MD Nastran Demonstration Problems 2010

MD Nastran
MD Demonstration Problems
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Revision 0 07/04/2010
MDNA*V2010*Z*Z:Z*MN-DPM
Contents
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 2-D Cylindrical Roller Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 3-D Punch (Rounded Edges) Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 3-D Sheet Metal Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4 3-D Loaded Pin with Friction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5 Bilinear Friction Model: Sliding Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6 Laminated Strip under Three-point Bending . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Wrapped Thick Cylinder under Pressure and Thermal Loading . . . . . . . . 115
8 Three-layer Sandwich Shell under Normal Pressure Loading. . . . . . . . . . 120
9 Bird Strike on Prestressed Rotating Fan Blades . . . . . . . . . . . . . . . . . . . . 126
10 Engine Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11 Elastic-plastic Collapse of a Cylindrical Pipe under External Rigid Body

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
12 Thermal/Pressure Loaded Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4 MD Demonstration Problems
13 Ball Joint Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
14 Time NVH Analysis – Chassis Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
15 Tube Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
16 Cup Forming Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
17 Double-sided Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
18 Demonstration of Springback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
19 3-D Indentation and Rolling without Friction . . . . . . . . . . . . . . . . . . . . . . . 312
20 Composite Fracture and Delamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
21 Occupant Safety and Airbag Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . 374
22 Multi-compartment Side Curtain Airbag Deployment . . . . . . . . . . . . . . . . 419
23 Bolted Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
24 Friction Between Belt and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
25 Modal Analysis with Glued Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
26 Interference Fit Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
27 Large Sliding Contact Analysis of a Buckle . . . . . . . . . . . . . . . . . . . . . . . . 462
28 Model Airplane Engine Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

Contents 5
29 Rapid Road Response Optimization of a Camaro Model using Automatic

External Superelement Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
30 Paper Feeding Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
31 Wheel Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
32 Pick-up Truck Frontal Crash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
33 Beams: Composite Materials and Open Cross Sections . . . . . . . . . . . . . . 516
34 Topology Optimization MBB Beam and Torsion . . . . . . . . . . . . . . . . . . . . . 526
35 Engine Mount Topology Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
36 Wheel Topology Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
37 Local Adaptive Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
38 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
39 Brake Squeal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
40 Multiple Bird-strikes on Box Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
41 Shaped Charge Penetrating Two Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
42 Mine Blast Under a Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
43 Blastwave Hitting a Bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
44 Concentric Spheres with Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798

45 Transient Thermal Analysis of Power Electronics . . . . . . . . . . . . . . . . . . . 855
46 Thermal Stress Analysis of an Integrated Circuit Board . . . . . . . . . . . . . . 920
47 Dynamic Impact of a Rigid Sphere on a Woven Fabric . . . . . . . . . . . . . . . 971
48 Shape Memory Analysis of a Stent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 984
49 Shell Edge Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 993
50 Large Rotation Analysis of a Riveted Lap Joint . . . . . . . . . . . . . . . . . . . . . 1037
51 Creep of a Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050
52 Hydro-forming of a Square Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
53 Chained Analysis: Fan Blade Out with Rotor Dynamics . . . . . . . . . . . . . . 1067
54 Ball Penetration using SPH Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088
55 Square Cup Deep Drawing using Forming Limit Diagram. . . . . . . . . . . . . 1097
56 Hydroplaning Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
57 Heating and Convection on a Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1131
58 Coupled Advection for Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 1143
59 Shallow Cylindrical Shell Snap-through . . . . . . . . . . . . . . . . . . . . . . . . . . . 1154
60 Deformable Baffle in a Duct using OpenFSI . . . . . . . . . . . . . . . . . . . . . . . . 1163

Contents 7
61 Steady State Heat Transfer due to Natural Convection between Two

Noncontacting Bodies located in Nearby Vicinity . . . . . . . . . . . . . . . . . . . 1167
62 Girkmann Problem using Axisymmetric Shell Elements . . . . . . . . . . . . . . 1177
63 Beam Reinforced Shell Structure using Offsets . . . . . . . . . . . . . . . . . . . . . 1186
64 Stent Analysis with Growing Rigid Body. . . . . . . . . . . . . . . . . . . . . . . . . . . 1198
65 Convection Correlations for Printed Circuit Board (PCB) . . . . . . . . . . . . . 1208
66 Satellite in Orbit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220
67 Thermal Contact on Surface, Edge and Solid Face . . . . . . . . . . . . . . . . . . 1234
68 Collection and Primitives Radiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1241
69 Simulation of Fuel Tank Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1253
70 User-defined Subroutines for Heat Transfer Coefficient . . . . . . . . . . . . . . 1269
71 Impact of a Rigid on Composite Laminate using GENOA PFA Material . . 1282
72 Automated Bolt Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
73 Cylinder Upsetting with Plastic and Friction Heat Generation . . . . . . . . . 1301
A Getting Started in SimXpert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1311

Preface
Preface
 Introduction 9

Feature Cross Reference 10

Overview of SimXpert 13

List of Nastran Books 14

Technical Support 15

Internet Resources 17
MD Demonstration Problems 9
Preface
Introduction
This demonstration problems manual, written for those with a working knowledge of Nastran, highlights the steps
necessary to use the advanced features of MD V2010 Nastran, including contact, elastic-plastic creep, elastomeric
material nonlinearities, heat transfer, and adaptive mesh refinement. The subsequent application examples focus on
how to include these advanced features by making relatively modest changes to existing MD Nastran bulk data files
using either a text editor or using a pre- and post-processing program like SimXpert exemplified in the video showcase
below. Click the thumbnails (Figure P-1) to open streaming videos, or read on and you’ll find these videos at the end
of the indicated chapters.
39 56
6
2 23
3
16 25
5
72
6
60
44 28
64 45 61 18
18 46
10
A
10
core
49
42
4 2 53
8
7 4
1
2 t
F
27
2
L
y 23 25
F
z 200
x
z=0
Figure P-1 MD Nastran “Another World” - Click Thumbnails for Streaming “How To” Videos
10
Every application example has a working input file(s) available to simulate the results found in each chapter, and upon
clicking its name, it will be downloaded into your browser to use. Once an understanding of how to invoke a new
feature has been reached, you are encouraged to experiment by changing some of the input parameters and rerunning
the application. Furthermore, as confidence grows, these models can serve as stepping stones to more complex
simulations that can help you better understand and improve your simulations.
Feature Cross Reference

The basic features in Table P-1 are cross referenced to each chapter for your convenience. Click the chapter number
in the table to go to the summary of that chapter.
Table P-1 Cross Reference of Solution Sequence, Element Types, Materials, Loads/BC, Contact, and
Load Control
Load
Ch. Sol Element Type(s) Material Loads/BC Contact Control
1 400 plane strain Isotropic Elastic Point Load yes NLPARM
axisymmetric &
2 400 Isotropic Elastic Pressure yes NLPARM
3-D
plane strain and 3-D Moving
3 400 Elastic-plastic yes NLPARM
shell Rigid Body
4 400 3-D Isotropic Elastic Point Load yes NLPARM
Gravity,
5 400 3-D Isotropic Elastic yes NLPARM
Pressure
Composite - Orthotropic
6 400 2-D & 3-D Point Load no NLPARM
Elastic
7 400 3-D shell Pressure no NLPARM
Elastic
8 400 3-D shell Pressure no NLPARM
Elastic
Centripetal,
9 700 3-D shell and solid Metal yes TSTEPNL
Impact
Pressure,
10 400 3-D Isotropic Elastic gasket yes NLPARM
Bolt Loading
11 400 3-D shell Elastic-plastic yes NLPARM
12 400 3-D Isotropic Elastic Pressure no NLPARM
13 400 axisymmetric Mooney, Ogden yes NLSTEP
103 &
14 3-D shell Isotropic Elastic Point Load no TSTEPNL
700
15 400 axisymmetric Elastic-plastic yes NLPARM
Preface
Load Control (continued)
Ch. Sol Element Type(s) Material Loads/BC Contact Load

Control
Moving
16 400 3-D shell Elastic-plastic yes NLPARM
Rigid Body
17 400 plane strain Elastic-plastic yes NLPARM
18 400 plane strain Elastic-plastic yes NLPARM
Moving
19 400 3-D Elastic-plastic yes NLPARM
Rigid Body
20 400 plane strain Isotropic Elastic cohesive VCCT yes NLSTEP
21 700 3-D Fabric, Seatbelt, Rigid, Airbag yes TSTEPNL
22 700 3-D Fabric, Seatbelt, Rigid, Side Airbag yes TSTEPNL
Bold Load,
23 400 3-D Isotropic Elastic Pressure, yes NLPARM
Thermal
24 400 3-D Isotropic Elastic Point Load yes NLPARM
Glued
Contact
Interference
Fit
27 400 3-D Isotropic Elastic Snap Fit yes NLPARM
Bolt Loads,
28 400 3-D Isotropic Elastic/gasket yes NLSTEP
Pressure
29 200 3-D Isotropic Elastic Point Load no
30 700 3-D Isotropic Elastic Rollers yes TSTEPNL
Isotropic Elastic, Composite,
31 700 3-D Impact yes TSTEPNL
Rubber, Elastic-Plastic
32 700 3-D Elastic-plastic, rigid Impact yes TSTEPNL
33 101 Beam Composites Point Load no
34 200 2-D, & 3-D Isotropic Elastic Point Load no
37 101 plane stress Isotropic Elastic Edge Load no
Distributed
Load
12

Control
Distributed
39 400 3-D Isotropic and Anisotropic yes NLPARM
Load
40 700 3-D Elastic-plastic Impact FSI TSTEPNL
41 700 3-D Elastic-plastic Explosion FSI TSTEPNL
42 700 3-D shell and truss Elastic-plastic Explosion FSI TSTEPNL
43 700 3-D Elastic-plastic Explosion FSI TSTEPNL
44 400-HT 3-D membrane Isotropic Radiation no NLSTEP
Thermal TSTEPNL,
45 400-HT 3-D Isotropic no
Loads NLSTEP
46 400-HT 3-D Isotropic Thermal no NLSTEP
Beam To
47 400 3-D beams Elastic-plastic yes TSTEPNL
Beam
Prescribed
48 400 3-D Shape Memory Displacemen NLPARM
t
Prescribed
49 400 3-D shells Isotropic Elastic Displacemen yes NLPARM
t
3-D shell, CWELD,
50 400 Isotropic Elastic Point Load no NLPARM
CFAST, CBUSH
51 400 Axisymmetric Isotropic Elastic Creep Pressure no NLSTEP
52 400 3-D Elastic-plastic Pressure yes NLSTEP
53 700 3-D Elastic-plastic Blade Out yes TSTEPNL
54 700 3-D shell Elastic-plastic, hydrodynamic Impact yes TSTEPNL
Anisotropic Elastic-plastic, Moving
55 700 3-D shell yes TSTEPNL
rigid Rigid Body
Hydroplanin
56 700 3-D solid & shell Mooney FSI TSTEPNL
g
400 -
57 2-D Isotropic Convection no NLSTEP
HT&RC
58 400-RC 3-D Isotropic Convection no NLSTEP
59 400 3-D shell Isotropic Point Load no NLSTEP
60 400 3-D Isotropic OpenFSI no TSTEPNL
Preface

