Improving Your Structural Mechanics Simulations With ANSYS Release 14.0

Improving Your Structural Mechanics Simulations with Release 14.
Tim Pawlak, R&D Fellow ANSYS Inc.

1 2011 ANSYS, Inc. December 8, 2011
Structural Mechanics Themes

MAPDL/WB Integration Physics coupling Rotating machines Composites & Fracture Mechanics Application Customization Thin structures modeling Contact analysis Performance Advanced Modeling Geometry Handling
Listening to your needs, we have been able to identify a number of themes which form the basis of our roadmap and guide our developments
What will Release 14.0 bring you?
2011 ANSYS, Inc.
December 8, 2011
MAPDL/WB Integration Finite Element Access within ANSYS Mechanical
2011 ANSYS, Inc.
December 8, 2011
Motivation Finite Element Access
ANSYS Workbench was originally a geometry based tool. However many users also need to work with mesh entities.
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December 8, 2011
Reviewing Connections
Spot Welds
Weak springs and MPC contacts as generated by the solver

Connections created internally at the solution level are available and can help understand the results
Selections of Nodes
Nodes can be grouped into named selections based on selection logic, using locations or other characteristics or manual selections
Box Selection Node Picking Lasso Selection
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December 8, 2011
Applying Loads and Orientations to Nodes
Nodal orientation allows users to orient nodes in an arbitrary coordinate system. Direct FE boundary conditions can be applied to selections of nodes.
Nodes are oriented in cylindrical system for loads and boundary condition definitions
Results on Node Selections
Results with first layer of quads removed
Results are displayed on elements for which all nodes are selected. Node named selections allow to scope on specific regions of the mesh or remove undesired areas.
Results on quads layers only

Restart and Direct FE Loads
Added after initial solve Analysis Settings tabular data: No restart point is lost
Second Load step modified for restart
Nodal Forces and Pressures objects can be added to a restart analysis without causing the restart points to become invalid. Other loads can now be modified without losing the restart points.
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MAPDL/WB Integration Linear Dynamics in ANSYS Mechanical
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Workbench and Mechanical enhancements

MSUP Transient Analysis supported Joint feature can now be used in Harmonics, Random vibration analysis Reaction Force & Moment results are now available in Harmonic analysis
Joints in Harmonic Analyses
Modal Superposition Transient
Reaction Forces in a Harmonic Analyses
Physics Coupling Data Mapping
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Motivation for Data Mapping

File exchanges are frequently used to transfer quantities from one simulation to another. Efficient mapping of point cloud data is required to account for misalignment, non matching units or scaling issues.
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Supported Data Types
New at R14.0
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Increased Accuracy
The smoothness of the mapped data depends on the density of the point cloud. Several weighting options are available to accommodate various data quality.
Triangulation versus Kriging
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Validating the Mapped Data
Visual tools have been implemented to investigate how well the data has been mapped onto the target structure
Importing Multiple Files
Multiple files can be imported for transient analyses or to handle different data to be mapped on multiple bodies
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Rotating Machines Studying Rotordynamics in ANSYS Mechanical
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Motivation for Rotordynamics
ANSYS Mechanical users need to be able to quickly create shaft geometries as well as analyze dynamic characteristics of rotating systems
Industrial fan (Venti Oelde)
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Specific Solver Settings
Rotordynamics analyses require a number of advanced controls: Damping Solver choice Coriolis effect
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Campbell Diagrams
Campbell diagrams are used to identify critical speeds of a rotating shaft for a given range of shaft velocities
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Composites Enhanced Analysis Workflow and Advanced Failure Models for Composites
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Motivation for Composites
Efficient workflows and in-depth analysis tools are required to model and understand complex composites structures
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Defining Material Properties
Composites material require specific definitions including orthotropic properties, as well as some constants for failure criteria (TsaiWu, Puck, LaRc03/04, Hashin)
Manually Defining Layers on Simple Geometries
Users can define simple layered sections for a shell body as well as define thicknesses and angles as parameters
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Defining Layers on Complex Geometries
Courtesy of TU Chemnitz and GHOST Bikes GmbH
For complex geometries, the ANSYS Composite PrepPost module is used to define layers and then imported them onto the assembly model in ANSYS Mechanical.
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Investigating Composites Results

