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Abaqus Tutorial - 3DSolder
Abaqus Tutorial - 3DSolder
ABAQUS Tutorial
Mohith Manjunath
July 30, 2009
Contents
1 Introduction
2 Problem Description
3 Pre-processing
3.1 Part . . . . . . . . . .
3.1.1 Ceramic . . . .
3.1.2 Cap . . . . . .
3.1.3 Solder . . . . .
3.1.4 Copper . . . . .
3.1.5 PC Board . . .
3.2 Property . . . . . . . .
3.2.1 Assign Sections
3.3 Assembly . . . . . . .
3.4 Step . . . . . . . . . .
3.5 Interaction . . . . . . .
3.6 Load . . . . . . . . . .
3.7 Mesh . . . . . . . . . .
3.7.1 Partitioning . .
3.7.2 Meshing . . . .
3.8 Job . . . . . . . . . . .
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4
5
5
6
10
16
18
19
20
21
22
24
24
26
26
37
44
4 Postprocessing
45
4.1 Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.1 Selecting the field output to display . . . . . . . . . . . 45
4.1.2 Plotting . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Introduction
ABAQUS is a finite-element analysis software. Abaqus/CAE provides a preprocessing and postprocessing environment for the analysis of models. It is
used in a wide range of industries like automotive, aerospace etc., and also is
extensively used in academic and research institutions due to its capability
to address non-linear problems. The Abaqus interface is shown in figure 1.
Problem Description
and can be very catastrophic. Figure 3 shows the failure of solder joint after
many cycles in operation.
Pre-processing
3.1
Part
Part module is used to build different parts of the model. So, for convenience,
divide the whole model into various parts and create each part using this
module. Later all the parts can be assembled to form the entire model.
Here, the model is divided into five parts - Ceramic, Cap, Solder, Copper
and PC Board. What follows now is a step-by-step procedure to create each
of these parts.
3.1.1
Ceramic
1. In the menu bar, click Part -> Create. Enter the name Ceramic and
select 3D, Deformable, Solid->Extrusion and enter Approximate size
as 10 (See Figure 4).
left-click to enter the dimension. Enter 0.25 and press enter. Select
the bottom side, left-click and enter 1.0 for the dimension and press
enter. Cancel procedure by pressing the X mark in the prompt
area(remember to do this every time you want to come out of a procedure and you can also press Esc key to exit an operation).
3. At the bottom click Done (Sketch the section for the solid extrusion).
Enter depth of 0.625 and click OK.
4. From the menu bar, click Shape -> Blend -> Round/Fillet. Select
the five edges as shown in Figure 5(Multiple edges can be selected by
holding shift key). Click Done. Enter radius of 0.03. Click Done.
3.1.2
Cap
1. In the menu bar, click Part -> Create. Enter the name Cap and select
3D, Deformable, Solid->Extrusion and enter Approximate size as 10.
2. Click Rectangle icon to create a rectangle. On the grid draw an arbitrary rectangle. Click Add Dimension tool and click the left side and
left-click to enter the dimension. Enter 0.25 and press enter. Select the
bottom side, left-click and enter 0.3 for the dimension and press enter.
6
3. In the menu bar, click Add -> Fillet. Enter fillet radius as 0.03 and
press enter. Now, select the top and right side edges of the rectangle.
Fillet has been created.
4. Click Add -> Point and create three points, one on the top left corner
of the rectangle and two on the corners of the arc of the fillet(See Figure
6). Click Edit -> Transform -> Translate and click Copy. Now, select
the points 1 and 2(holding shift key) and click Done. Enter 0,0 for the
start position, press enter and then enter 0,0.005 for the endpoint and
press enter again. Repeat the same procedure for point 3 and enter
0.005,0 for the endpoint. Repeat the same procedure for point 1 and
enter 0.135,0.01 for the endpoint. Repeat the same procedure for point
3 and enter 0,-0.095 for the endpoint. Repeat the same procedure for
point 3 and enter 0.01,-0.095 for the endpoint.
Solder
1. In the menu bar, click Part -> Create. Enter the name Solder and
select 3D, Deformable, Solid->Extrusion and enter Approximate size
as 10.
2. Click Rectangle icon to create a rectangle. On the grid draw an arbitrary rectangle. Click Add Dimension tool and click the left edge and
left-click to enter the dimension. Enter 0.6 and press enter. Select the
bottom edge, left-click and enter 0.6 for the dimension and press enter.
3. At the bottom click Done (Sketch the section for the solid extrusion).
Enter depth of 1.0 and click OK.
