CHAPTER- 5 VALIDATION IN ABAQUS The analysis done so far is a non linear static analysis; the real web process

line does not look like the model developed in COSMOS. Attempts to validate the results obtained from COSMOS in the laboratory were made by Jared Gale, research assistant at WHRC. Due to the limitations in the laboratory attempts of thinning and thickening of the web were proved to be unsuccessful. Hence validation of this model developed in COSMOS and the effects of these non uniform circular regions in webs were validated by another reliable way using finite elements. The web transits a number of rollers under certain tension and a specific velocity. This is a complex non-linear, dynamic; contact problem. There is boundary non linearity geometric non linearity, This non linear problem could be solved either using the Implicit Method or Explicit method. Talk about implicit and explicit fem In implicit methods global set of equations needed to be solved for every increment and hence the cost per increment is very high. The explicit methods however was found to be an effective way for solving complex non linear dynamic problems.It requires a large number of increments but the computational cost is low when compared to the implicit methods. Hence ABAQUS explicit solver was chosen for simulating this problem. The explicit method would be discussed briefly in the following paragraphs. In an explicit analysis, as the word explicit suggests, the state of the body at the end of the increment is determined by the velocity, acceleration and displacement at the beginning of the increment.In ABAQUS/explicit the equations of motion are integrated using the central difference method through time. The kinematic conditions of one increment are used to calculate the kinematic conditions of the next increment. The program starts with solving the dynamic equilibrium equation given by

M a= P-I The accelerations are calculated by A= M^-1 (P-I) And the mass matrix that is incorporated in the explicit methods is the lumped mass matrix. Once the accelerations are calculated at the nodes, which are assumed to be constant, these are integrated through time and the change in velocity from which the velocity at the middle of the current increment is evaluated. These velocities are integrated with respect to time and the displacements at the end of the increment are determined by adding the displacements to the beginning of the increment. Velocities It then calculates the elemental strain increments and strain rate. Next, the constitutive equations are used for computing the stresses and the internal forces are assembled. The computational cost of explicit analysis is said to high for calculating this.. The implicit method also uses the dynamic equilibrium for solving the nodal accelerations, but it is determined by solving simultaneous equations unlike the explicit method. The increment size is relatively large and it uses Newton iterative method which requires several iterations to obtain a solution. For the model in this context which is a web transiting on rollers which involves contact boundary conditions, large numbers of iterations are required as the quadratic convergence may be lost. Where as in explicit analysis the contact boundary conditions can be enforced without iterations by node to node basis. Also as the state of the model is determined

explicitly, iterations and tolerances are not required, simulating the given case in a way that is close to reality. After understanding the ability of ABAQUS/Explicit which could simulate the real web process line and its algorithm, the validation of the model was decided to be done using the same. It should be noted that ABAQUS standard was not chosen because of its high computation cost which requires solving simultaneous equations and when used for large models like the one in the current case, it might take up the memory of entire disk.ABAQUS/Explicit was found to computationally cheaper as it doesnt require simultaneous solving as discussed previously. However, the time is real in explicit analysis and it requires a large number of increments for getting good results. This requires tremendous amount of computation time. Typically for the runs that were performed in the model that was developed for analyzing the case of web with circular non uniformities the computation time for one simulation would take about 30- 50 hours depending upon the mesh density and the number of outputs requested. The parameters that were examined using COSMOS that were found to affect the formation of wrinkles are the thickness of the non uniformity (thin), diameter of the non uniformity, width of the web, thickness of the non uniformity (thick). The model set up in ABAQUS is shown in figure a single non uniform region was defined and this was allowed to pass through 2 rollers before it entered the test span. It then exits the test span by passing through the rollers R3 and R4. This is a typical kind of a web process line

Tension 1

Non uniformity

R2 Test span R3 R1 R4

velocity

Figure: Model Set up In ABAQUS- 1 non uniformity