ANSYS Mechanical supports layerwise display of results.
ANSYS Composite PrepPost offers comprehensive capabilities for global and plywise failure analysis.
Customization ANSYS Design Assessment
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Motivation Custom Results

Many of you have expressed the need for: Computing and displaying specific results Be able to achieve more complex User defined results
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Custom Results by Design Assessment
The Design Assessment system enables the selection and combination of upstream results and the ability to optionally further assess results with customizable scripts
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Design Assessment for Advanced User Defined Results

Design Assessment enable users to extend user defined results capabilities with:
Expressions using
mathematical operators as supported by Python Systems
Coordinate systems, Units Integration options Nodal, Element-Nodal &

Script used to display scalar element data stored in an external file
Elemental result types
Import from external tables
Customization Application Customization Toolkit (ACT)
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Motivation for Customization

As a Mechanical User, you may want to: Customize menus Create new loads and boundary conditions Create new types of plots Reuse APDL scripts without command snippets
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What is the Application Customization Toolkit?
A means to customize Mechanical.
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Toolbar Customization through XML Files
XML definition:
<load internalName="Convection on Blade" caption="Convection on Blade" icon="Convection" issupport="false" isload="true"> <version>1</version> <callbacks> <onsolve>Convection_Blade_Computation</onsolve> </callbacks> <details> <property internalName="Geometry" dataType="string" control="scoping"></property> <property internalName="Thickness" caption="Thickness" dataType="string" control="text"></property> <property internalName="Film Coefficient" caption="Film Coefficient" dataType="string" control="text"></property> <property internalName="Ambient Temperature" caption="Ambient Temperature" dataType="string" control="text"></property> </details> </load>
Python Driven Loads and Boundary Conditions

Python script:
# Get the scoped geometry: propGeo = result.GetDPropertyFromName("Geometry") refIds = propGeo.Value # Get the related mesh and create the component: for refId in refIds: meshRegion = mesh.MeshRegion(refId) elementIds = meshRegion.Elements eid = aap.mesh.element[elementIds[0]].Id f.write("*get,ntyp,ELEM,"+eid.ToString()+",ATTR,TYPE\n") f.write("esel,s,type,,ntyp \n cm,component,ELEM") # Get properties from the details view: propThick = load.GetDPropertyFromName("Thickness") thickness = propThick.Value propCoef = load.GetDPropertyFromName("Film Coefficient") film_coefficient = propCoef.Value propTemp = load.GetDPropertyFromName("Ambient Temperature") temperature = propTemp.Value # Insert the parameters for the APDL commands: f.write("thickness="+thickness.ToString()+"\n") f.write("film_coefficient="+film_coefficient.ToString()+"\n") f.write("temperature="+temperature.ToString()+"\n") # Reuse the legacy APDL macros: f.write("/input,APDL_script_for_convection.inp\n")
Writing APDL Commands From the New Definition

! APDL_script_for_convection.inp ! Input parameters: esel,s,type,,10 cm,component,ELEM thickness = 1.1 film_coefficient = 120. temperature = 22. ! Treatment: /prep7 et,100,152 keyop,100,8,2. et,1001,131 keyo,1001,3,2 sectype,1001,shell secdata,thickness,10 secoff,mid cmsel,s,component emodif,all,type,1001 emodif,all,secnum,1001 type,100 esurf fini alls /solu esel,s,type,,100 nsle sf,all,conv,film_coefficient,temperature alls
APDL
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WB Mechanical
An Example: ACT driven Submodeling
Users simply select the coarse models results file, all APDL commands are automatically created no more need for command blocks!
Thin Structures Mesh Connections
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Motivation for Mesh Connections

