ANSYS v14.

5
U d t
Update

March, 2013

CAE Associates Inc. and ANSYS Inc. Proprietary

2012 CAE Associates Inc. and ANSYS Inc. All rights reserved.
Agenda

9:00 Welcome 1:00 - Computing Utilities

Introductions HPC
GPU
What is new at CAEA
RSM
9:15 - Mechanical Demonstration HPC Parametric Pack)
CAD connection
ti utilities
tiliti (within
( ithi th
the CAD 1:30 - CFD Update
API) Design iteration/optimization using CFX
Mechanical setup Shape optimization using Fluent
Rigid Bodies, Joints, contact, meshing 1-way FSI
Using the Mechanical model as a template
template. 3:00 Break
Submodeling (parametric mesh refinement) 3:15 ANSYS Customization Toolkit
10:30 - Break What is ACT?
Examples (acoustics, wind load, DYNA drop test.
10:45 - Result evaluation: What do I do
with
i h this
hi stress?
? 4:00 Engineering Knowledge Manager
Fatigue calculation 4:15 ANSYS Composite Prep-Post
Automating the process 4:30 MAPDL
Direct Optimization
RSO(robust design, DFSS)
Fracture
12:00 Lunch

2
Mechanical Presentation

We are taking a different approach to presenting the update topics for this
release.
We will be minimizing the slide show part of the presentation in favor of
more live demonstration to illustrate ANSYS/Workbench tools
tools.
We will be pointing out many of the new features as well as existing
capabilities that users may not be fully utilizing.
We hope you find this format valuable and are eager to get your feedback
feedback.

3
Analysis Flow

Initial Design
Parametric Material Coefficients,
Mesh Controls, Loading and Output.

CAD Model Stress Analysis

Parametric Geometry
y
F t
Fracture
Parametric Crack
Parametric Cut
Length and K1
Boundary Submodel
Location

Parametric Load
Optimization/Robust Design Fatigue Analysis Mapping and Life
output.

Final Design

4
The Challenge

Determine if the grip design is robust given variability in the material

material,
loading, and geometric input data.

5
Begin at the CAD Level

We begin with a Solid Works Assembly of the vise grip

grip.
Geometric parameters are identified at the CAD level using a parameter
prefix.

6
Begin at the CAD Level

Named Selections defined at the CAD level can be used in both

DesignModeler and Mechanical.

7
CAD connection

Drag and Drop an Analysis System onto the Project

Project.
Specify parameter and Named Selection prefixes in the Geometry Details
menu.

8
CAD connection

Specify parameter and Named Selection prefixes in the Geometry Details

menu.

9
Materials

Double click on the Engineering Data row to add materials to the project
project.
In this case we will be using a carbon steel material model from the nCode
library.

10
Assigning Properties in Mechanical

Define the material and stiffness behavior (flexible versus rigid) for each
body.

11
Assigning Properties in Mechanical

Confirm the material definitions and the stiffness behavior by using

Display Style in the Geometry Details menu.

12
Assigning Properties in Mechanical

Note that the geometry parameters are found in the details of the clamp2
clamp2
part.
To use these parameters in the project, add them to the Parameter Set by
clicking in the box to the left of the parameter
parameter.

13
Joint and Contact Connections

We will use a combination of Contact Regions and Joint Connections for

this model.
First turn off automatic contact generation on update.
Open the Contact Folder and delete the automatic contact regions.
regions
Define an asymmetric frictional contact region between the jaws of the vise
grip using Named Selections from the CAD model.

14
Joint and Contact Connections

Insert a new Connection Group folder

folder.
Set the type to Joint
Define Body-Ground fixed and revolute joints on the main grip and the link
using Named Selections from the CAD model
model.

15
Joint and Contact Connections

RMB click on the Joints folder and create automatic connections

connections.
Delete the Fixed Joint between the upper and lower jaw (the contact region will
handle this).
Change the Fixed connections at the pins to Revolute (assign geometry and
reference coordinate system for each).

16
Joint and Contact Connections

Use the Connection Matrix (new at v14

v14.5)
5) to check a summary of the joints
and contacts defined.
Connections > Worksheet > Preferences >Connection Matrix > Refresh

17
Mesh Settings

Basic mesh settings will be used on the assembly model

model.
Define a global sizing of .06.
Add a local mesh size to the lower jaw of .03

18
Mesh Settings

Add a Multizone Method the lower jaw

jaw.
Add a Hex Dominant Method to the lower grip.

