Seminar Linear Contact Analysis Notes

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LinearContactAnalysis: Demystified
withFemapV10.1.1andNastran 7.0
AdrianJensen MechanicalEngineer Adrian.Jensen@PredictiveEngineering.com
2010 AllRightsReserved
LinearContactAnalysis:Demystified WORKINPROGRESS
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TableofContents
1. 2. Introduction......................................................66 Regions.........................................................66 a) Solids........................................ . .............66 i. BySurfaces..............................................66 ii. ByElements...................................... . .......66 b) Plates.....................................................66 i. BySurfaces...................................... . .......66 ii. ByElements...................................... . .......66 Connectors.......................................................66 a) SourceTarget...................................... ...........66 Properties....................................... . ................66 a) Friction....................................... . .............66 b) ContactSearchDistance.................................. . ........66 c) ) InitialPenetration...............................................66 d) Refinement....................................... . ...........66 i. EvaluationOrder..................................... . ......66 ii. RefineSource.............................................66 e) PenaltyFactor..................................... . ...........66 i. PenaltyFactorUnits..........................................66 ii. Autovs.ManualPenaltyFactor...................................66
3 3. 4.
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Introduction
Frustrated? Usinglinearcontactcanbefrustrating.Infact,itisprobablyoneofthemostfrequentsubjectsofcallsfortechsupportstaff.But whenyoubreakitdownintoitsmostsimplecomponents,itdoesnthavetobefrustrating.Itcanbeaquick,easyanduseful techniqueinyourFEAtoolbox.Itallboilsdowntoelementfacesintersectingotherelementfaces.Ifyoucorrectlyspecifythe contactregionsandtheinitialcontactconditionsyouwillhavesuccesswithlinearcontactanalysis. Whatislinearcontact? Linearcontactiscalledsuchbecausethereisnogeometricormaterialnonlinearityintheanalysis.Thatis,thestiffnessmatrixis notupdatedandthematerialbehavesinalinearelasticfashion.Takeforexampleasmallsteelpunchpressingagainstasurface. Letsassumeanominalelasticmodulusof29,000,000andayieldstrengthof60,000psi.Whenthesteelreachestheyieldstress, ithasastrainof0.2%(60,000psi/29,000,000psi).Ifthatpunchwasoriginally1long,ithascompressed0.002.Onecould safelyassumethatthebehaviorofthesystemhaschangedverylittle.Whatdoesthisallmean?Forproblemswithstiff engineeringmaterials(e.g. (e g steel)wherethematerialisnotstressedbeyondtheyieldstrength strength,linearcontactisareasonable analysismechanism. Howdoesitwork? Thiswhitepaperwillcoverawiderangeoflinearcontactproblemsfromthesimpletaskofsettingupcontactregionstothe more daunting gcharge g ofmanually yadjusting j gthepenalty p yfactors.Thekey ytoany ylinearcontactproblem p ittostartsimple. p Beforeyou y try y torunthat500,000nodemodelwith20contactregions,buildsmall,manageablemodelsofthedifferentcontactscenariosfor easydebugging.
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ConnectionRegions
Whenyoubreakalinearcontactproblemdownintoitsmostsimplecomponent,youhaveaConnectionRegion.Itmightseem likeanelementarystepintheanalysisbutifitisnotdonecorrectly,therewillbeproblemsthatcantbefixedbytoying withthe moreadvancedcomponentsoflinearcontact.
ConnectionRegions:Solids,bySurfaces
Theeasiestlinearcontactanalysistosetupisforasimplesolidmodelusingsurfaces.WhencreatingyourConnectionRegionby surfacesyoullnoticeanoptiontoselectthepositiveornegative.Forsolidmodels,thisoptionisnotnecessary.Ifyoucheckthe normalsofthesurfacesofthesolidbody,theyreallfacingoutward.Theoptiontomodifysurfacenormalsonlyworksforsheet solids.Additionally,evenifyoudoselectthenegativefaceofasurface,yourresultswillchangenegligibly.