Control
61 400 3-D Isotropic Convection yes NLSTEP
Gravity,
62 400 Axisymmetric Isotropic Elastic no
Pressure
63 400 3-D shell and beam Elastic-plastic Pressure no NLSTEP
Moving
64 400 3-D Elastic-plastic yes NLSTEP
Rigid Body
Convection,
65 400-RC 3-D Isotropic no NLSTEP
Advection
66 400-RC 3-D Isotropic, Honeycomb Radiation no NLSTEP
Prescribed
67 400-RC 3-D Isotropic Temperature yes NLSTEP
s
Radiation,
68 400-RC 3-D Isotropic Distributed no NLSTEP
Flux
69 700 3-D Isotropic FSI TSTEPNL
70 400-RC 2-D Temp. dependent Convection no NLSTEP
Orthotropic, Progressive
71 700 3-D shell Impact yes TSTEPNL
Failure
72 400 3-D Isotropic Elastic Bolt Load yes NLSTEP
Moving
73 400 Axisymmetric Elastic-plastic yes NLSTEP
Rigid Body
Overview of SimXpert
SimXpert is an integral component of the enterprise simulation environment. It incorporates direct integration with
SimManager and SimDesigner. SimXpert is a multi-disciplinary simulation environment for the analyst including
workspaces between which one common model can be shared. The workspaces provide different tools appropriate to
the discipline:
• Structures – linear and nonlinear, static and dynamic Finite Element Analysis (FEA) using MD Nastran
• Thermal – linear FEA using MD Nastran
• Motion – multi-body dynamics of rigid and flexible bodies using the Adams C++ solver
• Crash – nonlinear explicit dynamic FEA using LS-Dyna
• MD Explicit - nonlinear explicit dynamic FEA using MD Nastran
14
• Template Builder - Captures Simulation Procedures Consisting Of SimXpert Commands And Macros
• Process Builder - Creating Enterprise Processes (SimProcess)
All solvers are included. Workspaces also filter the simulation model. Only the parts of the model that have relevance
to a workspace are visible.
The simulation process allows knowledge capture and re-use through the use of templates.The template builder allows
you to: define a sequence of tasks and sub-tasks, drag-and-drop existing scripts in a visual editing environment, and
publish the finished template to SimManager for re-use across an organization.
To learn more about SimXpert, see Appendix A: Getting Started in SimXpert.
List of Nastran Books

Below is a list of some of the Nastran documents. You may order any of these documents from the MSC.Software
BooksMart site at http://store.mscsoftware.com.
Installation and Release Guides


Installation and Operations Guide

Release Guide
Reference Books

Quick Reference Guide

DMAP Programmer’s Guide
 Reference Manual
Preface
User’s Guides

Getting Started

Linear Static Analysis
 Dynamic Analysis


Thermal Analysis

Superelement

Design Sensitivity and Optimization

Implicit Nonlinear (SOL 600)

Explicit Nonlinear (SOL 700)

Aeroelastic Analysis

User Defined Services

EFEA User’s Guide

EFEA Tutorial

EBEA User’s Guide
Technical Support
For help with installing or using an MSC.Software product, contact your local technical support services. Our
technical support provides the following services:
• Resolution of installation problems
• Advice on specific analysis capabilities
• Advice on modeling techniques
• Resolution of specific analysis problems (e.g., fatal messages)
• Verification of code error.
If you have concerns about an analysis, we suggest that you contact us at an early stage.
16
You can reach technical support services on the web, by telephone, or e-mail:
Web Go to the MSC.Software website at www.mscsoftware.com, and click on

Support. Here, you can find a wide variety of support resources including
application examples, technical application notes, available training courses, and
documentation updates at the MSC.Software Training, Technical Support, and
Documentation web page.
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Fax: (34) (91) 5567280
E-mail Send a detailed description of the problem to the E-mail address below that
corresponds to the product you are using. You should receive an acknowledgement
that your message was received, followed by an E-mail from one of our Technical
Support Engineers.
MD Patran Support mscpatran.support@mscsoftware.com
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Marc Support mscmarc.support@mscsoftware.com
MSC Institute Course Information msctraining.support@mscsoftware.com

Preface
Internet Resources
MSC.Software (http://www.mscsoftware.com/)
MSC.Software corporate site with information on the latest events, products and services for the CAD/CAE/CAM
marketplace.
Training
The MSC Institute of Technology is the world's largest global supplier of CAD/CAM/CAE/PDM training products
and services for the product design, analysis and manufacturing market. We offer over 100 courses through a global
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Chapter 1: 2-D Cylindrical Roller Contact
1 2-D Cylindrical Roller Contact

Summary 19

Introduction 20

Solution Requirements 20

Analytical Solution 20

FEM Solutions 21

Modeling Tips 25

Pre- and Postprocess with SimXpert 28

Input File(s) 68
CHAPTER 1 19
2-D Cylindrical Roller Contact
Summary
Title Chapter 1: 2-D Cylindrical Roller Contact
Contact features • Advancing contact area
• Curved contact surfaces
• Deformable-deformable contact
• Friction
• Comparison of linear and parabolic elements
Geometry 2-D Plane strain (units: mm) F
• Block height = 200
• Block width = 200
• Cylinder diameter =100
• Thickness = 1
Material properties E cylinder = 210kN  mm 2 E block = 70kN  mm 2  cylinder =  block = 0.3

Linear elastic material
Analysis type Quasi-static analysis
Boundary conditions • Symmetric displacement constraints along vertical symmetry line.
• Bottom surface of the foundation is fixed  u x = u y = 0 
• Contact between cylinder and block
Applied loads Vertical point load F = 35kN
Element type 2-D Plane strain
• 8 -node parabolic elements
• 4-node linear elements
Contact properties Coefficient of friction  = 0.0 and  = 0.1
FE results 1. Plot of normal contact pressure against distance from center of contact
2. Plot of tangential stress against distance from center of contact
3. Plot of relative tangential slip against distance from center of contact
5000 Contact Pressure N/mm 2

Analytical
SOL 400 Contacting Surface
4000 SOL 400 Contacted Surface
3000
2000
1000
0
0 1 2 3 4 5 6 7 8
Distance (mm)
CHAPTER 1
Introduction
A steel cylinder is pressed into an aluminum block. It is assumed that the material behavior for both materials is linear
elastic. The cylinder is loaded by a point load with magnitude F = 35kN in the vertical direction. A 2-D approximation
(plane strain) of this problem is assumed to be representative for the solution. An analytical solution for the frictionless
case is known - (Ref: NAFEMS, 2006, Advanced Finite Element Contact Benchmarks, Benchmark 1 2D Cylinder
Roller Contact).
Solution Requirements
There are two solutions: one using a friction coefficient of 0.1 between the cylinder and block and one frictionless.
• Length of contact zone
• Normal pressure distribution as function of distance (x-coordinate) along the contact surface
• Tangential stress distribution as function of distance along the contact surface
These solutions demonstrate:
• More elements near the contact zone
• Which surface is treated as master (contacting) and slave (contacting)
The analysis results are presented with linear and parabolic elements.
Analytical Solution
An analytical solution for this contact problem can be obtained from the Hertzian contact formulae (Hertz, H., Über
die Berührung fester elasticher Körper. J. Reine Angew. Mathm. 92, 156-171, 1881) for two cylinders (line contact).
The maximum contact pressure is given by:
F n E*
p max = ------------------
2BR*
where F n is the applied normal force, E* the combined elasticity modulus, B the length of the cylinder and R* the
combined radius.
The contact width 2a is given by:
8F n R*
a = -----------------
BE*
Using the normalized coordinate  = x  a with x the Cartesian x-coordinate, the pressure distribution is given by:
p = p max 1 –  2
The combined elasticity modulus is determined from the modulus of elasticity and Poisson’s ratio of the cylinder and
block E cylinder , E block ,  cylinder , and  blo ck , as follows:
2E cylinder E block
E* = --------------------------------------------------------------------------------------------------------------
-
E block  1 –  cylinder  + E cylinder  1 –  block
2 2

CHAPTER 1 21
The combined radius of curvature is evaluated from the radius of curvature of the cylinder and block R cylind er and
R block , as follows:
R cylinder R block
R* = -------------------------------------------
R cylinder + R block
For the target solution, the block is approximated with an infinitely large radius. The combined radius is then evaluated
as:
R cylin der R block
R* = lim ------------------------------------------- = R cylinder
R block   R cylinder + R block
Using the numerical parameters for the problems the following results are obtained:
a = 6.21mm
p max = 3585.37N  mm 2
Note that half the contact length is equal to 6.21 mm which corresponds to approximately 7.1 degrees of the ring.
Hence, it is clear that, in order to simulate this problem correctly, a very fine mesh near the contact zone is needed.
FEM Solutions
A numerical solution has been obtained with MD Nastran’s solution sequence 400 (SOL 400) for the element mesh
shown in Figure 1-1 using plane strain linear elements. The elements in the entire cylinder and entire block have been
selected as contact bodies. Contact body IDs 5 and 6 are identified as a set of elements of the block and cylinder
respectively as:
BCBODY 5 2D DEFORM 5 0 .1
BSURF 5 1 2 3 4 5 6 7
...
and
BSURF 6 1242 1243 1244 1245 1246 1247 1248
...
Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other:
BCTABLE 0 1
SLAVE 6 0. 0. .1 0. 0 0.
0 0 0
MASTERS 5
BCTABLE 1 1
SLAVE 6 0. 0. .1 0. 0 0.
0 0 0
MASTERS 5
Thus, any deformable contact body is simply a collection of mutually exclusive elements and their associated nodes.
The order of these bodies is important and is discussed later. For the simulations with friction, a bilinear Coulomb
model is used (FTYPE = 6). The slave or contacting nodes are contained in the elements in the cylinder, whereas the
master nodes or nodes or contacted segments are contained in the elements in the block.
CHAPTER 1
Steel Cylinder Contact Body ID 6

Element IDs 1242 to 2641
Contact Body ID 5
Aluminium Block Element IDs 1 to 1241
Z X
Figure 1-1 Element Mesh Applied in Target Solution with MD Nastran
Nonlinear plane strain elements are chosen by the PSHLN2 entry referring to the PLPLANE option as shown below.
PLPLANE 1 1
PSHLN2 1 1 1 +
+ C4 PLSTRN L +
Herein referred to as plane strain quad4 elements (PLSTRN QUAD4) or (PLSTRN QUAD8) for the linear and parabolic
elements respectively listed in Table 1-1. All elements are 1 mm thick in the out-of-plane direction.
Table 1-1 Applied Element Types in Numerical Solutions

SOL 400
linear PLSTRN QUAD4
parabolic PLSTRN QUAD8
The material properties are isotropic and elastic with Young’s modulus and Poisson’s ratio defined as:
$ Material Record : steel
MAT1 1 210000. .3
$ Material Record : aluminum
MAT1 2 70000. .3
The nonlinear procedure used is:

NLPARM 1 1 PFNT
Here the PFNT option is selected to update the stiffness matrix during every iteration using the full Newton-Raphson
iteration strategy; the default convergence tolerance values (0.01) will be used. The convergence method and
tolerances may be specified explicitly as shown here since they will be discussed later.
CHAPTER 1 23
Table 1-2 Nonlinear Control Parameters

1 2 3 4 5 6 7 8 9 10
NLPARM 1 1 PFNT UP +pb1
+pb1 1.00E-02 1.00E-02 1.00E-05
The obtained lengths of the contact zones are listed in Table 1-3. The exact length of the contact zone cannot be
determined due to the discrete character of contact detection algorithms (nodes are detected to be in contact with an
element edge for 2-D, element face for 3-D). It is clear, however, that the numerical solution is in good agreement with
the analytical one.
Table 1-3 Length of the Contact Zone and Pmax

amin aavg amax Error Pmax Error
(mm) (mm) (mm) (%) (N/mm2) (%)
linear 5.99 6.33 6.67 2.6 3285 -8.38
parabolic 5.88 6.08 6.28 -1.5 3583 -0.05
The deformed structure plot (magnification factor 1.0) is shown in Figure 1-2. A plot of the Hertzian contact solution
for the pressure along the contact surface is obtained with linear and parabolic elements as shown in Figure 1-3 and
Figure 1-4.
amax
amin
Contacting Nodes
Contacted Nodes
Figure 1-2 Deformed Structure Plot at Maximum Load Level (magnification factor = 1)
CHAPTER 1

Analytical
SOL 400 Contacted Surface
4000 SOL 400 Contacting Surface
3000
2000
1000
0
0 1 2 3 4 5 6 7 8
Distance (mm)
Figure 1-3 Comparison of Analytical and Numerical Solutions for Linear Elements without Friction

Analytical
SOL 400 Contacting Surface
4000 SOL 400 Contacted Surface
3000
2000
1000
0
0 1 2 3 4 5 6 7 8
Distance (mm)
Figure 1-4 Comparison of Analytical and Numerical Solutions for Parabolic Elements without Friction
The contact pressure plotted for the contacting nodes shows, even with this mesh density, an oscillating type of
behavior. This is reduced for the parabolic elements. Generating the same plots along the contacted nodes produces a
smoother curve.
Numerical solutions have also been obtained with a friction coefficient of 0.1 (bilinear Coulomb). The contact normal
and tangential stress along the contacting nodes are shown in Figure 1-5.
All stresses show an oscillating type of behavior. This can be improved by refining the mesh in the contact zone.
CHAPTER 1 25
5000 Contact Stress N/mm 2 Pressure Linear

Pressure Parabolic
4000 Tangential Linear
Tangential Parabolic
3000
2000
1000
0
0 1 2 3 4 5 6 7 8
Distance (mm)
Figure 1-5 Normal and Tangential Stress Along Contact Surface
Modeling Tips
About Convergence
Although the nonlinearity of the force-displacement relation in this problem is quite mild, looking more closely at the
convergence of this problem will be useful for subsequent problems in this manual, and worthy of mention here as a
matter of introduction. Table 1-4 controls the number of iterations in the Newton-Raphson process illustrated below
in Figure 1-6.
Table 1-4 Convergence Output

Error Factors
Load Step No. Inc IRT Disp Load Work
1 1 1 1.00E+00 9.78E-01 9.78E-01
1 1 2 3.70E+00 8.83E-01 4.57E+00
1 1 3 2.80E+00 6.83E-01 3.98E+00
1 1 4 1.43E+00 3.81E-01 2.26E+00
1 1 5 4.96E-01 7.28E-02 8.84E-01
1 1 6 3.72E-04 1.51E-02 9.98E-04
1 1 7 6.00E-05 2.69E-05 8.69E-05
CHAPTER 1
60000 Load Fy (N)

Newton-Raphson Path
50000 Fy , v
2
Point C
40000
30000
20000 Point D
Applied Load = 17500 Point B
10000
Displacement v (mm)
Point A
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Figure 1-6 Newton - Raphson Path for Load-Displacement Curve
At the beginning of the analysis (Point A in Figure 1-6), the tangent modulus (slope of load-displacement curve) is
used to project to the applied load to Point B, which does not satisfy the convergence criteria. Then equilibrium is re-
established at Point C, and a new slope is computed. The Newton-Raphson iterative procedure continues until the
convergence tolerances are satisfied, Point D. The convergence criteria are based upon displacement, load or work
either individually or in some combination. The Newton-Raphson iterative scheme is recommended for all SOL 400
analyses because the degree of nonlinearity is typically significant. For the parameters in Table 1-3, the output
(Table 1-4) shows the following convergence characteristics. The percent sign helps to locate the line in the output
file. In this case, the criteria used is both the displacement, U, and load, P - specified through the UP keyword for the
convergence type on the NLPARM command - with a value of 0.01 for each. This means that both relative displacement
and load measures (error factors) must be below 0.01 for convergence to be permitted. This can be seen in Figure 1-7.
In this case, there is no checking on the work, even though it has a low tolerance.
1
Log(work)
0
Log(disp)
-1
Log(epsp = epsu) Log(load)
-2
-3
-4
Log(epsw)
-5
Figure 1-7 Error Factors For Each Iteration
About the Order of Contact Bodies

The nug_01aw.dat input file changes the order of the contact body detection, in which the coarser mesh (block) is
the contacting surface. Although acceptable to the contact algorithm, the results are degraded since it is best to have
CHAPTER 1 27
the body with the most nodes as the contacting body. Run nug_01aw.dat to see the differences as shown in
Figure 1-8.
nug-01aw.dat nug-01am.dat
Steel Cylinder Steel Cylinder
Contacted Nodes Contacting Nodes
Contacting Nodes Contacted Nodes
Aluminium Block Aluminium Block
Figure 1-8 Deformed Mesh of Different Contact Body Ordering

CHAPTER 1
Pre- and Postprocess with SimXpert
Units
All data imported or created in MSC SimXpert is assumed to be in a single consistent system of units, as specified in
the Unit Manager. It is important to specify the appropriate units prior to importing any unitless analysis files, such as
an MD Nastran bulk data file, or creating materials, element properties, or loads. This is so that the MSC SimXpert
user is assisted in being consistent with the use of numerical quantities that have units. The system of units is specified
in a dialog accessed by selecting Tools: Units Manager.
For the illustration below, the geometry is created, meshed with linear elements using frictionless contact, and finished
by comparing results with the analytic solution.
a. Tools
b. Options
c. Units Manager
d. Basic Units
c
d
b
CHAPTER 1 29
Create a Part for the Block

Parts are the main components of a model and may be used to specify specific attributes (geometry, properties etc.).
For example, here the part/block, is created (bottom right) that will be later used by picking the part from the model
tree in the Model Browser (bottom left). We will find that in defining material properties picking parts from the model
tree is easier than trying to pick a group of elements. Later the last part, cylinder, is created.
a. Assemble
b. Create Part
c. block; click OK
a
b
c
CHAPTER 1
Create the Block Geometry

The geometry of the part/block, is created here and results in a simple rectangular shaped object. More geometry is
added to this part in subsequent steps.
a. Geometry
b. Filler
c. X, Y, Z Input enter 0,200,0; click OK
X, Y, Z Input enter 30,200,0; click OK
p ( p )
a
c
CHAPTER 1 31
Create a Curve to Define a Surface Edge

Continuing to add geometry to the part/block, a curve (line) is created below the previous rectangle. This curve is used
to generate a surface between the rectangle and line.
a. Geometry
b. Curve
c. X, Y, Z Input enter 0,100,0; click OK
OK
a
b
c
CHAPTER 1
Create a Surface Between Two Curves

Now the surface is generated between the curve on the bottom of the rectangle and the previously created curve. The
part/block now contains two surfaces: a rectangle and quadrilateral.
a. Geometry
b. Filler
c. enter 2 Curves; click OK
c
CHAPTER 1 33
Create a Surface by Defining Its Vertices

Another surface is added using one point and three vertices.
a. Geometry
b. Filler
c. Enter 1 point, 3 vertices; click OK
d. X, Y, Z Input enter 100,200,0; click OK
c
d
CHAPTER 1
Create a Surface by Sweeping a Curve

The final surface added to the part/block, is created by sweeping the bottom horizontal curve downward for 100 mm.
a. Geometry
b. Sweep
c. Vector, two point normal, pick Curve, Length of Sweep; click OK
c
CHAPTER 1 35
Stitch Surfaces
Finally, all of the surfaces that comprise the part/block, are stitched together. Stitching surfaces creates congruent
surfaces with aligned normals within a stitch tolerance. Unconnected or free edges are displayed in red whereas shared
edges are displayed in green as shown below.
a. Geometry
b. Stitch
c. 4 bodies; click OK
a b
1
2
c
4
CHAPTER 1
Create a Part: Cylinder

Now the cylinder part is created.
a. Assemble
b. Create Part
c. Cylinder; click OK
• c. cylinder, OK
a
c
CHAPTER 1 37
Create an Arc
The cylindrical surface is generated by an arc and a line. The arc is defined below.
a. Geometry
b. Arc
c. Dir-Radius 0,250,0;0,250,-1
d. Arc.1, 40,0,180 VERTEX(indicated); click OK
d
CHAPTER 1
Create a Curve Along a Line of Symmetry

The cylindrical surface is generated by an arc and a line. The line is defined below.
a. Geometry
b. Curve
c. 2 Vertices; click OK
a
b
c
CHAPTER 1 39
Break Line and Arc into Two Curves for Two Surfaces
Before generating a surface from these two curves, each curve (line and arc) is broken into two equal pieces
respectively. This allows for generating two surfaces that ultimately generate different meshes.
a. Geometry
b. Edit Curve
c. Split
d. Parametric, 2 Curves; click OK
a
b
d
CHAPTER 1
Create Surfaces from Curves

Two surfaces (composing half of the cylinder) are generated from the curves previously constructed and are
stitched together.
a. Geometry
b. Filler
c. 2 Curves, click OK (repeat for other 2 curves
d. Stitch, 2 surfaces; click OK
d
CHAPTER 1 41
Create Mesh Seeds

With the parts completed, each curve of each surface is seeded prior to meshing. Here the curves that comprise the
surface of the lower portion of the cylinder are seeded with element sizes that include uniform and biased seeds.
a. Meshing
b. Seed: Arrows on curves indicate direction for nonuniform mesh seed
c. Curve (seed as indicated in the 3 curves); click OK
a
b
c
CHAPTER 1
Create Mesh
With the curves of this surface seeded, a quadrilateral dominate mesh is created by using the surface mesher.
a. Meshing
b. Surface
c. Pick Surface, Mesh type and Method (indicated)
d. Element Size 1
e. Quad Dominant
f. OK
yp ( )
a
f
CHAPTER 1 43
Create Mesh
The top cylindrical surface is meshed with a quadrilateral dominate mesh and the cylindrical part meshing is complete.
a. Meshing
b. Surface
c. Pick Surface
d. Element Size 2.5
e. Quad Dominant
f. OK
f
CHAPTER 1
Create Mesh
The block part consists of four surfaces that are now to be meshed with the smallest rectangular surface being mesh
with uniform elements with the indicated size using a quadrilateral dominate mapped mesher.
a. Meshing
b. Surface
c. Pick Surface
d. Element Size 1.5
e. Quad Dominant
f. OK
f
CHAPTER 1 45
Create Mesh Seeds

