ANSYS 12.0 Update Structural Mechanics

ANSYS 12.
0 New Features
Structural Mechanics Capabilities

2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
12.0 Highlights in Structural Mechanics Capabilities New Workbench Framework Advances in Meshing Technology
New Element Technology

Additional Material Models Solver Performance Enhancements More Native Workbench Capabilities
ELEMENT TECHNOLOGY

New 4-noded Tetra element : SOLID285
Internal DOFs
(u x , u y , u z , p)
DOF: Displacements & Hydrostatic Pressure Stabilized formulation to satisfy LBB check
1
(u x , u y , u z )e
(u x , u y , u z , p)
(u x , u y , u z , p)
Structural Mechanics
(u x , u y , u z , p)
Benefits Can be used to mesh complex geometries Element is less sensitive to distortion Vital to rezoning and nonlinear adaptivity analysis Applications

Automotive Suspension Mount
Good for incompressible materials Ideal for Forming and Hyperelasticity

4
ZF Boge Elastmetall
By use of "solid285" the operating time for meshing of complex structures is considerably reduced. The close correlation between analysis and the physical measurement enables the spring rate determination of strongly deformed structures possible, without complex and time consuming meshing with hexahedral elements.
Measurement: Solid 285:
Only the use of "Solid 285" enables the determination of stresses and strains for durability calculation in a reasonable time possible.
6000.00 5500.00 5000.00 4500.00 4000.00 3500.00

Force [N]
3000.00 2500.00 2000.00
Hans-Jrg Hinterkeuser FEA Engineering Norbert Urban FEA Engineering

1500.00 1000.00 500.00 0.00 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00 14.00 15.00
Displacement [mm]
Measurements vs. Simulation

5

General Axi-symmetric Element: 272/273
3D elements generated based on 2D mesh Boundary conditions applied in 3D space Nonlinearities, Node to surface contact
A
I J
LY
Z K
Benefits Multiple Axis can be defined in any direction Take advantage of axi-symmetry but deformation is general in 3D 1 element in (hoop) direction Application Detailed simulation of threaded connections Bio-Medical: Tooth implanting
3D view of shaft
6
Example: Cam-Shaft
3D elements
Cams meshed with SOLID272
Shaft Valve Ball Valve
FULL 3D : 13.7 hrs

SOLID272:
7
hrs

3D Finite-strain Element: PIPE288/289 Linear or quadratic pipes in 3D Thin pipe (plane stress) and Thick pipe (3D stress) option Internal fluid and external insulation
Benefits Increased accuracy Robust nonlinear infrastructure including stabilization Hydrostatic, current, and wave loading Application Slender or stout pipe like structures Undersea piping and cabling, Chemical, Nuclear Power Industry,
8
Pipe 288
Pipe 289
Piping Assembly

New Curved Pipe Element: ELBOW290 Internal nodes for C/S deformation C/S Deformation with Fourier series Radial expansion, ovalization & warping Follower effects of distributed pressures
Warping & Ovalization
Benefits Accurate and easy to use Supports layered cross-section Broad nonlinear material library 3D Visualization Applications Accurate modeling of curved pipe structures Composite pipes, cables, nuclear piping
9

Shell Formulation Improvements: SHELL181/281/208/209: Improved shell thickness updating scheme SHELL 281: include initial curvature effects
Benefits Increased Accuracy Improved solution convergence Accounts for increase/decrease in curvature Application All thin structures with curved shape Example: Cooling of a curved plate shows accurate calculation of displacement
10
Curved Plate Cooling Problem

Standard Shell Rotation of the free tip Curved Shell Reference
0.0
0.91519 0.92091

BEAM188 with Cubic shape F/n Allow cubic shape function used for interpolating displacements & rotations Implemented through internal nodes
Benefits Higher accuracy for coarse mesh A single element can be used for modeling beam members Allows for more general loading pattern Facilitate interaction with load estimation codes such as ANSYS/AQWA Applications Beam/truss like Civil structures Off-Shore industry
11
Picture from http://www.mms.gov/tarprojectcategories/structur.htm
Off-Shore Structures

