ANSYS Mechanical APDL for Finite Element Analysis

journey.

Chapter 1

Introduction to ANSYS and Finite Element Modeling

Abstract

This chapter provides an introduction to finite element analysis and the ANSYS Mechanical APDL family of software. It begins with an overview of the finite element method, its benefits, and its limitations. Next, it introduces a basic 10-step procedure for finite element analysis. This is followed by a brief history of ANSYS and finite element software programs. Next, it summarizes the current ANSYS Mechanical APDL products and program capabilities. Finally, it describes the program’s evolution and how that influences the use of ANSYS, Inc. products.

Keywords

Analysis procedure; engineering analysis; finite element analysis; ffinite element method; ANSYS Inc.; ANSYS Mechanical APDL; history of ANSYS; software license; forward compatibility; backward compatibility

Chapter Outline

1.1 What Is the Finite Element Method?

1.2 Why Use the Finite Element Method?

1.3 Basic Procedure for Finite Element Analysis

1.4 Engineering Software—Not an Engineer

1.5 A Brief History of ANSYS and Finite Element Analysis

1.6 ANSYS Today*

1.7 ANSYS Licensing

1.8 Functionality and Features of the ANSYS Mechanical APDL Family

1.9 ANSYS: Backward Compatibility and Legacy Code

Suggested Reading Assignments:

None

This chapter provides an introduction to finite element analysis and the ANSYS Mechanical APDL family of software. It begins with an overview of the finite element method, its benefits, and its limitations. It summarizes the current ANSYS Mechanical APDL products and program capabilities. Finally, it describes the program’s evolution and how that influences the use of ANSYS, Inc. products.

1.1 What Is the Finite Element Method?

The finite element method (FEM) is a mathematical technique for setting up and solving systems of partial differential (or integral) equations. In engineering, the finite element method is used to divide a system whose behavior cannot be predicted using closed form equations into small pieces, or elements, whose solution is known or can be approximated. The finite element method requires the system geometry to be defined by a number of points in space called nodes. Each node has a set of degrees of freedom (temperature, displacements, etc.) that can vary based on the inputs to the system. These nodes are connected by elements that define the mathematical interactions of the degrees of freedom (DOFs). For some elements, such as beams, the closed form solution is known. For other elements, such as continuum elements, the interaction among the degrees of freedom is estimated by a numerical integration over the element. All individual elements in the model are combined to create a set of equations that represent the system to be analyzed. Finally, these equations are solved to reveal useful information about the behavior of the system.

Just as a regular polygon approaches a perfect circle as the number of sides approaches infinity, a finite element model approaches a perfect representation of the system as the number of elements becomes infinite. Since it is impossible to divide the system into an infinite number of elements, the finite element method produces the exact solution to an approximation of the problem that you want to solve. When the number of elements becomes sufficiently large, the approximation becomes good enough to use for engineering analysis. However, this may increase the number of equations to be solved beyond the point where it is practical or desirable to solve them by hand. For this reason, the finite element method is associated with computer programs that set up, solve, and visualize the solutions of these large sets of equations for you.

1.2 Why Use the Finite Element Method?

The cost, in terms of the manpower and computer resources, required to set up and solve a finite element model for a simple problem like a cantilever beam is very high compared to the benefit. Simple problems can—and should—be solved with simple methods (or obtained from engineering handbooks). But not all problems are simple. For example, if a bridge is built using a simple truss supported by two piers, the deflections and stresses in the bridge can be found using information taught in an introductory statics and strength of materials class. But as the complexity of the truss increases, solving this problem using the engineering fundamentals becomes more difficult, leaving the analyst with long hours of error-prone calculations. As system complexity continues to increase, closed-form analysis rapidly becomes impossible. The real benefit of finite element analysis lies in the ability to solve arbitrarily complex problems for which analytical solutions are not available or which would be prohibitively time consuming and expensive to solve by hand.

1.3 Basic Procedure for Finite Element Analysis

There are 10 basic steps in any finite element analysis. First, the solid model geometry is created, the element type(s) and material properties are defined, and the solid model geometry is meshed to create the finite element model. In ANSYS, these steps are performed in the Preprocessor (PREP7). Next, loads and constraints are applied, solution options are defined, and the problem is solved. These steps are performed in the Solution processor (SOL). After the solution is ready, the results are plotted, viewed, and exported in one of the postprocessors (POST1 or POST26). Finally, the results are compared to first-order estimates, closed-form solutions, mathematical models, or experimental results to ensure that the output of the program is reasonable and as expected. (Processors will be addressed in more detail in chapter 2.)

