Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Workshop on
connection modeling with LS-DYNA
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General introduction
Spotweld modeling modeling of punctiform con.
Adhesives modeling modeling of line and area shaped con.
Bolted connections
N
Y
Tobias Graf
{tg}@dynamore.de
copyright, 2014
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General introduction
Preliminary remarks
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Anisotropy
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Y
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Fracture growth
Damage
by courtesy of DAIMLER AG
Plasticity
Failure
Connection failure
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General introduction
2
failure forces
main focus in connection modeling lies on the correct prediction
of the respective failure forces
one has to distinguish between two totally different connection categories:
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General introduction
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N
Y
General introduction
4
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adhesive
t2
Discretization
on
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middle plane
of flange
thickness flange 2
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thickness flange1
(t1 + t2)/2
adhesive layer
Reality
N
Y
B
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Simulation
General introduction
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General introduction
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line-shaped
MIG welding, MIG soldering,
currently used robust material model:
*MAT_ARUP_ADHESIVE,
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area-shaped
adhesive bonding: Structural adhesive, hood adhesive, PU windshield,
currently used robust material models:
*MAT_ARUP_ADHESIVE,
*MAT_FU_CHANG_FOAM,
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General introduction
7
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spotweld hexahedron
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MIG welding
MIG hexahedron
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spotweld hexahedron
adhesive hexahedron
General introduction
8
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General introduction
9
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t1 ET
t = 0
2
t3 0
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0
ET
0
0 1
0 2 N / mm 2 = N / mm3 [ mm ]
EN 3
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1
2
1
N
Y
General introduction
10
cohesive elements
attached via coincident nodes or tied contact
element numbering defines thickness direction
5
in plane integration: 2x2 Gauss
INTFAIL: Number of integration points
1
required for the element to be deleted
(*MAT_COHESIVE_...)
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ELFORM=19
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Y
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ELFORM=20
General introduction
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General introduction
12
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3
keyword definition
*MAT_ADD_COHESIVE
$
PID
ROFLG
$
I
F
N
Y
INTFAIL
F
THICK
F
General introduction
13
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Cohesive formulation
in LS-DYNA
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1.5F
1.5F
1.5F
1.5F
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Y
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F
F
1.5F
1.5F
General introduction
14
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General introduction
15
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Shear
Pure normal
tension
Kopfzug
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90
60
Peel-test
30
N
Y
20 mm
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1
50
30
Pure shear
Scherzug
0F
15
Schlzug
Peeling
8,5
General introduction
16
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Spotweld modeling
Modeling of punctiform connections
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17
Spotweld modeling
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*MAT_SPOTWELD_{DAMAGE-FAILURE}
discretization techniques
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ELFORM=1
hourglass stabilization IHQ=6
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Master
Tied-Contact
Slave
N
Y
Spotweld modeling
18
material model
bilinear elastoplastic von Mises material law
isotropic hardening
always try to use real material parameters to circumvent instabilities!!!
Adjust the elasticity modulus to get an acceptable time step.
II
II
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I
III
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Eh = Et
yiso
iso
y
isotropic
N
Y
2
max( N rr , 0) N rs
+
N rr
N rs
F
III
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N
+ rt
N rt
M
+ rr
M rr
M
+ ss
M ss
M
+ tt
M tt
1 > 0
Spotweld modeling
19
OPT
-1
-2
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5
6
N
Y
D
-9
11
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*MAT_SPOTWELD_DAMAGE-FAILURE
several failure criteria are available and can be specified via variable OPT (CARD 3)
like OPT=1, LS-DYNA looks for failure parameter for each beam node,
FC is evaluated for each beam node independently, failure parameters have to be
defined for each connected part, strain rate effects can be defined (TOYOTA)
stress resultant based, LS-DYNA looks for fail. param. dep. on flange partners,
failure parameters have to be defined for every flange connection combination,
strain rate effects can be defined, definition of default values possible
like OPT=6 but failure is split into nugget pull out and fracture failure (TOYOTA)
like OPT=9, FC is comp. and written, element is not deleted
Spotweld modeling
20
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*MAT_SPOTWELD_DAMAGE-FAILURE
new failure model OPT=11 for beam elements, where failure depends on loading
direction via curves
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0
90
ISO thread
round thread
trapezoidal thread
buttress thread
Spotweld modeling
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Spotweld modeling
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*MAT_SPOTWELD_DAIMLER
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ELFORM=1, IHQ=6
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Master
Tied-Contact
Slave
Spotweld modeling
23
material model
bilinear elastoplastic von Mises material law
isotropic hardening
always try to use real material parameters to circumvent instabilities!!!
