Advanced Simulation of Sealings

CADFEM GmbH
Rainer Rauch
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Recent developments in ANSYS V12 for the simulation of sealings
Element technology
Material models
Contact
Robust design and optimization
- 2 -
New Element: 4 Node Tetrahedron: SOLID285
Motivation for 4-node tetrahedral elements
Current mesh generators produce triangular and tetrahedral elements reliably
Can be used to mesh very complex geometrical shapes
Element is less sensitive to distortion
Element is vital to rezoning and large deformation problems such as metal-forming
Drawbacks with 4-node tetrahedral elements
Standard displacement element is hopelessly locked by the incompressibility
Mixed displacement and pressure u/P formulation improves slightly the volumetric locking,
however
Stability is of utmost concern of mixed u/P formulation
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SOLID285: Stabilized Mixed u/P Formulation
DOF's at each node
Displacements
Hydrostatic pressure (HDSP)
Interpolation functions
Linear functions for both displacements and pressures
InternaI DOF's
Added to satisfy LBB condition
Introduced with enhanced strain method
Condensed out at element level
DOF: HDSP
A new DOF in ANSYS
Its energy-conjugate partner: DVOL volume change
Convergence check for both is controlled by CNVTOL
e z y x
u u u ) , , (
) , , , ( p u u u
z y x
) , , , ( p u u u
z y x
e z
)
1
2
3
4
) , , , ( p u u u
z y x
) , , , ( p u u u
z y x
DOFs Internal
- 4 -
New Element Solid285
Poisson
Ratio
Theory
Mixed u/p
enhanced
Tetra
Error (%) Mixed u/p Error(%)
Pure
Displace
ment
Error (%)
0.0000 3.7500 3.7275 0.5994 3.7274 0.6015 3.7235 0.7058
0.2500 4.4531 4.4242 0.6489 4.4237 0.6594 4.4124 0.9134
0.3000 4.5825 4.5520 0.6642 4.5513 0.6805 4.5365 1.0029
0.4900 5.0399 5.0008 0.7747 4.9701 1.3841 4.7941 4.8760
0.4990 5.0602 5.0204 0.7850 4.8935 3.2927 3.7532 25.8278
0.4999 5.0623 5.0224 0.7876 4.6940 7.2738 1.1884 76.5242
SOLID285
Regular u/P
1
2
3
4
e z y x
u u u ) , , (
) , , , ( p u u u
z y x
) , , , ( p u u u
z y x
4
e z
) ) , , , ( p u u u
z y x
) , , , ( p u u u
z y x
DOFs Internal
Expansion of a Thick walled cylinder under internal pressure
Unstructured mesh with 10 divisions in thickness directions
Compare SOLID285 (Enhanced Tetra), regular mixed u/P and pure displacement formulations
Radial stress for v=0.4999
Analytical solutions: inner radius =-1, outer radius =0
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Tension Bending Torsion
Shear
Accuracy
Tension Bending Torsion Shear
Efficiency
Tension
Bending Torsion Shear
Robustness
Solid186
Solid285
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0.00
6000.00
0.00 15.00 Weg [mm]

K
r
a
f
t
[
N
]
Messung:
Berechnung mit Solid 285:
Computer xp64
- 2 CPUs, 3 GHz
Meshing
- 3 Min.
Analysis
- 50 min.
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Import Mesh Regenerate Geometry Parameterize Geometry
- 8
Linear Tets
SOLID285
SOLID187
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Recent developments in ANSYS V12 for the simulation of sealings
Element technology

Contact
Robust design and optimization
- 10
New Formulations: Bergstrm-Boyce
Bergstrm-Boyce (TB, BB) polymer viscoelasticity for current element
technologies
Elements: SOLID 185, 186, 187; SOLSH190; SHELL 208, 209, 281;
Features: pressure sensitive, combined with creep,
Combinations: isotropic damage (Ogden-Roxburgh's Mullins),
Drawback: no curve fitting available;
Benefits and Applications
Technologies: filled/unfilled elastomers; biocompatible devices; artificial
tissues.
Robustness: experimentally validated;
Physicality accounted: rate-dependence; hysteresis; symmetric stress
relaxation; (mild) Mullins effects.
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New Formulations: Mullins efect
Modified Ogden-Roxburgh (TB, CDM) isotropic damage model for current
element technologies
Elements: SOLID 185, 186, 187; SOLSH190; SHELL 208, 209, 281;
Features: isotropic cyclic softening in filled polymers (Mullins effect),
Combinations: almost all nearly-, or fully incompressible isotropic
hyperelasticity models
Drawback: no curve fitting available; not applicable for foams.
Benefits and Applications
Technologies: filled/unfilled elastomers; damage in biocompatible devices and
artificial tissues.
Robustness: validated;
Physicality accounted: amplitude dependent damage softening.
- 12
Example: TB,CDM (Ogden-Roxburgh)
Objective: simulation of the cyclic, high-
pressure response of rubber sealing;
Specifics: Mullins effect and BC induced
incompressibility;
Material models: neo-Hooke with
Ogden-Roxburgh;
Element technology:
-PLANE182 (ESF).
Sealing
Steel cylinders
- 13
Mullins effect: amplitude dependent (tangent) stiffness reduction
-0,2
0
0,2
0,4
0,6
0,8
1
1,2
-0,05 0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45
Uniaxial strain measure
N
o
r
m
a
l
i
z
e
d

u
n
i
a
x
i
a
l
s
t
r
e
s
s

m
e
a
s
u
r
e
0,0292
0
,
2
0,0458
0
,
2
- 14 -
Recent developments in ANSYS V12 for the simulation of sealings
Element technology
Material models
Contact
Robust design and optimization
- 15
Rigid contact in Workbench
WB now supports all types of rigid contacts
Solid, Shells and 2D; w,w/o midside nodes
Benefits and Applications
Highly efficient contact simulation together with
the flexible definitions of joints and drivers
- 16
Fluid Pressure Penetration
Modeling fluid pressure penetration
- Fluid penetrating two contact surfaces
- 2D/3D surface-to-surface contact pair
- Small and large sliding contact
- Rigid-flexible and flexible-flexible contact
- Pressure progresses with contact status
Benefits and Applications
- Leakage Simulation
- Easy to use with few commands
- Makes complex macros obsolete
- 17 -
Recent developments in ANSYS V12 for the simulation of sealings
Element technology
Material models
Contact
Robust design and optimization
- 18 -
- 19 -
- 20 -
- 21 -
Workflow: Parameters and optimization
- 21
geometry
material properties
b.c. from any
physics
Overview in the
project page
- 22 -
Sensitivities how
big is the influence of
an Input parameter
on an Output
parameter?
Correlation matrix
Which are the best
parameters to control
the model behaviour?
Define a goal and
let Design
Exploration
optimize your
model by searching
on a response
surface
Workflow: Parameters and optimization
- 23 -