In order to connect meshes of different surface parts so as to merge nodes at intersections, users do not always want or cannot merge the topologies at the geometry level. Mesh based connections are a valuable option.
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Mesh Connections
Mesh connections work at part level: As a post mesh operation Base part mesh is stored to allow for quick changes in connections
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Modal Analyses Shows Proper Connections of the Various Bodies
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Further Meshing Enhancements
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Virtual Topologies Interactive Editing
Direct access to operations from RMB menu
Virtual topologies are handled more interactively through direct graphics interaction rather than tree objects.
User selects entities then applies VT operations
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Virtual Topology Hard Vertex, Edge, and Face Splits

Hard vertices can be added at any location on an edge or a face.
Hard vertices can then be used to create face splits from virtual edges.
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Virtual Topologies Applications
Get swept mesh on non-sweepable bodies
Improve shell mesh quality and orthogonality with VT combinations

Contact Analysis Rigid Body Dynamics
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Motivation for RBD Contact

Many mechanisms and assemblies have components that operate through contact. In order to maintain the rapid turnaround for RBD simulations, there has been a subsequent focus on improving speed, accuracy and reliability of the contact capability.
Performance Improvements
Applicability, robustness, and efficiency of the contact has been improved for speed and accuracy expect a typical 2-5x speed-up
Valve: 158 sec elapsed time (2x speed up)
Piston: 9 sec elapsed time (7.5x speed up)
Transition and jump prediction have been greatly improved
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Contact Analysis Flexible bodies
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Motivation for Contact
While already providing leading edge technology, ANSYS continues to enhance its ability to robustly and efficiently solve complex contact problems
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Projected Contact
Regular contact Projection based
Smoother temperature results on a multilayered structure
The Surface Projection Based Contact provides more accurate results (stresses, pressures, temperatures) and is now also available for bonded MPC contacts
Improved pressure results with surface projection

Contact accuracy and robustness
Adjust to touch causes rigid body motion and leaves a gap
New contact stabilization prevents rigid motion
Contact stabilization technique dampens relative motions between the contact and target surfaces for open contact
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Performance Further benefits from GPU boards
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Motivation for GPUs

Taking advantage of the latest hardware is mandatory to solve your large models.
A combination of relatively new technologies provides a breakthrough means to reduce the time to solution
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Distributed ANSYS Supports GPUs
GPU Acceleration can now be used with Distributed ANSYS to combine the speed of GPU technology and the power of distributed ANSYS
Speed-up from GPU technology
Linux cluster : Each node contains 12 Intel Xeon 5600series cores, 96 GB RAM, NVIDIA Tesla M2070, InfiniBand
Solder balls
Results Courtesy of MicroConsult Engineering, GmbH
Mold
Solder Joint Benchmark - 4M DOF, Creep Strain Analysis
PCB
Advanced Modeling Material Models
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Motivation for Material Models

ANSYS provides a comprehensive library of advanced materials. Some users however need even more advanced models to include complex nonlinear phenomena in their simulations.
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Advanced Materials for Biomechanical Applications
Anisotropic Hyperelasticity plus
Viscoelasticity for strain rate effects
Hyperelasticity coupled with Pore

Pressure element
Hydrocephalus analysis Hyperelastic material with porous media
Shape Memory Alloy enhanced with
superelasticity, Memory effect, New Yield Function, Differentiated Moduli (Austenite, Martensite)
Holzapfel Model - Capture the

Stent modeling using shape memory alloys
behavior of fiber-reinforced tissue
Nonlinear materials support for coupled field elements
Coupled field-elements for strongly coupled thermo-mechanical analysis now accounts for plasticity induced heat generation along with friction effects
Friction Stir Welding including heat generation due to friction and plastic deformation
Advanced Modeling Brake Squeal
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Motivation for Brake Squeal

Auto owner complaint and is associated with high warranty costs. ANSYS provides the best solution for such analyses, including complex Eigen-Methods to predict onset of squeal, new state-of-theart linear methods and parametric studies.
ANSYS Solution for Brake Squeal