4. In the context bar, click Module -> Assembly. Now, click Instance
10
11
Figure 13: Solder - Cut the geometry of cap in the rectangular solid
5. Click Instance -> Merge/Cut. Give part name as Solder-1. Select Cut
geometry and click Continue. Now, select the solder for the instance
to be cut and select the other two(ceramic and cap) for the instances
that will make the cut(holding down the shift key). Click Done. Select
Part -> Solder-1 in the context bar. See figure 14.
6. Click Shape -> Cut -> Extrude. Select the front facing plane and then
the right edge. Now, click Add -> Point and click on the top-left point.
Click Edit -> Transform -> Translate and click Copy. Select the point
12
Figure 17: Solder - Top view, after the extrusion on both sides
path. Click Add. Select the top curve and the bottom curve(one after
another, by clicking add) which was created using partition method
and click OK. Now, remove the part that got cut by using Shape ->
Cut -> Extrude and by selecting any face and any edge draw a closed
14
Copper
1. In the menu bar, click Part -> Create. Enter the name Copper and
select 3D, Deformable, Solid->Extrusion and enter Approximate size
as 10.
16
17
3.1.5
PC Board
1. In the menu bar, click Part -> Create. Enter the name PC Board and
select 3D, Deformable, Solid->Extrusion and enter Approximate size
as 10.
2. Click Rectangle icon to create a rectangle. On the grid draw an arbitrary rectangle. Click Add Dimension tool and click the left edge and
left-click to enter the dimension. Enter 1.6 and press enter. Select the
bottom edge, left-click and enter 3.5 for the dimension and press enter.
3. At the bottom click Done (Sketch the section for the solid extrusion).
Enter depth of 2 and click OK. See figure 24.
18
3.2
Property
(1)
Where is the strain rate, C is the power law multiplier, a the hyperbolic law multiplier, n the stress order, Q the activation energy and R
the universal gas constant. The values of these parameters have been
taken from reference 2.
Power Law
Hyperb Law
Eq Stress
Multiplier(/s) Multiplier(/MPa)
Order
4.41E5
0.005
4.2
19
Activation
Universal Gas
Energy(J/mol/K) Const(J/mol/K)
4.5E4
8.314
Click OK.
7. Click Create. Enter the material name Copper and click Mechanical
-> Elasticity -> Elastic. Now, enter the value 90000 MPa in the box
below Youngs Modulus and 0.32 for Poissons Ratio. Click Mechanical
-> Expansion and enter 1.65E-5 for Expansion Coeff alpha. Click OK.
8. Click Create. Enter the material name FR4-PC Board and click Mechanical -> Elasticity -> Elastic. In the drop-down menu for Type select Engineering Constants and tick the checkbox next to Use temperaturedependent data and enter the following values. Directions 1,2 and 3
refer to the X, Y and Z directions respectively in the material. The
values have been taken from reference 3.
E1(MPa) E2(MPa) E3(MPa) Nu12 Nu13 Nu23
19300
8300
19300
0.4
0.15
0.4
G12(MPa) G13(MPa) G23(MPa) Temp(K)
8400
8400
8400
293
Click Mechanical -> Expansion and select Type as Orthotropic and
enter the following values.
alpha11 alpha22 alpha33
1.5E-5
8.4E-5
1.5E-5
Click OK.
3.2.1
Assign Sections
After the materials have been creates we need to assign these materials to
the parts which were previously created.
1. Click Section -> Create. Enter name as Ceramic. Select Solid ->
Homogenous and click Continue. From the material list select Ceramic
and click OK.
2. Click Section -> Create. Enter name as Cap. Select Solid -> Homogenous and click Continue. From the material list select Cap and click
OK.
3. Click Section -> Create. Enter name as Solder. Select Solid -> Homogenous and click Continue. From the material list select SolderSnAgCu and click OK.
20
4. Click Section -> Create. Enter name as Copper. Select Solid -> Homogenous and click Continue. From the material list select Copper and
click OK.
5. Click Section -> Create. Enter name as PC Board. Select Solid ->
Homogenous and click Continue. From the material list select FR4-PC
Board and click OK.
6. In the context bar select part as Ceramic. Click Assign -> Section.
Select the ceramic by clicking on it and click Done. In the window that
opens, select Ceramic from the list and click OK.
7. In the context bar select part as Cap. Click Assign -> Section. Select
the cap by clicking on it and click Done. In the window that opens,
select Cap from the list and click OK.
8. In the context bar select part as Solder-1. Click Assign -> Section.
Select the solder by clicking on it and click Done. In the window that
opens, select Solder from the list and click OK.
9. In the context bar select part as Copper. Click Assign -> Section.
Select the copper by clicking on it and click Done. In the window that
opens, select Copper from the list and click OK.