Adjust the elasticity modulus to get an acceptable time step.
II
II
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I
III
III
N
Y
E pl
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Eh = Et
yiso
tangent modulus Eh
relation between stress and total strain
Plastic modulus Epl
relation between stress and
plastic strain
E Eh
=
E Eh
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iso
y
isotropic
Eh
y
E
Epl
pl
Spotweld modeling
24
failure model
the failure model consists of three terms that take normal stresses,
shear stresses and stresses due to bending into account:
N
n = rr
A
M rs2 + Mrt2
b =
Z
Nrs2 + Nrt2
M rr
=
+
2Z
A
f = Fn
sn
mn
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+ Fb
sb
mb
+ F
ss
d3
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N
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Spotweld modeling
SS
SB
Measured force
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N S
N
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Displacement
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keyword definition
*MAT_SPOTWELD_DAIMLER
$
MID
RO
10
7.85E-6
$
EFAIL
E
10.0
PR
0.3
DT
TFAIL
m
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NF
30.0
RS
ASFF
TRUE_T
CON_ID
1.0
1.0e-10
1
$------------------------------------------------------------------------------*DEFINE_CONNECTION_PROPERTIES
$
CON_ID PROPRULE
AREAEQ
DG_TYP
MOARFL
1
1
1
1
$
D_SIGY
D_ETAN
D_DG_PR
D_RANK
D_SN
D_SB
D_SS
0.3124
1.400
0.001
0.1 1.000E+20 1.000E+20 1.000E+20
$
D_EXSN
D_EXSB
D_EXS
D_LCSN
D_LCSB
D_LCSS
D_GFAD D_SCLMRR
2.E+00
2.E+00
2.E+00
1002
1002
1002
N
Y
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Eh = Et
iso
y
yiso
isotropic
Spotweld modeling
N S
N
SB
SS
f = Fn
sn
mn
+ Fb
sb
mb
+ F
ss
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Spotweld modeling
MOARFL
I
D_SN
F
D_LCSS
I
D_SB
F
D_GFAD
F
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N
Y
DG_TYP
I
D_RANK
0.3
D_LCSB
I
RANK
0.5
D_LCSB
I
RANK
0.2
D_LCSB
I
SN
F
D_LCSS
I
SN
F
D_LCSS
I
SB
F
D_GFAD
F
SB
F
D_GFAD
F
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D_SS
F
D_SCLMRR
F
default
values
metal sheet 1
SS
F
D_SCLMRR
F
metal sheet 2
SS
F
D_SCLMRR
F
N
Y
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Spotweld modeling
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ISLCHK
2
NSBCS
0
EDC
0.0
SKIPRWG
0
PENOPT
1
XPENE
4.0
TH
0.0
SPOTSTP
0
N
Y
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THKCHG
0
SSTHK
0
TH_SF
0.0
SPOTDEL
1
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SHLTHK
0
INTERM
0
VFC
0.0
OUTSEG
0
ORIEN
2
ECDT
0
PEN_SF
0.0
SPOTHIN
0.5
Spotweld modeling
ENMASS
0
TIEDPRJ
0
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Spotweld cluster
1 hex elements
RPBHX:
PRTFLG
2
T_ORS
0
RPBHX
8
16 hex elements
BMSID
ID_OFF
N
Y
T_ORT
0
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8 hex elements
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*CONTROL_SPOTWELD_BEAM
$
LCT
LCS
0.1
0.0
4 hex elements
Spotweld modeling
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Adhesives modeling
modeling of line and area shaped con.