Provides for sliding contact with friction No match mesh needed Supports higher order elements Complex Eigen solve Animate: Complex Mode Shape Contact Status at Pads
Automated Meshing
CAD
Bi-Directional CAD Connectivity
Mesh & Connection

Automated Contact Detection
Setup & solver

Flexibility to use Linear & Non-linear solver capabilities Friction sensitivity study Contact damping Sliding velocity Run set of DOEs dependent Friction
Significant time reduction
Post Processing
Root locus plots Correlation of modes List Strain energy per component per mode
Physical prototyping time consuming and expensive
Can include Squeal and cycle Provide more analysis early in the design
Parametric Study by changing friction coefficient Reuse symmetric modes and just run unsymmetric part
System Level Simulation Rigid Body Dynamics Simplorer Co-simulation
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Motivation for System Level Simulation

Most mechanisms and assemblies are managed via control systems. System simulation, including the details of the mechanism or assembly, are needed in order to improve modeling accuracy, fidelity and ultimately system optimization.
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Linking Mechanical and Simplorer
Inputs and outputs are defined as pins in the Mechanical model and connected to the schematics of Simplorer
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Simulation Results
Force Applied on Pistons
Rotational Displacement Rotational Velocity
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Some Examples
Aircraft Landing Gear
Robotic Arm Control RBD model Trace of arm trajectory
Simplorer schematic of hydraulic circuit and control

And there is much more
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check the Release Notes!
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Remember Technology Demonstration Guide
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Questions?
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Improving Your Structural Mechanics Simulations With ANSYS Release 14.0

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Improving Your Structural Mechanics Simulations with Release 14.

Tim Pawlak, R&D Fellow ANSYS Inc.

Structural Mechanics Themes

What will Release 14.0 bring you?

2011 ANSYS, Inc.

MAPDL/WB Integration Finite Element Access within ANSYS Mechanical

2011 ANSYS, Inc.

Motivation Finite Element Access

2011 ANSYS, Inc.

Weak springs and MPC contacts as generated by the solver

2011 ANSYS, Inc.

Applying Loads and Orientations to Nodes

Results on Node Selections

Results with first layer of quads removed

Results on quads layers only

Restart and Direct FE Loads

Second Load step modified for restart

2011 ANSYS, Inc.

MAPDL/WB Integration Linear Dynamics in ANSYS Mechanical

2011 ANSYS, Inc.

Workbench and Mechanical enhancements

Modal Superposition Transient

Reaction Forces in a Harmonic Analyses

Physics Coupling Data Mapping

2011 ANSYS, Inc.

Motivation for Data Mapping

2011 ANSYS, Inc.

Supported Data Types

2011 ANSYS, Inc.

Triangulation versus Kriging

2011 ANSYS, Inc.

Validating the Mapped Data

Importing Multiple Files

2011 ANSYS, Inc.

Rotating Machines Studying Rotordynamics in ANSYS Mechanical

2011 ANSYS, Inc.

Motivation for Rotordynamics

2011 ANSYS, Inc.

Specific Solver Settings

2011 ANSYS, Inc.

2011 ANSYS, Inc.

2011 ANSYS, Inc.

Motivation for Composites

2011 ANSYS, Inc.

Defining Material Properties

Manually Defining Layers on Simple Geometries

2011 ANSYS, Inc.

Defining Layers on Complex Geometries

Courtesy of TU Chemnitz and GHOST Bikes GmbH

2011 ANSYS, Inc.

Investigating Composites Results

Customization ANSYS Design Assessment

2011 ANSYS, Inc.

Motivation Custom Results

2011 ANSYS, Inc.

Custom Results by Design Assessment

2011 ANSYS, Inc.

Design Assessment for Advanced User Defined Results

mathematical operators as supported by Python Systems

Coordinate systems, Units Integration options Nodal, Element-Nodal &

Elemental result types

Import from external tables

Customization Application Customization Toolkit (ACT)