3D discrete Reinforcement: REINF264 Reinforcing fibers modeled with embedded reinforcing elements Fibers can be oriented arbitrarily Reinforcement can account for a variety of nonlinear behavior Benefits Explicit & accurate modeling of reinforcements Predict stresses in reinforcements separately Allows for tension-only treatment
Application Tire industry, Biomedical devices Aerospace, Civil engineering
12
Discrete Reinforcements
SOLVER TECHNOLOGY
13
Advances in Solver Technology

2D Rezoning Enhancements Allow to read in generic mesh from a third party mesher in rezoning Allow user to split selected elements to refine mesh in rezoning Automatically create transition region meshes Benefits Provides flexibility in remeshing Solve problems otherwise can not be solved
Application Any large deformation analyses Forming and rubber sealing simulation
14
Sealing Applications

New SNODE Solver for Modal Analysis Splits FE matrix in to smaller pieces SuperNodes Solves reduced Eigen-value problem Transforms eigenvectors back to the original FE domain Benefits Ideal for > 3 mil. DOFs , >500 modes Non-iterative i.e. will not fail to converge Does not miss modes
80000
Block Lanczos Supernode
60000
CPU Time
40000
20000
Applications Beam-Shell or thin geometries Automotive, Aerospace High frequency response analysis, etc.
15
0 100 1000 4000 8000
Number of Modes
Single Xeon 3.4 GHz processor 17+ hours reduced to ~1 hour 7 TB of I/O reduced to <300 GB

Many Misc. Solver Improvements
VT applied to Complex Eigen solver: Frequency Derivative Algorithm used DSPARSE solver supports unsymmetric matrices
Benefits/Applications
Solution time

Significant improvement in solve speed Better performance for large number of contact pairs & constraints
10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Elapsed CPU
Lanczos FD
16

DANSYS Improvements Support HF-EMag calculations PSTRESS, PSOLVE support Cyclic Symmetry support
Representative Geometry
Benefits More problems can take advantage of Parallel solvers Scalability of solves improved by 10-20 % Applications Problems involving stress stiffening Rotardynamics problems EMAG problems
17
Machine
Problem Size
Win x64 CCS 480K DOF
CPUs Time (hr)
1 2
36.7 22.3
Bolted Joints, N/L Contact, Thermal loads Unsymmetric option
4
8
14.5
8.4
DANSYS: Benchmarks on Win CCS

DANSYS Revised Benchmark Set Speedups
Intel Cluster Ready, 4 nodes 3 Ghz dual cores, 16 Gb, TCP interconnect
6
5 4
Universal Joint 400k DOF Small DSP sparse
Gas-Struct 1M DOF Thermal JCG Carrier Model 2 M DOF PCG msave,on
Speedup
3 2
1 0
Block Assembly 5M DOF Large PCG msave,on Wing Model 1M DOF Lanpcg 10 Modes
Wing Model 5M DOF PCG msave,off
12
16
Number of Processors
18
CONTACT MODELING
19
Advances in Contact Modeling

Fluid Pressure Penetration Support Model fluid penetrating 2 contact surfaces 2D/3D surface-to-surface contact pair Small and large sliding contact Rigid-flexible and flexible-flexible contact
Usage Pressure applied normal to contact & target elements Can be cut off when contact is restored or contact pressure is larger than the fluid pressure Applications Post-Leakage simulation Sealing performance evaluation
20
Fluid pressure is applied
Fluid pressure is Not applied
Seals

Contact Performance Enhancements New Contact search algorithm Smart over-constraint elimination & display New Contact pair trimming logic Solver files size reduced by 50%
Benefits Speed improved by 1x-200x Computation time reduced Less Disk I/O observed
Applications Most problems involving contacts should observe speed improvements Problems involving bonded MPC contacts
21
Contact Speed-up Example