N
Y
31
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Adhesives modeling
Mechanical behavior of bonding materials
hood adhesive
foam-like,
viscoelastic
=0
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PU windshield
rubber-like,
viscoelastic
= 0.5
N
Y
structural adhesive
elasto-viscoplastic
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Material behavior
Adhesives modeling
32
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*MAT_ARUP_ADHESIVE (*MAT_169)
&
(
)
max
PWRT
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( & )
+
( & ) SHL _ SL ( & )
max
(0)
max
= TENMAX
max
N
Y
(0)
max
= SHRMAX
PWRS
1.0 = 0
max
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Area=GCSHR
Area=GCTEN
d fail ,tension
dp
d fail , shear
Adhesives modeling
33
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(0)
max (& ) =SDFAC ( & ) max
SDFAC
&
(0)
= EDOT0
& ( 2) = EDOT2
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SDFAC ( & )
1.0
( )
log &
(0)
log ( & )
( )
log &
( 2)
( 0)
log (plastic
strain rate)
N
Y
Adhesives modeling
34
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Adhesives modeling
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MODE I
Material Parameter:
E= 50.0 [kN/mm]
GCTEN = 0.25 [kNmm]
GCSHR = 0.10 [kNmm]
TENMAX = 4.0 [kN/mm]
SHRMAX = 2.0 [kN/mm]
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stress in x-direction
2.0
3.0
2.0
1.0
0.2
energy
0.3
N
Y
0.2
0.1
0.0
0.0
1.5
1.0
MODE II
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0.5
0.0
0.1
0.1
0.2
0.3
0.0
0.4
0.1
0.2
0.3
0.4
0.1
0.2
0.3
0.4
0.12
0.10
energy
stress in z-direction
4.0
0.0
0.0
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0.08
0.06
0.04
0.02
0.3
relative z-displacement
0.4
0.00
0.0
relative x-displacement
Adhesives modeling
36
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Adhesives modeling
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*MAT_COHESIVE_MIXED_MODE_ELASTOPLASTIC_RATE (*MAT_240)
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N
Y
Adhesives modeling
38
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N
Y
Adhesives modeling
39
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BOLTED CONNECTIONS
N
Y
40
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Bolted connections
Preliminary remarks
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N
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Bolted connections
41
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N
Y
Bolted connections
42
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*INITIAL_AXIAL_FORCE_BEAM
$
I
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F
$
BSID
LCID
SCALE
1
1
2
BSID:
LCID:
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Beam set ID
Load curve ID defining preload force versus time.
When the load curve ends or goes to zero,
the initialization is assumed to be completed.
Scale factor on load curve
SCALE:
remarks:
use contact damping with VDC={0.1-0.2} and/or
*DAMPING_PART_STIFFNESS with COEF=0.1
always use a smooth ramp in the load curve starting at the origin to apply the load
when the end of the load curve is reached or the value of the load decreases
form the maximum value, the initialization stops.
N
Y
Bolted connections
43
numerical example
file: initial_axial_force_beam.key
keyword definition
*INITIAL_AXIAL_FORCE_BEAM
$
BSID
LCID
SCALE
99
98
0.0
*SET_BEAM
$
SID
99
$
ID1
100
*DEFINE_CURVE
$
LABEL
SIDR
SFA
SFO
98
0
0.1
1.0
$
XVALS
YVALS
0.0
0.0
10.000000
83.000000
20.000000
83.000000
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OFFA
0.0
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OFFO
0.0
DATTYP
0
N
Y
Bolted connections
44
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initialize the stress in solid elements that are part of a section definition to create a preload.
stress component in the direction normal to the cross-section plane is initialized.
option works with a subset of materials that are incrementally updated.
rubbers, foams, and materials that are combined with equations-of-state
cannot be initialized by this approach.
NEW: Hyperelastic materials # 57, 73 and 83 can be initialized with this approach.
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*INITIAL_STRESS_SECTION
$
I
A8
$
ISSID
CSID
1
1
ISSID:
CSID:
LCID:
PSID:
VID:
I
LCID
2
I
PSID
I
VID
m
G
N
Y
Bolted connections
45
H
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remarks:
use contact damping with VDC={0.1-0.2} and/or
*DAMPING_PART_STIFFNESS with COEF=0.1
always use a smooth ramp in the load curve starting at the origin to apply the load
when the end of the load curve is reached or the value of the load decreases
form the maximum value, the initialization stops.
solid elements types 1, 2, 3, 4, 9, 10, 13, 15, 16, 17 and 18 are supported
ALE elements are not supported
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N
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Bolted connections
46
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numerical example
file: initial_stress_section.key
keyword definition
*INITIAL_STRESS_SECTION
$
ISSID
CSID
LCID
PSID
1
99
98
97
*SET_PART
$
PID
97
$
ID1
1
*DATABASE_CROSS_SECTION_PLANE_ID
$
label
title
99
$
PSID
XCT
YCT
ZCT
97
17.0
17.0
44.5
$
XHEV
YHEV
ZHEV
LENL
-17.0
17.0
44.5
0.0
*DEFINE_CURVE
$
LABEL
SIDR
SFA
SFO
98
0
0.1
1.0
$
XVALS
YVALS
0.0
0.0
10.000000
83.000000
20.000000
83.000000
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m
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N
Y
VID
0
m
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XCH
17.0
LENM
0.0
YCH
17.0
ID
0
ZCH
45.0
ITYPE
0
OFFA
0.0
OFFO
0.0
DATTYP
0
Bolted connections
47