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ConnectionRegions:Solids,byElements
InsomecasesyoubeunabletoselectyourConnectionRegionsbysurfaces.Theotheroptionistoselectyourregionsby elements.ThistechniquegivesyoumorecontroloverselectingyourConnectionRegion,butalsoopensupthepossibilityfor error.StarttocreateyouConnectionRegionbyselectingtheElementsradiobuttonundertheDefinedBysectionofthe ConnectionRegiondialoguebox. A Assuming i youd dont twant tto t select l telements l t oneby b one,click li kthe th Multiple M lti l button. b tt There Th aretwo t stages t to t the th region i selection l ti byelements:theelementselectionandtheelementfaceselection.Theelementselectionissimple;graballelementsthathave facesyouwanttoincludeintheConnectionRegion.
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Regions:Solids,byElements
Theelementfaceselectionisabittrickier. trickier Onceyouhaveselectedtheelementsyouwant, want youarepresentedfiveoptionsforface selection.Thefollowingpagesprovidesexamplesofeach. FaceID: Eachfaceofanelementhasafaceid.Plateelementsusefaces1&2,tet elementsusefaces14andhexelementsusefaces16. Thisoptionisgenerallytheleastusefulforasolidmodelbecausetheelementfacesonthesurfaceofthesoliddonotnecessarily shareacommonfaceID.ThegraphicsbelowshowtheConnectionRegionscreatedbyselectingalloftheelementsandusingthe FaceIDfaceselectionmethod.Thefirstgraphicshowsface1,thesecondshowsface2andsoforth.
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NearSurface: ThisoptionisusefulifyouhavegeometrytoworkwithbutyoudontwanttolimittheelementsinyourConnectionRegion.The graphicsbelowshowtheConnectionRegionscreatedbyselectingaclusterofelementsinthecorneroftheblockandusingthe NearSurfacefaceselectionmethod.
NearCoordinates: TheNearCoordinatesmethodisverysimilartoNearSurface.Insteadofspecifyingasurface,however,youchoosea coordinatesystem,directionandposition.Thisdefinesaplanarsurface,whichisusedalongwiththetolerancetofindtheclosest faces.
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AdjacentFaces: Apowerfulmethodforchoosingfaces,especiallyforcomplexsolidandplanarelementmodels.Youchoosejustoneinitialface (andtheassociatedelementID).Thiscanbedoneveryeasilybygraphicallyselectingtheface.Youthenspecifyatolerance angle. FEMAPwillsearchallselectedelementsforfacesthatareconnectedtothefacethatyouchoseandthatarewithinthespecified tolerancefrombeingcoplanarwithanalreadyselectedface.
ModelFreeFaces TheModelFreeFaces methodsimplyincludesevery"freeelementface"inyourelementselection.Agoodtechniqueifyoucan grabexactly g ytheelementsy youwantwithintheelementselectiondialogue g box.
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ConnectionRegions:Plates,bySurfaces
Platemodelsaregenerallyrequiremorecarewhenselectingyour regions.WhenselectingyouplatemodelConnectionRegionsby surfaces,youneedtopayspecialattentiontothesurfacenormals andelementnormals.Sincebothfacesofaplateelementare linkedtothesamesurface,youwillneedtoturnthePositive Sid option Side ti onand doff ffwhere h appropriate. i t Thesurfacenormalsareshownintheuppermostgraphiconthe right.ThemiddleimageshowsthefirstConnectionRegion.The surfacewasselectedwiththePositiveSideoptionunchecked. ThebottomimageshowsthesecondConnectionRegion. Region The surfacewasselectedwiththePositiveSideoptionchecked. NotethattheConnectionRegiondirectionsfaceeachotherina properlyconfiguredcontactanalysis.Youcancheckthisbyusing Window>ShowEntities.SelectRegionforyourentitytypeand checktheShowNormalsstyleoption.
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ConnectionRegions:Plates,byElements
InsomecasesyoubeunabletoselectyourConnectionRegionsbysurfaces.Theotheroptionistoselectyourregionsby elements.ThistechniquegivesyoumorecontroloverselectingyourConnectionRegion,butalsoopensupthepossibilityfor error.StarttocreateyouConnectionRegionbyselectingtheElementsradiobuttonundertheDefinedBysectionofthe ConnectionRegiondialoguebox.Youprobablydontwanttoselectelementsonebyone.UsetheMultiplebuttontospeed thingsup.