19
Mesh Settings

Assign a Mapped Face Meshing using a Named Selection from the CAD
model.

20
Mesh Settings

Set the number of divisions on the lower grip using a Named Selection
from the CAD system.

21
Mesh Settings

Generate the mesh

mesh.
Use the new Manual Mesh Setting to activate the Show Mesh button.

22
Loads and Supports

Add a frictionless support and a pressure load using Named Selections

from CAD model.

23
Static solution

Generate a static solution

solution.
Note rigid body motion due to the open (missed) contact at the jaws.

24
Setting Joint and Contact connections

Use the Contact Tool to determine the initial condition status

status.
Note that there is an initial gap between the upper and lower jaw.

25
Setting Joint and Contact connections

Set the Interface Treatment to Adjust

Adjust to Touch
Touch and solve.
solve
Note resulting contact pressure.

26
Setting Joint and Contact connections

Set the Interface Treatment to back to the default (Add Offset

Offset, Ramped
Effects).
Add Stabilization Damping Factor of 0.5 and solve.
Compare the contact press
pressure
re bet
between
een the ttwo
o sol
solutions.
tions

Adjust to touch

Stabilization
Damping

27
Evaluating Results

Evaluate reaction forces (via the joint probes)

probes), deflections and stress in the
lower jaw.
Note the stress concentration at the re-entrant corner.

28
Using the Analysis System as a Template

With a consistent set of Named Selections we can now substitute a

different geometry file into the Analysis System and take advantage of the
automatic mapping of all the Mechanical settings onto the new geometry.

29
Evaluating Stress Results

Back with original model

model, we need to resolve the singular stress solution in
the lower jaw before we can determine if the design is robust.
Our choices are:
Add a fillet to the lower jaw in the assembly model and resolve the entire
model.
Extract a submodel of the region in question, add the fillet to the submodel and
generate a local stress solution.

30
Submodeling in Workbench

Cut boundary displacement interpolation is a new feature in Workbench

v14.5.
DesignModeler can be used to extract the submodel from a duplicate of
the global geometry
geometry. Simply create a copy of the analysis system and
modify the submodel geometry locally in DesignModeler.
In this fashion both the assembly (global) model and the submodel can
reside in the same project
project.

31
Submodeling

RMB click on the Geometry row (B3) and select Duplicate.

Duplicate
Drag and drop the Solution row from the global model onto the Setup row
of the submodel to import the global displacements.
Update the Sol
Solution
tion ro
row (B6) and Refresh the Set
Setup
p ro
row (C4)
(C4).
Open the submodel in Mechanical

32
Submodeling

Assign the 1045 steel material model to the submodel.

submodel
Delete unused connections, mesh controls and loads.
Assign the same global mesh size used in the global model (0.03).
Generate the initial submodel mesh.

33
Submodeling

RMB on the Imported Load folder an insert an imported displacement for

each cut face.
RMB click to import the loads.
Note that this can be done for any result step of the global solution
solution.

34
Submodeling

Generate the initial solution

solution.

35
Results Scoping via Direct Node Selection

With Manual Mesh control turned on you can select nodes and scope
result quantities directly.

36
Results Scoping via Direct Node Selection

Use the Annotation Preferences to turn on node numbers

numbers.

37
Cut Boundary Verification

Forces:
Create a surface in the global model at the cut boundary using Construction
Geometry.
Scope a force reaction probe to the surface and compare with the submodel.
submodel

38
Cut Boundary Verification

Stress:
Use the surface in the global model to compare stress as well.

39
Submodel Mesh

Add mesh refinement controls to the submodel in the form of:

Global sizing : 0.02
Local sizing : 0.005 at the high stress region in the fillet (make a parameter).
Global settings for smoothing and transition rate
rate.

Low Transition High Transition

Fast Smoothing Slow Smoothing

40
Submodel Mesh Refinement

Use a parametric mesh study to refine the mesh to a converged stress

solution.

41
So now what?

We have a solution for stress but what do we do with it?

How can we be certain the part is not going to fail?

42
Types of failure

Dynamic/cyclic loading:
Impact failure.
Fatigue.
Static loading: Independent of the time loads are sustained:
Static failure exceed ultimate stress.
Excessive elastic deformation.
Di t ti or plastic
Distortion l ti strain.
t i
Buckling.
Brittle or ductile fracture.
D
Dependent
d t on ththe titime lloads
d are sustained:
t i d
Creep failure.