The upper quadrilateral surface curves are seeded appropriately, and the surface is meshed. A similar exercise is done
for the lower quadrilateral surface (not shown).
a. Meshing
b. Seed: Arrows on Curves indicate direction for nonuniform mesh seed
c. Surface
OK
a
b
c
b
b
CHAPTER 1
Create Mesh
Finally, the lower rectangular surface of the block is meshed using the mapped mesher with uniform element sizes.
a. Meshing
b. Surface
c. Pick Surface
d. Element Size 5
e. Quad Dominant
f. OK
g. Pick Surface
h. Element Size 5
i. Quad Dominant
j. OK
h
f
j
CHAPTER 1 47
Enforce Consistent Normals

Although the surfaces of the cylinder and block parts were stitched together, the surface mesher may create elements
with inconsistent outward normals. This is the case here, and elements need to be fixed such that their outward normals
all point in one direction (+z). This is done by showing the element normals, then fixing the normals using a reference
element to set the normal direction. Continue this process until all normals are consistent; namely, they all point in the
same direction.
a. Quality
b. Fix Elements
c. Normals
d. Show (Fix) Normals, click OK
a b
c
d
d
CHAPTER 1
Define Material Data

Materials are defined by naming the material (steel and Al, respectively) while entering the properties. The problem
statement required that the cylinder be made of steel and the block made of aluminum (Al). Since the basic units
selected have derived units of pressure (stress or modulus) as N   mm  2 , Young’s modulus for the steel is entered as
210x10 3 and 70x10 3 for aluminum. Poisson’s ratio is dimensionless and entered as 0.3 for both materials.
a. Materials and Properties

b. Isotropic
c. steel, (properties); click OK
d. Al, (properties as shown); click OK
• d. Al, (properties), OK a
c d
CHAPTER 1 49

The properties defined are now applied to the parts accordingly along with the planar element properties. Parts and
materials are selected from the Model tree (not shown).
a. Materials and Properties

b. Plane
c. Plane Property (cylinder and block); click OK
c. Plane Property (cylinder and block), OK

a
c
CHAPTER 1
Contact Data for Cylinder

Since the cylinder will come into contact with the block, contact data needs to be specified. A contact body consists
of a set of elements and their associated nodes that are mutually exclusive from other elements. While we know that
only a small number of elements in the cylinder and block will ultimately come into contact, there is no need to specify
this information; the contact algorithm completely determines where and when contact happens. Hence, our choice is
simple. We will create two contact bodies, consisting of all elements in the two parts we have defined: the cylinder
and block.
Although one might be tempted to only pick those elements suspected of coming into contact, it is best (and less time
consuming) to just pick all the elements in the part as done here.
a. Loads and Boundary Conditions (LBC)

b. Deformable Body
c. Select cylinder; click OK
• b. Deformable Body
• c. Select cylinder, OK a
b
c
CHAPTER 1 51
Contact Data for Block

Similar to the cylinder contact body, all elements in the block are selected to be in the next deformable contact body.

b. Deformable Body
c. Select block; click OK
a
b
• Define a deformable contact body for the block
c
CHAPTER 1
Define Contact Tables

Although a contact table is not necessary for this particular problem (see BCONTACT = ALLBODY in the QRG), one is
used here for illustration. Here, the contact table indicates that all contact bodies touch each other, including
themselves.
In general, contact tables describe how contact is to take place between contact bodies (touching, glue, none) and may
change during the analysis by selecting different contact tables. A contact table allows one to define the coefficient of
friction between the two touching bodies and its nonzero value overrides any previous value.

b. Table
c. BCTABLE_INIT; click OK
• c. BCTABLE_INIT
a
c
CHAPTER 1 53
Define Constraints
The horizontal component of displacement for all nodes on the symmetry plane is fixed to be zero by selecting the
associated curves.

b. General
c. Symmetry (Tx = 0 only)
d. 5 Curves; click OK
y y( y)
• d. 5 Curves, OK
a
d
CHAPTER 1
Define Constraints
The horizontal and vertical displacement components of all nodes on the bottom of the block are fixed by selecting
the associated curve.

b. General
c. Bottom (Tx, Ty = 0 only)
d. 1 Curve; click OK
c. Bottom (Tx, Ty 0 only)

• d. 1 Curve, OK a
d
CHAPTER 1 55
Define Point Load

The load of 35 kN is applied to the top node in the downward direction. However, since only half of the material is
being modeled because of the plane of symmetry, a load of 17.5 = 35/2 kN is applied to this “half” of the model.

b. Force
c. 1 Node
d. 17500, (direction); click OK
• d. 17500, (direction), OK
a
c
d
CHAPTER 1
Create Nastran SOL 400 Job with Default Layout

An analysis job is set up using a general nonlinear analysis type (SOL 400) and the name of the solver input file
is specified.
a. Right click File Set

Create new Nastran job
b. Job Name
c. General Nonlinear Analysis (SOL 400)
d. Name input file; click OK
d
CHAPTER 1 57
Create Nastran SOL 400 Job with Default Layout

The global loadcase is created and the initial contact table is selected.
a. Right click Load Cases

b. Create Global Loadcase
OK
c. Under Global Loadcase, Right click Loads/Boundary Conditions
d. Select Contact Table BCTABLE_INIT; click OK
a c
b
d
CHAPTER 1
Select Contact Table BCTABLE_INIT for Loadcase DefaultLoadCase

The default loadcase is created using the same contact table.
a. Right click Loads/Boundaries under DefaultLoadCase

b. Select Contact Table
c. Select Contact Table BCTABLE_INIT
d. Click OK
d
a
b
CHAPTER 1 59
Define Large Disp. and Contact in SOL 400 Nonlinear Parameters

Here, we are specifying some nonlinear parameters that allow forces to follow in a large displacement analysis and set
the bias factor used in contact detection.
a. Double click Solver Control

b. Select Solution 400 Nonlinear Parameters
c. Large Disp and Follower Force, Apply
d. Contact Control Parameters
e. Bias = 0.90
f. click Apply
g. click Close
c
a
d
e
f
g
CHAPTER 1
Define Nonlinear Static Parameters

Finishing the selection of nonlinear parameters, we select the stiffness update method along with convergence criteria.
a. Loadcase Control
b. Subcase Nonlinear Static Parameters
c. Pure Full Newton, 1, 50
d. Check Displacement error, enter 1.0e-2
e. Check Force Error, enter 1.0e-2
f. Check Vector Component Method
b
c
d
a e
f
CHAPTER 1 61
Request Output
In order to visualize results, nodal and elemental output requests are made.
a. Output Request
b. Nodal Output Requests
c. Create Constraint Force output Request; click OK
d. Elemental Output
e. Create “Nonlinear” Stress Output,; click OK
d
a
b
c e
CHAPTER 1
Run Analysis
The preprocessing is now complete and the job is submitted. Upon successful completion of the job, the results are
attached and visualized.
a. Right click job, cylinder_roller_contact, under Simulations

b. Run.
b
CHAPTER 1 63
Results
The results are attached.
a. Attach Results
b. Select *_xdb file
a
b Select *.xdb file
CHAPTER 1
Results - Fringe Plot

A fringe plot of the Y-component of the Cauchy stress tensor is plotted below.
a. Results
b. Fringe
c. Cauchy Stress
d. Y Component
e. Update
• b. Fringe a
• c. Cauchy Stress
• d. Y Component
• e. Update
b
e
c
d
CHAPTER 1 65
Results - Chart Data

Since the contact area is very small, it is useful to plot the Y component of Cauchy stress along the X component of
the nodal positions, which is done by constructing the chart below.
a. Results
b. Chart
c. Stress, Y Comp., Nodes
d. Advanced Picking Tool
e. From Curve
f. Select Curve
g. X Global
h. Add Curves
a. Results
• b. Chart
• c. Stress, Y Comp., Nodes
• d. Advanced Picking Tool b
• e. From Curve a
• f. Select Curve
• g. X Global d
• h. Add Curves
f
CHAPTER 1
Chart Data - Exporting Chart to Excel

Ultimately, we wish to compare the data contained in the chart above with the analytical solution. The results in the
chart can be extracted to the clipboard by selecting the Table under XY Chart Properties; then right click the table,
Select All, and then copy. Once in the clipboard, the data can be pasted into Excel to be used in further comparisons.
a. XY Chart Properties, Check Table

b. Mouse on Table, Select All, Copy
c. Paste into Excel
a c
b
CHAPTER 1 67

The chart data in the clipboard one pasted into Excel is then compared to the analytical solution.
a. Plot with Analytical Solution in Excel

• a. Plot with Analytical Solution in Excel
a
CHAPTER 1
Input File(s)
Snippets from the first four Nastran input files listed below are used to illustrate the simulation throughout various
sections of this chapter except the section, Pre- and Postprocess with SimXpert. This later section illustrates the
simulation using the SimXpert workspace environment, instead of the Nastran input file(s). While both illustrations
ultimately lead to the same solution, viewing the simulation from these two different viewpoints facilitates a better
understanding of how to perform the simulation.
For example, nug_01am.dat, uses contact body IDs 5 and 6 as the set of elements for the block and cylinder,
respectively; whereas the input file, ch01.bdf, (derived from the SimXpert workspace’s database, ch01.SimXpert)
uses contact body IDs 1 and 2 as the set of elements for the block and cylinder, respectively. It is important to
understand that while the contact bodies in these two input files are different (they use different IDs with a different
set of elements), they yield the same solution since the loads, boundary conditions, and material properties are
the same.
File Description
nug_01am.dat Linear Elements Without Friction
nug_01aw.dat Same as above but contact bodies are in wrong order
nug_01bm.dat Linear Elements With Friction
nug_01cm.dat Parabolic Elements Without Friction
nug_01dm.dat Parabolic Elements With Friction
ch01.SimXpert SimXpert Model
ch01.bdf Nastran input model (Linear Elements Without Friction)
Chapter 2: 3-D Punch (Rounded Edges) Contact
3-D Punch (Rounded

2 Edges) Contact

Summary 70

Introduction 71

Requested Solutions 71

FEM Solutions 71

Results 74

General Analysis Tips 77

Input File(s) 78

Video 78
CHAPTER 2
Summary
Title Chapter 2: 3-D Punch (Rounded Edges) Contact
Contact features • Axisymmetric/3-D contact
• Analytical deformable body contact
• Friction along deformable-deformable contact plane
• Comparison of linear and parabolic elements
Geometry Axisymmetric and 3-D continuum elements (units: mm)
• Punch Diameter = 100
• Punch Height = 100
• Foundation Diameter = 200
• Foundation Height = 200
• Fillet radius at edge of punch contact = 10
Material properties E punch = 210kN  mm 2 E foundation = 70kN  mm 2   punch =  foundation = 0.3
Analysis type • Linear elastic material

