RP1001689 - Contact Methodology Using Abaqus

CONTACT METHODOLOGY USING ORIGIN EDSAZ
ABAQUS/EXPLICIT TO BE USED BY AIRBUS RSP REFERENCE RP1001689
Technical Report ISSUE 1.0 DATE 17 Dec 2009
Contact Methodology using Abaqus/Explicit to be used

by AIRBUS RSP
Technical Report
REFERENCE RP1001689
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SUMMARY:
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This document aims to provide contact modelling rules using ABAQUS /Explicit in impact and
crash related analyses.
A detailed description of the definition process is given.
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KEYWORDS
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NAME SIGLUM - FUNCTION DATE SIGNATURE
AUTHORING V.LAVIGNE EDSAZB - Engineer

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AUTHORIZATION M.MAHE EDSAZB
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TABLE OF CONTENTS
1 Objectives............................................................................................................................ 8
2 General contact interaction modelling ................................................................................. 8
2.1 Contact domain ................................................................................................................... 8
2.2 General contact penalty method ....................................................................................... 10
2.3 Mechanical contact properties model ................................................................................ 11
2.4 Contact surface properties ................................................................................................ 12
2.4.1 Surface thickness..................................................................................................... 12
2.4.2 Midsurface offset...................................................................................................... 13
2.4.3 Surface feature edges.............................................................................................. 15
2.4.4 Process to correctly define the contact surface ....................................................... 15
2.5 Initial overclosure .............................................................................................................. 17
2.6 Contact controls ................................................................................................................ 17
2.6.1 Node deletion ........................................................................................................... 17
2.6.2 Thickness reduction checks ..................................................................................... 18
2.7 Output 19

TABLE OF FIGURES
Figure 1) Classical approach and general contact................................................................ 8
Figure 2) Case of eroding element based surface................................................................ 9
Figure 3) Penalty approach................................................................................................. 11
Figure 4) Default definition of surface thickness properties ................................................ 13
Figure 5) Assigned surface thickness properties ................................................................ 13
Figure 6) Default definition of surface offset properties ...................................................... 14
Figure 7) Assigned surface offset properties ...................................................................... 14
Figure 8) Corrected surface properties in case of overthickness........................................ 15
Figure 9) Default definition and corrected surface properties in case of T section ............. 16
Figure 10) Initial penetration within the surface itself............................................................ 18

TABLE OF REFERENCES
N° TITLE REFERENCE ISSUE DATE SOURCE
SIGLUM NAME

1 Objectives
This report provides guidelines for modelling contacts and interactions that are used in Vulnerabil-
ity related applications.
2 General contact interaction modelling

For standard vulnerability applications, the recommendation is to use the general contact, which is
the main focus of this report. The general contact is defined by specifying:
• a domain where bodies could potentially be in contact with others or with themselves, sur-
faces that interact with one another,
• any algorithmic contact controls for the analysis,
• the mechanical contact property models, such as the pressure-overclosure relationship and
the friction coefficient,
• any non default surface properties to be considered in the contact interactions,
• any non default aspects of the contact formulation.
2.1 Contact domain

The general contact in Abaqus/Explicit is a surface-based contact-definition approach, which al-
lows very simple definitions of contact with very few restrictions on the types of surface involved.
Indeed, contrary to a “classical” contact approach which needs the definition of surface pairs and
self contact, the general contact requires the definition of a domain in which it will automatically
take into account the self contact and interactions between surfaces, as shown in figure 1.
Classical contact General contact approach

Figure 1) Classical approach and general contact
By default, Abaqus defines the domain by an all-inclusive surface that includes all exterior element
faces, all analytical rigid surfaces and all edges based on beam and truss elements in the model.
Nodes that are not part of an element based surface and cohesive elements are not included. The
whole domain shares the same contact property (normal and tangent behaviour).
By default in Abaqus the default domain and the element-based surfaces only contain the exterior
facets of the elements. In the case of eroding continuum elements, the interior facets of the ele-
ments have to be added to the domain, as shown in figure 2.