43
Fatigue and Fracture

Fatigue is typically based on crack formation

formation.
No cracks are included in the analysis model.
Life is based on comparing un-cracked stress/strain state with S-N test data.

Fracture mechanics is based on crack growth.

Cracks are included in the analysis model.
C d
Can determine
t i if crack
k will
ill propagate
t tto ffailure
il under
d currentt static
t ti lload.
d
Can combine with fatigue to determine remaining life under cyclic load.

Crack Growth
Crack Formation

44
nCode Fatigue Analysis

nCode provides the ability to perform fatigue analysis based on ANSYS

results:
Within the Workbench environment (drop nCode onto your solution):

Or standalone (open the ANSYS RST file within nCode):

As well as results files from DYNA, NASTRAN, and ABAQUS.

45
Advantages of nCode

nCode provides easy-to-use

easy to use, comprehensive fatigue analysis:
Has a extensive material database.
Performs life prediction based on specimen life data.
Uses multi-axial
multi axial stress states.
Extracts cyclic content from complex loading.

46
Advanced nCode Features at v14.5

nCode has many more advanced features

features, some of which were added in
the recent new release.
Temperature-dependent fatigue.
Custom S-N methods
methods.

47
Fatigue Analysis using nCode

Drag and drop one of the nCode Analysis Systems and onto the Solution
row of the Submodel.
Update the Submodel Solution row and Refresh the nCode Solution row.
Open nCode.
nCode

Refresh
Update

48
Fatigue Analysis using nCode

Set the Simulation_Input

Simulation Input display to stress.
stress
Edit the following in StrainLife_Analysis:
Load Mapping Max = 1, Min = 0 (non reversible loading).
C fi th
Confirm thatt material
t i l mapping
i iis using
i ththe 1045 St
Steell model.
d l
Run
Change from Damage to life in the Fatigue_Results_Display

49
Fatigue Analysis using nCode

Drag and drop the Design Explorer glyph from the DesignLife tool box
box.
Connect it to the output of the StrainLife_Analysis glyph.

50
Fatigue Analysis using nCode

Exit nCode
Update the nCode Solution row on the Project Page.
Note that output from nCode is being fed to the Parameter Set.

51
Fatigue Analysis using nCode

Note that the output parameter Life

Life has been added to the Parameter
Set.

52
nCode Fatigue Analysis

Fatigue material properties:

nCode has a built-in material library, accessed within the Engineering Data in
Workbench or directly within nCode (currently 186 different sets).
If data is available,
available can import and create your own fatigue material
material.
From within Engineering Data or directly in nCode.

nCode provides many different types of fatigue material property

definitions:
High cycle (Stress Life) and low cycle (Strain Life).
Standard S-N curve linear segments on log-log plotplot.
S-N mean multi-curve digitized curves at different mean stress values.
S-N R-ratio multi-curve digitized curves at different load ratios.
S N temperature
S-N temperature-dependent
dependent multi
multi-curve
curve digitized curves at different
temperatures.
Custom S-N data via python programming.
Other: Haigh,
Haigh Bastenaire.
Bastenaire

53
nCode Fatigue Analysis

There are many other material factors that

have an effect on the life.

All of these factors are a

available
ailable in nCode:
nCode
Scale factors.
Offsets.
K f t for
K-factor f surface
f treatment.
t t t
K-factor for surface roughness.
User-defined K-factor.
St d d error and
Standard d certainty
t i t off survival.
i l
Standard error describes the spread of data.
Certainty of survival describes where within
the spread the S-N
S N data should be used in
the analysis.
Default in nCode is 50% certainty of survival
probably not what you want.

54
nCode Fatigue Analysis

nCode provides several ways to define the cyclic loading from your FE
results:
Can use one or more results and assume all are constant amplitude.
Provide min and max scale factors for each loading
loading.
Can use two or more results to define the cycle.
For example, can use 100 DYNA result sets to define the cycle.
Can combine the FE results with test data to define the cycle.
Can superpose different types of loading (e.g. stress and temperature).
Can combine all types above in a duty cycle.

55
Standard nCode Fatigue Analysis

nCode provides many options and defaults to provide a comprehensive

fatigue analysis:
Stress combination and multiaxial assessment.
Rainflow count to extract cyclic information from complex loading.
loading
Damage accumulation due to different cyclic loadings.
Mean stress correction.
Stress gradient correction at stress concentrations
concentrations.
Elastic-plastic correction (Neuber approach shown below).

56
Calculate life

Plug nCode into the project and calculate life from the submodel stress
solution.
Highlight scoping the fatigue life calculation to a selected region.