BOOTSEAL 3D Elem: 11090 Nodes: 5040 Dofs: 30240 Rigid-Deformable +Self Contact
Boot Seal
11.0
12.0
speedup
Contact database Contact Search Contact Elements Other Elements
11.72 3465.04 505.64 4907.18
0.216 75.64 188.95 2301.7
54.26 45.80 2.67 2.13
Eq. Solver
Total CPU Elapsed Time No. of Iterations No. of Substeps
276.77
9154.65 9207 246 42
211.35
2777.64 2788 240 43
22
1.30
3.29 3.30 1.02 0.97

Friction Definition Improvements Tabular data for with up to 2 fields, eg. Velocity, pressure, frequency etc. USERFRIC : A general API for user-defined friction definitions
Benefits Account for complex friction behavior Support friction definitions that do not follow Coulombs law of friction
Applications Wear or bearing analysis Pipeline on a sea bed Brake Squeal analysis
23
LINEAR DYNAMICS
24
Advances in Linear Dynamics

Rotordynamics Improvements Gyroscopic effect for shells and 2D planar elements Rotating damping to model hysteretic damping in material
Benefits Versatility in modeling rotating shell and 3D axi-symmetric structures. Rotating damping model enables rotor instability predictions. Applications Aero gas turbine engines. Electrical motors, pumps, etc Computer disk drives
25

PSD (random vibration) Enhancements Increased # of input PSD points - no longer limited to 50. Improved performance of mode combination in spectrum analysis. Number of modes that can be combined increased from 1,000 to 10,000
Benefits Usability of random vibration features. Performance improved Applications Structures subject to random vibration such as aircrafts, automobiles, et al.
26
Boundary Conditions and Loading

Improvements to PSD Analysis
Base excitation: Individual or ALL Goodness of fit for PSD data
Response PSD Results available

Response PSD Result
Applications Predict Dynamic response of a structure seismic loading Loading due to Ground transport Machine operation
27

Spectrum Analysis Improvements Missing Mass and Rigid response method supported Residual vector method extended to Spectrum analysis
Benefits Accurate representation of higher frequency content on structural response. Missing Mass method meets NRC requirements Applications Random vibration response prediction on airborne structures, nuclear reactors, et al.
Courtesy: NASA
28
Spectrum Analysis in WB
Response Spectrum Analysis Singe-Point and Multi-Point spectrum Excitation applied at fixed DOFs Results: Max response spectrum
Benefits A Deterministic option for Shock analysis Very easy to setup Mode combinations: SRSS, CQC, ROSE Applications Seismic response of a structure Shock and Vibration analysis
Graphics Card
Courtesy: U.S. Geological Survey
29

Harmonic Analysis Enhanced Cyclic Symmetry now supports Harmonic Analysis. Variational Technology (VT cyclic) based modal cyclic solve approach Benefits Vibration response of cyclic structures subject to harmonic excitation. VT cyclic gets 3 4 X speed up of modal cyclic solution.
Applications Aero gas turbine engine design, electric motor / generator design
30
Modal Cyclic Symmetry
Elapsed (sec) Ratio Standard Win32 Linux 64 2905 1281 VT 533 406 ~ 5.5 ~ 3.2

Modal Superposition Enhancements Harmonic & Transient performance improved, Results expansion pass Tabular load as a function of frequency Multiple load vectors supported for Mode Sup. Harmonic & Transient
Benefits Ability to solve very large models. Ease of applying frequency dependent loading. Improved usability of MSUP methods in ANSYS and ANSYS WB environment. Applications Very large structures, for example, in nuclear industry, space applications etc.
31
Circuit Board No. of equations No. of Modes Analysis No. of Threads

11.0SP1 CP (hr) Elapsed (hr) ~ 14.4 ~ 12.35
2408595 21 PSD 2
12.0 ~ 4.4 ~3

PSOLVE Method for Brake Squeal Linear QR Damped Modal Analysis with PSOLVE Improved performance of QR damp Eigensolver. Contact element enhancements for sliding friction modeling Benefits Significantly faster problem setup due to the flexibility of contact modeling Taking advantage of advanced contact capabilities to model brake squeal Applications Instability prediction in automotive and aircraft landing gear brakes.
32
Brake Assembly