/PREP7

1. Define the Solid Model Geometry

2. Select the Element Types

3. Define the Material Properties

4. Mesh

/SOLUTION

5. Define the Boundary Conditions

6. Define the Loads

7. Set the Solution Options

8. Solve

/POST1 or /POST26

9. Plot, View, and Export the Results

10. Compare and Verify the Results

It is sometimes possible to omit one or more steps. For example, the default solution options are often sufficient for a simple analysis. It is possible to perform some steps out of order. For example, the element types and material properties can be defined in either order. Similarly, the loads and boundary conditions can be defined in either order. It is occasionally necessary to perform these steps out of order. For example, solid model geometry is not required for a finite element analysis. When the nodes and elements are generated directly, the element type(s) must be specified before the geometry can be created. Finally, complicated analyses may involve multiple trips through one or more processors.

For simplicity, this 10-step procedure will be used in this book whenever possible.

1.4 Engineering Software—Not an Engineer

As with all computer programs, the quality of your results will depend on the quality of your model. This includes the accuracy of the material properties, the appropriateness of the material models, how closely the simulated geometry and loads match the actual geometry and loads, and the validity of the simplifications and assumptions made. Simply put, Garbage In=Garbage Out. Finite element software programs can be thought of as very sophisticated calculators that help you to analyze engineering systems that could not otherwise be evaluated. They integrate the section properties of the system with the material properties to generate the equations to be solved. They convert the applied loads to the appropriate forms and apply them to the specified DOFs. They solve the generated system of equations. And, they help you to visualize and understand the results. But a finite element program will not comment on the validity of any assumptions made in setting up the model as long as the laws of physics are not violated. It also will not ensure that you are using the correct laws of physics for a given problem. Any errors that the program reports will be associated with the use of the program, and not with the physical or analytical system. In addition, it will not provide any commentary on the quality or implications of the results. Finite element software is only a tool. In the end, you, and you alone, are responsible for determining whether or not the results of your finite element model can be used to make or justify engineering decisions.

1.5 A Brief History of ANSYS and Finite Element Analysis

The finite element method was first proposed in the early 1940s as a numerical technique for solving partial differential equations. At that time, a mesh of elements could be defined and the interaction of the elements could be used to create the system of equations to be solved. However, the system of equations still had to be solved by hand. This limitation rendered the finite element method an academic curiosity until the early 1960s when computers that could solve large systems of simultaneous equations started to become available. This made it possible to apply the finite element method to general problems. As a result, interest in using the finite element method in engineering practice began to grow.

Early finite element programs were specialty codes that were developed to solve a specific type of problem. They generally contained a single element type (e.g., beams, axisymmetric shells, or plane stress solids) and included a single type of physics (structural, thermal, etc.). This limited the type of problem that each program could solve. It also meant that there were no standard analysis tools. It was common for different groups in the same organization to use different computer programs. In many cases, each group of engineers developed and used its own finite element code. This led to concerns about the compatibility of results from different programs, the overall quality of those results, and whether the engineers’ time was being used efficiently.

1.5.1 The Development of NASTRAN

In 1965, the United States National Aeronautics and Space Administration (NASA) issued a request for proposals to create a computer program that could be used by all of its engineering organizations to solve a variety of structural problems related to the development of lunar exploration technology. The resulting program was known as NASTRAN. In 1969, NASA began to develop coupled thermal-structural capabilities in order to predict the optical performance of a large space telescope system that was exposed to changing orbital thermal conditions. By 1971, NASTRAN® was available for commercial use. It is still the default finite element program in the aerospace industry today.

1.5.2 The Development of ANSYS

While NASA was focused on lunar exploration, Westinghouse Electric Corporation was developing nuclear reactors for space propulsion and nonconventional energy production. Like their aerospace counterparts, the Westinghouse mechanical and nuclear engineers needed to predict transient stresses and displacements in reactor systems due to thermal and pressure loads. Dr. John Swanson, then an employee at the Westinghouse Astronuclear Labs in Pittsburgh, believed that an integrated, general-purpose finite element program would save both time and money when doing these types of calculations. He began developing such a program, called STASYS, for Westinghouse in 1969.

