Contact Mechanic

Training Manual
Basic Structural Nonlinearities 5.6 Basic Structural Nonlinearities 5.6 Basic Structural Nonlinearities 5.6 Basic Structural Nonlinearities 5.6
7. Introduction to Contact
7. Introduction to contact
What is contact? When two separate surfaces touch each other such that they become mutually tangent, they are said to be in contact. In the common physical sense, surfaces that are in contact have these characteristics:
They do not interpenetrate. They can transmit compressive normal forces and tangential friction forces. They often do not transmit tensile normal forces. They are therefore free to separate and move away from each other.
Training Manual
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Introduction to contact
Training Manual
In this chapter, we will present an introduction to nonlinear contact analysis via the following topics:
A. Basic concepts B. Using the contact wizard C. Obtaining the solution D. Postprocessing E. Workshop F. Assembly contact
The purpose is to introduce you to contact analysis procedures for simple (easily converged) models. Other, more advanced aspects of contact analysis that are used to handle more difficult models are discussed in the Advanced Contact and Bolt Pretension training manual.
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A. Basic Concepts
Contact is a changing-status nonlinearity. That is, the stiffness of the system depends on the contact status:
Training Manual
Status = Open
Status = Closed and Sticking
Status = Closed and Sliding
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... Basic Concepts
Training Manual
Contact is a strong nonlinearity, because both the normal and tangential stiffness at contact surfaces change significantly with changing contact status.
Large, sudden changes in stiffness often cause severe convergence difficulties.
Open contact
Closed contact
u
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... Basic Concepts

Other factors that make contact analysis complicated include:
Training Manual
The region of contact is typically unknown at the start of the analysis. Most contact problems include friction. Friction is a path-dependent (energy-dissipating) phenomenon that requires an accurate load history, with small time steps. Frictional response can be chaotic, making solution convergence difficult. Parts might be unconstrained except for contact with other parts. Prior to establishment of contact, such parts are initially unconstrained free bodies, with zero overall stiffness. In a static analysis, unconstrained free bodies are mathematically unstable. The solution blows up.
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... Basic Concepts
Training Manual
Fortunately, current ANSYS contact technology enables you to analyze a broad class of contact models fairly easily.
Many models can be solved successfully with very little user intervention.
For those models that exhibit more difficult convergence behavior, a rich library of contact element options are available to help you overcome such difficulties.
These more advanced features are discussed in the Advanced Contact and Bolt Pretension training manual.
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... Basic Concepts

Contact classification Contact problems fall into two general classes: rigid-to-flexible and flexible-to-flexible. Rigid-to-flexible
One or more contacting surfaces are treated as rigid. (One surface has a significantly higher stiffness than the other.) Many metal forming problems fall into this category. Stresses within the rigid body are not calculated.
Training Manual
Flexible-to-flexible
Both or all contacting bodies are deformable. (All surfaces have similar stiffnesses.) A bolted flange connection would be an example of flexible-to-flexible contact.
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... Basic Concepts
Training Manual
Rigid-to-flexible contact
Rigid Surface
Deformable Body
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... Basic Concepts

Flexible-to-flexible contact
Training Manual
Splined shaft interference fit, both parts are flexible.
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... Basic Concepts

Contact compatibility
Training Manual
Physical contacting bodies do not interpenetrate. Therefore, the program must establish a relationship between the two surfaces to prevent them from passing through each other in the finite-element analysis.
When the program prevents interpenetration, we say that it enforces contact compatibility.
Penetration occurs when contact compatibility is not enforced.