New Result Item for Linear Dynamics Modal Assurance criterion calculated (RSTMAC command) The nodes need not to be identical
Benefits Compare results between 2 different models Study the effect of design changes on a machine component. Applications Mis-tuning of gas turbine blades Validate new component designs
file1.rst
file2.rst
Match geometries
Calculate Modal Assurance Criterion
Match Solutions
33
Example: Modal Assurance Criterion

Part
Initial Design
New Blade Design
34
MATERIALS TECHNOLOGY
35
New Material Models Added

Rate Dependent Chaboche Plasticity Model
Based on Chaboche Nonlinear Kinematic Hardening model Plastic Strain Rate-dependent effects Captures cyclic hardening & softening
Applications/Benefits

Applicable for turbine and engine design Simulation of Ratcheting and Shakedown
3.E+08 2.E+08 Stress 1.E+08 0.E+00 -1.E+08 -2.E+08 -3.E+08 -0.015 -0.010 -0.005 0.000 0.005 0.010 0.015 Displacement
Strain rate dependent applications: for ex. Impact simulations
36

Improved Extended Drucker-Prager model
Structure Ocean
Include creep effect for all options except CAP option Capture strain rate effect of a geological material
Analyze geological materials that exhibit pressure dependency such as sand, soil, ceramics etc.
37

New Bergstrm-Boyce Model
Combines Hyperelastic & Viscoplastic effects The model decomposes the mechanics response of material into two distinct networks: A: time-independent B: timedependent.
Bio -Tissues
Accurately capture material behavior under various loading conditions Model hysteretic behavior of Elastomers under large strain deformation Simulation of Polymers, Elastomers, Plastics, Bio-tissues which are strain-rate dependent
38
Keyboard

New Elastomer Damage Model
Based on Ogden-Roxburgh model

A continuum damage model for rubber like material
Isotropic damage assumption

Reaction Forces soften with the 2nd load cycle

Captures cyclic softening of elastomers Simulation of Mullins effects
Applicable to rubber like materials such as polymers, elastomers, plastics and etc.
39

Anands Viscoplasticity Model Implemented for current generation elements Unified viscoplastic constitutive model Includes an internal state variable - the deformation resistance No yield surface
Benefits & Applications Highly nonlinear large deformation problems High temperature metal forming simulations Electronic Packaging, Solder joint simulation
40
Metal Forming Applications
Fracture Mechanics Improved

Enhancements to J-integral Calculations
Thermal strain is automatically included in the J-Integral calculation Surface pressure load on element surfaces or edges is automatically included in the J-Integral calculation
Provide accurate estimation of J-Integral when there are thermal strain and surface pressure on crack faces Structural integrity assessments Nuclear reactor safety analysis
42
Spot Weld Failure Analysis
Example: Turbine Blade Crack

Analysis
Penny Crack
PRCINT prints calculated J-Integral values to Solution Information Window
43
Fracture Mechanics Improved

Mixed Mode Stress Intensity Factors Based of Interaction integral approach by Gosz and Moran Minimum input Crack front/tip nodes Crack plane normal or extension direction Number of contours Benefits Much easier to use Improved accuracy observed
Applications Mixed mode stress intensity factor calculation , Safety analyses
44
Stress Intensity Factor calculation
Advanced Analysis Functions

Improvements in Initial State
Support Initial strains Support Plastic stress and strain

Analysis of residual stress/strain Analysis of Weldment with residual stress Transfer state of a 2D analysis to 3D Start in 2D and continue analysis in 3D Pre-stressed modal, Transient type analysis
45
RIGID AND FLEXIBLE DYNAMICS