10. In the context bar select part as PC Board. Click Assign -> Section.
Select the PC Board by clicking on it and click Done. In the window
that opens, select PC Board from the list and click OK.
Now, the sections have been assigned to the parts with corresponding material.
3.3
Assembly
In this module, all the parts created earlier can be put together(assembly)
to get the required model. After doing this we can apply the necessary
constraints and loads on the assembly.
1. Select Module -> Assembly. Click Instance -> Create. Select Ceramic
and Cap holding down Ctrl. Now, click Constraint -> Coincident point
and select the center of the top arc in the ceramic and the corresponding
point in the cap so that they fit together.
2. Click Instance -> Create, select Solder-1 and toggle on auto-offset from
other instances. Repeat the same procedure as before to make the
solder fit right under the cap. See figure 21.
21
3.4
Step
This module is used to perform many tasks, mainly to create analysis steps
and specify output requests.
1. Select Module -> Step. Click Step -> Create. Type Extra-Step for
name and select Procedure type -> General -> Visco and click Continue. In the description field enter Abkhlung and enter time period as
30. Go to incrementation tab and enter the following. Type:Automatic,
22
4. Select Module -> Step. Click Step -> Create. Type Step-3-Aufheizen
for name and select Procedure type -> General -> Visco and click Continue. Enter time period as 10. Go to incrementation tab and enter the
following. Type:Automatic, Maximum number of increments:10000,
Increment size:Initial=0.5, Min=1E-6, Max=10, Tolerance=0.005 and
Integration:Explicit/Implicit. Go to Other tab and select Iterative
method and select ramp linearly over step. Click OK.
5. Select Module -> Step. Click Step -> Create. Type Step-4-Haltenauf-125C for name and select Procedure type -> General -> Visco and
click Continue. Enter time period as 900. Go to incrementation tab
and enter the following. Type:Automatic, Maximum number of increments:10000, Increment size:Initial=0.5, Min=1E-6, Max=900, Tolerance=0.005 and Integration:Explicit/Implicit. Go to Other tab and
select Iterative method and select ramp linearly over step. Click OK.
3.5
Interaction
3.6
Load
Load module is used to define and manage various conditions like loads,
boundary conditions and predefined fields.
1. Select Module -> Load. Click BC -> Create. Select Displacement/Rotation
and click Continue. Select the whole of left section(plane) and hold
down control key to deselect the bottom-left point(see figure 27). Click
Done and then just tick the box next to U1 to constrain that degree of
freedom.
2. Click BC -> Create. Select Displacement/Rotation and click Continue.
Select the corner point which was previously not selected and click
Done and then just tick the box next to U2 to constrain that degree of
freedom.
3. Click BC -> Create. Select Displacement/Rotation and click Continue.
Select the whole of front section(plane X-Y)(for easier selection click
the icon in the prompt area and select faces from the list and then
24
Figure 29: Predefined Field - Initial temperature for the entire model
3.7
Mesh
This is one of the most important modules since accuracy of the results
will depend on the meshing of the assemblies. This module can be used to
generate meshes and even verify them.
3.7.1
Partitioning
1. Select Part -> Full-Model from the list in the left window. Select
Module -> Mesh. See figure 30.
2. Click Tools -> Partition. Select Cell -> Extend face, select the entire
model and click Done. Select the face as shown in the figure 31 and
click Create partition. A partition should be created and it should
turn green(structured mesh). Repeat the same procedure for the faces
as shown in the figure 32 and 33 and now entire PC Board should turn
green(figure 33).
3. Select Cell -> Extrude/Sweep edges, select the entire model and the
edge 1(choose by edge angle) as shown in figure 34. Click Done. Select
Extrude Along Direction and select the edge 2(pointing down) as shown
in the same figure. Check for direction and flip if required. Click Create
partition. See figure 35.
26
Figure 30: Partitions are required for the whole model(for orange colored
ones, it is mandatory)
27
28
29
30
4. Select Cell -> Define cutting plane, select the entire model and click
Done. Then, click Point and Normal. And select point and normal as
shown in the figure 36 and click Create partition. See figure 37.
Figure 36: Partition - Select the point as pointed by the arrow and the line
in pink
5. Select Cell -> Define cutting plane, select the entire model and click
Done. Then, click Point and Normal. And select point and normal as
shown in the figure 38 and click Create partition. See figure 39.
6. Select Cell -> Define cutting plane, select the entire model and click
Done. Then, click Point and Normal. And select point and normal as
shown in the figure 40 and click Create partition. At the end of this
operation, the model should look similar to figure 41.