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Regions:Plates,byElements
Onceyouhaveselectedtheelementsyouwant, want youarepresentedfiveoptionsforfaceselection selection.Whenworkingwithplate elements,onlytheFaceIDandAdjacentFacesoptionsshouldbeused. FaceID: Asmentionedearlier,plateelementsusefaces1&2forConnectionRegions.Beawarethatafoursidedplateelementhassix facesandFemapwillallowyoutoselectanyofthesefacesbutonlyfaces1&2aresupportedforcontact.TheFaceIDmethod allowsyoutoenterthefaceIDnumericallyorselectafacefromthemodel.Thismodelismoreeffectivewithplatemodels becausethefacesoftheelementsaremorecommonlyaligned. AdjacentFaces: ThismethodisusefulforcreatingConnectionRegionswhenelementsdonothaveconsistentorientationorwhenthemodelhas complex l geometry t (see ( Adj Adjacent tFaces F i inthe th solid lidelement l tsection). ti )
Hint:TurnonelementthicknesstohelpyouchecktheConnectionRegionyouhavecreated.
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Connectors
OnceyouhaveproperlysetupyourConnectionRegions,youmustestablishcontactpairs,calledConnectorsintheFemap interface.AConnectorspecifiesacontactmechanisminthemodelwithaSourceConnectionRegion,aTargetConnection RegionandaConnectionProperty.
SettingupaConnectorisquitesimple,selectaConnectionPropertyfromthedropdownlistorusethequickbuttontotheright tocreateanewone.LeavethefieldsoftheConnectionPropertyblankfornow.ConnectionPropertieswillbediscussedingreater detaillaterinthiswhitepaper.Next,selectMaster(Target)andSlave(Source)ConnectionRegionsfromthedropdownlistsor selectbyclickingonthedesiredConnectionRegionsinthemodel.TheConnectionRegionswillhighlightasyouplacethecursor overthemtomaketheselectionprocesseasier(seethegraphicabove).
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Connectors:SourceRegionsandTargetRegions,fromtheNXNastran7UsersGuide
It'simportanttounderstandhowcontactelementarecreatedwhenselectingwhichregionwillbethesourceandwhichthe target,sincethetwocanbeinterchangeable.Thesolverprojectsvectornormalsfromthesourceregiontothetargetregion. It thencreatescontactelementswhenthesenormalsintersectelementsinthetargetregionandarewithinthesearchdistance criteriaforthecontactpair.Thismeansthatwhenthetworegionsofapairdonothavecorrespondingonetooneelements,the numberofcontactelementsthatthesolvercreatescanchangedependingonwhichregionitprojectstheelementsfromand whichregionitprojectsthemto. Ingeneral,ofthetwocontactregionsyouuseforthepair,choosetheonewiththefinermeshforthesourceregion.Whenthe sourceandtargetregionshavedifferentmeshdensities,moreelementsonthesourceregionwillmeanthatmorecontact elementsarecreated,whichwillproduceamoreaccuratesolution. Forexample,thetworegionsbelowarebothcomposedoflinearshells.Thesourceregion(A)hasoneelementandthetarget region(B)hasfourelements.
Whencreatingthecontactelementsbetweentheseregions,thesoftwareprojectscontactelementsfromthesingleelementon thesourceregiontothefourelementsinthetargetregion region.Thisresultsinthecreationofasinglecontactelement(seethegraphic ontheleft). However,ifyouweretousetheregionwithfourelementsasthesource(C)andtheregionwithoneelementasthetarget(D),the solutionwillcreate4contactelements(seethegraphicontheright).