Target
Contact
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Contact compatibility penalty method
Training Manual
The penalty method of enforcing contact compatibility uses a contact spring to establish a relationship between the two surfaces.
The spring stiffness is called the penalty parameter or, more commonly, the contact stiffness. The spring is inactive when the surfaces are apart (open status), and becomes active when the surfaces begin to interpenetrate (closed). The spring will deflect an F amount , such that equilibrium is satisfied: F=k where k is the contact stiffness.
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... Basic Concepts

contact compatibility penalty method
Training Manual
Some finite amount of penetration, , is required mathematically to generate a contact force at the interface.
This contact force is needed for equilibrium. Thus, must be greater than zero for equilibrium.
However, physical contacting bodies do not interpenetrate. Therefore, for best accuracy, the goal is to minimize the amount of penetration that occurs at the contact interface.
Minimum penetration gives maximum accuracy. This implies that, ideally, the contact stiffness should have a very great value. However, too high of a value can lead to convergence difficulties.
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... Basic Concepts
Training Manual
If the contact stiffness is too great, a slight penetration will generate an excessive contact force, potentially throwing the contacting surfaces apart in the next iteration. F
Fcontact
Iteration n
Iteration n+1
Iteration n+2
Using too great a contact stiffness usually leads to oscillating convergence, and often to outright divergence.
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... Basic Concepts

Contact compatibility Lagrange multiplier method
Training Manual
An alternative method, the Lagrange Multiplier method, adds an extra degree of freedom (contact pressure), to satisfy the impenetrability condition.
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Contact compatibility augmented Lagrangian method
Training Manual
The most modern ANSYS contact elements can combine both the penalty method and the Lagrange multiplier to enforce contact compatibility. This is called the augmented Lagrangian method. In the first series of iterations, contact compatibility is determined based on the penalty stiffness. Once equilibrium is achieved, the penetration tolerance is checked. At this point, if necessary, the contact pressure is augmented and the iterations continue.
Penetration Tolerance
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... Basic Concepts

contact compatibility augmented Lagrangian method
Training Manual
Penetration correction due to equilibrium.
Augmenting contact stresses to reduce penetration. Oscillation occurs during correction stage.
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... Basic Concepts

Surface-to-surface elements
Training Manual
The most modern contact elements available in ANSYS are the surface-to-surface elements.
Targe169 and 170 Rigid or deformable target surfaces Conta171 to 174 Deformable contact surfaces
These elements are well suited for surface-to-surface contact applications such as interference fit assembly contact, entry contact, forging, and deep drawing.
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... Basic Concepts

surface-to-surface elements
Training Manual
These contact elements use the concept of a contact pair, which is composed of a target surface and a contact surface.
The surface-to-surface contact elements overlie the underlying finite element model like a skin. Separate element types define the target and contact surfaces. The contact pair is identified through a shared real constant set.
Contact elements (REAL = N ) on the contact surface Target elements (REAL = N ) on the target surface
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Training Manual
ANSYS supports both rigid-to-flexible and flexible-to-flexible surface-to-surface contact models.
Rigid target element Underlying mesh Contact elements
Flexible-to-flexible models have a deformable target surface, which is created whenever target elements overlie deformable elements. Rigid-to-flexible models have a rigid target surface, which does not overlie any deformable elements.
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Training Manual
The surface-to-surface contact elements use the augmented Lagrangian to enforce contact compatibility (default).
Augmented Lagrangian uses both a contact stiffness and a penetration tolerance.
For simple contact models, you will normally need to specify just three characteristics of the contact pair:
A value for the contact stiffness A value for the penetration tolerance. You will also need to determine which surface in the pair should be the target, and which should be the contact.
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... Basic Concepts

Contact stiffness The contact stiffness is the most important parameter affecting both accuracy and convergence behavior.
Training Manual
Recall that greater stiffness gives better accuracy, but more difficult convergence.
You must carefully determine an appropriate value for contact stiffness.

The best value is often problem-dependent. Program-supplied default value will often not be appropriate. Some experimentation may be required to determine an appropriate value that generates a converged solution with an acceptable level of accuracy.
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... Basic Concepts

contact stiffness
Training Manual
For the surface-to-surface elements, you specify the contact stiffness as a factor (FKN). That is, the program determines the contact stiffness by multiplying the stiffness of the underlying element times a factor that you specify.
kcontact = FKN x f(kunderlying)
For the surface-to-surface elements, the contact stiffness has units of stiffness per unit area, or (F/L)/(L2). A good value for contact stiffness is often obtained by making the contact stiffness equal to the stiffness of the underlying elements.
As a starting estimate, try: FKN = 1.0 for bulky solids in contact. FKN = 0.1 for more flexible (bending-dominated) parts.
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... Basic Concepts

contact stiffness
Training Manual
Sometimes, different regions of a model may need to have different contact stiffnesses.
Bulky contact; try FKN = 1.0
Flexible contact; try FKN = 0.1
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... Basic Concepts

contact stiffness
Training Manual
Determining a good stiffness value may require some experimentation. The following procedure may be used as a guideline:
Use a low value of FKN to start. Run the analysis to a fraction of the final load. Check the penetration and number of equilibrium iterations used in each substep. If convergence is being driven by the penetration tolerance, FKN may be underestimated (or the penetration tolerance may simply be too tight). If no force convergence, or if many iterations are required to obtain force convergence, FKN may be overestimated. Adjust FKN and run the full analysis.
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... Basic Concepts

contact stiffness
Training Manual
Because results can be sensitive to the value used for FKN, you should always verify the validity of your results.
If you have any doubts about the validity, perform a sensitivity study. Vary the contact stiffness and re-run. Monitor some item of significance to your analysis, such as: Contact pressure. Maximum stress. Look for a value of FKN beyond which results stabilize to a fairly consistent value.
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... Basic Concepts

contact stiffness
Training Manual
As an example, FKN was varied for an interference-fit analysis of a collar on a shaft. Maximum equivalent von Mises stress was monitored.
FKN 0.001 0.01 0.1 1 10 100 Max. SEQV 4,000 20,000 65,000 91,000 92,900 93,000
In this particular case, a value of FKN = 1.0 proved to give adequate accuracy.
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A. Contact stiffness Workshop
Training Manual
Please refer to your Workshop Supplement for instructions on: W14. Introduction to Contact - Contact Stiffness Study (FKN)
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... Basic Concepts

Penetration tolerance The penetration tolerance also affects convergence and accuracy, although to a lesser extent than the contact stiffness.
Training Manual
As the penetration tolerance is tightened, the accuracy may improve, but at the expense of more difficult convergence.
As with the stiffness, you specify the penetration tolerance by means of a factor (FTOLN).
The program determines the penetration tolerance by multiplying the depth of the underlying element (h) times a factor that you specify. Tolerance = FTOLN x h
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... Basic Concepts

penetration tolerance Dont use a soft FKN and a tight FTOLN.
Training Manual
Best convergence behavior is usually obtained if the contact stiffness does most of the work of enforcing compatibility. Use a reasonably stiff value for FKN. Fine-tune the penetration with a reasonable value of FTOLN.
Too small a value for FTOLN will lead to convergence difficulty. Never use too small of a tolerance! Increasing the penalty stiffness (FKN) will reduce the penetration. Although increasing FKN by 100 times will usually reduce the penetration accordingly, other items of significance, such as the contact pressure, might change by as little 5%.
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A. Penetration tolerance Workshop
Training Manual
Please refer to your Workshop Supplement for instructions on: W15. Introduction to Contact - Penetration Tolerance Study (FTOLN)
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... Basic Concepts

Designating contact and target surfaces
Training Manual
The program defines the contact surface by a set of discrete contact points (the element Gauss points). The program defines the target surface as a continuous surface. The two surfaces can interpenetrate between the Gauss points, without contact being recognized. This causes inaccuracies. Contact Surface The target can penetrate the contact surface in between the Gauss points. Target Surface
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designating contact and target surfaces
Training Manual
You can reduce the amount of unrecognized interpenetration by careful designation of the target and contact surfaces. However, for rigid-to-flexible contact, the choice of target and contact is unchangeable. The rigid surface must always be the target.
Steel shaft (rigid) must be the target surface
Rubber boot (flexible) must be the contact surface
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... Basic Concepts

Training Manual
For flexible-to-flexible contact, best accuracy is achieved by maximizing the number of contact points. Follow these guidelines when designating flexible-to-flexible contact and target surfaces:
If one surface has a coarse mesh and the other a fine mesh, the surface with the coarse mesh should be the target surface. Consider what would happen if the designations were reversed: If the finer mesh were the target, it would droop across the Gauss points, and penetrate as shown.
x x x x
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Training Manual
Other guidelines for designating contact and target surfaces:

If a convex surface comes into contact with a flat or concave surface, the flat or concave surface should be the target surface. If one surface is stiffer than the other, the stiffer surface should be the target surface. If one surface is higher order and the other is lower order, the lower order surface should be the target surface. If one surface is larger than the other, the larger surface should be the target surface.
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Training Manual
When all contact elements are on one surface and all target elements are on another surface, the model is said to have asymmetric contact.
Asymmetric contact is generally the most efficient way to model surface-to-surface contact. However, under some circumstances asymmetric contact will not perform satisfactorily. No clear distinction exists between target and contact surfaces. Both target and contact surface have coarse meshes.
Sometimes the target-contact distinction is not clear
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... Basic Concepts

Training Manual
An alternative approach is to create a double set of contact pairs. This is known as symmetric contact. After creating one contact pair, simply create a second contact pair having a reversed target-contact designation, for the same surfaces.
Contact Target
Target
Contact
Step 1 - Create 1st Contact Pair
Step 2 - Create 2nd (Symmetric) Contact Pair
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... Basic Concepts

Training Manual
Although some models may require symmetric contact for accuracy, be aware that it is less efficient than asymmetric contact.
Therefore, dont use symmetric contact unless it is required.
Note also, that when using symmetric contact, postprocessing is more difficult.
The contact pressure is the average value from both sets of contact elements. This average value is not automatically available as a standard results item. You will need to calculate it using APDL or ETABLE.
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A. Contact & target Workshop
Training Manual
Please refer to your Workshop Supplement for instructions on: W16. Introduction to Contact - Contact & Target Designation
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... Basic Concepts

Rigid target surfaces pilot node
Training Manual
By default, the program will automatically constrain a rigid target surface. That is, it will automatically ground the target with zero-value displacements and rotations. To model more complicated behavior of the rigid target, you can create a special one-node target element, called a pilot node.
This element is associated with the target surface by means of having the same REAL attribute.
The pilot node acts as a handle for the entire rigid surface.
You can specify nonzero displacements, rotations, forces, and/or moments at the pilot node to model rigid-body motion of the target surface. Note that if a pilot node exists, the program will not autoconstrain the rigid surface.
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... Basic Concepts