Figure 2) Case of eroding element based surface
The contact domain can also be defined by specifying the individual contact surface pairings.
This is useful to define:

• non default included surfaces (for instance surface with eroding continuum elements),
• specific contact properties for several parts (for instance different friction property),
• specifically the contact between the impactor and the impacted surface in order to assess
properly the impact load.
In addition regions of the model initially included in the domain can be excluded, such as:
• element-based deformable and rigid surfaces;
• node-based deformable and rigid surfaces;
• analytical rigid surfaces
• Eulerian material surfaces
Only one contact inclusions and one contact exclusions instruction can be defined for contact defi-
nition.
Abaqus corresponding card:

• Surface
o Default definition:
*Surface, name=Surface_1, type=element
Name_of_the_element_set_composing_the_surface,
Note: Optionally, an element face, edge, or end identifier can be specified as the
second entry on a data line.
For shell element, a blank in the second entry defines a double-sided surface. Sin-
gle-sided surfaces can also been specified replacing the blank by key word SPOS or
SNEG.
o Definition with interior facets:

In the case of eroding continuum elements, the interior facets have also to be added
in the surface definition:
Name_of_the_element_set_composing_the_surface, INTERIOR
Note: the key word INTERIOR automatically generates the interior facets of the
element set.

• Contact
o Default definition:
*Contact
*Contact inclusions, all exterior
o Definition of surface to be added:

*Contact
*Contact inclusions
,
Surface_1, Surface_2
Impacted_surf, Impactor
Note: A blank in the first cell defines the default domain and a blank in the second
cell defines the self contact with the first defined surface. Surface_1 and surface_2
can be defined as above.
o Definition of individual surface pairings:

*Contact
*Contact inclusions
… , …
Surface_3,
Note: the domain is then defined by the set of surface pairings, each line defines a
new surface pairing. A blank in the second cell defines a self contact.
o Definition of surface to be excluded:

*Contact
*Contact inclusions, all exterior
*Contact exclusions
Surface_3,
Note: this definition implies that the contact is managed between each component
(including self contact) except the interaction between surfaces 1 and 2 and the self
contact of surface 3.
2.2 General contact penalty method

The general contact uses a balanced master-slave approach. This means that in the case of two
surfaces interacting, each surface will be successively master and slave of the other one.
It is based on a penalty enforcing method.
In the case of a node-to-face contact, the penalty method introduces forces that are function of the
penetration distance. These forces are applied to the slave nodes to oppose the penetration, while
equal and opposite forces act on the master surface at the penetration point. This master surface
contact forces are distributed to the nodes of the master faces being penetrated.
In the case of edge-to-edge contact, the opposing contact forces are distributed to the nodes of the
two contacting edges, as shown in figure 3.

Figure 3) Penalty approach

The contact stiffness k that relates the contact force to the penetration distance is defined by
Abaqus solver to minimize the effect on time increment and remains constant as long as the con-
tact is effective. The stiffness may not be sufficient to prevent large penetration in case of massless
node.
Moreover, node penetration can be monitored during simulation: in case of excessive penetration,
a diagnostic message is written in .sta file and the set of nodes is stored in the .odb file.
The threshold is set by default to 0.5, which means that a penetration of 50% of the typical element
face dimension is assumed to be excessive and leads to a warning message. This limit can be
modified by using the following card:
*Diagnostics, deep penetration factor= value
Abaqus/Explicit allows also to modify the contact stiffness in order to reduce the large penetration.
This can be justified if two bodies in contact have very different Young modulus, for instance bird
and metallic/composite structure. However it has to be used with caution because it has an effect
on the time step. Consequently, all other contact parameters have to be double checked be-
fore this modification.
As defined before, the contact interaction is balanced by default, surfaces are successively slave
and master. However for specific needs, unbalanced contact can be also defined as follows:
*Contact formulation, type=pure master-slave

surface_1, surface_2, MASTER
Surface_1 being the master surface and surface_2 being slave surface.
2.3 Mechanical contact properties model

The default contact pressure-overclosure relationship named “hard” contact model implies that:
• the surfaces transmit no contact pressure unless the nodes of the slave surface contact the
master surface;
• there is no limit to the magnitude of contact pressure that can be transmitted when the sur-
faces are in contact.
Different contact property definition can be assigned to specified regions of the general contact
domain. This includes, for example, the definition of friction.
The friction is defined in Abaqus/Explicit by the Coulomb coefficient relating allowable shear stress
and contact pressure:
τ crit = μ ⋅ p eq1
where μ and p are friction coefficient and contact pressure respectively.

When τ crit is reached, there is sliding of the two surfaces in contact.

By default, the contact is frictionless.