In 1970, John Swanson left Westinghouse and founded Swanson Analysis Systems, Inc. (SASI) where he continued to develop a commercial general-purpose finite element program that he called ANSYS®. The original version of ANSYS contained 40 elements of various types (springs, dampers, beams, bricks, etc.) including several elements with thermal degrees of freedom. Westinghouse became ANSYS’s first customer by the end of the year. The program was rapidly adopted by other companies and became the default finite element program for much of the power industry. Today, ANSYS products are used in all major engineering fields including the aerospace, automotive, chemical processing, construction, consumer goods, electronics, energy, health care, offshore, marine, and materials industries.

1.5.3 The Evolution of ANSYS

With every new release since 1970, new features and functionality have been added to ANSYS. Many additions were specifically developed for the program. For example, the first elements with thermoelectric (1975) and electromagnetic (1983) DOFs were developed by ANSYS engineers. Some capabilities have been added by interfacing ANSYS with other programs. For example, computational fluid dynamics (CFD) capabilities were first added in 1989 by building an interface between SASI’s ANSYS and Compuflo’s FLOTRAN. Similarly, explicit dynamics capabilities were added in 1996 by developing an interface between ANSYS and Livermore Software Technology Corporation’s LS-DYNA™. Finally, some capabilities have been added by incorporating other programs into ANSYS. For example, SASI purchased Compuflo in 1992 and FLOTRAN was fully integrated into the program by 1994 (revision 5.1).

In 1994, SASI was sold to TA Associates and the company was renamed ANSYS, Inc. This introduced a need to distinguish the company from its flagship product. It also marked a major shift in the strategic development of the company’s software.

In the late 1990s, ANSYS, Inc. began to move from a single product to a portfolio of simulation products by acquiring other businesses. For example, they acquired ICEM CFD in 2000, CFX in 2003, and Fluent in 2006 to strengthen their computational fluid dynamics offerings. Similarly, ANSYS, Inc. purchased Century Dynamics in 2005 to add AUTODYN® to its suite of explicit dynamics capabilities. The company has also continued to invest in the development of new products and technologies. For example, in 2009 (revision 12.0), ANSYS, Inc. introduced a new explicit dynamics product named ANSYS Explicit STR™.

In the 1990s, development also began on a new user-friendly platform that would become the ANSYS Workbench environment. Workbench was intended to combine the strengths of existing ANSYS, Inc. technology with new capabilities including improved solid modeling and more robust CAD importation. From this point on, new technology that was purchased from other companies was no longer integrated into the original ANSYS environment. Instead, new products and new capabilities were to be integrated into the Workbench environment and all ANSYS, Inc. products would interface with each other using Workbench.

1.6 ANSYS Today*

Today, ANSYS, Inc. offers a wide variety of computer-aided engineering products. Some are for general use while others offer capabilities that are specifically designed for certain applications like electronics, turbo machinery, and offshore structures. Some can be used to perform all steps of a finite element analysis while others offer support for a specific stage of analysis like solid modeling or meshing. Some products use the same underlying technology but access it through different (or multiple) user interfaces. Finally, some products are built on the same platform but have different capabilities depending on the licensing options.

This book provides an introduction to the family of products offered by ANSYS, Inc. that evolved from the original ANSYS finite element software program. Throughout this book, the term ANSYS is used to refer to any (or all) of the ANSYS, Inc. commercial and academic products that provide access to the general-purpose structural, thermal, and/or multiphysics finite element simulation capabilities via the original (non-Workbench) user interface. Collectively, this group is known as the ANSYS Mechanical APDL family and is referred to as such in the program documentation.

Today, the ANSYS Mechanical APDL family includes ANSYS Mechanical Enterprise, ANSYS Mechanical Premium, and ANSYS Mechanical Pro. It also includes versions of the program intended for university use, such as ANSYS Student, ANSYS Academic Teaching, ANSYS Academic Research, and ANSYS Academic Associate. The ANSYS Mechanical APDL product portfolio and the names of those products are constantly evolving. Therefore, this part of the book will always be out of date. For up-to-date product information, please refer to the company website (http://www.ansys.com).

The exercises in this book are limited to structural and thermal analyses. However, the information in the book is equally valid for analyses that use other physics (fluid, electric, magnetic, and low-frequency electromagnetic) and multiphysics (thermal-fluid, piezoelectric, acoustic-structural, electromagnetic-thermal-structural, etc.) capabilities. As a result, information related to these capabilities will be referred to in the text.

