2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Workshop 2 SimuIate the Crushing of an Empty Soda Can ANSYS ExpIicit Dynamics Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-2 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Workshop GoaI and Procedure GoaI: Crush an aIuminum beverage can and aIIow it to "springback" Procedure: Create an ExpIicit Dynamics (ANSYS) AnaIysis System Project SeIect the units system and define the materiaI properties Import, modify, and mesh the soda can geometry Define anaIysis settings, boundary conditions, and externaI Ioads Initiate the soIution (AUTODYN - STR) and review the resuIts Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-3 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 1 - Create the Project Schematic Start ANSYS Workbench and foIIow the sequenced steps using the abbreviations shown beIow: DC = ouble Click with Left Mouse Button SC = Single Click with Left Mouse Button RMB = #ight Mouse Button SeIection D&D = rag and rop = HoId Left Mouse Button down on item whiIe dragging it to new Iocation and then reIease it (i.e., Copy or Move) DC 1. Create an ANSYS ExpIicit Dynamics AnaIysis System Project Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-4 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 2 - Specify the Project Units 2.a SeIect MKS for the Project Units from the Units List provided 2.b Request that Native Applications in Workbench have their vaIues be isplayed in the Project Units 2.c Check those unit systems to Suppress from appearing in the Units List Note: Engineering ata is native in Workbench, but Mechanical is NOT at this time (but wiII be in the future). Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-5 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 3 - Define Engineering Data MateriaI 3.a Edit the Engineering ata ceII to add a materiaI to the defauIt Iibrary. 3.b SeIect the Iast sIot under Engineering ata to define a new materiaI modeI. SC 3.c Enter materiaI modeI name: "My_Aluminum" Note: An existing materiaI modeI in the Explicit Materials Iibrary couId have been seIected, but there are restrictions on eIement types that can be used with certain materiaI modeIs, which wiII be discussed Iater. DC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-6 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual DC DC DC Step 3 - Define Engineering Data MateriaI ... SC 3.e Add the foIIowing Physical Properties to the materiaI definition: Density Isotropic EIasticity BiIinear Isotropic Hardening 3.d Make sure the new materiaI is active in order to define its properties Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-7 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 3 - Define Engineering Data MateriaI ... 3.f Enter the foIIowing vaIues: Density = 2710 kg m^-3 Young's ModuIus = 7e10 Pa Poisson's Ratio = 0.30 YieId Strength = 2.9e8 Pa Tangent ModuIus = 0.0 Pa Since the materiaI is sufficientIy defined, the bIue question marks and yeIIow fieIds are no Ionger present in the data tabIe. Note: The resuIting stress-strain curve is eIastic - perfectIy pIastic. No strain hardening can deveIop. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-8 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 3 - Define Engineering Data MateriaI ... 3.g Return to the Project Schematic 3.h Save the Project by seIecting the "Save As ..." icon and Browse to the directory indicated by your instructor. Use the name "empty_soda_can" for the Project name. Note: Saving the Project saves aII of the important fiIes. The Project may aIso be Archived, in which aII of the supporting fiIes are compressed and saved in one fiIe. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-9 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 4 - Import and Modify the Geometry 4.c Workbench has now identified the geometry fiIe (note green checkmark in Geometry ceII). It is now OK to DoubIe CIick on "Geometry", as the new defauIt action is to Edit the geometry. DefauIt actions are shown in boId type after RMB seIects. RMB SC 4.a Import the geometry by the procedure shown. Do NOT DoubIe CIick on the "Geometry" ceII ... 4.b Browse to the DesignModeIer 11.0 SP1 geometry fiIe named: "soda_can_filled_110.agdb" RMB SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-10 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 4 - Import and Modify the Geometry ... 4.d Suppress the soIid "Soda" and the surface body "Hole". RMB SC 4.e Generate the changes in the geometry. AIthough additionaI modifications couId be made, but none are needed. 4.f Save the entire Project via the DM "Save" icon. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-11 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 5 - Edit the ModeI in MechanicaI 5.a Edit the modeI in Workbench MechanicaI. Since Edit is the defauIt action, doubIe-cIicking on the Model ceII is aIso acceptabIe here. RMB SC 5.b SeIect the MKS Units system RecaII that MechanicaI is not native in Workbench, so the Units here may not match the Project Units Note: AIthough the unit system used for data entry and post-processing is the MKS system, the actuaI unit system used by the AUTODYN soIver is the mm-mg-ms system, because it provides higher accuracy. This wiII be shown Iater when the Analysis Settings are discussed. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-12 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 5 - Edit the ModeI in MechanicaI ... Rigid SteeI Punch (moved downwards) FIexibIe AIuminum Soda Can (crushed) Rigid SteeI Die (fixed) 5.c Define the AIuminum Can properties: Stiffness Behavior = FIexibIe Thickness = 0.00025 meters MateriaI Assignment = My_AIuminum 5.d Define the Punch and Die properties: Stiffness Behavior = Rigid MateriaI Assignment = StructuraI SteeI Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-13 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 5 - Edit the ModeI in MechanicaI ... 5.e Review the Contact specifications Keep contact definition defauIts 5.f Save the Project Note: There is no Save icon in MechanicaI Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-14 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 6 - Set Sizing ControIs and Mesh ModeI 6.d Orient the modeI to seIect the 8 edges that define the can circumferences (with the Left Mouse Button). Use the Ctrl key for muItipIe seIections, as needed. 6.a SeIect the Mesh branch 6.b Specify the Mesh etails: Physics Preference = ExpIicit EIement Size = 0.010 meters 6.c Choose the Edge seIection fiIter RMB (anywhere) 6.e With the 8 edges stiII highIighted, Insert (RMB anywhere on graphics screen) an Edge Sizing SC SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-15 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 6 - Set Sizing ControIs and Mesh ModeI ... 6.f Specify the Edge Sizing etails: Type = Number of Divisions Number of Divisions = 36 Behavior = Hard 6.g Generate the Mesh (RMB on either Mesh branch or Edge Sizing branch) RMB SC Mesh view Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-16 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 7 - Define the AnaIysis Settings 7.a Specify the Analysis Settings: End Time = 6.0e-4 seconds Automatic Mass ScaIing = Yes Minimum CFL Time Step = 1.0e-7 sec SC 7.b Set the SoIve Units = mm, mg, ms Note: The mm, mg, ms unit system is the most accurate in most simuIations, so it is the onIy one currentIy avaiIabIe. AIthough more solver unit systems wiII be avaiIabIe in the future, any unit system in the drop-down Iist may be used to enter data and/or display the resuIts. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-17 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 7 - Define the AnaIysis Settings ... 7.c Keep the remaining defauIts Note: There are muItipIe ways to controI the erosion of an eIement. In this case, the eIement wiII onIy faiI when the geometric strain reaches 150%. 7.d Use the defauIt number of data sets to save during the soIution. Depending on the anaIysis, this number may need to be increased, but that requires additionaI disk space, so be judicious here. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-18 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 8 - AppIy BCs and ExternaI Loads 8.a ix the SteeI Die (base): SeIect the Body fiIter Insert a ixed Support under Explicit ynamics SeIect the steeI die Apply the seIection RMB SC SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-19 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 8 - AppIy BCs and ExternaI Loads ... 8.b isplace the SteeI Punch Insert a isplacement under Explicit ynamics SeIect the steeI die Apply the seIection RMB SC SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-20 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 8 - AppIy BCs and ExternaI Loads ... Note: The punch speed and abrupt change in direction are unreaIistic, but sufficient for demonstration purposes. NormaIIy, the movement wouId be prescribed according to a SINE wave function. 8.c Specify the verticaI (Y) dispIacement to be a Tabular Ioad and set both the X and Z dispIacements to be zero. 8.d Ramp the Y dispIacement as foIIows: Time = 0.0 sec Y = 0.0 meters Time = 5e-4 sec Y = -0.060 meters Time = 6e-4 sec Y = -0.030 meters Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-21 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 9 - Insert ResuIt Items to Postprocess 9.a Insert a Total eformation pIot request under the Solution branch. 9.b Insert an Equivalent (von-Mises) Stress pIot request under the Solution branch. The rigid bodies (i.e., the punch and die) wiII not show stress. RMB RMB SC SC SC SC SC SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-22 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 9 - Insert ResuIt Items to Postprocess ... 9.c Insert an Equivalent Plastic Strain pIot request under the Solution branch. RMB SC SC SC Note: Even though a singIe time point (at the end of the run) is specified, the compIete set of resuIts can be viewed, incIuding animations. RecaII that the defauIt output controIs (20 equaIIy spaced time points) was retained under the Analysis Settings branch. 9.d Save the Project again. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-23 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 10 - Run the AUTODYN SimuIation 10.a SeIect Solver Output under Solution Information and Solve the simuIation. The Solver Output shows the run statistics, incIuding the estimated cIock time to compIetion. Any errors or warnings are aIso noted. Termination due to "wrapup time reached" is expected here. SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-24 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 10 - Run the AUTODYN SimuIation ... 