• Definition of friction:
*Surface interaction, name=Friction_prop
*Friction
0.2
• Definition of contact property for specified region:

*Contact property assignment
, ,
surface_1, surface_2, Friction_prop
Usually, contact between metallic components is modelled using a friction coefficient of

0.2. Contact between impactor (bird, tyre debris, hail or hard debris) and structure will be
considered as frictionless.
2.4 Contact surface properties

The most common surface is the element-based deformable one defined as follows:
Two-dimensional, axisymmetric, and three-dimensional elements cannot be mixed in the same

surface definition. The surface perimeter edges are generated automatically from the surface fac-
ets for use in edge-to-edge contact but geometric feature edges can also be added.
When shell and membrane elements are used in a element-based surface, the thickness and mid-
surface offset of the shell or membrane elements are kept from the shell section.
However it is possible to assigned different values for these data and add a contact thickness for
regions of a surface based on solid elements.
Surfaces can also be based on nodes for deformable and rigid bodies and analytical rigid surfaces:
*Surface, name=Surface_1, type=node
Node_number or Name_of_the_node_set,
When the nodes of shell and membrane elements are used in a node-based surface, the thickness
and midsurface offset of the shell or membrane at each node are not considered. A nonzero thick-
ness can be assigned also to node-based surfaces.
The surface properties which can be assigned or modified, are:

• Thickness: to assign the contact surface thickness
• Midsurface offset fraction: to assign the surface offset as a fraction of the surface thickness.
• Feature edges criteria: to control which feature edges should be added in the general con-
tact domain.
2.4.1 Surface thickness

By default, the nodal thickness for surfaces based on shell, membrane, or rigid elements equals
the minimum original thickness of the surrounding elements, as shown in figure 4.

Figure 4) Default definition of surface thickness properties

However it is possible to assign a specific thickness as follows. This will only affect the contact but
not the mechanical properties.
*Surface property assignment, property = thickness

Surface_2, thickness_value
In the previous example, if the contact surface needs to be 4 mm thick at node #3, the three follow-
ing cards have to be added (see figure 5):
*Nset, nset=node#3
3
*Surface, name=Overthickness, type=node
node#3,
Overthickness, 4
Figure 5) Assigned surface thickness properties
There is however a limitation: the contact thickness cannot exceed a fraction of the surface facet
edge lengths or diagonal lengths (between 20 and 60%). If it is superior the solver tries to scale
back the contact thickness (message in .sta file). This thickness reduction can be controlled by
defining specific controls settings (cf. § 2.6.2)
2.4.2 Midsurface offset

The offset represents the fraction of the distance between the midplane of a thin body and its ref-
erence plane.

By default, the nodal offset for surfaces based on shell, membrane, or rigid elements equals the
average of the maximum and minimum original offset of the surrounding elements, as shown in
figure 6.
Figure 6) Default definition of surface offset properties
In this example, the default definition leads to a shift on the contact surface and likely a contact
defect. To solve this problem it is possible to assign a specific offset, figure 7.
It will only affect the contact (not the mechanical characteristics).

*Surface property assignment, property = offset fraction

Surface, offset_value
In the previous example the three following cards have to be added (see figure 7):
*Nset, nset=node#3
3
*Surface, name=ModOffset, type=node
node#3,
*Surface property assignment, property = offset fraction
ModOffset, 0
Figure 7) Assigned surface offset properties
Offset can be assigned only on shell, membrane, rigid and element based surface as above.
At complex intersection (edges connected to more than 2 faces) the nodal offset is null.

2.4.3 Surface feature edges

Feature edges of a model are defined on beam and truss elements and edges of faces of solid and
structural elements.
By default, edge-to-edge contact accounts for perimeter edges as well as “contact edges” of beam
and truss elements.
Any edge-to-edge contact can be removed by using the no feature edges parameter.
The edges of a surface can also be added automatically using the “ALL EDGES” option.
*Surface property assignment, property=feature edge criteria