pilot node The pilot node can be specified at any location. This allows for general rotations of the rigid target surface. Only the pilot node can connect to other elements. For example, to account for the mass of a rigid body, define a mass element (MASS21) at the pilot node. Each target surface can have only one pilot node.
Training Manual
Rigid surface rotated
Pilot node (at center of rotation)
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B. Using the contact wizard
Training Manual
Surface-to-surface contact elements can be created using standard element-generation procedures: establish element TYPE, REAL, and MAT data, set element attributes, designate target and contact surfaces, and then either mesh or use ESURF operations. This procedure forces you to carry a fairly heavy mental overhead as you create your contact pairs. Fortunately, there is a better way ...
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... Using the contact wizard
Training Manual
The contact wizard provides a simple way to construct a contact pair for most contact problems. The contact wizard will guide you through the process of creating a contact pair.
Preprocessor > Create > Contact Pair > Contact Wizard
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Benefits of the Contact Wizard:
Training Manual
Automatically defines element types and real constant sets Quickly accesses the contact options and parameters Contact pair viewing tools Quickly displays and reverses contact normals
The Contact Wizard is not available until you have meshed some portion of your model.
Before launching the wizard to create a flexible-to-flexible model, mesh all parts of the model that will be used as contact surfaces. To create a rigid-to-flexible model, mesh only the parts of the model that will be used as flexible contact surfaces.
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Training Manual
Lets see how we could add a contact pair to the connector model from the Chapter 6 workshops.
First, designate rigid or flexible target type (if a choice is applicable), and pick the target surface. You can pick nodes, node components, lines, or areas, depending on what entities are present in the model.
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Training Manual
Next, pick the contact surface. Again, you can pick nodes, node components, lines, or areas, depending on what entities are present in the model.
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Training Manual
If you need to include friction effects, specify the coefficient of friction. (More on friction on the next slide.)
Click on Optional settings to specify the contact stiffness and penetration tolerance. (Other options will be discussed in the Advanced Contact and Bolt Pretension training course.)
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A note about friction
Training Manual
The surface-to-surface elements provide a basic Coulomb friction model that defines the equivalent friction stress at which sliding occurs: =xp
is the coefficient of friction, defined as a material property, as shown in the contact wizard on the previous slide. If equals zero (default), no shear stress will be transmitted. p is the contact pressure.
When the shear stress between the two surfaces exceeds x p, the two surfaces will slide relative to each other. More advanced friction options are also available. They are discussed in the Advanced Contact and Bolt Pretension training manual.
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Training Manual
Last, click on Create to create the contact and target elements that comprise this contact pair.
The REAL constant set used for this pair is identified.
The elements in the pair are automatically plotted, with their ESYS symbols ON to indicate outward normal directions. If any normals are pointing in the wrong direction, you can flip them now.
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Training Manual
At any time after a contact pair is created, you can also use the wizard to view and list the elements.
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You can also use the wizard to delete a contact pair.
Training Manual
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Pilot node
Training Manual
The contact wizard does not enable you to create a pilot node for a rigid target surface. To create a pilot node, you will have to use meshing or direct generation:
First, set the element attributes (MAT, REAL, TYPE) for the target elements. Remember to use the same REAL set as for the rest of the contact pair. Then mesh a keypoint that is located at the desired position for the pilot node. Recall that the pilot node can be at any location it is not required to be physically attached to the other target elements. Alternatively, for direct generation, set an additional attribute for the target-element shape (TSHAP,PILO) and then create the element at the desired node.
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C. Obtaining the solution
Training Manual
Automatic solution control, along with the default option settings for surface-to-surface elements, generally leads to fairly robust solutions for a broad class of contact analyses. If convergence difficulties are encountered, they generally arise due to one or more of three causes:
Too great a value for contact stiffness. Too tight a value for penetration tolerance. Too large a value for minimum time step size.
To improve convergence, try these modifications to your model, in the following order of implementation:
Use a smaller FKN. Use a larger FTOLN. Use a smaller minimum time step size (or larger maximum number of substeps).
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... Obtaining the solution
Training Manual
If your model still wont converge with modified FKN, FTOLN, and time step size, then the advanced contact options will probably be needed.
These are discussed in the Advanced Contact and Bolt Pretension training manual.
If your model includes friction, small time step sizes are required for accuracy, because friction is a path-dependent phenomenon.
Unlike plasticity, there is no cutback control that will trigger bisection if a friction time step is too large.
Note that in a contact solution, all equilibrium iterations are carried out before bisection for the first substep, to help establish initial contact conditions.
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D. Postprocessing
Training Manual
Results from contact models will contain many additional items related to contact. Some of the more commonly used items include:
STAT PENE GAP PRES SFRI Contact Status Penetration Gap Contact Pressure Friction Stress
These items are associated with the contact element (not the target element), and can be readily accessed in the GUI.
Using the General Postprocessor, you can display them in Nodal (averaged) or Element (unaveraged) contour plots. Animated plots are especially helpful for contact analyses. Using the Time-History Postprocessor, you can plot them as time-history variables.
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... Postprocessing
Training Manual
The contact status is an integer number that designates the current status of the contact element:
STAT = 0: Open and not near contact. STAT = 1: Open, but near contact. STAT = 2: Closed and sliding. STAT = 3: Closed and sticking.
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... Postprocessing
Training Manual
Note that a Nodal (averaged) contour plot of status will exhibit noninteger contour values, due to the averaging. Element (unaveraged) contour plots are usually more appropriate for contour plots of element status. Similarly, anomalous Nodal contour plots can occur for other contact results items. If a Nodal (averaged) contour plot doesnt seem to make sense, try an Element (unaveraged) plot instead.
Contact Region
Status >1 in nodal contour plot
Status = 1 in element contour plot
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... Postprocessing
Training Manual
The penetration or gap distance represents the actual amount of penetration (for STAT = 2 or 3) or open gap (for STAT = 1), in consistent units of length.
In listings, penetration distance is positive, and gap distance is negative. Because contour plots display either penetration or gap (not both simultaneously), the contours always display as positive values for both items.
The contact pressure (PRES) and friction stress values (SFRI) represent the current values for the contact element, copied from the Gauss points to the nodes.
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E. Workshop
Training Manual
Please refer to your Workshop Supplement for instructions on: W17. Introduction to Contact - Snap-fit
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F. Assembly contact