• Geometric nonlinearity
• Nonlinear boundary conditions
Boundary conditions • Symmetry displacement constraints in 3-D model (quarter symmetry)
• Noncontacting surface of the foundation is fixed u x = u y = u z = 0
Applied loads A uniform pressure (distributed load) is applied to the punch in the axial direction,
P = 100N  mm 2
Element type Axisymmetric 3-D continuum

• 4-node linear elements • 8-node linear elements
• 8-node parabolic elements
Contact properties Coefficient of friction  = 0.0 and  = 0.1
FE results 1. Plot of contact pressure versus radius
2. Plot of contact normal force and friction force versus radius
3. Plot of radial displacement and relative tangential slip versus radius
0.005 Radial Displacement (mm)

Radius (mm)
0 20 40 60 80 100
0.000
Friction
-0.005
-0.010
-0.015 No Friction
-0.020 NAFEMS Friction No Friction

CHAPTER 2 71
3-D Punch (Rounded Edges) Contact
Introduction
An axisymmetric steel punch is compressed on an aluminium cylinder. It is assumed that the material behavior is linear
elastic. The punch is loaded by a uniform pressure with magnitude P = 100N  mm 2 in the axial direction. The effect of
friction is studied along the contact zone. Axisymmetric 2-D solutions are used to serve as a target solution for a 3-D
analysis. For the 3-D solutions, one quarter of the assembly is modeled, using symmetry conditions. (Ref: NAFEMS,
2006, Advanced Finite Element Contact Benchmarks, Benchmark 2, 3-D Punch (Rounded Edges) Contact)
Requested Solutions
Both 2-D (axisymmetric) and 3-D solutions are requested. Two solutions, one frictionless and the other using a friction
coefficient of 0.1 between the punch and foundation, are requested. The displacement, force, and stress fields in the
contact zone (contacting surface of the punch and contacted surface of the foundation) are of interest and are obtained
with both linear and parabolic elements in the axisymmetric case and with linear elements in the 3-D case. The SOL
400 elements specified through suitable extensions to the PLPLANE or PSOLID entries are demonstrated. In the 3-D
case, solutions obtained with these elements are also compared to those obtained using existing HEX elements.
The solutions presented include:
• Radial displacement of top contact surface of punch as function of coordinate.
• Contact force, friction force, and contact pressure distributions as a function of coordinate.
FEM Solutions
Numerical solutions have been obtained with MD Nastran’s solution sequence 400 for multiple 2-D axisymmetric and
3-D cases. The axisymmetric cases include linear and parabolic elements, with and without friction. The 3-D case
includes linear elements with and without friction.
The contact, material, geometry, convergence, and other parameters are explained below - primarily with respect to
the axisymmetric linear element case and are representative for both 2-D and 3-D cases.
Contact Parameters
The element mesh using axisymmetric linear elements is shown in Figure 2-1 and is further described as follows: Two
contact bodies, one identified as the punch and the other identified as the foundation, are used. Pressure is applied at
the top of the punch in the axial direction. The bottom of the punch, in turn, compresses the foundation. Typical
element length along the punch and foundation is 4 mm and 3.5 mm, respectively. Contact body ID 4 is used to identify
the punch and body ID 5 is used to identify the foundation.
BCBODY 4 2D DEFORM 4 0 .1 -1
BSURF 4 1 2 3 4 5 6 7
........
BSURF 5 229 230 231 232 233 234 235
..........
CHAPTER 2
BCBODY with ID 4 is identified as a two-dimensional deformable body with BSURF ID 4 and friction coefficient of
0.1. Furthermore, -1 on the 8th field indicates that BCBODY 4 is described as an analytical body, wherein the discrete
facets associated with the element edges are internally enhanced by using cubic splines. Since the punch has rounded
edges in the contact zone, using an enhanced spline representation of the punch yields better accuracy. The minus sign
indicates that the nodal locations defining the spline discontinuities are automatically determined. Note that since the
foundation is a rectangular shape with sharp angles, using the spline option with this body is not necessary since it
would only increase the computational cost without an associated improvement in accuracy.
Figure 2-1 Element Mesh used for Axisymmetric Case in MD Nastran (Benchmark 2)
The BCTABLE bulk data entries shown below identify the touching conditions between the bodies:
BCTABLE 0 1
SLAVE 4 0. 0. .1 0. 0 0.
0 0 0
MASTERS 5
BCTABLE 1 1
SLAVE 4 0. 0. .1 0. 0 0.
0 0 0
MASTERS 5
BCTABLE with ID 0 is used to define the touching conditions at the start of the analysis. It should be noted that this is
a required option that is required in SOL 400 for contact analysis. It is flagged in the case control section through the
optional BCONTACT = 0 option. Note that BCTABLE 0 and other contact cards with ID 0 (e.g., BCPARA 0) would be
applied at the start of the analysis even without the BCONTACT = 0 option. For later increments in the analysis,
CHAPTER 2 73
BCONTACT = 1 in the case control section indicates that BCTABLE with ID 1 is to be used to define the touching
conditions between the punch and the foundation.
The BCPARA bulk data entry shown below for the frictional linear axisymmetric case defines the general contact
parameters to be used in the analysis:
BCPARA 0 NBODIES 2 MAXENT 84 MAXNOD 84
FTYPE 6 BIAS 9.0E-01 ISPLIT 3 RVCNST 1.0E-04
Note that ID 0 on the BCPARA option indicates that the parameters specified herein are applied right at the start of the
analysis and are maintained through the analysis unless some of these parameters are redefined through the BCTABLE
option. Important entries under BCPARA option include FTYPE - the friction type, RVCNST - the slip-threshold value
and the BIAS - the distance tolerance bias. As per general recommendation, BIAS is set to 0.9 (note that the default
value of BIAS is 0.9). For the frictional case, FTYPE is set to 6 (bilinear Coulomb model) and RVCNST is set to 1e-4
(this is a non-default value that is used in this particular problem - the need for a non-default value is discussed in more
detail later). Note that when other parameters on the BCPARA option like ERROR (distance tolerance), FNTOL
(separation force) are not specified, left as blank or specified as 0, program calculated defaults are used. It should also
be noted that while the BCPARA parameters generally apply to all the bodies throughout the analysis, some of the
parameters like ERROR, BIAS, FNTOL can be redefined via the BCTABLE option for specific body combinations and
for specific times through the analysis.
Material/Geometry Parameters
The two material properties used herein for the punch and foundation are isotropic and elastic with Young’s modulus
and Poisson’s ratio defined as
$ Material Record : steel
MAT1 1 210000. .3
$ Material Record : aluminum
MAT1 2 70000. .3
For the 2-D case, axisymmetric elements are chosen via the CQUADX option pointing to a PLPLANE entry which in
turn, points to an auxiliary PSHLN2 entry as shown below.
PLPLANE 1 1
PSHLN2 1 1 1 +
+ C4 AXSOLID L +
+ C8 AXSOLID Q
where the C4 entries indicate that linear 4-noded full integration axisymmetric solid elements are to be used and the
C8 entries indicate that parabolic 8-noded full integration axisymmetric solid elements are to be used. Note that the
PSHLN2 entry enables SOL 400 to access a robust 2-D element library featuring linear and parabolic plane stress,
plane strain or axisymmetric elements. Multiple element topologies (4-noded, 6-noded, 8-noded) can be defined as
plane stress, plane strain, or axisymmetric through the PSHLN2 options. These elements which can be used for
isotropic/orthotropic/ anisotropic elastic/elasto-plastic applications augment previous SOL 400 hyperelastic element
technology that could be used in conjunction with the PLPLANE and MATHP options.
For the 3-D case, hex elements are chosen via the CHEXA option pointing to a PSOLID entry. For elastic or small strain
applications, the user has two choices: Use existing 3-D solid elements with just the PSOLID option or use 3-D solid
element technology accessed by the PSOLID entry pointing to an auxiliary PSLDN1 entry. For large strain elasto-
plastic applications, the user should always use the 3-D solid elements; i.e., the primary usage of the 3-D solid
CHAPTER 2
elements is for large strain elasto-plasticity for which the PSLDN1 + NLMOPTS,LRGSTRN,1 bulk data entry is
recommended. However, as in the current example, these elements can also be used for elastic applications when used
in conjunction with PSLDN1 and with NLMOPTS,ASSM,ASSUMED entry.
Convergence Parameters
The nonlinear procedure used is defined through the NLPARM entry:
NLPARM 1 10 PFNT 0 25 UP YES
where 10 indicates the total number of increments; PFNT represents Full Newton-Raphson Technique, wherein the
stiffness is reformed at every iteration; KSTEP = 0 in conjunction with PFNT indicates that the program
automatically determines whether the stiffness needs to be reformed after the previous load increment is completed
and the next load increment is commenced. The maximum number of allowed recycles is 25 for every increment and
if this were to be exceeded, the load step would be cut-back and the increment repeated. UP indicates that convergence
will be checked using both displacements (U) and residual criteria (P). YES indicates that intermediate output will be
produced after every increment (note that this has been turned to NO for the 3-D case due to voluminous output). The
second line of NLPARM is omitted here, which implies that default convergence tolerances of 0.01 will be used for U
and P. It should be noted that the PFNT iterative method used conducts checking over incremental displacements and
is generally more stringent than for the FNT iterative method which convergence is checked over weighted total
displacements.
Case Control Parameters

Some of the case control entries to conduct these analyses are highlighted as follows: SUBCASE 1 indicates the case
being considered. There are no STEP entries in this analysis since a single loading sequence is being considered. For
multiple loading sequences that follow one another, STEP entries can be used within a single SUBCASE to identify
each sequence. BCONTACT = 1 is used to indicate the contact parameters for SUBCASE 1. NLPARM = 1 is used to flag
the nonlinear procedure for SUBCASE 1. In addition to regular output requests like DISPLACEMENTS, STRESSES,
the option that is required for contact related output in the F06 file is BOUTPUT. It should be noted that with the
BOUTPUT option, one can obtain normal contact forces, frictional forces, contact normal stress magnitudes, and
contact status for the contact nodes.
Results
The radial displacements obtained for the frictionless and frictional cases for the linear axisymmetric element case are
compared in Figure 2-2. The results match very well with the corresponding NAFEMS results (Benchmark 2 of
NAFEMS 2006).
It is noteworthy to study the effect of the slip threshold value, RVCNST, on the friction results. The radial
displacements for two different values of RVCNST are compared in Figure 2-3. It is seen that RVCNST has a significant
influence on the radial displacements. It should be noted that the default value of RVCNST is calculated as 0.0025 times
the average edge length of all elements that can participate in contact. For the linear axisymmetric problem, the default
RVCNST is of the order of 0.015. Relative radial displacements which are smaller than this value imply a transition
CHAPTER 2 75
zone and the frictional force linearly increases from 0 to the peak value within this zone. In order to capture the
frictional force and the relative sliding more accurately, a smaller value of RVCNST (= 1e-4) is required in this
problem. In general, for friction problems, a good check to be made from the f06 file or by postprocessing is whether
the friction force is of the order of F n , where  is the friction coefficient and F n is the nodal contact normal force.

