Achieving Convergence &amp Best Practices OS Nonlinear v2021 March2021

© Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
OptiStruct for Nonlinear Analysis v2021
OPTISTRUCT FOR NONLINEAR ANALYSIS V2021

ACHIEVING CONVERGENCE & BEST PRACTICES
1
OptiStruct for Nonlinear Analysis - Agenda
Nonlinear Nonlinear
Working with Simulating Axisymmetric
Problems & Loads & Explicit
Nonlinear Nonlinear Joints & Plane Strain
Solution Loading Analysis
Materials Geometry Solutions
Methods History
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7
Integrating Achieving
Nonlinear
Setting Up Pretension Gasket Convergence Nonlinear
Thermal
Contact and Modeling & Best Optimization
Analysis
Preloading Practices
Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13
2
Achieving Convergence & Best Practices: Detailed Agenda

Achieving Convergence & Best Practices • Exercise 12A: Debugging Nonlinear Model 01
• Reading Output for Debugging • Exercise 12B: Debugging Nonlinear Model 02
• Using the *.out file • Exercise 12C: Debugging Nonlinear Model 03
• Using the *_nl.out file • Questions & Answers
• Monitoring Nonlinear Analyses
• Output Files Best Practices
• Convergence
• Numerical Non-Convergence
• Error Tolerances
• Convergence: Typical error messages
• Non-convergence Example: Buckling of a Stringer
Panel
• Nonconvergence and Contacts
• Best Practices
• Contact Best Practices
• Best Practices Regarding Convergence
3
READING OUTPUT FILES FOR DEBUGGING
4
OptiStruct *.out file

The OptiStruct *.out file is always output along with every analysis or optimization run. Within the file
there are several sections common to all out files that help the user understand the information the
solver is parsing, manipulating, and solving.
• Header
• Solver Information
• Warnings & Errors
• Model Parse
• Subcase/Run Summary
• Memory/Disk Summary
• Analysis/Optimization Information
• Analysis Complete/Incomplete
• Compute Summary
5
USING THE *.OUT FILE
6
How to Read .out File: Header
OptiStruct solver version name
Server/Hardware information
Build number for Altair user only
7
How to Read .out File: Solver Information
After the OptiStruct banner, it will write solver

information.
If Job is submitted on cluster (Server) with
multiple nodes (host) and MPI, then it writes
host information.
This area shows where the Optistruct Solver

is installed with .cfg information.
This area will inform which PARAM cards have been used in the current job
8
How to Read .out File: Warnings & Errors
All Warnings and any useful information will appear in this

area.
Suggestion: Please read all Warnings, Notes, and
Information, which will help users understand the solver
settings used for the current run
This area will show which solver is used with

subcase information.
9
How to Read .out File: Model Parse
Optimization File and Parameter Information
Here, it will show case the FEM model information.
10
How to Read .out File: Model Parse
Here, it will show case what type of

elements are used in
the current model.
Here, it will show case what type of

loads and boundary conditions
Here, it will show case material type and

property information.
11
How to Read .out File: Subcase/Run Summary

Optimization Parameter Information
Subcase summary information.
Run type, Scratch location and free

hard drive space.
Numbers of CPU usage information
( For SMP run)
Memory Estimation Module (v2020)

Run type, Scratch location, and free hard drive space.
Number of CPU usage information
MPI processes and maximum memory utilization
Total Number of Threads. (only for DDM run only)
12
How to Read .out File: Memory/Disk Summary
Memory Estimation Information is

for SMP. For DDM its considered
for each node Estimation (need to
multiply with host).
Disk Space Estimation Information (SMP).
13
How to Read .out File: Analysis & Optimization Information
This area will either show Beginning

Analysis Solution or information
showing that the analysis has not
started, if the model contains errors
that terminate the run.
14

For nonlinear statics, the *.out file will show the following information:
Nonlinear subcase number
(Defined in load step)
Current load increment
Current load step (summation of

advancements/adjustments to this point)
Current increment iteration for

convergence
Represents the average displacement of

all elements for a particular iteration for a
subcase. It is an I2 norm of the solution
vector U, including both displacements
and rotations, then divided by the # of dof
Represents the relative error in This shows the number of GAP/contact Frozen shows the number of contact
displacements element status in open or closed element are in TIE or Freeze contact
condition. condition.
Represents the relative error in in terms
of loads Stick and Slip condition -- STICK and Represents the Maximum Plastic Strain
SLIP are related to friction. The closed
Represents the error in terms of work gaps can either be sticking or slipping
15

As the load increment converges, the iterations will finish & the current increment will advance
Current increment (load increased)
• If the error index for the above fall within acceptable limitations, the solution is accepted as converged
• OptiStruct may increase the load increment by up to 50% for the next increment, depending on the factors
that led to the converged solution
16