31
32
Figure 38: Partition - Select the point as pointed by the arrow and the line
in pink
33
Figure 40: Partition - Select the point as pointed by the arrow and the line
in pink
34
7. Select Cell -> Define cutting plane, select the entire model and click
Done. Then, click Point and Normal. And select point and normal as
shown in the figure 42 and click Create partition. At the end of this
operation, the model should look similar to figure 43.
Figure 42: Partition - Select the point as pointed by the arrow and the line
in pink
35
8. Select Cell -> Define cutting plane, select the entire model and click
Done. Then, click Point and Normal. And select point and normal as
shown in the figure 44 and click Create partition. At the end of this
operation, the model should look similar to figure 45.
Figure 44: Partition - Select the point as pointed by the arrow and the line
in pink
36
Now, you can proceed to the meshing section but it is suggested that you
try different partitioning methods and analyze the results. In the process
you will be able to learn how to partition any complicated geometry with
minimum partitioning.
3.7.2
Meshing
1. Click Mesh -> Controls. Select the entire model, click Done and select
Structured from the list and click OK.
2. Click Mesh -> Element Type. Select the entire model, accept the
default options and click OK.
3. Click Seed -> Part. In the approximate global size field enter 0.01 and
click OK.
4. Click Seed -> Edge Biased. Switch to wire-frame view. Select the
edges(click near the left end of the edges) as shown in the figure 46 and
click Done. Enter bias ratio as 10 and number of elements as 18.
5. Click Seed -> Edge Biased. Select the edges(click near the top end of
the edges) as shown in the figure 47 and click Done. Enter bias ratio
as 10 and number of elements as 18.
37
38
6. Click Seed -> Edge Biased. Select the edges(click near the right end of
the edges) as shown in the figure 48 and click Done. Enter bias ratio
as 10 and number of elements as 8.
39
8. Click Seed -> Edge Biased. Select the edges(click near the top end of
the edges) as shown in the figure 50 and click Done. Enter bias ratio
as 10 and number of elements as 8.
Figure 51: Ceramic - Edge by number operation for the edges shown
10. Click Mesh -> Controls and select all the cells except the ones in the
corner edge(see figure 52). Click Done and in the window that opens
select Sweep and click OK. Then, click Mesh -> Region and select all
the cells(the whole ceramic) and click Done. See figure 53.
40
41
12. Now, click the create display group icon, select solder from the list of
sets and click replace. Click Seed -> Edge By Number. Select the edges
as shown in the figure 54 and enter 14 for the number of elements.
Figure 54: Solder - Edge by number operation for the edges shown
13. Click Mesh -> Controls and select all the cells except the ones in the
corner edge(see figure 55). Click Done and in the window that opens
select Sweep and click OK. Then, click Mesh -> Region and select all
the cells(the whole solder) and click Done. See figure 56.
42
It should be noted that the mesh created above is not a perfect mesh.
There are quite a few dark patches which should not have been there.
I would suggest, since you have gained a little experience in Abaqus
now, you to experiment with the mesh by playing around with the mesh
controls, seeding etc., so that you will become familiar with different
kinds of meshes. Then, you can try to create a better mesh than this
one and be proud of doing it.
3.8
Job
Job module can be used to create and manage analysis jobs and submit them
for analysis.
1. Select Module -> Job.
2. Click Job -> Manager. In the window that opens, click Create. Enter
job name as 3DSolder and click Continue. Now, just explore all the
tabs and leave the default options as it is. Click OK. Now, select the
current job and click Submit. After the job has been submitted, the
analysis can be monitored by clicking Monitor.
44
Postprocessing
The results generated from the analysis can be enormous so it requires additional processing which is termed postprocessing.
4.1
Visualization
Here the model can be viewed and various plots can be generated.
4.1.1
1. Select Result -> Field Output from the main menu bar. Here, one of
the various parameters like CEEQ, PEEQ, stress components etc. can
be selected. Click OK.
4.1.2
Plotting
1. To plot undeformed shape select Plot -> Undeformed Shape from the
main menu bar.
2. To plot deformed shape select Plot -> Deformed Shape from the main
menu bar.
Here, not all the modules of postprocessing are explained. You can explore
different modules and try to generate plots for different parameters and get
meaningful results out of them.
45
Bibliography
1. Abaqus 6.7-4 Documentation.
2. Improving Solder Joint Reliability of WLP by Means of a Compliant
Layer , Lee Hun Kwang et al., International Electronic Manufacturing
Technology 2006
3. FEM-Simulationen und Zuverlssigkeit von Advanced Packages LWF,
Uni Paderborn, IFM, TU Berlin
46