Radius (mm)
0 20 40 60 80 100
0.000
Friction
-0.005
-0.010
-0.015 No Friction
Figure 2-2 Radial Displacement as Function of the Radial Coordinate (friction coefficient =0.0 and 0.1)
Obtained with Linear Axisymmetric Elements
Radial Displacement (mm)

0.005
Distance (mm)
0 20 40 60 80 100
0.000
μ = 0.1 RVCNST=1e-4
-0.005
-0.010
μ = 0.1
RVCNST=default
-0.015
No Friction
-0.020
Figure 2-3 Effect of slip threshold value, RVCNST, on Radial Displacement
The contact normal force and friction force along the punch for the linear axisymmetric element is plotted in
Figure 2-4. It is instructive to check that equilibrium is well-maintained (the sum of the contact forces transmitted via
the punch should be equal to the total force being applied to the punch). It can be shown that the sum of all contact
forces at the punch-foundation interface is within .03% of the total force applied on the punch
2
=PR punch = 10050 2 = 7.85e5N . Also, the friction forces are about 0.1 times the contact normal forces.
CHAPTER 2
The contact pressure is plotted for the contacting nodes for both the linear and parabolic axisymmetric elements of the
punch in Figure 2-5. The parabolic solution shows a rather oscillating type of behavior. Also, as may be expected, the
parabolic solution shows a more localized stress peak. These trends are consistent with the NAFEMS benchmark 2
results. The oscillatory behavior can be improved by refining the mesh in the contact zone (and the surrounding part
assuring connection with the remaining part of the structures).
Force (N)
350000
300000
250000 Contact Normal
200000 Force
150000
Contact Friction
100000 Force
50000
Distance (mm)
0
0 10 20 30 40 50 60
Figure 2-4 Contact Normal Force and Friction Force at Punch as a Function of Radial Coordinate Along
Punch-Foundation Contact Interface
Contact Normal Stress (N/mm 2)

800
Parabolic Elements
700
600
Linear Elements
500
400
300
200
100 Distance (mm)
0
0 10 20 30 40 50 60
Figure 2-5 Variation of Contact Normal Stress Along Radial Coordinate of Punch for Linear and
Parabolic Axisymmetric Elements
The displacement contours in the punch for the 3-D frictional case are shown in Figure 2-6. The left-hand side shows
the solution for the 3-D solid elements identified through the PSOLID + PSLDN1 options. The right-hand side shows
CHAPTER 2 77
the solution for the existing 3-D solid elements identified through the PSOLID options only. As seen, the solutions are
very close to each other.
Figure 2-6 Comparison of Punch Displacement Contours in Two different Solid Elements Available in
SOL 400
General Analysis Tips

• While the contact checking algorithm in SOL 400 provides a number of options for the searching order via the
ISEARCH parameter on the BCTABLE option, the user should be aware of a few recommendations regarding
the touching (slave) body and the touched (master) body: The touching body should be convex, generally be
less stiff, and be more finely meshed than the touched body. This allows for better conditioning of the
matrices and provides for better nodal contact. Note that these recommendations may not all be satisfied at the
same time; for example, in this benchmark, the punch which has been identified as the first body is convex
and smaller than the foundation but has a slightly coarser mesh and is somewhat stiffer than the foundation.
• The accuracy of the friction solution should be judged by checking that the frictional forces at the nodes are
generally equal to F n . If this is violated, the slip-threshold value, RVCNST, may need to be adjusted. Note
also that to ensure a quality solution with friction, in general, the incremental displacements need to converge
well. This can be ensured by using PFNT on the NLPARM option and checking on U.
• The PSHLN2 entry in conjunction with PLPLANE entries allows the users to flag 2-D elements for plane
stress, plane strain, or axisymmetric applications with isotropic/orthotropic/ anistropic elastic/elasto-plastic
materials. Similarly, PSLDN1 entries in conjunction with PSOLID entries allows the users to flag nonlinear
3-D solid continuum elements. The 2-D elements offer a range of abilities for small strain and large strain
elastic/elasto-plastic analysis. The fundamental application of the 3-D elements is for large strain elasto-
plastic applications, wherein use should be made of the NLMOPTS,LRGSTRN,1 option to flag appropriate
element behavior. It should be noted that the 3-D elements can also be used in the elastic regime (as in this
current example - see nug_02em.dat). In such situations, it is highly recommended that one not use
NLMOPTS,LRGSTRN,1 but use NLMOPTS,ASSM,ASSUMED to ensure better behavior in elastic bending.
Existing 3-D element technology for SOL 400 can be used for elastic applications too (see nug_02en.dat
for example). In this case, one simply uses PSOLID without the PSLDN1 addition.
CHAPTER 2
• For the axisymmetric case, the pressure load is applied through PLOADX1. It should be noted that the pressure
value to be specified on the PLOADX1 option is not the force per unit area  100N  mm 2  but the pressure over a
circular ring of angle 2 Accordingly, on the LOAD bulk data entry, the pressure load is scaled by a value of
2 
Input File(s)
File Description
nug_02am.dat Axisymmetric Linear Elements Without Friction
nug_02bm.dat Axisymmetric Linear Elements With Friction
nug_02cm.dat Axisymmetric Parabolic Elements Without Friction
nug_02dm.dat Axisymmetric Parabolic Elements With Friction
nug_02em.dat 3-D Linear Elements Without Friction - PSLDN1 used along with PSOLID to flag nonlinear
HEX elements
nug_02en.dat 3-D Linear Elements Without Friction - existing HEX element technology flagged through
PSOLID
nug_02fm.dat 3-D Linear Elements With Friction - PSLDN1 used along with PSOLID to flag nonlinear
HEX elements
nug_02fn.dat 3-D Linear Elements With Friction - existing HEX element technology flagged through
PSOLID
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately 18 minutes and
explains how the steps are performed.

Radius (mm)
0 20 40 60 80 100
0.000
Friction
-0.005
-0.010
-0.015 No Friction
Figure 2-7 Video of the Above Steps

Chapter 3: 3-D Sheet Metal Forming
3 3-D Sheet Metal Forming

Summary 80

Introduction 81


FEM Solutions 82

Modeling Tips 92

Input File(s) 93

Video 93
CHAPTER 3
Summary
Title Chapter 3: 3-D Sheet Metal Forming
Contact features • Rigid and deformable bodies
• Mesh dependency
• Elasticity, plasticity and spring back
• Sliding contact around circular surface
Geometry 2-D Plane strain elements or shell elements (units: Original
Position
mm)
Punch
• Punch radius = 23.5 Sheet

Final
• Die radius R2 = 25.0 W

Position
• Die shoulder R3 = 4.0

R2
R3
Die
• Width of tools = 50.0

• Length of sheet (initially) =120.0
• Thickness of sheet = 1.0
• Width of sheet = 30.0
• Punch stroke = 28.5
Material properties • Young’s modulus: E = 70.5kN  mm 2 • Hollomon hardening:
• Poisson’s ratio:  = 0.342  = K n
• Initial yield stress:  0 = 194N  mm 2 K = 550.4N  mm 2
n = 0.223
Analysis type • Quasi-static analysis

• Elastic plastic material (isotropic hardening)
• Nonlinear boundary conditions
Displacement boundary • Symmetric displacement restraints (half symmetry).
conditions • Bottom surface fixed.
• Prescribed vertical displacement for the punch.
Element type 2-D Plane strain - 4-node linear elements; 3-D Shell - 4-node shell elements
Contact properties Coefficient of friction  = 0.1342
FE results 1. Forming angle and angle after release
2. Plot of punch force versus punch displacement compared to experimental values
2D Plane Strain With Friction
300 Punch Force (N)
SOL 400
250
Marc
200
150
100 Experimental
50
0
0 5 10 15 20 25 30
Punch Displacement (mm)
CHAPTER 3 81
3-D Sheet Metal Forming
Introduction
This benchmark problem is an approximation of the Numisheet 2002 – Benchmark B problem. Simulations are carried
out using MD Nastran solution sequence 400 to find the angles before and after spring back. Experimental results are
available for this benchmark, but it is noted that the sheet is slightly anisotropic. The text setup and reference details
of these experimental results are given in Figure 3-1. The current problem uses an isotropic elastic-plastic hardening
behavior.
SOURCE
FREE BENDING BENCHMARK TESTING OF 6111-T4 ALUMINUM ALLOY SAMPLE
John C. Brem*, Frederic Barlat**, Joseph M. Fridy** Alcoa Technical Center, Pennsylvania,
Numisheet 2002 Conference, Korea
Figure 3-1 Test Setup for Numisheet 2002 - Benchmark B Problem
Two solutions: one using friction coefficient 0.1342 (bilinear Coulomb friction model) between the sheet and both
tools, and one frictionless solution are requested for:
• Forming angle (the angle  at the end of the punch stroke)
• Angle after release (the angle after tool removal)
• Punch force - punch displacement diagram
Figure 3-2 shows the definition of angle  . The solutions, obtained with shell elements and plane strain elements,
include the following:
• Element size (in particular near the curved zones)
• Method used in discretization of the tools
• Method for normal contact detection (hard/direct contact)
• Method for stick slip approximation (bilinear Coulomb friction model)
CHAPTER 3
Unit: mm
A C
20 20
B D
20
y
x θ D
Figure 3-2 Requested Angles for Benchmark 3
FEM Solutions
FEM solutions have been obtained with MD Nastran’s solution sequence 400 for the 2-D plane strain and 3-D shell
representations of the present sheet metal forming problem. The details of finite element models, contact simulations,
material, load, boundary conditions, and solution procedure of both the 2-D plane strain and 3-D shell approaches are
discussed.
Finite Element Models

The finite element model used for the 2-D plane strain approach is shown in Figure 3-3. The punch and die are
modeled in analytical form. The finite element mesh for the sheet contains 850 elements with 5 elements over the
thickness. Only half of the sheet is modeled. The applied element lengths can be determined from Table 3-1. MD
Nastran’s 2-D plane strain solid elements with material ID 1 are selected using the following PLPLANE and PSHLN2
entries. The 30 mm for the width of the sheet is specified in PSHLN2 option.
PLPLANE 1 1
PSHLN2 1 1 1 30.0 +
+ C4 PLSTRN L
CHAPTER 3 83
Figure 3-3 FE Model for 2-D Plane Strain Approach
Table 3-1 Number of Elements in Length Direction (2-D Plane Strain Model)
Position Number of Elements
0  x  27mm 50
27  x  40.2mm 100
40.2  x  60mm 20
The finite element model used for the 3-D shell approach is presented in Figure 3-3. Also, in this case, only half of the
plate has been modeled with appropriate symmetry conditions at the middle of the plate. The sheet is modeled using
1020 thick shell elements with 6 elements across the width and 170 elements along the length (as in Table 3-2). MD
Nastran’s thick shell elements with material ID 1 are selected using the following PSHELL and PSHLN1 entries. The
thickness 1 mm for the sheet is specified in PSHELL option.
PSHELL 1 1 1. 1 1
PSHLN1 1 1 1 NO +
+ C4 DCT L
Figure 3-4 FE Model for 3-D Shell Approach

CHAPTER 3
Table 3-2 Number of Elements in Length Direction (Benchmark 3)