If the load increment does not converge and the iterations reach a maximum limit for iterations,
OptiStruct will cut back the load increment up to 25% to correct for nonconvergence
Current increment after load
cutback
Due to non convergence in

previous increment, the load
is adjusted (reduced) after
cutback
Non-convergence in this
example17 is due to UPW being
larger than default tolerances
How to Read .out File: Analysis Complete or Incomplete
Both nonlinear solutions that converge will show an

information summary regarding the subcases in the
analysis
Note that Increment/Iteration/Cutback summary will

not be shown for non-converged solutions
If the run converged without any issues, the *.out

file will have the ANALYSIS COMPLETED message
If the run did not converge, the *.out file will have an
error message. Check error and stat file after this
section for more information on the solution.
18
How to Read .out File: Compute Time Information
Elapsed time will inform about total run time

took for convergence and result generation
(Compute time information)
19
USING THE *_NL.OUT FILE
20
The *_nl.out File

OptiStruct will generate additional output information
specifically for LGDISP nonlinear loadcases in a file named
<filename>_nl.out.
Note that for small displacement it will only write iteration
information, not details.
Look for ERROR and CORRECTION messages which are
designed to debug the model to see where the
model has difficulties converging
For users, both the error and correction messages can help
to debug the model along with a large amount of
information available in the *_NL.OUT file: change certain
areas of the model or modify some input parameters to get
model to converge
21
How to Read _nl.out File: LGDISP Analysis Information

Non linear sub case number.
(Defined in load step)
Initial/Current increment
Current load step (summation of

advancements/adjustments to
this point)
Max. Penetration Error: this will

show which node [16649] is
getting the relative maximum
penetration of contact 0.0117
(relative %) and the name of the
contact interface experiencing
max penetration error
Max. Pressure Error: this will

show which node [16649] is
experiencing max. pressure of
contact 0.411D+3 (relative %), Max. Force: Which node and Max. Residual Force: Which
the maximum change in the degree of freedom [24 DOF 1] node and degree of freedom
absolute pressure value, and the and value of applied force [16747 DOF 1] along with value
contact interface name. 0.0D+0 (relative %). of residual -0.2D2 (relative %).
22
Contact Difficulties Issue

For MAX penetration error, it only tracks the nodes that are closed in the current or pervious
iteration. It will compute the change in the penetration and find the node with maximum change
(absolute value).
For MAX pressure error, it will only compare those nodes that are closed in the current or previous
iteration. It print out the maximum change in the absolute pressure value.
23
Contact Difficulties Issue: Penetration & Pressure Error

Penetration error and pressure error can be key metrics in debugging
These two metrics in particular help us to identify difficult contact areas – usually those areas involve
maximum changes in penetration and/or pressure.
With those node IDs printed out into the file as well as contact names printed out in the *.out file, we
can use HyperView to visualize and analyze the behavior to prepare a debugging course of action.
24
How to Read _nl.out File: LGDISP Analysis Information
Force and Force residual (out-of-balance Max. Rotation Increment: particular Max. Displacement Correction: this
force) is a useful metric to help identify increment its show rotation at node shows Node 33883 DOF 3 correction of
convergence issues. For example, the number along with DoF. Displacement of -0.40D+1. Correction of
node with the maximum residual in the displacement is very high – as it
increment/iteration where convergence Max. Rotation correction: as with the decreases, the residual will vary less.
problems start to occur is often a good residuals, corrections should remain very This lead to very high amount of
place to start looking when the symptom small relative to the increment. instability in component displacement.
is a diverging solution.
Element Distortion : If some element is Max. Residual Moment: Residual
Max. Displacement Increment: this will experiencing distortion which causes the moment at node is a relative %. The
show relative % and the node number problem to exceed the convergence closer the residual is to zero, the less
and degree of freedom (N258056 DOF 3) criteria at that time, it is shown here. chance the moment is a leading factor in
which is the maximum displacement of NOTE: check if plastic strains increase non convergence.
Component/Assembly on the noted element during that time
25
increment by referencing this element #.
Convergence Issues Can Be Investigated Using _nl.out

Consider the following: on a contact surface: might be unstable separation or stick-slip behavior: use
force and force residual to monitor.
An element (CELAS, CBUSH) which might be spinning in rotational dof
Could likely either the load is too great or the ultimate yield stress is too low, etc
MAX Displacement Increment and Max Displacement Correction can be used for more than just
contact areas.
For example, if some local sudden change in displacement correction is detected, it may be caused
by buckling or other local instabilities. These two are not necessarily on the same nodes though. If
they happen to be on same node and same dof, they should be consistent (when added together will
result in new displacement increment on that DOF).
If the model is converging, the max displacement correction should be decreasing and small relative
to the maximum displacement increment
Increasing value of displacement usually means convergence is struggling.
26
Converged _nl.out file
27
Monitor Bulk/Subcase Request

