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Convergence
g
Best
Practices
Peter R. Barrett, P.E.
September 27, 2012
Rev. 2/3/2016
2016 CAE Associates
Nonlinearities Overview:
Step-by-Step
p y
p Convergence
g
Procedure
1.
2.
3.
Large Deflection
Material Nonlinearities
Contact
Q&A
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Status
changes,
friction,
pressure
When,
When where?
What is the pressure?
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Easier Problems
Deformations
D
f
ti
are relatively
l ti l smallll
Nonlinear strains (plasticity, creep, swelling) are small
Contact status does not oscillate
M d l are smallll and
Models
d simplified
i lifi d (2D
(2D, Axisymmetric)
A i
ti )
Symmetric boundary conditions are utilized
Displacement based loads
L d result
Loads
lt iin ttensile
il member
b stresses
t
Nonlinear buckling to the point of instability (Post buckling not needed)
409 Parts
967 Contact Pairs
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Harder Problems
Very large
V
l
d
deformation
f
ti
Large strains with large distortion
Contact chatter and/or loose fitting assemblies
C t t sliding
Contact
lidi with
ith hi
high
h ffriction
i ti coefficient
ffi i t
Post buckling response
Large 3D models with complex geometry
N symmetry
No
t b
boundaries
d i
Force based loads
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Hard Solution
Easier Solution
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Gasket Assembly
Hard Problem
Large model
Complex loading sequence
Multiple bolt loads
Frictional Contact
Nonlinear material response
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Springs can be used to imposed loads and/or prevent rigid body motion
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17
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Streamlines
Deformation
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Insufficient supports
Individual parts of an assembly are not supported. This is the most common
form that is found in a contact analysis where rigid body motion occurs
in the parts not associated with any supports.
Insufficiently connected dissimilar element types (i.e. beams to solids, etc.)
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The example below is a converged solution where the rigid body motion is only
restrained by weak springs
Note the unrealistic 10e-6 displacement scaling
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A modal analysis determines the vibration modes including rigid body motion.
Each rigid body mode is predicted as a zero frequency mode
Animating the zero frequency mode shape illustrates the rigidly moving model.
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Axisymmetry
Rotational
Planar or reflective
Repetitive or translational
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Adding a rigid region and pushing it with displacements will usually converge
better than a force loading.
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Can use adjust to touch ANSYS option, but be careful since the geometry will
be changed
Add friction
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Li
Linear
solution
l ti
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Fn
Ft
Contact
Target
Pd1,d
Pdn
Pdn d n u n
Pd 1 d t u1
Pd 2 d t u 2
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Example: Consider a fixed pin interfacing with a hole in plate with initial
radial clearance and under a force based load
Stabilization captures localized stress distribution more accurately because it
does not change the shape of the pin
Conventional Adjust to Touch
Contact Stabilization Damping
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Buckling Response
Nonlinear stabilization
Local instabilities and global
instability.
Used
U d ttogether
th with
ith liline search
h and
d
automatic time stepping
Arc-length method
Circumvent g
global instability
y when
forces are applied.
Simulate the negative slope portion
of a load-vs.-displacement curve.
Running
R
nning a static problem as a
"slow dynamic" analysis in ANSYS
Running a static problem as a
"slow
slow dynamic"
dynamic analysis in
ANSYS/LS-DYNA
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Constraint equations
Springs
Spot
Welds
Beam connections
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Definition:
Convergence value is greater than criterion after min. load increment and max.
number of iterations are solved
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Equilibrium Iterations
Load
F
2
A full Newton-Raphson
iterative analysis for one
increment of load. (Four
iterations are shown.)
1
u
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Displacement
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Convergence Procedure
The goal is to iterate until the residual becomes acceptably small; less
than the criterion, where the solution is then considered converged.
Fa
{
{Fa}
{Fnr}
Fnr
u
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Definition of non-convergence,
sum of R (unbalanced forces)
never gets
t below
b l
.5%
5% off th
the
sum of F (sum of external loads,
reactions, etc.))
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Use more substeps to reduce iterations, use less if only one or two are
needed. (One exception: If contact without friction is the only nonlinearity,
sometimes one substep
p with lots of iterations can be an efficient solution
method)
Load
Load Step 2
2
1
4
equilibrium
iterations
Load Step 1
Substeps
Time
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Contact Stiffness is too large. Note: In V16 and beyond default stiffness
h been
has
b
reduced
d
d by
b about
b t a ffactor
t off 10
10x ffrom previous
i
versions.
i
Oscillation of contact status & force balance caused by contact stiffness.
F=KU
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Time
tstart
tmin
Incorrect
Strain Energy
tmax
Rule of Thumb:
The more nonlinearities, the
more substeps required
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Step
p Control - Load steps
p and substeps
p
Nonlinear Controls - N-R convergence criteria
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Contact Settings
g
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Default
PINB*
Contact
Classification
Contact Surface
Behavior
3 x Depth**
Rigid/Flex
Standard
4 x Depth
Rigid or Flex
Standard
2 x Depth
Flex/Flex
Standard
0.50x Depth
Flex/Flex
Bonded or No Separation
0.75x Depth
p
Rigid/Flex
g
Bonded or No Separation
p
1.00x Depth
Rigid/Flex
Bonded or No Separation
* Values are for NLGEOM,ON and are reduced by 50% for NLGEOM,OFF
**Depth
Depth = Underlying element depth (for solid elements)
**Depth = 4 x element thickness (for shells and beams)
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Depending upon the size of the residual these can be caused by large
force unbalance or can be a result of incorrect material properties
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Material law cannot handle large load and/or time increment. If the force
unbalance is very large, the material model might not be the problem
Element distorted shape results in negative volume calculation
calculation. Check the
mesh, but again with very large force unbalances the material model might not
be the problem
Max. increment can be adjusted as part of cutback controls, but typically force
balance is the controlling criterion and thus this is rarely changed.
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Buckling
V
Very
llarge fforce unbalance
b l
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l ln 1
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Element Selection
Use Higher Order elements for curved surface contact for faster
faster, more
accurate results
20 node bricks
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Suggest using Direct (Sparse) solver unless PCG is significantly faster per
iteration
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Adjust the starting mesh shapes this is the most common solution
Change Element type / formulation
Use shell or beam elements
Generally only used for very large strain cases like forming operations or seals
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Complex 3-D
geometries
Shell elements
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Slender structures
(twisted pipe
model)
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Rezoning
Automatically map existing stresses and strains so that the solution history is
preserved
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Make sure the material converges for all stress / strain levels expected with the
one element model before running full model
Especially critical step for hyperelastic and creep analyses
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Element Shape
Robust well shaped elements can improve solution convergence and time
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Mesh Controls
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Mesh refinement
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Element Formulation
2D Plain Strain
Elastic material or
Metal Plasticity with
lower order elements
Fully incompressible
hyperelasticity with
h h or lower
higher
l
order elements
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Default URI
Enhanced Strain
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The Force Convergence graph clearly indicates that starting with more
substeps would eliminate the 27 iterations performed before the first
bisection. Reducing the starting number of substeps might eliminate this
bisection
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List and plot results to check to make sure you solved the problem
intended and that the results make sense
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