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ConnectionProperties
AfteryouhavecreatedandcheckedyourConnectionRegionsand ConnectorsyoucansetuptheConnectionProperty. AlthoughaConnectionPropertyisrequiredtocreateaConnector, itisrecommendedthatfully yconfiguring g gtheConnectionProperty p y shouldbesavedforlast.Thisisbecauseitiseasytoget overwhelmedwiththeoptionsprovidedonaConnectionProperty card.Additionally,unlesstheConnectionRegionsandConnectors areconfiguredcorrectly,noneoftheoptionsoftheConnection Propertywillallowforaaccuratecontactanalysis. TheConnectionPropertycardisdividedintothreesections: ContactPair(BCTSET),ContactProperty(BCTPARAM)and CommonContactParameters(BCTPARAM).CommonGlue Parameters(BGPARAM)andGluedContactProperty(BGSET)will notbecoveredinthiswhitepaper paper.
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ConnectionProperties:ContactPair(BCTSET)
TheoptionsinthisportionofthedialogboxcanbesetindividuallyforeachConnector(contactpair)thatiscreatedinthemodel. TheseoptionswillbewrittenouttotheBCTSETentryforeachindividualcontactpair.Eachcontactpairwillbedesignatedinthe graphicswindowwithasinglelinegoingfromoneConnectionRegiontoanotherandthislineisacontactelement. Friction EntersavalueintheFRICi fieldontheBCTSETentry.DesignatestheStaticCoefficientoffrictionforcontactpair"i". Note: Ingeneral,ifdifferentfrictionvaluesareNOTneededthenthecontactpairsshouldallreferencethesamecontactproperty. MinContactSearchDist EntersavalueintheMINDi fieldontheBCTSETentry.DesignatestheMinimumsearchdistancefor contactpair"i". Note:Theminimumdistancecanbenegativeandusedforaninterferencefitconditionmodeledasoverlappingsurfaces. MaxContactSearchDist EntersavalueintheMAXDi fieldontheBCTSETentry.DesignatestheMaximumsearchdistancefor contactpair"i". Note: Themaxdistancemustbedefinedforallcontactproblems.ThisisthedistancethatNXNastranwillsearchforcontactfrom theelementnormal.
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ConnectionProperties:ContactProperty(BCTPARM)
Theseoptionsneedtoonlybedefinedonceforacontactanalysis,regardlessofhowmanyConnectors (contactpairs)aredefined inthemodel.EachConnector hasanIDassignedtoitandcanreferenceadifferentConnectionProperty.FEMAPwillusethe ConnectionProperty referencedbytheConnector withthelowestIDtodefinetheBCTPARMentryfortheentiremodel.For example,ifamodelhas2Connectors (contactpairs)withIDnumbers101and102,theConnectionPropertyvaluesdefinedinthe propertyassociatedwithConnectorID101wouldbeusedfortheanalysis. M Force Max F It Iterations ti Creates C t the th MAXFfield fi ldonthe th BCTPARMentry. t Designates D i t th themaximum i number b of fiterations it ti f foraf force (inner)loop(Default=10). MaxStatusIterations CreatestheMAXSfieldontheBCTPARMentry.Designatesthemaximumnumberofiterationsforastatus (outer)loop(Default=20). ForceConvergenceTol CreatestheCTOLfieldontheBCTPARMentry.DesignatestheContactForceconvergencetolerance (Default=0.01). ConvergenceCriteriaandNumForConvergence Together,thesetwovaluescreatetheNCHGfieldontheBCTPARMentry.The valueandtypeofnumber(realorinteger)enteredforNumForConvergencedependsontheoptionsetforConvergenceCriteria: 0..NumberofChanges Whenthisoptionisset,NumforConvergence mustbeaninteger>1.Thisvaluedefinestheallowable numberofcontactchanges. 1..PercentageofActive Whenthisoptionisset,NumforConvergence mustbeenteredasapercentage(between1and99, whichwillappearas0.01to0.99intheNXNastraninputfile).Thesolvertreatsthisvalueasapercentageofthenumberofactive contactelementsineachouterloopofthecontactalgorithm.Thenumberofactivecontactelementsisevaluatedateachouter loopiteration.