The <filename>.monitor file is output by default
for any nonlinear analysis, however, it will contain
the maximum displacement occurring for each
increment, which may occur at different grid
points as increments advance. To get the
displacement results for specific nodes and
DOFs, the MONITOR Bulk and Subcase
information entries should be used.
This MONITOR subcase information entry can be

used to activate Nonlinear Displacement
Monitoring for a subcase by referencing a
corresponding MONITOR Bulk Data Entry.
28
DOF Monitor
The MONITOR request can be added to the subcase to get the *.monitor file
29
More Diagnostic Data Available for *_nl.out and *_nl.h3d Files
More diagnostic data available through the

*_nl.out file includes:
• Grid IDs with Contact Status Change (CONTCHG)

• Default output to *.out file is no reporting of elements
• Default output to *.h3d file is all elements
• Element ids with distortion (ELEMDIST)

• Default output to *.out file is the first 10 elements
• Default output to *.h3d file is all elements
• NLPRINT subcase entry to adjust the output in _nl.out
• SET output in _nl.h3d
• Contact Status Change
• Distorted Element
30
Analysis Type
Details of NLPARM Card
Details of NLADAPT Card
31
Where diagnostic data is available in H3D format,

that information can be read in and post-processed
in the HyperView client.
For example, requests for distorted elements can be

reviewed as sets in HyperView in the *_nl.h3d
file.
32
MONITOR Request Details
33
OUTPUT FILES BEST PRACTICES
34
Errors or Warnings: Sample
35
CONVERGENCE
36
General Best Practices for Modeling

Nonlinear analysis is often a process of tuning to achieve convergence within a practical set of
assumptions. Modeling practices that help OS find a converged solution include:
1. Build the initial model with linear analysis setup or a single type of nonlinearity throughout the
model
2. Running this model and debug that nonlinearity
3. Add nonlinearities and analytical stages to the debugged initial model one at a time through the
entire model (material data, contact friction, heat/thermal, pretension, etc), debugging after each
new addition
4. Keep the default tolerances to begin with and tweak over time
5. Request NLOUT and use h3d file to look for behavior that causes nonconvergence or other error
6. Ensure there are enough increments in the nonlinear solution to solve the model and to provide
quality debugging information
37
CONVERGENCE: NUMERICAL NON-CONVERGENCE
38
Convergence: What Is It?

Convergence in FEA could mean:
• Mesh convergence or
• Accuracy of numerical solution from a nonlinear solution procedure
This chapter’s discussion is based on convergence of nonlinear procedure which includes:

• Proper material definition
• Appropriate stiffness in the model
• Eg. Loads, BCs, buckling, contact loss etc.
• Convergence of Newton-Raphson method
39
What Causes Numerical Non-Convergence?

Non-convergence in OptiStruct is due to the numerical technique not able to obtain a solution that
satisfies all the nonlinear convergence criteria
• Recall the relative errors for Displacement, Load and Work printed to OUT file
• If the error index for the above fall within the acceptable limit, the solution is accepted as a
converged solution
Default
Error Symbol *.out file Formula
Tolerance
𝑞𝑞 𝐴𝐴 � ∆𝑢𝑢
Displacement EU EUI 𝐸𝐸𝑈𝑈 = 1.0E-3
1 − 𝑞𝑞 𝐴𝐴 � 𝑢𝑢
𝑅𝑅 � 𝑢𝑢
Load EP EPI 𝐸𝐸𝑃𝑃 = 1.0E-3
𝑃𝑃 � 𝑢𝑢
𝑅𝑅 � ∆𝑢𝑢
Work EW EWI 𝐸𝐸𝑊𝑊 = 1.0E-7
𝑃𝑃 � 𝑢𝑢
40
CONVERGENCE: ERROR TOLERANCES
41
Convergence Error Tolerances

It is not generally recommended to change the default values. Varying the tolerances or excluding
criteria may help achieve a solution, but will affect the result accuracy.
Excerpt from a typical OUT file:
Nonlinear iteration summary for Subcase 2

Load Increment
Subcase 2 Load step: 1.0000E-01
--------------------------------------------------------------------------------
Nonlinear Error Measures Gap and Contact Element Status Maximum
Iter Avg. U EUI EPI EWI Open Closed Stick Slip Frozen Plststrn
Newton
--------------------------------------------------------------------------------
Iterations 1 5.49E-04 9.90E+01 2.14E-13 2.14E-13 0 0 0 0 0 0.00E+00
2 5.49E-04 6.13E-13 2.16E-13 7.18E-26 0 0 0 0 0 0.00E+00
Convergence Criteria
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
1 1.37E-03 5.94E+01 2.17E-13 1.30E-13 0 0 0 0 0 0.00E+00
2 1.37E-03 3.81E-13 2.07E-13 4.61E-26 0 0 0 0 0 0.00E+00
42
Convergence Information in *.out File