Because explicit dynamics capabilities can be accessed through the ANSYS Mechanical APDL family of products (with an appropriate license), we will make occasional references to ANSYS LS-DYNA® in this book. It will be referred to as LS-DYNA for simplicity.

Because much of the underlying technology is the same, a considerable amount of the information presented in this book is still relevant to products like ANSYS DesignSpace® that exclusively use the ANSYS Workbench environment. However, this book does not address the Workbench environment in any detail.

1.7 ANSYS Licensing

As noted above, access to ANSYS, Inc. products is based on product licenses. You can download and install all of the software that ANSYS, Inc. offers from the ANSYS Customer Portal. (See chapter 2 for more details.) However, you cannot run any ANSYS, Inc. products without a valid license. Each ANSYS license specifies which ANSYS, Inc. products or capabilities can be used, the maximum number of elements that may be included in a model, and how many people can use the software at the same time. It may also limit the physical distance that you may be from the license server while using the software or impose other restrictions. The software in the ANSYS Mechanical APDL family is basically the same for all products. Only the licenses are different.

1.8 Functionality and Features of the ANSYS Mechanical APDL Family

The features of the products in the ANSYS Mechanical APDL family are constantly evolving and new capabilities are added regularly. This section outlines some of the functionality and features that you can expect in the full multiphysics version of the program.

1.8.1 Can ANSYS…?

New users often want to make sure that the program can be used for their intended application(s) so the very first question that they usually ask is Can ANSYS do…?. As long as you want the program to do engineering analysis (and not the dishes), the answer is usually Yes. It may not be quick or easy. You may need licenses for additional ANSYS, Inc. products. You might need a more powerful computer. You might need to write some code. You might even need to recompile or relink the program. But there is very little engineering analysis that ANSYS can’t do given enough time, resources, and creativity.

1.8.2 Steady-State and Time-Dependent Analyses

ANSYS supports a variety of steady-state and time-dependent analyses. These include static analyses where inertia effects are not included and dynamic analyses where inertia effects are important. It permits two types of static analyses: single step analyses where all loads are applied at the same time and multistep static analyses where different loads can be applied or removed with each load step. Multistep analyses allow multiple combinations of loads to be solved in a single run. They also allow loads to be applied gradually in nonlinear analyses, such as creep analysis, where time is important but mass effects are not.

ANSYS permits nonlinear transient dynamic analysis where the response of the system is time dependent due to changing loads and other system nonlinearities, mode-frequency analyses where the outputs are the natural frequencies (eigenvalues) and mode shapes (eigenvectors) of the system, spectrum analyses to model phenomena such as earthquakes where the loads applied to the system are frequency dependent, harmonic analyses where the excitation loads are harmonic (sinusoidal), and analyses with random vibrations.

1.8.3 Physics Capabilities*

The full multiphysics version of ANSYS offers structural, thermal, fluid, electric, magnetic, and electromagnetic physics capabilities.

Structural analyses may include linear and nonlinear buckling; fracture; composites; fatigue; and contact with and without friction, gaskets, joints, pretension, and spot welds. They can involve geometric nonlinearities such as large strain and large deflection, and may use linear and nonlinear material models including rate-dependent and rate-independent plasticity, hyperelasticity, viscoelasticity, and creep. Structural analyses where time is important but time steps are very short, such as high-speed impacts and explosions, should be performed using one of the ANSYS explicit dynamics products such as ANSYS LS-DYNA® or ANSYS AUTODYN®.

Pure thermal analyses may include conduction, convection, radiation, phase change, or some combination of the four.

Fluid analyses may include laminar and turbulent compressible and incompressible flow, multiphase flow, free surfaces, porous media, fans or pumps, smooth or rough walls, cavitation, multiple species transport, particle tracing, and swirl. Other types of fluid analyses should be performed using one of the ANSYS CFD products, such as ANSYS CFD®, ANSYS Fluent®, ANSYS CFX®, ANSYS CFD-Flo™, or ANSYS Polyflow®.

Electromagnetic analyses may include electric fields, magnetic fields, alternating current (AC), direct current (DC), far fields, and electric circuits. Other types of electromagnetic analyses, especially those involving high-frequency analysis, should be performed using an ANSYS Electronics product such as ANSYS HFSS™ or ANSYS