Training Manual
Many analysts now import solid models from CAD packages, and then mesh and analyze the imported models in ANSYS. For most CAD programs, a single volume, however complex, represents a single part. Multiple-volume models will have several parts associated together in an assembly.
Part A
Part B
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... Assembly contact
Training Manual
The boundaries between parts within an assembly usually represent mathematical discontinuities within the CAD model.
When meshed in ANSYS, there will be a discontinuity in the mesh at these part boundaries. Nodes on one side of the boundary will not talk with nodes on the other side of the boundary.
Surface-to-surface contact elements can be used to connect the mesh across part boundaries, using a concept known as assembly contact.
Glue parts A & B together using assembly contact
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Training Manual
Although assembly contact uses advanced contact features to glue parts together, the procedure is straightforward and very consistent for different models.
In fact, ANSYS Inc.s designer-level product, DesignSpace, includes automated assembly-contact procedures. It has been used successfully by designers who have no concept of nonlinear analysis procedures.
Because assembly contact is widely applicable, and is usually simple (i.e., having robust convergence behavior), we will present the procedure here, with little explanation of the advanced features being used.
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The CAD assembly must have these characteristics:
The parts must touch each other along a boundary. The boundary surfaces need not match perfectly; some mathematical noise in the geometry is tolerable.
Training Manual
The two adjacent parts must be meshed before an assembly contact pair can be generated.
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Training Manual
As a tool for gluing interfacing boundaries together, assembly contact is more generally applicable than NUMMRG, EINTF, CPINTF, CEINTF, and other such tools that have been used in the past.
It is valid in large-displacement analyses (unlike coupling and constraint equations). It can connect mismatched meshes (unlike NUMMRG and EINTF).
Assembly contact takes advantage of the bonded contact feature of the surface-to-surface contact elements to glue disconnected parts together. To model a stronger bond, a very stiff value of FKN is often used.
It is not unusual to use FKN = 10.
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Training Manual
The key to assembly contact is the creation of an initially perfect contacting surface having no initial forces acting across the contact interface.
This is achieved by using the Exclude everything initialpenetration option, along with the Bonded (always) contact surface behavior:
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Training Manual
If the only nonlinearity in your model is assembly contact, you can sometimes turn nonlinear iterations off in your analysis.
Solution > Unabridged Menu > -Load Step Opts- Solution Ctrl Turn automatic solution control OFF Solution >Unabridged Menu >-Load Step Opts- Nonlinear >Equilibrium Iter Specify ONE equilibrium iteration
However, realize that turning off nonlinear iterations could produce a model that is not in perfect equilibrium.
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Training Manual
A model that has parts glued together with assembly contact can be used in many types of analyses, including:
Nonlinear static. Nonlinear transient dynamic. Linear modal. Linear eigenvalue buckling.
The initial status of the contact elements is frozen in a linear analysis (such as modal or eigenvalue buckling analysis).
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F. Assembly contact Workshop
Training Manual
Please refer to your Workshop Supplement for instructions on: W18. Introduction to Contact - Assembly Contact
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Contact Mechanic

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Training Manual

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Status = Closed and Sticking

Status = Closed and Sliding

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... Basic Concepts

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Splined shaft interference fit, both parts are flexible.

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Penetration occurs when contact compatibility is not enforced.

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Penetration correction due to equilibrium.

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... Basic Concepts

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... Basic Concepts

ANSYS supports both rigid-to-flexible and flexible-to-flexible surface-to-surface contact models.

Rigid target element Underlying mesh Contact elements

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... Basic Concepts

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... Basic Concepts

You must carefully determine an appropriate value for contact stiffness.

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... Basic Concepts

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Bulky contact; try FKN = 1.0

Flexible contact; try FKN = 0.1

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... Basic Concepts

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... Basic Concepts

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A. Contact stiffness Workshop

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... Basic Concepts

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... Basic Concepts