULTS
qFEA = 56.1°
As per the experimental data from Alcoa, the minimum

and experimental values are:
53.4° < qEXPERIMENTAL < 55.8°
It is an error between 0.5% and 5%
Very good correlation

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RESULTS
This curve shows the Force-Displacement curve of
the punch.
It is obtained by extracting the data from the 310 load

increments of the load history.
Again, the correlation with the experimental data is

good (the dashed line represent the error at ±10%).

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MODELING TIPS
Very local contact between the plate and the curved shoulders of the die.
The contact is almost a line with a large amount of sliding.
If large elements are used near the shoulder of the die, in the discrete steps of the displacement history, nodes can be identified
where no contact is detected.
Consequently, the following are some guidelines and tips for modeling this problem:
 A fine mesh must be used to describe the contact of the nodes of the plate with the die properly.
 The surface of the rigid body of the die must be very accurate in order to capture properly its geometry.
 The unloading behavior is characterized by the removal of the tool and at the same time adding boundary conditions
preventing the possibility of rigid body motion.
 The unloading behavior should be done in many steps (200 in our case).

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Modeling a Highly Nonlinear Problem
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👉 Part #2: Workshop - Modeling a Highly

© 2024 FEA Academy 2

© 2024 FEA Academy 3

© 2024 FEA Academy 4

© 2024 FEA Academy 5

 Stress stiffening (tension-bending coupling). The

© 2024 FEA Academy 6

© 2024 FEA Academy 7

© 2024 FEA Academy 8

The Types of Contact

Normal Direction Tangential Direction

Can or Cannot Separate Can Slide With or Without Resistance

© 2024 FEA Academy 10

Computational Methods in Nonlinear Analysis

F To solve nonlinear problems, an iterative

FINT(u3, l3) The sum of The sum of

© 2024 FEA Academy 13

Iterative process is based on:

The loading sequence and load increments will strongly

© 2024 FEA Academy 14

The loading is applied gradually in increments, and equilibrium iterations

The tangential stiffness matrix is calculated at the beginning of each load

If a divergence is detected by the solver, the tangent stiffness matrix

Here the Ri are the unbalanced loads.

© 2024 FEA Academy 15

Workshop: Highly Nonlinear Problem (Geometric, Material & Contact)

© 2024 FEA Academy 16

👉 Definition of the geometry

Workshop: Highly Nonlinear Problem (Geometric, Material & Contact)

© 2024 FEA Academy 17

Free Bending Benchmark Testing of 6111-T4 Aluminum Alloy

DIE DIE DIE

PLATE DIE DIE

© 2024 FEA Academy 18

FINITE ELEMENT MODEL

• For the ELASTIC properties:

• Hollomon Hardening Model is used to represent the PLASTIC stress-

sty = 194 Mpa

© 2024 FEA Academy 20

Large strain formulation using additive plasticity is a method

It is based on the idea that the deformation of a material can be

These internal variables are used to describe the history of plastic

Additive plasticity is a specific type of large strain formulation in

sty = 194 Mpa

© 2024 FEA Academy 21

Fixed node [Tx, Tz, Rx, Ry, Rz]

© 2024 FEA Academy 22

Friction factor of 0.15 with bilinear Coulomb friction model.

© 2024 FEA Academy 24

SET THE NONLINEAR PARAMETERS

Geometric Nonlinear: Large Displacement activated

Material Nonlinear: Activated by the definition of an elastic-plastic material model

Nonlinear Boundary: Activated by the definition of contact pairs

Number of load increments: See table

Convergence criteria: See table

#1 Punch in 100 10-2 10-2

The tangential forces due to friction result in a stretching of the sheet,

© 2024 FEA Academy 26

The tangential forces due to friction result in a stretching of the sheet,

© 2024 FEA Academy 27

As per the experimental data from Alcoa, the minimum