The symptoms associated with most convergence issues can be found in the *.out file
• Check for error messages
Adjusting load increment 151 (correction #5), Current increment 1.3633E-005
• Often some error messages
may not identify the ‘real’ issue --------------------------------------------------------------------------------
• Check for any warnings or other Iter Avg. U EUI EPI EWI Open Closed Stick Slip Frozen Plststrn
--------------------------------------------------------------------------------
information in the *.out file even 1 6.60E-02 4.16E-03 1.09E-04 9.36E-07 21 21 0 0 0 0.00E+00
2 6.58E-02 8.45E-03 3.45E-03 2.20E-05 21 21 0 0 0 0.00E+00
for a converged solution 3 6.66E-02 2.84E-02 4.48E-03 1.68E-04 42 0 0 0 0 0.00E+00
4 6.64E-02 4.63E-03 1.85E-04 1.75E-06 42 0 0 0 0 0.00E+00
5 6.50E-02 4.34E-02 2.04E-01 2.19E-02 0 42 0 0 0 0.00E+00
6 6.57E-02 3.06E-02 6.01E-04 1.24E-05 21 21 0 0 0 0.00E+00
7 6.58E-02 2.62E-03 3.39E-03 8.14E-06 21 21 0 0 0 0.00E+00
8 6.76E-02 6.46E-02 2.20E-02 2.02E-03 42 0 0 0 0 0.00E+00
*** ERROR # 4965 ***

Maximum number of time increment cutbacks reached, analysis aborted.
Saved the last (NOT-CONVERGED!) iteration for diagnostics.
*** Nonlinear solution failed to converge for Subcase 1 ***
Note: The number of cutbacks can be controlled by the

NCUTS parameter on the NLADAPT card
43
Reasons for Non-Convergence

Remember that non-convergent solutions are more common than you think!
The reasons for non-convergence can be broadly classified into two groups
• No solution available for the set of assumed PDE
• Examples: buckling and collapse, material flowing plastically
• Error in the user input
• Examples: Incorrect (often non-physical) FE data such as material, loading, contact

definition and constraints etc.
44
Non-Convergence at the Beginning of an analysis

If the increments start cutting back from the beginning of the analysis and the analysis terminates,
either after 5 corrections or upon reaching minimum time increment:
• Check for any unconstrained rigid body modes
• See if the structure is properly constrained
• Sometimes contact at the beginning is not yet closed and could be the only constraint between
two parts
• For subcase specific contact stabilization CNTSTB through bulk data entry can be used
• Ideally CNTSTB may not be required in subsequent subcases
45
Non-Convergence Due to Rigid Body Motion

If there initially is unconstrained rigid body motion between contacting parts, there are several ways to
handle this issue,
• Contact Stabilization CNTSTB bulk card for S2S and large displacement N2S
• Stabilization applied to the contact is gradually ramped down to zero by end of loadstep
• Displacement can be applied in first step to close the gap and actual load can be applied in
the second loadstep
u F
Step 1 Step 2
• Grounded spring with negligible stiffness can be used to provide stability in first step with
small load and apply actual load in second step
F
Fmin
46
Step 1 Step 2
Non-Convergence Due to Contacts

Contact separation or contact chatter represents a dynamic instability and can become a potential
cause for non-convergence anytime during the analysis
• CNTSTB might help, but transient analysis may be required
• Run first load step until instability
• Run second load step with DTRAN
If your non-linear contact converges well until it gets to LOAD=1.0 then you might want to assign the
CNTSTB loadcollector to your subcase and give it a very small S1 value
If the contact you set-up works with SLIDE, but not friction (MU1=number), try to convert the contact
from node-to-surface (N2S - default) to surface-to-surface (S2S)
47
Non-Convergence Due to Size of Load Increment

Upon checking for divergence after several iterations, OptiStruct may cutback the increment to 25% of
applied for the next correction (e.g. below).
By default after 5 cutbacks, if convergence is not achieved, the solver will error out
If convergence happens more easily, OptiStruct may increase the load increment by 50%
Starting load increment 11 Current increment 3.7542E-003

--------------------------------------------------------------------------------
Increment
-------------------------------------------------------------------------------- reduced
1 2.12E-02 2.44E-01 6.34E+01 6.45E+02 63 84 0 0 0 0.00E+00 25%

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
1 2.24E-02 6.93E-02 1.19E-01 2.45E-02 105 42 0 0 0 0.00E+00
48 2 2.24E-02 9.98E-02 1.49E-02 2.34E-03 126 21 0 0 0 0.00E+00
Non-Convergence Due to Mesh Distortion

If the solver reports excessive mesh distortion, consider the following reasons:
Subcase 1 Load step: 6.9373E-01 • Excessive or unrealistic loading