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MinContactPercentage CreatestheMPERfieldontheBCTPARMentry.DesignatestheMinimumContactSetPercentage (Default=100). InitialPenetration CreatestheINIPENEfieldontheBCTPARMentry.ControlshowNastranhandlesinitialgaporpenetrationof thegeneratedcontactelements(Default=0). 0..Calculated Usethevaluecalculatedfromthegridcoordinates.Inthecaseofpenetrations,amodelmayexperience"pressfit" behaviorwhenusingthisoption. 2 C l l t d/Z Penetrations 2..Calculated/Zero P t ti Same S as0..Calculated, 0 C l l t d but b tifpenetration t ti is i detected, d t t d set tthe th value l to t zero. 3..ZeroGap/Penetration Setsthepenetration/gaptozeroforallcontactelements. ShellOffset CreatestheSHLTHKfieldontheBCTPARMentry.ShellThicknessOffsetflag.(Default=0) 0..Includeshellthickness Includehalfshellthicknessassurfaceoffset. 1..Donotincludethickness Doesnotincludethicknessoffset. Avg Methods CreatestheAVGSTSfieldontheBCTPARMentry.Determinestheaveragingmethodforcontactpressure/traction results(Default=0). 0..IncludeAllElements TheaveragingofPressure/TractionvaluesforacontactgridwillincludetheresultsfromALLcontact elementsattachedtothegridregardlessofwhethertheyareactiveorinactiveinthecontactproblem 1..IncludeActiveElements TheaveragingofthePressure/Tractionvaluesforacontactgridwillexcludethosecontactelements whicharenotactiveinthecontactsolutionandthushaveazeroPressure/Tractionvalue. ContactStatus CreatestheRESETfieldontheBCTPARMentry.Flagtoindicateifthecontactstatusforaspecificsubcase isto startfromthefinalstatusoftheprevioussubcase.(Default=0) 0..StartfromPrev Subcase Startsfromprevioussubcase. 1..StartfromInitState Startsfrominitialstate. ContactInactive CreatestheCSTRATfieldontheBCTPARMentry entry.Whensetto"1 1..Restrict RestrictFromInactive Inactive",preventsallofthe contactelementsfrombecominginactive. 0..CanBeInactive(Default) Allcontactelementscanbecomeinactive 1..RestrictFromInactive Solverwillreducethelikelihoodofallofthecontactelementsbecominginactive.Note: Undercertainconditions,allofthecontactelementscouldbecomeinactivewhichmayleadtosingularities.Settingthe parameterto"1..RestrictFromInactive"willreducethep p possibility yofthishappening. pp g
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ShellZOffset AllowsyoutochooseiftheZOffsetonshellelementsshouldbeincludedindetermining"GluedContact."Creates ZOFFSETfieldinBGPARMentryandgivesyou2choicesforthecorrespondingValuefield: 0..IncludeZOffset(Default) Zoffsetofshellsisincludedfordetermininggluedsurfaces. 1..NonotIncludeZOffset ZoffsetofshellsisNOTincludedfordetermininggluedsurfaces.Note: TheDefaults buttonwillautomaticallyfillinthedialogboxwiththedefaultvaluessuggestedbyNXNastran.Itmaybehelpfulto tryandruntheanalysiswiththedefaultsandthenrunitagainifanymodificationsareneededtocreatemoreaccurateresults or achieve hi convergence. AdaptiveStiffness Thisisaflagtoindicatewhetheradaptivestiffnessisactivated.CreatesPENADAPTfieldonBCTPARMentry (Default=0).Whennotchecked,itplacesa"0"(NoAdaptiveadjustment)intothePENADAPTfield,whencheckedplacesa"1" (Adaptivity adjustscontactstiffness)intothePENADAPTfield. PenetrationFactor CreatesthePENETFACfieldontheBCTPARMentry(Default=1.0E4).Designatesthepenetrationfactorfor adaptivepenaltystiffnessadjustment.OnlyusedwhenAdaptiveStiffnessis"on"andshouldusuallyonlybesettoalowervalue toreducetheamountofpenetrationallowedtooccurinananalysis.
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ConnectionProperties:CommonContact(BCTPARM)andGlue(BGPARM)Parameters
ThissectioncontainsoptionsforGluedcontactandseveraloptionsavailableforbothGluedContactandLinearContact. Eval Order Determinesthenumberof"LinearContactorGluePoints"forasingleelementonthesourceregion.CreatesINTORD fieldinBCTPARMorBGPARMentryandgivesyou4choices: 0..Default DoesNOTwritetheINTORDfieldorcorrespondingvaluefieldtotheBCTPARMorBGPARMentry.Simplyusesthe defaultvaluefor"Linear"or"Glued"contactbuiltintotheNXNastransolver. 1 L Lowest 1..Low L torder d of fpoints i t onsourceregion. i 2..Medium Mediumorderofpointsonsourceregion.Thisisthedefault. 3..High Highestorderofpointsonsourceregion. Thehighertheintegrationorder,thelongerthesolvewilltake. RefineSource Determinesifthesourceregionisrefinedforthe"Linear" Linear or"Glued" Glued Contactsolution.CreatesREFINEfieldonthe BCTPARMorBGPARMentryandgivesyou2choicesforthecorrespondingValuefield: 0..DoNotRefine Doesnotrefinethe"LinearContact/Glue"sourceregionbasedontargetsurfacedefinition. 1..RefineSourcetoTarget(Default) Refinesthe"LinearContact/Glue"sourceregionbasedontargetsurfacedefinition. 2..NXN7.0Method Refinesthe"LinearContact/Glue"sourceregionusingtheNXNastran7.0method.
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ConnectionProperties:CommonContact(BCTPARM)andGlue(BGPARM)Parameters
PenaltyFactorUnits CreatesthePENTYPfieldontheBCTPARMorBGPARMentry.Specifieshowcontactelementstiffnessis calculated. WhensettingpenaltyfactorsforlinearcontactorgluedcontactwhenGlueType=1..Spring(GLUETYPE=1) 1..1/Length(Default) NormalPenaltyFactor(PENN)andTangentialPenaltyFactor(PENT)areenteredinunitsof1/Length. 2..Force/(LengthxArea) NormalPenaltyFactor(PENN)andTangentialPenaltyFactor(PENT)areenteredinunitsof Force/(LengthxArea). Wh setting When tti penalty lt factors f t for f glued l dcontact t twhen h Gl GlueT Type=2..Weld 2 W ld(GLUETYPE (GLUETYPE=2) 2) 1..ScaleFactor GlueFactor(PENGLUE)isaunitless value. 2..F/L^2 GlueFactor(PENGLUE)hastheunitsofF/Lengthsquared. AutoPenaltyFactor Thisisaflagtoindicatewhethernormalandtangentialpenaltyfactorswillbeautomaticallycalculated. WhenthisboxischeckedinFEMAP,nospecialfieldwillbewrittentotheBCTPARM.ThisisthedefaultforNXNastran. NormalFactor CreatesthePENNfieldontheBCTPARMorBGPARMentry.Designatesthepenaltyfactorforthenormaldirection (Default=10.0forBCTPARM,100forBGPARM). TangentialFactor CreatesthePENTfieldontheBCTPARMorBGPARMentry.Designatesthepenaltyfactorforthetangential direction(Default=1.0forBCTPARM,100forBGPARM).
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ConnectionProperties ConnectionProperties:Friction ConnectionProperties:ContactSearchDistance ConnectionProperties:InitialPenetration ConnectionProperties:Refinement ConnectionProperties:Refinement,EvaluationOrder ConnectionProperties:Refinement,RefineSource ConnectionProperties:PenaltyFactor ConnectionProperties:PenaltyFactor,Units ConnectionProperties:PenaltyFactor,Automaticvs.Manual

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Seminar Linear Contact Analysis Notes

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NearCoordinates: TheNearCoordinatesmethodisverysimilartoNearSurface.Insteadofspecifyingasurface,however,youchoosea coordinatesystem,directionandposition.Thisdefinesaplanarsurface,whichisusedalongwiththetolerancetofindtheclosest faces.

ModelFreeFaces TheModelFreeFaces methodsimplyincludesevery"freeelementface"inyourelementselection.Agoodtechniqueifyoucan grabexactly g ytheelementsy youwantwithintheelementselectiondialogue g box.

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