57
Using DesignXploration

The parametric nature of the Workbench environment is ideal for

automating the study of a designs sensitivity to changes in the input
variables.
Begin by dragging one of the Design Exploration tools for Direct
Optimization, Response Surface Optimization, or Six Sigma Analysis.

58
Consistent Mesh Sizing

Before generating the design point solution for any optimization run you
may want define a consistent mesh size for each design point.
Edit the Parameter Set and make the mesh sizing a function of the fillet
radius.
radius
Below the mesh sizing is the fillet is set to the radius/8.

59
DesignXplorer Direct optimization

New at v14
v14.5.
5
Set objectives and constraints and iterate towards an optimum design.

60
Response Surface and Six Sigma Analysis

Drag and drop a Six Sigma Analysis onto the project pagepage.
Double click on the Design of Experiments row.
Specify the statistical distribution type and the ranges for each input
variable
ariable (E
(Ex: normal distribution
distrib tion for the load magnit
magnitude
de

61
Six Sigma Analysis Settings

Preview the design points and update solution

solution.

62
Six Sigma Analysis Settings

Return to the project and edit the Response Surface row to view the
mapped response and local parameter sensitivity.

63
Six Sigma Analysis Settings

Return to the project and edit the Six Sigma Analysis row to view the life
probability distribution.

64
Six Sigma Analysis Settings

Return to the project and edit the Six Sigma Analysis row to view the life
probability distribution.
Switch to Percentile-Quantile in the probability table and enter in a value
of .9999966
9999966 (3.4
(3 4 in 1 million) to determine the six sigma life number
number.
This will return a 4.5 sigma level accounting for the 1.5 sigma shift over
time in the manufacturing process.
In this case 33.4
4 in 1 million parts will have a life of 4489 cycles or less
less.

65
 Fracture
M h i
Mechanics
in Workbench
v14.5

CAE Associates Inc. and ANSYS Inc. Proprietary

2012 CAE Associates Inc. and ANSYS Inc. All rights reserved.
Fracture Mechanics

Fracture mechanics is an important tool of engineering analysis that:

Makes it possible to determine whether a crack of given length in a material of
known fracture toughness will propagate to fracture at a given stress level.

The stress at the tip of a crack is infinite based on theory of elasticity.

In fracture mechanics, the stress intensity factor, K, is calculated to determine
the behavior at the crack tip
tip.

Fracture toughness, KIC, is a measured material property.

If KI > KIC: The crack will propagate
propagate.

67
Fracture Mechanics Analysis

Performing a fracture analysis requires:

Including a crack in the finite element mesh.
Calculating K along crack front.
Comparing result to material fracture toughness
toughness.

68
Fracture Mechanics Analysis

Creating a finite element mesh with a crack can be a challenging and time-
consuming effort.
In addition, it is often of interest to model various crack sizes to determine the
critical crack size and location.

Workbench v14.5 provides two options for quickly and efficiently including
a crack in the finite element model:
Pre-meshed crack that can be imported.
Automatic crack creation within Mechanical.

Crack definition input can be assigned as parameters in Workbench.

Can parametrically model the effect of different size and locations of cracks.

69
Fracture Mechanics Analysis

Workbench v14
v14.5
5 has 3 methods available to calculate K via post-
processing:
Stress Intensity Factor (SIF) extraction.
J-Integral (J).
(J)
Energy release rate (G) using Virtual Crack Closure Technique (VCCT).

70
Fracture Mechanics Analysis

Workbench uses the CINT (contour integration) approach to perform the

fracture post-processing calculations.
Contours are numbered outward from the crack front.
No limit on the number of contours user-controlled.
user-controlled
Radial/ring mesh is not required but usually results in more accurate solution.
For 3D models, hexahedral elements are desirable.

ANSYS performs this crack meshing automatically.

71
3D Automated Crack Procedure

The procedure to include a crack in an

existing model in Workbench v14.5 includes
the following steps:
Create base mesh (no cracks) must use
quadratic tetrahedrons in the region where the
crack will be modeled.
Create a crack coordinate system using the hit
point method to automatically create a local
coordinate system normal to the surface.
Insert the Fracture branch into the Outline Tree,
and insert a Crack Object
Object.
Define the crack geometry and mesh via the
Details of the Crack Object.

72
3D Automated Crack Procedure

Automatically define the location of the crack using the hit point coordinate
approach.
Toggle on the Hit Point Coordinate button in the Graphics Toolbar.