--------------------------------------------------------------------------------
Iter Avg. U
EUI EPI EWI Open Closed Stick Slip Frozen Plststrn
• Over-constrained FE model
--------------------------------------------------------------------------------
1 6.60E-02 4.16E-03 1.09E-04 9.36E-07 21 21 0 0 0 0.00E+00 • Inconsistent unit system between
2 6.58E-02 8.45E-03 3.45E-03 2.20E-05
3 6.66E-02 2.84E-02 4.48E-03 1.68E-04
21
42
21
0
0
0
0
0
0 0.00E+00
0 0.00E+00
model, material and/or loading
4 6.64E-02 4.63E-03 1.85E-04 1.75E-06
5 6.50E-02 4.34E-02 2.04E-01 2.19E-02
42
0
0
42
0
0
0
0
0 0.00E+00
0 0.00E+00
that lead to excessive deformation
6 6.57E-02 3.06E-02 6.01E-04 1.24E-05 21 21 0 0 0 0.00E+00
7 6.58E-02 2.62E-03 3.39E-03 8.14E-06 21 21 0 0 0 0.00E+00 Reviewing the last non-converged
8 6.76E-02 6.46E-02 2.20E-02 2.02E-03
9 6.69E-02 1.30E-02 1.72E-03 2.97E-05
42
40
0
2
0
0
0
0
0 0.00E+00
0 0.00E+00
iteration in HyperView will help
*** ERROR # 4965 ***
Maximum number of time increment cutbacks reached,
analysis aborted.
*** ERROR # 5905 ***

Severe element distortion detected,
analysis aborted.
Saved the last (NOT-CONVERGED!) iteration for diagnostics.
*** Nonlinear solution failed to converge for Subcase 1 ***

49
CONVERGENCE: TYPICAL ERROR MESSAGES
50
Convergence: Error Messages Due to User Input

Errors due to input occur before the start of nonlinear solution procedure
Most of these error messages are due to insufficient or incorrect user input and are typically
straightforward
Examples as shown below:
51
Convergence: Typical Error Messages

Other common error messages for nonlinear solutions include the following:
52
Non-Convergence Error Messages

A nonlinear run may produce one of those previously mentioned error messages,
• These common error messages may reveal little or no information on the actual cause of the
convergence issue,
• For example, the following error message indicates the that the nonlinear solution procedure is
cutting back and it has cutback till the minimum time increment has reached as specified on
DTMIN in NLADAPT
• This notification does not necessarily help you locate the proper point of resolution within the
model!
53

Similarly,
• The following error message indicates that the maximum number of cutbacks has reached.
• OptiStruct by default allows for 5 cutbacks which can be varied in NLADAPT using NCUTS.
• Increasing the NCUTS to a higher value may not necessarily help obtain convergence
54

Common error messages may provide suggestions that may not be valid for your model
• Error messages can be informative but often may be misleading too!
• Increasing NINC value in NLPARM card may not help here
• But, misleading error messages may often leave some clues behind!
• It is high recommended to read notes and warnings with extreme care to look for those clues
55
NON-CONVERGENCE: BUCKLING OF STRINGER

PANEL EXAMPLE
56
Non-Convergence
Excessive loading could actually be realistic. E.g. Failure loads, worst case loads, etc.
• This could lead to non-convergence of numerical solution
• Global stiffness matrix not positive definite
• Numerically no solution exists due to loss of stiffness in a implicit static problem
• No way to dissipate the strain energy released
Under these circumstances, a solution can be obtained by couple of ways

• Change the loading to displacement controlled
• This will work until there is free fall (no change in force for a given displacement)
• Run a nonlinear transient procedure
• Since the mass terms are included, the released strain energy get converted into kinetic energy
57
Non-Convergence Example
Example: Buckling of a stringer panel
• The panel is fixed at one end and a highly compressive load is applied at the other end
• The analysis is setup as nonlinear static
• Will the panel buckle under give loading condition and can this be captured with the current
loadstep?
Constrained
End
58 Force
Nonlinear solution fails at the first onset of instability
• Similar to first mode of natural frequency
First mode from natural frequency

59
Rerunning the analysis with nonlinear transient procedure
• Accounts for mass terms
• Strain energy released is converted into kinetic energy
Note: For simple loading, an enforced

displacement could also be tried with
nonlinear statics
60
Viewing Non-Converged Iteration Information

The last non-converged iteration is saved for diagnostics in HyperView when using NLOUT
• SVNONCNV = YES by default -- Output the non-convergent solution flag
Starting load increment 149 Current increment 8.7154E-003

--------------------------------------------------------------------------------
δ
--------------------------------------------------------------------------------
1 6.75E-02 9.98E-03 3.21E-06 2.45E-08 21 21 0 0 0 0.00E+00
2 6.75E-02 1.13E-06 3.74E-10 4.12E-16 21 21 0 0 0 0.00E+00
...
... Result at load increment 149 (converged)

--------------------------------------------------------------------------------
-------------------------------------------------------------------------------- δ
1 6.36E-02 4.24E-01 4.88E-03 1.40E-05 0 0 0 0 0 0.00E+00
*** ERROR # 4965 ***

Maximum number of time increment cutbacks reached,
analysis aborted.
Saved the last (NOT-CONVERGED!) iteration for diagnostics. Result at load increment 150 (not converged)
Contacts are failing
61 *** Nonlinear solution failed to converge for Subcase 1 ***
NON-CONVERGENCE AND CONTACTS
62
Working With Contacts