, PERIMETER EDGES (default)
, NO FEATURE EDGES
Surface_1, ALL EDGES
The surface name can be omitted when using the PERIMETER EDGES, NO FEATURE EDGES,
then the parameter is applied to the entire general contact domain. A non-blank surface name is
required if the ALL EDGES options are specified.
The amount of contact data used to describe the surface topology is proportional to the number of
faces included in the contact domain. Including a large number of interior faces in the contact do-
main can potentially increase memory use significantly compared to analyses in which the contact
domain is defined using only exterior faces.
Therefore, it is recommended to include in the contact domain only those interior element faces
that could possibly participate in contact.
The option ALL EDGES should be used when dealing with eroding component such as bird.
Note: this option is not supported in CAE, it has to be added directly in .inp file.
2.4.4 Process to correctly define the contact surface

Two causes of contact issues have been identified:
• Overthickness on a component: usually the midsurface is defined at the thinner part and
the rest is modelled with offset.
The default contact surface properties are not correct on the nodes between both thick-
nesses so corrected properties (thickness and offset) have to be assigned for this set of
nodes. See figure 7 for correcting offset only or figure 8 for correcting thickness and offset.
Figure 8) Corrected surface properties in case of overthickness

• Complex intersection like T section: whichever the surrounding elements offset, the nodal
offset at complex intersection remains null. Consequently if surfaces are defined with non
null offset, the thickness property has to be assigned to correct the contact defect as shown
in figure 9.
Figure 9) Default definition and corrected surface properties in case of T section
Abaqus corresponding card (2nd example):
*Nset, nset=node#3
3
*Surface, name=Tsection, type=node
node#3,
Tsection, 0

2.5 Initial overclosure

Abaqus/Explicit automatically adjusts the positions of surfaces to remove small initial overclosures
that exist in the general contact domain in the first step of a simulation. The adjustments are made
with strain-free initial displacements.
This automatic adjustment of surface position is intended to correct only minor mismatches associ-
ated with mesh generation.
Conflicting adjustments from separate contacts, boundary conditions, tie constraints, and rigid
body constraints can cause incomplete resolution of initial overclosures.
This can occur when a slave node is pinched between two master facets. Initial overclosures that
are not resolved by repositioning nodes are stored as temporary contact offsets to avoid large con-
tact forces at the beginning of an analysis. The penalty contact force is computed as follows:
f = k ⋅ (d eur − d 0 ) eq2
where k is the penalty stiffness,
d0 is the initial unresolved penetration distance
deur is the current penetration distance.
If deur ever decreases below d0, d0 is reset to deur.
Alternatively, contact offsets can be created for clearance specifications. These offsets are perma-
nent (as opposed to temporary offsets created during the default initial overclosure resolution pro-
cedure) and are not ramped to zero as the surfaces separate. Then nodes are not adjusted but
contact offsets are created.
*Contact clearance, NAME=clear name, ADJUST=YES (default)
Initial overclosure information, including node adjustment data, contact offsets, crossed surfaces,
nodes that could not be corrected, and any warnings, is copied to the .sta file, the .msg file, and the
.odb file.
Before running any calculation, it is strongly recommended to check these data. It is a way
to check the model, flag meshing error or bad offset definition and to assess potential con-
tact defect and the relevance of the solution given by the solver.
2.6 Contact controls

Main contact controls are:
• the scale of the default penalty stiffness for particular regions within a general contact do-
main.
As discussed before, the penalty stiffness should not be scaled.
• the removal of nodes from the contact domain once all of the faces and edges to which
they are attached are deleted.
• the modification of the default contact thickness reduction checks.
2.6.1 Node deletion

This option controls if the nodes whose surrounding faces and edges have eroded due to failure
remain in the contact domain or not.
By default, nodes, even freed, remain in the contact domain.
*Contact controls assignment, nodal erosion = NO (default and recommended)

Computational cost can increase as a result of free-flying nodes if nodal erosion is not specified,
particularly for analyses conducted in parallel. The increased computational cost is related to the
likelihood of free-flying nodes moving far away from the elements that remain active, which
stretches the volume of the contact domain and thereby tends to increase contact search costs as
well as the cost of communication between processors in parallel analysis.
Despite this, in case of impacts, it is recommended to use the parameter ‘nodal erosion=no’ to en-
sure that the nodal masses of the impactor are not removed from the analysis as the elements to
which they are attached fail.
2.6.2 Thickness reduction checks

By default, the general contact algorithm requires that the contact thickness does not exceed a
certain fraction of the surface facet edge lengths or diagonal lengths. This fraction generally varies
from 20% to 60% based on the geometry of the element. The general contact algorithm will scale
back the contact thickness automatically where necessary without affecting the mechanical thick-
ness.
Figure 10) Initial penetration within the surface itself

It is a side effect of the contact algorithm. The thickness reduction can affect the perimeter but also
the interior nodes as shown in figure 10.
It can be considered minor if it happens in areas where there is no initial contact but it becomes a
real issue in areas with initial contact. Indeed due to the contact thickness reduction, components
that should be in contact at initial time will be separated by an equivalent gap.
There are ways to limit the thickness reduction checks.