10.b SeIect Energy Summary under Solution Information to review the gIobaI statistics. Note the abrupt changes in kinetic energy due to the unreaIistic Ioading scenario ... TIME = 5.0e-4 seconds occurs around 3200 cycIes into run Constant veIocity after starting from rest Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-25 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 11 - Review the ResuIts 11.a SeIect Total eformation and Show the Elements under True Scale. The maximum deformation (-0.060 m) exceeds the punch vaIue due to the momentum invoIved (i.e., an excessive punch speed was used to reduce the required computer run time). SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-26 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 11 - Review the ResuIts ... 11.b Animate the resuIts by setting the controIs as shown beIow and then pressing the Animation button. For transient dynamics, the defauIt istributed mode is inadequate, as it IinearIy interpoIates between saved resuIts. The #esult Sets mode is optimaI, as it uses the actuaI saved data. To review a static resuIt, just cIick on the desired Time or VaIue from the Tabular ata and use the RMB to pick #etrieve This #esult. The given state wiII then be shown. RMB Pick these 2 first Then pick this Pick this to save the animation To retrieve a given resuIt ... Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-27 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 11 - Review the ResuIts ... 11.c Repeat the procedure, if desired, for the von-Mises equivaIent stress resuIts. Note: No stress can deveIop in a rigid body. The punch and die are each condensed out to a mass at their respective centers of gravity with six DOFs active. Contact is based on the exterior surface, so a six DOF body can have a compIicated contact surface. SC Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-28 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 11 - Review the ResuIts ... 11.d Repeat the procedure one Iast time for the equivaIent pIastic strain resuIts. 11.e. Hide the Punch and Die for a better view of the resuIts. Per the Analysis Settings, erosion does not occur untiI the geometric strain is 1.50 SC SC RMB Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-29 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 12 - Review the Output FiIes 12.a Pick iles under the View menu to access the Project fiIes 12.b SeIect Open Containing older via the RMB option for the AUTODYN print fiIe (admodeI.prt). RMB Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-30 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 12 - Review the Output FiIes ... 12.c DoubIe cIick on the fiIe admodel.prt 12.d As noted earIier, the soIver units system was mm-mg-ms in order to maximize the accuracy. After the SimuIation is done, the resuIts are converted back into the current MechanicaI units system. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-31 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 12 - Review the Output FiIes ... 12.e The AUTODYN print fiIe aIso contains the Material Summary information and run statistics. The Energy and Momentum are shown on both a materiaI basis and a Part basis (shown here). Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-32 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 12 - Review the Output FiIes ... 12.f The Energy and Momentum Balance, Mass Scaling, and #un Times are aIso incIuded in the admodel.prt fiIe. 12.g No mass was added to the modeI, since the time steps were aII above the Minimum CFL Time Step of 1.0e-7 sec set in Step 7.a under AnaIysis Settings Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-33 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 12 - Review the Output FiIes ... 12.h CIose the admodel.prt fiIe and review the setup.log fiIe in the same directory (F:\exp_dyn\soda_can\empty_soda_can_fiIes\dp0\SYS\MECH). 12.i The setup.log fiIe contains the information pertaining to the transfer of data from the ExpIicit Dynamics (ANSYS) AnaIysis System to the AUTON Cycle Zero fiIe, which is then run by the AUTODYN soIver. 12.j CIose the fiIe and return to the MechanicaI window (i.e., view the modeI itseIf again). Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-34 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 13 - Generate a Report 13.a CIick on the SoIution branch in the Project tree and then cIick on the Report Preview tab at the bottom of graphics window. ANSYS does the rest! It wiII now automaticaIIy generate a report by going through the entire tree and summarizing the modeI and the resuIts. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-35 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 13 - Generate a Report ... 13.b The modeI properties are summarized, incIuding voIume, mass, centroid, and moment of inertia properties. 13.c Loading information is aIso shown in cIear tabIe format. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-36 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 13 - Generate a Report ... 13.d Even the energy pIots are convenientIy assembIed into the report. Workshop 2. Simulate the Crushing of an Empty Soda Can WS 2-37 ANSYS, nc. Proprietary 2009 ANSYS, nc. All rights reserved. February 27, 2009 nventory #002665 Training Manual Step 13 - Generate a Report ... 13.e The resuIts data is shown. 13.f FinaIIy, SAVE the modeI and exit ANSYS.