Contact separation represents a dynamic instability and can become a potential cause for
nonconvergence, particularly early within the analysis
CNTSTB may not be able to help obtain convergence in this case
Under these circumstances, it is worthwhile to consider implicit nonlinear transient dynamic procedure
The user may choose run the first subcase with a nonlinear quasi-static procedure until the model
reaches the instability
The instability can be solved in a second subcase with implicit nonlinear transient dynamic procedure
(DTRAN)
• With the inertial terms, the strain energy released are effectively converted into kinetic energy
• Example: Snap-fit problems, Friction driven loads etc.
63
BEST PRACTICES
64
On the Fly Output of Displacement Results

For nonlinear static (both small and large displacement) and nonlinear transient analysis, the
displacement results are written to an .h3d file at each iteration or increment
• The name of the .h3d file is filename_nl.h3d
These results can be viewed in HyperView as the job is running to monitor the solution process
To request this output from every SUBCASE at each load increment and at each iteration, use
PARAM,NLMON,DISP
65
Monitoring Nonlinear Analyses

Starting from v2020.1, the NLMON functionality is been enhanced to support the features of
MONITOR card.
NLMON can now be used to print and monitor the displacement results for desired grid and it’s DOF
(In addition to the on-the-fly output of displacement results to the _nl.h3d file). The displacement
results are printed to the .monitor and _Id.monitor files
The displacement values (TRANS/ROT) is output in the Global Coordinate system. The Global
Coordinate system in OptiStruct is a collection of all local coordinate systems in the model (CD on
GRID entry)
66
Nonlinear Bulk Data: NLMON Parameters

The NLMON card defines the settings for runtime monitoring of nonlinear analysis.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
NLMON ID PARAM1 VALUE1 PARAM2 VALUE2 PARAM3 VALUE3
Where:
ID Nonlinear Monitoring Entry ID
Controls the output of displacement results in the _nl.h3d file. The _nl.h3d file is output on-the-fly to help with
DISP
monitoring of Nonlinear Analysis runs. (INC or ITER)
Grid point identification number for which the displacement results are being monitored in the .monitor and
GRID
_ld.monitor files.
Degree of freedom of the Grid point specified via the GRID parameter on this entry. The displacement value is
DOF output in the Global Coordinate system. The Global Coordinate system in OptiStruct is a collection of all local
coordinate systems in the model (CD on GRID entry).
Notes:
• To request this output from a specific SUBCASE at each load increment or at each iteration, use NLMON=SID in the
SUBCASE and the bulk data NLMON data
67
Monitoring and Debugging Results

You can choose from:
• Monitoring Results (INT field on NLMON bulk entry is set to INC)
• Debugging Results (INT field on NLMON bulk entry is set to ITER or PARAM,NLMON,DISP is
used)
68
NLMON Results With INT = ITER

If the INT field on NLMON bulk data entry is set to INC, you can monitor the progression of the model
during the run by following the steps below:
• Open HyperView and load the <filename>_nl.h3d file result file.
• You will see the Displacement results in HyperView until the point at which the model has run.
• In this way, you can monitor the deformation of the model during runtime.
69
NLMON Example
.MONITOR FILE
INPUT FILE USAGE

_Id.MONITOR FILE imported into HG
70
Debugging Results from NLMON in HyperView

If the INT field of the NLMON Bulk Data Entry is set to ITER, you can generate results and diagnostic
data for each iteration of the nonlinear run.
Diagnostic data for debugging purposes such as Max Residual Force for LGDISP analysis can be
viewed with a HyperView script to parse the data to highlight the problematic nodes. The procedure is
as follows:
• Open HyperView and load the <filename>_nl.h3d file result file. You will see the model results in
HyperView at this point.
• Import the TCL script. The script is located in the installation at:
<install_directory>/altair/hwsolvers/scripts/os_out_file_parser.tcl
• Click File > Run > Tcl/Tk Script and select the os_out_file_parser.tcl script and click Open.
• In the subsequent OptiStruct OUT File Parser window, select <filename>.out from your working
directory for the OUT file: field.
71

Click Open and the debugging results for each iteration are now loaded into the Window, as shown
below:
72

Activate the checkbox of the result type whose peak value occurrence you wish to investigate and
click on the corresponding Iteration in the Convergence Table.
The corresponding grid point at which the result type attains its peak value is displayed in the
Graphics browser of HyperView.
Click Open and the monitored results are now loaded into the Window
73
Support for Optimization

NLMON is also supported for optimization
Results are written on the fly for all the optimization iterations
Results can be written out at every load increment or every iteration of every load increment based on
the definition of NLMON bulk data card
74
BEST PRACTICE: CONTACT STABILIZATION
75
Best Practice for Stabilizing Contacts

The matrix below will assist in understanding using two ways of stabilization with contact
Model with SMDISP analysis Model with LGDISP analysis