Select a point on a surface.

Right-click
Right click the Graphics window and select Create Coordinate System Aligned
with Hit Point.

73
3D Automated Crack Procedure

The Crack Shape is currently set to Semi-Elliptical

Semi-Elliptical.
Indicate the body where the crack will be scoped.
Indicate the local crack coordinate system.
Define the crack size and shape by major and minor
radii.

Crack lies in X-Z plane.

plane
Z is major direction, X is minor direction.
Y is perpendicular to crack face.

MajorRadius

MinorRadius

74
3D Automated Crack Procedure

Define mesh settings for crack.

crack

Can also automatically create named selections of

crack nodes
nodes.
For example, can create top and bottom crack face
nodes which can be used to apply pressure on the
crack faces.
faces

75
3D Automated Crack Procedure

Mesh crack which will eventually connect to base mesh

mesh.
Bonded contact used between buffer zone and base mesh.

R static
Run t ti structural
t t l analysis.
l i

76
3D Automated Crack Procedure

Insert Fracture Tool under Solution

Solution, and Insert either J-Integral or SIFS
Results.
VCCT is not available with the automated Crack Object since it requires linear
elements in Workbench v14.5.

77
3D Automated Crack Procedure

Graphics display and plot with contain crack front variation

variation.
Can export results to text or XLS file.

78
Using Parameters With Crack Object

Crack input and fracture output can be defined as parameters

parameters.

79
Using Parameters With Crack Object

Crack input and fracture output can be defined as parameters

parameters.

80
 Other New
F t
Features in
i
Mechanical

CAE Associates Inc. and ANSYS Inc. Proprietary

2012 CAE Associates Inc. and ANSYS Inc. All rights reserved.
Additional v14.5 features in WB

Tagging and filtering of the outline

outline.
2D bolt pretension
Annotation/View Preferences
Pre-stress mode superposition transient.

82
 MAPDL Updates

CAE Associates Inc. and ANSYS Inc. Proprietary

2012 CAE Associates Inc. and ANSYS Inc. All rights reserved.
Results File Modifications

Element results that are written to the result file using single precision to reduce
the results file size which include the following:
Stresses
Strains
Nodal forces
Miscellaneous data (SMISC and NMISC), etc.
Nodal solution results such as displacements and reaction solutions (PRRSOL)
remain
i as d double
bl precision.
i i
Result file sizes are reduced in size by up to 50 percent.
Single precision 8 significant digits with exponent range of +/-E37 when compared
to double precision 15 significant digits with exponent range of +/
+/-E308.
E308

84
Results File Modifications

The modal results file (jobname

(jobname.MODE)
MODE) is also smaller when the element
results are written during the modal expansion pass:

MXPAND nmode,
MXPAND, nmode freqb,
freqb freqe,
freqe Ecalc,
Ecalc signif,
signif MSUPkey
MSUPke

Elcalc = YES
Calculate element results
results, reaction forces
forces, energies
energies, and the nodal degree of freedom solution
solution.

MSUPkey = YES
Write element result to the mode file for use in the expansion pass of a subsequent mode-superposition
PSD transient
PSD, transient, or harmonic analysis (default if Elcalc = YES)
YES).

85
New Features/Elements

Diffusion elements
New pure diffusion elements PLANE228, SOLID239 and SOLID240.
PLANE223, SOLID226, and SOLID227 coupled field elements support new surface
load of diffusion flux (DFLUX) and new body load of diffusion substance generation
(DGEN)
2.6 THOPT uses radiosity solver.
2.7.3 PCG solver supports Lagrange Multiplier Method for all MPC184
elements.
To activate this functionality, set LM_Key = ON on the PCGOPT command.
2.8.2. Support for Superelements
The use of superelements (MATRIX50) during a linear perturbation static or
modal analysis is now supported.

86
Modified Element Types

Modified Element Types

Shell181 - new formulation option for incorporating initial curvature effects
COMBIN14 - stiffness and damping coefficients can be function of frequency.
Useful for modeling frequency dependent material
LINK180 (not shown in Release Notes) real constant input replaced as follows
AREA now input using SECTYPE and SECDATA commands
ADDMASS now input
p via SECCONTROL command
TENSKEY now set via KEYOPT(3) to control tension/compression behavior

See the Release notes for full details.

87
Element Manual:

Documentation change Each elements

element s special features section in the
Elements Reference no longer includes any material behaviors. Under
the material properties section there is a reference to the TB command
section on Element
Element Support for Material Models
Models

88