46
Rigid Dynamics
Bushing Joint Free motion in some directions, constrained in others Elastic and damping forces in constrained directions Benefits Add flexibility at joints w/o large CPU cost Add realism to rigid simulations Applications Suspensions Pivots with compliance Vibration isolation
47
Rigid Dynamics
Rigid Dynamics
Stops and Locks All Translational DOFs Single rotational axis joints
Rigid Dynamics
Benefits Simplifies mechanism modeling Much requested feature Faster than modeling contact Applications Travel limiters Non-moving impact points
48
Rigid Dynamics
Remote Loads Remote displacements Remote forces now supported
Rigid Dynamics
Benefits Much requested feature Allows load input w/o requiring geometry Applications Partial assembly modeling Inverse Dynamics
49
Rigid Dynamics
Spring Preload Specify free spring length Specify preload
Rigid Dynamics
Benefits More realistic modeling of spring mechanisms Applications Valve trains, Plungers, Solenoids
50
Rigid Dynamics
Load Data Fitting Complex load input Multi-channels Piecewise linear tables added Benefits Fitting not required Time savings on complex load input Applications Equipment durability testing Seismic loading Shipping loading
Rigid Dynamics
51
Rigid Dynamics
Redundancy Analysis and Repair Troubleshooting tool Common problem with mechanism models Benefits Points out over constrained joints Allows selective unconstraining Help prevent problems going from Rigid to Flex Applications All but the very simplest mechanisms All models that will be solved in flex dynamics
52
Rigid Dynamics
Rigid Dynamics
Solver Updates Runge Kutta 5 RSM Benefits RK5 faster for most problems Remote Solver offloads solve to server Applications All but the very simplest mechanisms Longer running rigid dynamics simulations Complex load/time history problems
53
Rigid Dynamics
Rigid Dynamics
Load Export Rigid Dynamics solve Forces and moments are loads for static structural analysis User selectable time point(s) Benefits High degree of user control Less CPU than full flexible dynamics solution at all time points Applications Rapid what-if studies First order simulation modeling
Rigid Dynamics
54
Flexible Dynamics
Component Modal Synthesis Uses substructuring approach Standard command objects Requires linear materials Large rotation/translation Benefits Potentially huge time savings CMS for linear parts or model, flex for others Applications Mechanisms and machines with linear materials Non-contact dominated parts of assembly
55
Flexible Dynamics
Rigid Flexible Flexible Flexible Flexible Flexible Dynamics Dynamics Dynamics Dynamics Dynamics Dynamics Rigid Full Mesh CMS CMS Full Mesh Parts Total # DOF 7 60 ~75k ~75k ~1 mill ~1 mill Total Iterations 625 2520 2297 830 1015 ??? Time for Gen N/A N/A N/A 27 s 24 min N/A Time for Use N/A N/A N/A 25 s 1 min N/A Time for Exp N/A N/A N/A N/A Total Time 1s 60 s 217 min 52 s 25 min Too long!
WORKBENCH INTERFACE
56
Preprocessing in WB
Shell and Beam Modeling Improved Element Order support for 2D, Shells and Beams Shell offset: Top, Middle, Bottom or user Beam offset: Centroid, Shear Center, Origin or user defined
Benefits More accurate representation of curved shell or beams Accurate modeling of assemblies involving shell, beam and solid elements Applications Automotive, Aerospace, Pressure vessels All models involving plates and trusses
57
Shell and Beam offsets
Preprocessing in WB
Gasket Element Support More automated thin model meshing Higher order on the faces and lower order on the sides
Benefits Contact definitions automatically handled Multi-body part gasket meshing Material definitions using command snippets Applications Simulation of Gaskets used in Engines Compressors Heat exchangers etc,
58
Gasket Element Supported
Example: Solid-Shell Meshing
Solid-Shell Mesh
Multiple Elements Through Thickness

Courtesy Parametric Technology Corporation
59

Spatially Varying Load Spatial variation along one coordinate direction Load as a Table or function Pressure or temperature Benefits Visualize Loads which vary with respect to position Loads can be imported from 3rd party applications
Applications Aerospace, Automotive applications Turbo machinery related problems Hydrodynamic loading
60
Pressure Varying Load

New Boundary Conditions Support
Coupling Constraint
Coupling of two or more faces Cylindrical coordinates for Displacement
Directional Control for Fixed Rotation
Applications

Use Coupling to model various joint/hinges

Apply rotation as an applied displacement For 2D modeling, more granular control for rotations
Fixed Rotation, Cylindrical Coordinates
61

New Remote Point Feature
Scoping mechanism for remote B.C.s Applied to face, edge, vertex of bodies
Promote Remote B.C.s to a remote point Benefits
Multiple boundary conditions scoped to a point Avoid over constraint conditions
Remote Points
Applications

For 2D and 3D modeling of structures Point Mass, Springs, Joints, Remote Loads, Moments
62

Contact for Surface Bodies
Applicable to contact with Surface bodies Specify Contact or Target to a shell face
Applied on Top or Bottom shell face
Benefits At v12.0 full contact features support for shell models Contact conditions supported on either side of a surface body Applications Assembly model of thin structures Shell and Solid assemblies All industries
63
Shell-Shell Contact
Post Processing Enhancements

Custom Post Processing Full range of .RST results exposed in WB Accessed through the Worksheet view Details view enables expressions Benefits Post advanced MISC data from .RST file Math Operations on results sets Linearized Stress results for Shells
Applications Post advanced results from - .rst, .rth files Calculate custom values from any predefined result set Check for compliance with various codes
64
Acoustics Post in WB Fluid30 Element
Linearized Stress Plot

Post Processing Enhancements

Advanced Post Processing Features Post results of complex modes View results along a slice with Path plots Review unaveraged contour plots Results in Solution coordinate system Post results during a solve Benefits Plot results along a load or stress path Orient results in a user coordinate system Monitor results during a solve
Applications Plot temperature as a function of distance More intuitive knowledge into the behavior of a nonlinear solution
65
Path Plot
Unaveraged Stress Plot

Example:
Results
PostProcessing of Complex
Unstable Mode
Damped Mode
66
ANSYS 12.0 Summary
Continued Innovation in Element Technology

Additional Productivity with Native Workbench Features Committed to Advanced Solver Performance New Framework for Multiphysics Simulations
67
Siddharth.Shah@ansys.com
THANK YOU
68

ANSYS 12.0 Update Structural Mechanics

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ANSYS 12.0 Update Structural Mechanics

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ANSYS 12.

Structural Mechanics Capabilities

ANSYS, Inc. Proprietary

New Element Technology

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

New Element Technology

Automotive Suspension Mount

Good for incompressible materials Ideal for Forming and Hyperelasticity

2009 ANSYS, Inc. All rights reserved.

6000.00 5500.00 5000.00 4500.00 4000.00 3500.00

3000.00 2500.00 2000.00

Hans-Jrg Hinterkeuser FEA Engineering Norbert Urban FEA Engineering

Measurements vs. Simulation

New Element Technology

2009 ANSYS, Inc. All rights reserved.

Shaft Valve Ball Valve

FULL 3D : 13.7 hrs

New Element Technology

2009 ANSYS, Inc. All rights reserved.

New Element Technology

2009 ANSYS, Inc. All rights reserved.

New Element Technology

Curved Plate Cooling Problem

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

New Element Technology

Picture from http://www.mms.gov/tarprojectcategories/structur.htm

2009 ANSYS, Inc. All rights reserved.

New Element Technology

2009 ANSYS, Inc. All rights reserved.

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Advances in Solver Technology

2009 ANSYS, Inc. All rights reserved.

Advances in Solver Technology

Block Lanczos Supernode

0 100 1000 4000 8000

2009 ANSYS, Inc. All rights reserved.

Advances in Solver Technology

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Advances in Solver Technology

Win x64 CCS 480K DOF

CPUs Time (hr)

Bolted Joints, N/L Contact, Thermal loads Unsymmetric option

2009 ANSYS, Inc. All rights reserved.

DANSYS: Benchmarks on Win CCS

ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Advances in Contact Modeling

Fluid pressure is applied

Fluid pressure is Not applied

2009 ANSYS, Inc. All rights reserved.

Advances in Contact Modeling

2009 ANSYS, Inc. All rights reserved.

Contact Speed-up Example

Contact database Contact Search Contact Elements Other Elements

11.72 3465.04 505.64 4907.18

0.216 75.64 188.95 2301.7

54.26 45.80 2.67 2.13