N2S
S2S N2S S2S
(CGAPG core)
PARAM,EXPERNL, Uses default settings of Uses default settings of Uses default settings of
Effective
CNTSTB bulk card CNTSTB bulk card CNTSTB bulk card CNTSTB
Bulk card
Not Applicable More options available Effective Effective
CNTSTB
PARAM,EXPERNL,
CNTSTB Stabilization with
Bulk card CNTSTB take Bulk card CNTSTB take Bulk card CNTSTB take
+ the PARAM is
precedence if present precedence if present precedence if present
Bulk card effective.
CNTSTB
76
Best Practice for Rigid Body Motion

Contact stabilization for initial rigid body motion
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
CNTSTB ID APSTB LMTGAP S0 S1
SCALE TFRAC
• Effective in overcoming instabilities that occur at the beginning, mid-analysis or end-of-analysis

• Can be applied globally to all subcases or can be subcase dependent
• Two ways to define the stabilization:
• PARAM, EXPERTNL, CNTSTB
• CNTSTB Bulk card
• PARAM, EXPERTNL, CNTSTB applies weak springs on all the contacts and then releases it to
zero
• CNTSTB defines damping stabilization parameters in normal and tangential directions (based on
contact penalty stiffness) for the contacts
77

There are two types of stabilization routines within OS: normal and tangential
normal
Normal Stabilization for CNTSTB, opening < LMTGAP: 𝐾𝐾𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 � 𝑓𝑓 𝑡𝑡 ∗ � 𝐾𝐾𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶
normal
Normal Stabilization for CNTSTB, opening ≥ LMTGAP: 𝐾𝐾𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =0
tangent normal
Tangential Stabilization for CNTSTB: 𝐾𝐾𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 � 𝐾𝐾𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶
where, KCREF is the automatically calculated reference stiffness (10-5 times the contact penalty
stiffness) for contact stabilization
• For time, 𝑡𝑡 in a subcase, 𝑡𝑡 ∗ is calculated as: 𝑡𝑡 ∗ = 𝑡𝑡 − 𝑡𝑡0 ⁄ 𝑡𝑡1 − 𝑡𝑡0
where, 𝑡𝑡0 is the time at the start of the subcase and 𝑡𝑡1 is the time at the end of the subcase
• f (t*) is calculated using S0 and S1 as f (t*) = S0 * (1 - t*) + S1 * t*
where S0 and S1 are scale factor for stabilization at start and end of subcase respectively
• SCALE is scale factor for normal stabilization (1.0 by default) and TRFAC is the factor for scaling
tangential stabilization wrt normal stabilization and is 0.1 is by default
78

Additional notes about stabilization in contact solutions:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
CNTSTB ID APSTB LMTGAP S0 S1
SCALE TFRAC
• For N2S contacts in small displacement analysis, use PARAM, EXPERTNL, CNTSTB
• For N2S contacts in large displacement analysis and S2S contacts in small/large displacement
analysis, using PARAM, EXPERTNL, CNTSTB activates the stabilization parameters used in
CNTSTB
• For temporary instabilities that might occur at the end of analysis, you can specify S1 (scale factor
for stabilization at end of subcase) to be a non-zero value
• For convergence difficulties, may also change the default tangential stabilization factor TRFAC
(default = 0.1)
79
Best Practice for Contact with Sharp Corners

Modeling sharp corners
• Generally, having a smooth corner is always desired, however, it may not be practical in certain
scenarios or models
• S2S is more stable and accurate than N2S for sharp corner contact
• A N2S setup in this case could lead to convergence issues or unrealistic results due to snagging
or large penetration
• Two S2S contacts with one on each side is recommended here.
Contact 2
(S2S)
Contact 1
(S2S)
80
Best Practice for Point and Edge Contact

Point-to-Surface and Edge-to-Surface contacts are sometimes necessary
• In this case, a N2S contact would be more suitable with reduced penetration
• The sharp edge, being the node, obviously will be the slave
• Example: Some clip insertion problems
Secondary
Main
81

It is common to have problems that involve sudden and/or intermittent loss of contact
• Examples: Snap-fit or clip insertion problems
This leads to dynamic instability towards the end of the analysis with contact separation therefore loss
of stiffness.
Here, the strain energy released needs to be damped to run the analysis to completion
Contact Stabilization as a bulk data entry can be used to solve this problem
• The strain energy released is damped with contact stabilization
Here too, the analysis can be split to multiple subcases and the remaining part of the analysis from
contact separation can be run as displacement controlled or as nonlinear transient
82
Best Practice for Contacts
Use PARAM, EXPERTNL, CNTSTB (contact stabilization) to help with convergence

when only contacts are connecting the structure/assembly together.
If your non-linear contact converges well until it gets to LOAD=1.0 then you might want to
assign the CNTSTB load-collector to your subcase and give it a very small S1 value
If the contact you set-up works with SLIDE, but not friction (MU1=number), try to convert
the contact from node-to-surface (N2S - default) to surface-to-surface (S2S)
83
BEST PRACTICES: CONVERGENCE HANDLING
84
Helping OptiStruct Find Converged Solution

Understand the Physics!
• Structures behavior for applied loading
• Helps to choose the correct procedure (Static, Transient)
• Appropriate loading (force, follower force, displacement) and large or small displacement
• Helps in choosing the appropriate material model (linear elastic, elastic-plastic, hyperelastic)
• Appropriate mesh size so that element distortion can be avoided
• Constraints on the structure and between the structures

• Incorrect boundary conditions often lead to underconstraint or overconstraint issues
• Choosing the correct contact conditions (sliding algorithm, freeze/friction/slip/stick, N2S/S2S
etc.)
85

Build the model slowly!
• One of the primary issues with a typical nonlinear analysis is adding all nonlinear
definition/complexities in the first run
• This can make debugging impossible. Building the model slowly always helps!
• Adding complexities such as contact, friction, plasticity etc., one at a time will help narrow down
the issue causing one
Quickly run a linear static analysis with same loads and boundary conditions
• This helps to understand the model behavior in a broader sense
• It is often worth considering linearization of some of the nonlinearities with safe assumptions
Although this may appear to increase the time needed to complete the final analysis task, it often
reduces the time spent on debugging a non-converging problem with all the complexities
86

Convergence!
• It is important to remember convergence may not necessarily mean the solution is correct!
• Browse through the OUT file for all information and warnings
• Understand if they influence the solution or not
• Study the deformation pattern & deformed shape
• Check if the contact works as expected and the deformation is as expected for the applied
load
• Accept the solution only after thorough investigation of all conditions and assumptions!
87
Exercise 12A: Debugging Nonlinear Model 01

File Name and Location (Manual Page 175):
…/12A_DEBUG_01/Debugging_1.fem
Objectives:
Debug the nonlinear model
Review the results in HyperView
88
Exercise 12B: Debugging Nonlinear Model 02

…/12B_DEBUG_02/Debugging_2.fem
Objectives:
89
Exercise 12C: Debugging Nonlinear Model 03

…/12C_DEBUG_03/chair.fem
Objectives:
90
QUESTIONS & ANSWERS
91
Questions & Answers
92

Achieving Convergence &amp Best Practices OS Nonlinear v2021 March2021

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Achieving Convergence &amp Best Practices OS Nonlinear v2021 March2021

Uploaded by

Copyright:

Available Formats

© Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

OptiStruct for Nonlinear Analysis v2021

OPTISTRUCT FOR NONLINEAR ANALYSIS V2021

OptiStruct for Nonlinear Analysis - Agenda

Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7

Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13

Achieving Convergence & Best Practices: Detailed Agenda

READING OUTPUT FILES FOR DEBUGGING

OptiStruct *.out file

USING THE *.OUT FILE

How to Read .out File: Header

OptiStruct solver version name

Build number for Altair user only

How to Read .out File: Solver Information

After the OptiStruct banner, it will write solver

This area shows where the Optistruct Solver

How to Read .out File: Warnings & Errors

All Warnings and any useful information will appear in this

This area will show which solver is used with

How to Read .out File: Model Parse

Optimization File and Parameter Information

Here, it will show case the FEM model information.

How to Read .out File: Model Parse

Here, it will show case what type of

Here, it will show case what type of

Here, it will show case material type and

How to Read .out File: Subcase/Run Summary

Subcase summary information.

Run type, Scratch location and free

Memory Estimation Module (v2020)

How to Read .out File: Memory/Disk Summary

Memory Estimation Information is

Disk Space Estimation Information (SMP).

How to Read .out File: Analysis & Optimization Information

This area will either show Beginning

How to Read .out File: Analysis & Optimization Information

Current load increment

Current load step (summation of

Current increment iteration for

Represents the average displacement of

How to Read .out File: Analysis & Optimization Information

Current increment (load increased)

How to Read .out File: Analysis & Optimization Information

Due to non convergence in

How to Read .out File: Analysis Complete or Incomplete

Both nonlinear solutions that converge will show an

Note that Increment/Iteration/Cutback summary will

If the run converged without any issues, the *.out

How to Read .out File: Compute Time Information

Elapsed time will inform about total run time

USING THE *_NL.OUT FILE

The *_nl.out File

How to Read _nl.out File: LGDISP Analysis Information

Current load step (summation of

Max. Penetration Error: this will

Max. Pressure Error: this will

Contact Difficulties Issue

Contact Difficulties Issue: Penetration & Pressure Error

How to Read _nl.out File: LGDISP Analysis Information

Convergence Issues Can Be Investigated Using _nl.out

Converged _nl.out file

Monitor Bulk/Subcase Request

This MONITOR subcase information entry can be

More Diagnostic Data Available for _nl.out and _nl.h3d Files

More Diagnostic Data Available for _nl.out and _nl.h3d Files

More Diagnostic Data Available for _nl.out and _nl.h3d Files

* ERROR # 4965 *

* Nonlinear solution failed to converge for Subcase 1 *

* ERROR # 5905 *

* Nonlinear solution failed to converge for Subcase 1 *

* ERROR # 4965 *