First it can be limited to potential self-contacts with neighbouring facets. As there is no need to re-
duce the thickness in the perimeter, it is recommended to add the following card in all cases.
*Contact controls assignment, contact thickness reduction = noperimself
Then, if the thickness reduction due to self-contact with neighbouring facets is unacceptable, the
self-contact can be excluded to the contact domain via contact exclusion definitions:
*Contact
*Contact exclusions
Surface-1,
Both cards should solve the undesirable thickness reduction.
Note: In Abaqus/Explicit, the general contact algorithm eliminates problematic, nonphysical “bull-
nose” extensions that may arise at shell surface perimeters in the contact pair algorithm.

2.7 Output
Contact diagnostics in Abaqus/Explicit provide detailed information about the surfaces and pro-
gress of contact interactions. Diagnostics are available:
• to review automatic adjustments between two surfaces,
• to reveal potentially problematic initial surface configurations in a model,
• to track excessive penetrations between two contacting surfaces,
• to review warnings associated with contact between warped surfaces.
By default, Abaqus/Explicit writes all nodal adjustments and contact offsets to the .msg file along
with a summary listing of the maximum initial overclosure and the maximum nodal adjustment to
the .sta file.
The information written to the message and status files are also written to the .odb file.
Abaqus solver creates node and element sets for the nodes and elements with initial contact is-
sues:
• InfoNodeOverclosureAdjust: node set with automatically adjusted nodes
• InfoNodeUnresolvInitOver: node set with non adjusted nodes but stored offset
• WarnElemGContThickReduce: element set with an automatic contact thickness reduction.
It is strongly recommended to check these data. It is a way to check the model, flag mesh-
ing error or bad offset definition and to assess potential contact defect and the relevance of
the solution given by the solver.
Moreover it is essential to post-process at least the contact load on the impactor-structure surface.
The variable CFNM gives the magnitude of the normal contact load which is the sum of all the con-
tact pressure applied on the surface.
Therefore, the impacted surface should be only used in the definition of the impactor-structure in-
teraction to insure that the given value is really the impact load.
Reminder of definition of surface and contact

*Surface, name=impacted_surface, type=element
Element_set_composing_the_impacted_surface,
*Surface, name=impactor, type=element
Element_set_composing_the_surface,
Element_set_composing_the_surface, INTERIOR (if eroding 3D elements)
*Contact
*Contact inclusions
,
impacted_surface, impactor
Post-processing of the impact load history

*Output, history
*Contact output, surface=impacted_surface
CFNM

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CONTACT METHODOLOGY USING ORIGIN EDSAZ

ABAQUS/EXPLICIT TO BE USED BY AIRBUS RSP REFERENCE RP1001689

Technical Report ISSUE 1.0 DATE 17 Dec 2009

Contact Methodology using Abaqus/Explicit to be used

A detailed description of the definition process is given.

NAME SIGLUM - FUNCTION DATE SIGNATURE

AUTHORING V.LAVIGNE EDSAZB - Engineer

AUTHORIZATION M.MAHE EDSAZB

AN EADS JOINT COMPANY AIRBUS FRANCE S.A.S SIÈGE SOCIAL:

Technical Report_FM0200016_v1.2 Page 1 of 19

ABAQUS/EXPLICIT TO BE USED BY AIRBUS RSP REFERENCE RP1001689

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2 General contact interaction modelling

2.1 Contact domain

Classical contact General contact approach

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Figure 2) Case of eroding element based surface

This is useful to define:

Abaqus corresponding card:

o Definition with interior facets:

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o Definition of surface to be added:

o Definition of individual surface pairings:

o Definition of surface to be excluded:

2.2 General contact penalty method

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Figure 3) Penalty approach

*Diagnostics, deep penetration factor= value

*Contact formulation, type=pure master-slave

2.3 Mechanical contact properties model

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When τ crit is reached, there is sliding of the two surfaces in contact.

Abaqus corresponding card: