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LinearContactAnalysis:
Demystified
withFemapV10.1.1andNastran 7.0
AdrianJensen
MechanicalEngineer
Adrian.Jensen@PredictiveEngineering.com
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TableofContents
1. Introduction......................................................66
2. Regions.........................................................66
a) Solids........................................ . .............66
i. BySurfaces..............................................66
ii. ByElements...................................... . .......66
b) Plates.....................................................66
i. BySurfaces...................................... . .......66
ii. ByElements...................................... . .......66
3 Connectors 66 3. Connectors.......................................................66
a) SourceTarget...................................... ...........66
4. 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
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Introduction
Frustrated?
Using linear contact can be frustrating. In fact, it is probably one of the most frequent subjects of calls for tech support staff. But 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
engineering materials (e g steel) where the material is not stressed beyond the yield strength linear contact is a reasonable engineeringmaterials(e.g.steel)wherethematerialisnotstressedbeyondtheyieldstrength,linearcontactisareasonable
analysismechanism.
Howdoesitwork?
Thiswhitepaperwillcoverawiderangeoflinearcontactproblemsfromthesimpletaskofsettingupcontactregionstothe more
dauntingchargeofmanuallyadjustingthepenaltyfactors.Thekeytoanylinearcontactproblemittostartsimple.Beforeyoutry g g y j g p y y y p p y 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 i d t t t l t l t b li k th M lti l b tt Th t t t th i l ti Assumingyoudontwanttoselectelementsonebyone,clicktheMultiplebutton.Therearetwostagestotheregionselection
byelements:theelementselectionandtheelementfaceselection.Theelementselectionissimple;graballelementsthathave
facesyouwanttoincludeintheConnectionRegion.
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Regions:Solids,byElements
The element face selection is a bit trickier Once you have selected the elements you want you are presented five options for face Theelementfaceselectionisabittrickier.Onceyouhaveselectedtheelementsyouwant,youarepresentedfiveoptionsforface
selection.Thefollowingpagesprovidesexamplesofeach.
FaceID:
Eachfaceofanelementhasafaceid.Plateelementsusefaces1&2,tet elementsusefaces14andhexelementsusefaces16.
Thisoptionisgenerallytheleastusefulforasolidmodelbecausetheelementfacesonthesurfaceofthesoliddonotnecessarily
shareacommonfaceID.ThegraphicsbelowshowtheConnectionRegionscreatedbyselectingalloftheelementsandusingthe
FaceIDfaceselectionmethod.Thefirstgraphicshowsface1,thesecondshowsface2andsoforth.
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ConnectionRegions:Solids,byElements
NearSurface:
ThisoptionisusefulifyouhavegeometrytoworkwithbutyoudontwanttolimittheelementsinyourConnectionRegion.The
graphicsbelowshowtheConnectionRegionscreatedbyselectingaclusterofelementsinthecorneroftheblockandusingthe
NearSurfacefaceselectionmethod.
NearCoordinates:
TheNearCoordinatesmethodisverysimilartoNearSurface.Insteadofspecifyingasurface,however,youchoosea
coordinatesystem,directionandposition.Thisdefinesaplanarsurface,whichisusedalongwiththetolerancetofindtheclosest
faces.
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ConnectionRegions:Solids,byElements
AdjacentFaces:
Apowerfulmethodforchoosingfaces,especiallyforcomplexsolidandplanarelementmodels.Youchoosejustoneinitialface
(andtheassociatedelementID).Thiscanbedoneveryeasilybygraphicallyselectingtheface.Youthenspecifyatolerance angle.
FEMAPwillsearchallselectedelementsforfacesthatareconnectedtothefacethatyouchoseandthatarewithinthespecified
tolerancefrombeingcoplanarwithanalreadyselectedface.
ModelFreeFaces
TheModelFreeFaces methodsimplyincludesevery"freeelementface"inyourelementselection.Agoodtechniqueifyoucan
grabexactlytheelementsyouwantwithintheelementselectiondialoguebox.
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ConnectionRegions:Plates,bySurfaces
Platemodelsaregenerallyrequiremorecarewhenselectingyour
regions.WhenselectingyouplatemodelConnectionRegionsby
surfaces,youneedtopayspecialattentiontothesurfacenormals
andelementnormals.Sincebothfacesofaplateelementare
linkedtothesamesurface,youwillneedtoturnthePositive
Sid ti d ff h i t Sideoptiononandoffwhereappropriate.
Thesurfacenormalsareshownintheuppermostgraphiconthe
right.ThemiddleimageshowsthefirstConnectionRegion.The
surfacewasselectedwiththePositiveSideoptionunchecked.
The bottom image shows the second Connection Region The ThebottomimageshowsthesecondConnectionRegion.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
Once you have selected the elements you want you are presented five options for face selection When working with plate Onceyouhaveselectedtheelementsyouwant,youarepresentedfiveoptionsforfaceselection.Whenworkingwithplate
elements,onlytheFaceIDandAdjacentFacesoptionsshouldbeused.
FaceID:
Asmentionedearlier,plateelementsusefaces1&2forConnectionRegions.Beawarethatafoursidedplateelementhassix
facesandFemapwillallowyoutoselectanyofthesefacesbutonlyfaces1&2aresupportedforcontact.TheFaceIDmethod
allowsyoutoenterthefaceIDnumericallyorselectafacefromthemodel.Thismodelismoreeffectivewithplatemodels
becausethefacesoftheelementsaremorecommonlyaligned.
AdjacentFaces:
ThismethodisusefulforcreatingConnectionRegionswhenelementsdonothaveconsistentorientationorwhenthemodelhas
l t ( Adj t F i th lid l t ti ) complexgeometry(seeAdjacentFacesinthesolidelementsection).
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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.
For example, the two regions below are both composed of linear shells. The source region (A) has one element and the target Forexample,thetworegionsbelowarebothcomposedoflinearshells.Thesourceregion(A)hasoneelementandthetarget
region(B)hasfourelements.
Whencreatingthecontactelementsbetweentheseregions,thesoftwareprojectscontactelementsfromthesingleelementon
the source region to the four elements in the target region This results in the creation of a single contact element (see the graphic thesourceregiontothefourelementsinthetargetregion.Thisresultsinthecreationofasinglecontactelement(seethegraphic
ontheleft).
However,ifyouweretousetheregionwithfourelementsasthesource(C)andtheregionwithoneelementasthetarget(D),the
solutionwillcreate4contactelements(seethegraphicontheright).
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Connection Properties ConnectionProperties
AfteryouhavecreatedandcheckedyourConnectionRegionsand
ConnectorsyoucansetuptheConnectionProperty.
AlthoughaConnectionPropertyisrequiredtocreateaConnector,
itisrecommendedthatfullyconfiguringtheConnectionProperty y g g 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
not be covered in this white paper notbecoveredinthiswhitepaper.
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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.
Max Contact Search Dist Enters a value in the MAXDi field on the BCTSET entry. Designates the Maximum search distance for 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 F It ti C t th MAXF fi ld th BCTPARM t D i t th i b f it ti f f MaxForceIterations CreatestheMAXFfieldontheBCTPARMentry.Designatesthemaximumnumberofiterationsforaforce
(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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ConnectionProperties:ContactProperty(BCTPARM)
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 P t ti S 0 C l l t d b t if t ti i d t t d t th l t 2..Calculated/ZeroPenetrations Sameas0..Calculated,butifpenetrationisdetected,setthevaluetozero.
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.
Contact Inactive Creates the CSTRAT field on the BCTPARM entry When set to "1 Restrict From Inactive" prevents all of the ContactInactive CreatestheCSTRATfieldontheBCTPARMentry.Whensetto 1..RestrictFromInactive ,preventsallofthe
contactelementsfrombecominginactive.
0..CanBeInactive(Default) Allcontactelementscanbecomeinactive
1..RestrictFromInactive Solverwillreducethelikelihoodofallofthecontactelementsbecominginactive.Note:
Undercertainconditions,allofthecontactelementscouldbecomeinactivewhichmayleadtosingularities.Settingthe
parameterto"1..RestrictFromInactive"willreducethepossibilityofthishappening.
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ConnectionProperties:ContactProperty(BCTPARM)
ShellZOffset AllowsyoutochooseiftheZOffsetonshellelementsshouldbeincludedindetermining"GluedContact."Creates
ZOFFSETfieldinBGPARMentryandgivesyou2choicesforthecorrespondingValuefield:
0..IncludeZOffset(Default) Zoffsetofshellsisincludedfordetermininggluedsurfaces.
1..NonotIncludeZOffset ZoffsetofshellsisNOTincludedfordetermininggluedsurfaces.Note:
TheDefaults buttonwillautomaticallyfillinthedialogboxwiththedefaultvaluessuggestedbyNXNastran.Itmaybehelpfulto
tryandruntheanalysiswiththedefaultsandthenrunitagainifanymodificationsareneededtocreatemoreaccurateresults or
hi achieveconvergence.
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 L t d f i t i 1..Low Lowestorderofpointsonsourceregion.
2..Medium Mediumorderofpointsonsourceregion.Thisisthedefault.
3..High Highestorderofpointsonsourceregion.
Thehighertheintegrationorder,thelongerthesolvewilltake.
Refine Source Determines if the source region is refined for the "Linear" or "Glued" Contact solution. Creates REFINE field on the RefineSource Determinesifthesourceregionisrefinedforthe Linear or 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 tti lt f t f l d t t h Gl T 2 W ld (GLUETYPE 2) WhensettingpenaltyfactorsforgluedcontactwhenGlueType=2..Weld(GLUETYPE=2)
1..ScaleFactor GlueFactor(PENGLUE)isaunitless value.
2..F/L^2 GlueFactor(PENGLUE)hastheunitsofF/Lengthsquared.
AutoPenaltyFactor Thisisaflagtoindicatewhethernormalandtangentialpenaltyfactorswillbeautomaticallycalculated.
When this box is checked in FEMAP, no special field will be written to the BCTPARM. This is the default for NX Nastran. 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
Connection Properties: Initial Penetration ConnectionProperties:InitialPenetration
ConnectionProperties:Refinement
ConnectionProperties:Refinement,EvaluationOrder
ConnectionProperties:Refinement,RefineSource
ConnectionProperties:PenaltyFactor
ConnectionProperties:PenaltyFactor,Units
ConnectionProperties:PenaltyFactor,Automaticvs.Manual
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