Position Number of Elements
0  x  40mm 160
40  x  60mm 10
Contact Models
In defining the contact model for the 2-D plane strain case, the sheet is modeled as a deformable body and the punch
and die are modeled as rigid bodies. Elements comprising the sheet are used to generate a deformable contact body
with ID 4 using the following BCBODY and BSURF entries. Contact body ID 5 is used to define the load controlled
rigid body with a control node ID 1 for the punch and contact body ID 6 is used to define the position controlled rigid
body for the die. The geometry profiles of these rigid bodies are defined using 2-D NURB curves that describe the true
surface geometry and most accurately represent the punch and die geometry. The friction factor of 0.1342 is defined
for all these contact bodies.
BSURF 4 1 2 3 4 5 6 7
...
BCBODY 5 2D RIGID 0 .1342 1 1
0 0. 0. 0. 0. 0. 0. 0.
RIGID 1 4 CBODY2
NURBS2D -3 3 50
...
BCBODY 6 2D RIGID 0 .1342 1 -1
0 0. 0. 0. 0. 0. 0. 0.
RIGID 0 6 CBODY3
NURBS2D -2 2 50
...
The contact bodies for the 3-D shell models are also defined in similar way with the punch and die surfaces defined
using 3-D NURB surfaces. The following BCBODY entries are used to define contact bodies for 3-D shell model. The
control node ID 1198 is used in this case to define the load controlled rigid body for the punch.
BSURF 1 1 2 3 4 5 6 7
...
BCBODY 2 3D RIGID 0 .1342 1 1198
0 0. 0. 0. 1. 0. 0. 0.
RIGID 1198 1 CBODY2
NURBS -19 4 4 4 50 50 14
...
BCBODY 3 3D RIGID 0 .1342 1 -1
0 0. 0. 0. 1. 0. 0. 0.
RIGID 0 5 CBODY3
NURBS -7 13 4 4 50 50 0
...
The following BCPARA bulk data entry defines the general contact parameters to be used in the analysis. The ID 0 on
the BCPARA option indicates that the parameters specified herein are applied right at the start of the analysis and are
maintained through the analysis unless some of these parameters are redefined through the BCTABLE option.
Important entries under BCPARA option include: FTYPE – the friction type and the BIAS - the distance tolerance bias.
For all the models, the bias factor, BIAS, is set to 0.99. The bilinear Coulomb friction model is activated by setting
FTYPE to 6. For the models without friction, FTYPE is set as 0.
BCPARA 0
BIAS .99 FTYPE 6
CHAPTER 3 85
The following BCTABLE entries identify how the contact bodies can touch each other. The BCTABLE with ID 0 is used
to define the touching conditions at the start of the analysis. This is a mandatory option required in SOL 400 for contact
analysis and is flagged in the case control section through the optional BCONTACT = 0 option. Similar BCTABLE
options with ID 1, 2 and 3 are used to define the touching conditions for later steps in the analysis, and it is flagged
using the option BCONTACT = n (where n is the step number 1, 2 or 3) in the case control section. Two contact pairs
are defined in the BCTABLE option: one between the sheet and punch and one between the sheet and die. Both the 2-
D plane strain and 3-D shell models have similar BCTABLE entries.
BCTABLE 0 2
SLAVE 4 0. 0. .1342 0. 0
0 0 0
FBSH 1.+20 .99 0.
MASTERS 5
SLAVE 4 0. 0. .1342 0. 0
0 0 0
FBSH 1.+20 .99 0.
MASTERS 6
Material
The isotropic elastic and elastic- plastic material properties of the sheet are defined using the following MAT1, MATEP,
and TABLES1 options. The Hollomon hardening behavior,  = K n with K = 550.4N  mm 2 ,and n = 0.223 is
represented in the form of stress-strain data defined in TABLES1 option.
MAT1 1 70500. .342 1.
MATEP 1 Table 1 Isotrop Addmean
TABLES1 1 2
0. 194. .02 230.043 .04 268.496 .06 293.904
.08 313.378 .1 329.365 .2 384.423 .3 420.802
.4 448.681 .5 471.573 .6 491.14 .7 508.317
.8 523.682 .9 537.619 1. 550.399 1.1 562.224
1.2 573.239 1.3 583.564 1.4 593.287 ENDT
The following NLMOPTS entry enables large strain formulation using additive plasticity with mean normal return.
NLMOPTS,LRGS,1
Loading and Boundary Conditions
The following set of boundary conditions has been applied for both 2-D plane strain and 3-D shell models:
• Symmetry conditions (i.e., no displacement in horizontal direction) have been applied to the left size of the
strip
• For the position controlled rigid body used for the die surface, all degrees of freedom have been suppressed.
For the control node of the load controlled rigid body used for the punch surface, the displacement
components in horizontal directions are suppressed, while the displacement in vertical direction is specified as
a function of the time (refer to Table 3-3).
CHAPTER 3
Table 3-3 Vertical Displacement of Punch as a Function of Time

Time Vertical Displacement
0.0 0
1.0 -28.5
2.0 -28.5
3.0 0
The following data in the case control section of the input file defines the load and boundary conditions at the four
different steps of the analysis. The bulk data entries SPCD, SPCR and SPC1 are used to define the loads in these steps.
The SPCD data presented here shows the application of the imposed downward displacement of 28.5 in vertical
direction in steps 1 and 2 at node 1 for the 2-D plane strain model. A similar imposed displacement is applied at node
1198 for the 3-D shell model. The SPCR data presented here shows the application of the imposed upward relative
displacement of 10.0 in vertical direction in step 3 and its fixation in step 4 at node 927 for the 2-D plane strain model.
A similar imposed relative displacement is applied at node 1167 for the 3-D shell model.
SUBCASE 1
STEP 1
NLSTEP = 1
BCONTACT = 1
SPC = 2
LOAD = 1
STEP 2
NLSTEP = 2
BCONTACT = 2
SPC = 2
LOAD = 2
STEP 3
NLSTEP = 3
BCONTACT = 3
SPC = 3
LOAD = 3
$ Loads for Load Case : step-1
SPCADD 2 7 9
SPCD 1 1 2 -28.5
SPC1 7 1 2 3 4 5 6 7
SPC1 9 12 1
SPCD 2 1 2 -28.5
SPCADD 3 7 8 9
SPCD 3 1 2 -18.5
SPCR 3 927 2 10.
SPC1 8 2 927
Solution Procedure
The present analysis of metal forming and gradual spring back is carried out in four different steps on both the 2-D
plane strain and 3-D shell models. In each of these models, the analysis has been carried out for the cases with and
without friction using SOL 400 in MD Nastran. The first step analyses the metal forming process, the second step is
used to achieve a more accurate solution before the spring back analysis starts in steps 3 and 4.
In the first step, the metal forming operation is simulated by applying a vertical downward displacement of punch. The
nonlinear procedure is defined through the following NLSTEP entry with ID 1. Here 100 indicates the total number
CHAPTER 3 87
of increments; PFNT represents Pure Full Newton-Raphson Technique wherein the stiffness is reformed at every
iteration; 500 is the maximum number of allowed recycles for every increment. UP indicates that convergence will
be checked on displacement (U) and residuals (P). The 0.01 defined in the fourth line of NLSTEP indicates the
convergence tolerances of 0.01 for displacement and residual checking. The negative sign of displacement tolerance
indicates that iteration on displacements will be checked against the incremental displacement quantity instead of total
displacement.
The second step is considered to be a dummy one in which the load applied in the first step is maintained with very
fine convergence tolerances on displacement and residual. This step is used to ensure that the model reaches the good
equilibrium condition at the end of step 2 and before starting step 3 involving the more complex spring back operation.
It can be seen from the NLSTEP ID 3 that this spring back operation is done over 200 increments with a convergence
check only on displacement.
NLSTEP 1 1.
GENERAL 500 1 10
FIXED 100 1
MECH UP -0.01 0.01 PFNT -1
0 0
NLSTEP 2 1.
GENERAL 500 1 10
FIXED 10 1
MECH UP -0.0001 0.0001 PFNT -1
0 0
NLSTEP 3 1.
GENERAL 500 1 10
FIXED 200 1
MECH U -0.01 PFNT -1
0 0
To restrict rigid body movement during the springback step-3, a spring with very small stiffness (1e-5) is added at the
free end using the following CELAS1 and PELAS cards.
CELAS1 851 2 927 2
PELAS 2 1.E-5
Results
The characteristic deformed stages from the 2-D plane strain analysis without friction and with friction during the
forming step are shown in Figure 3-5. The deformed shapes during the release in various stages are shown in
Figure 3-6.
CHAPTER 3
Figure 3-5 Various Deformed Stages during Forming Step

CHAPTER 3 89
Figure 3-6 Various Deformed Stages during Spring Back Step
In the analysis without friction, contact is initially present between the sheet and the lower section of the punch. Near
the end of the deformation, the sheet separates at the lower section of the punch and gets in contact with the lower
section of the die. As soon as this contact is detected, the sheet is further bent into the final shape and the required force
in the force displacement history curve increases (Figure 3-5). In the analysis with friction, the deformation behavior
is different. The tangential forces due to friction result in a stretching of the sheet causing contact between the punch
and the sheet to be present during the complete forming history.
The characteristic load displacement curves for the analysis from SOL 400 without friction and with friction are shown
in Figure 3-7. The differences in the shape of the curves are caused by the different contact conditions at the end of
the forming stage.
CHAPTER 3
2D Plane Strain MD Sol 400

350 Punch Force (N)
300
250 No Friction
200
150
With Friction
100
50
0
0 5 10 15 20 25 30
-50
Figure 3-7 Load Displacement Diagram for 2-D Plane Strain Model
Observe that the unloading stage is analyzed in two steps. In the first unloading step the punch and the strip are moved
simultaneously in upward direction. This releases the strip from the die, while it remains in contact with the punch. In
the second unloading step the strip is fixed in vertical direction while the punch is moved further upward to its original
position. This gradually releases the strip from the punch and allows it to spring back to its final configuration. Note
that the fixation of the strip is such that there are no reaction forces after it has lost contact with both the die and the
punch. This, of course, is a requirement in order to capture the proper spring back behavior. The fixation primarily
serves to suppress rigid body motions of the model during the unloading stage.
The characteristic values of the angles at the end of the forming stage and after removal of the tool are listed in
Table 3-4.
Table 3-4 Characteristic Angles during Forming and Release Process (2-D Plane Strain Model)
Friction Coefficient Forming Angle Angle After Release
0 20.42 46.24
0.1348 20.35 54.56
A comparison of the results obtained with Marc and SOL 400 of MD Nastran is shown in Figure 3-8 (no friction) and
Figure 3-9 (friction). In the last figure, a comparison is also made with the experimental result. The results from SOL
400 are found to be on the higher side, particularly towards the end of forming. The results exhibit more oscillations
in the load displacement curve and this is caused by the use of hard contact approach in Marc and SOL 400. It should
be noted that no experimental data points are reported for the unloading.
CHAPTER 3 91
2D Plane Strain No Friction

300 Punch Force (N)
250
No Friction Marc
200
150
100
No Friction MD SOL 400
50
0
0 5 10 15 20 25 30
Figure 3-8 Load Displacement Curves from Marc and SOL 400 (without friction)
2D Plane Strain With Friction

300 Punch Force (N)
SOL 400
250
Marc
200
150
100 Experimental
50
0
0 5 10 15 20 25 30
Figure 3-9 Load Displacement Curves from Marc and SOL 400 (with friction)
The results of analyses from 3-D shell models have been compared with the plane strain analysis for both the cases
with and without friction. The load displacement curves for these two models are shown in Figure 3-10 (no friction)
and Figure 3-11 (friction=0.1348).
2D & 3D No Friction
300 Punch Force (N)
250 3D
200
150
100 2D
50
0
0 5 10 15 20 25 30
Figure 3-10 Comparison of Plane Strain and Shell Analyses (no friction)
CHAPTER 3
2D & 3D With Friction

300 Punch Force (N)
250
200
150 3D
100 2D
50
0
0 5 10 15 20 25 30
Figure 3-11 Comparison of Plane Strain and Shell Analyses (friction = 0.1348)
The resulting values of the characteristic angles are listed in Table 3-5 (no friction) and Table 3-6 (with friction). For
the case with friction, the results are compared with experimental predictions from Numisheet 2002. The predictions
of SOL 400 from both 2-D plane strain case and 3-D shell models are found to match well with the experiment.
Table 3-5 Comparison of Angles for Plane Strain and Shell Approach (no friction)
Forming Angle Angle After Release
Plane strain 20.42 46.24
Shell 20.38 46.67
Table 3-6 Comparison of Angles for Plane Strain and Shell Approach (Friction 0.1348)
Forming Angle Angle After Release
Plane strain 20.35 54.56
Shell 20.45 54.07
Numisheet 19.6 to 21.0 53.4 to 55.8
Modeling Tips
One of the complicating characteristics in this benchmark problem is a very local contact between the plate and the
curved shoulders of the die. In fact, the contact is almost a point (2-D) or line (3-D) contact with a large amount of
sliding. Contact is only verified between the nodes of the plate and the rigid dies. Hence, in the discrete steps of the
displacement history, points can be identified where no contact is detected; especially, if large elements are used near
the shoulder of the die.
The following are some guidelines and tips for modeling this benchmark:
• A fine mesh has to be used to describe the contact of the nodes of the sheet with the die properly
• A smooth representation of the die has to be chosen, either in an analytical form or by a piecewise linear curve
using a high number of segments
CHAPTER 3 93
• The unloading behavior is characterized by removal of the tools and at the same time adding boundary
conditions preventing the possibility of rigid body movement.
• The unloading behavior should preferably be done in a number of steps. Note that in these steps low values of
the normal and, consequently, the friction forces are present which makes it difficult to obtain a converged
solution
• Numerical damping is often recommended to stabilize the solution, but it can be shown that this greatly
influences the accuracy of the solution.
Input File(s)
File Description
nug_03a.dat MD Nastran SOL 400 input for 2-D plane strain model (without friction)
nug_03b.dat MD Nastran SOL 400 input for 2-D plane strain model (with friction)
nug_03c.dat MD Nastran SOL 400 input for 3-D shell model (without friction)
nug_03d.dat MD Nastran SOL 400 input for 3-D shell model (with friction)
Video
Original
Punch Position
Sheet
Final
Position
W
R2
R3
Die

Chapter 4: 3-D Loaded Pin with Friction
4 3-D Loaded Pin with Friction

Summary 95

Introduction 96

Required Solution 96

FEM Solutions 96


Input File(s) 101

Video 101
CHAPTER 4 95
3-D Loaded Pin with Friction
Summary
Title Chapter 4: 3-D Loaded Pin with Friction
Contact features • Receding contact area
• Friction along the contact surface
Geometry 3-D continuum (units: mm) L1
• L1 = 200 R2
H θ
• L2 = 20 R1
• R1 = 50
t
• R2 = 100
F
• H = 100
2
L
• t = 10 F
Material properties E pin = 210kN  mm 2 , E sheet = 70kN  mm 2 ,  sheet =  pin = 0.3
Analysis type • Quasi-static analysis

• Linear elastic material
Displacement boundary • Symmetric displacement constraints (quarter symmetry).
conditions and • Left side of sheet is fixed.
applied loads • Two equal point forces, resulting in a total force on the pin of 100kN .
Element type 3-D Continuum - 8-node linear elements
Contact properties • Deformable-to-deformable bodies contact
• Coefficient of friction  = 0.1
FE results 1. Plot of contact pressure against angle 
2. Plot of tangential stress against angle 
3. Plot of relative tangential slip against angle  .
Displacement X (mm)
0.8
Pin_x
0.7
0.6
0.5 Strip_x
0.4
0.3
0.2
Angle (degrees)
0.1
0 60 120 180 240 300 360
CHAPTER 4
Introduction
This application example evaluates the performance of contact algorithms at curved boundaries between deformable
bodies. A cylindrical pin is located in the cylindrical hole of a strip. The diameters of the hole and the pin are identical.
Two equal point forces are applied to the center of the end surfaces of the pin. It is assumed that the tangential contact
forces can be described with a Coulomb friction model using friction coefficient 0.1. Due to the symmetry condition,
a quarter of the assembly is sufficient for the finite element analysis.
Required Solution
The displacement components and contact normal and tangential forces are of interest. In addition, the relative
tangential slips along the contact surfaces of the two bodies as functions of angle  (see Figure 4-1) are also worth
investigating. One analysis is conducted with MD.Nastran SOL 400 with standard HEX elements and compared with
available advanced HEX elements. In the current version of MD Nastran SOL 400, the advanced HEX elements are
defined by a PSOLID entry pointing to an auxiliary PSLDN1 entry.
Figure 4-1 Angle Definition in Requested Displacement Field
FEM Solutions
Numerical solutions have been obtained with MD Nastran solution sequence 400 for the 3-D case. First, the advanced
3-D elements are used to conduct the analysis with contact and friction. In comparison, the same analysis is also
conducted with the standard 3-D solid elements.
The contact, material/geometry, solution/convergence schemes and other parameters are explained below.
Contact Parameters
The element mesh using the 3-D solid element is shown in Figure 4-2. The contact body named as cbody1 (shown
in pink) represents the pin. The contact body named as cbody2 defines the strip. A point load (black arrow) is applied
at the center point of top end of the pin. It should be noted that the symmetry has been taken into consideration.
CHAPTER 4 97
Figure 4-2 FE Model for the Numerical Solution
In the input data file, the contact bodies are defined as below:
BSURF 1 1 2 3 4 5 6 7
Ö.
BCBODY 2 3D DEFORM 2 0 .1 -1
BSURF 2 2296 2297 2298 2299 2300 2301 2302
Ö.
The BCBODY with ID 1 defines the pin as a three-dimensional deformable body. The BCBODY with ID 2 defines the
sheet also as a three-dimensional deformable body. Furthermore, BCBODY 2 is described as an analytical body by set
value of –1 at the 8th field.
The BCTABLE bulk data entries shown below define the touch conditions between the bodies:
BCTABLE 0 1
SLAVE 1 0. 0. .1 0. 0
1 1 0
FBSH 1.+20 .99 0.
MASTERS 2
BCTABLE 1 1
SLAVE 1 0. 0. .1 0. 0
1 1 0
FBSH 1.+20 .99 0.
MASTERS 2
As shown above, BCTABLE with ID 0 is used to define the contact touching conditions at the start of the analysis. Zero
(0) identifies the case number. The BCTABLE entry is mandatory for the contact analysis with SOL 400. Also, the
options (BCONTACT with ID 0 and BCPARA with ID 0) are all applied at the start of the analysis. For the loading
analysis defined as load case 1 under the case control section, the contact touching conditions are redefined by options
of BCTABLE, BCPARA, and BCONTACT with ID 1. In this example, the BCPARA is only defined once because the
parameters specified herein are applied through the analysis from the beginning unless some of these parameters are
redefined by BCTABLE entry with ID 1. It should be mentioned is that the BIAS parameter is defined as 0.99 (the
default value is 0.9).
CHAPTER 4
BCPARA 0
BIAS .99 FTYPE 6
The both bodies in this analysis are defined as isotropic elastic materials. The Young’s modulus and Poisson ratio are
defined as:
MAT1 1 210000. .3 1.
MAT1 2 70000. .3 1.
As shown above, the material IDs are given as 1 and 2 for the pin and the sheet, respectively.

There is a single loading sequence in the analysis. The control parameters are defined by the NLPARM option. As
shown below, SUBCASE with ID 1 defines all necessary conditions applied to the analysis which includes bulk data
options: TITLE, NLPARM, BCONTACT, SPC, LOAD, and requested output information. Particularly, it is necessary to
note the analysis control options NLPARM, NLMOPTS, and the parameter LGDISP. For the FE analysis with SOL 400,
the advanced 8-node 3-D continuum elements are well designed for this type of analysis with large strain and large
displacement. In this example, the NLMOPTS option defines that assumed strain formulation is used. The LGDISP
parameter indicates that geometric nonlinearity includes the stiffness of follower forces. NLPARM defines the loading
schemes used for the analysis. Here, the full Newton-Raphson method is used. The total number of loading increments
is set to 10. The maximum iteration for each increment is set to 25. The default convergence scheme is used and NO
for output of analysis results for intermediate loading steps except for the results at the end of the last loading
increment.
SUBCASE 1
TITLE=This is a default subcase.
NLPARM = 1
BCONTACT = 1
SPC = 2
LOAD = 2
DISPLACEMENT(SORT1,REAL)=ALL
SPCFORCES(SORT1,REAL)=ALL
STRESS(SORT1,REAL,VONMISES,BILIN)=ALL
NLSTRESS(PRINT)=ALL
BOUTPUT (PRINT)=ALL
$ Direct Text Input for this Subcase
BEGIN BULK
NLMOPTS,ASSM,ASSUMED
PARAM LGDISP 1
NLPARM 1 10 PFNT 25 NO
The element type is defined by the PSOLID and PSLDN1 bulk data options as shown below where (C8 SOLI L)
defines the 3-D continuum solid element with linear integration scheme.
PSOLID 1 1 0
PSLDN1 1 1 +
+ C8 SOLI L +
+ C20 SOLI Q
CHAPTER 4 99
Results
Numerical solutions have been done with current versions of MD Nastran SOL 400 and Marc. As seen in Figure 4-3,
a relatively coarse mesh is used for the strip and a fine mesh is used for the pin. The nodes on the pin surface are defined
as slave nodes and the surfaces of the strip are specified as master contact surface in this analysis. In order to describe
the contact body more accurately, the contact surface of the strip is defined analytically. Therefore, a smoother surface
(Coons Patch) is used during the analysis for the strip.
Figure 4-3 Contact Normal Forces on the Contact Surfaces
The resulting contact normal nodal forces are shown in Figure 4-4. The peak value in the contact normal force is found
to be around 1933 N. The peak contact tangential force is found to be around 193 N, which equals to F n . That is
consistent with the coefficient of friction applied during the analysis.
Figure 4-4 Contact Friction Forces on the Contact Surfaces
The displacement in x and y directions along the circular edge of the pin (slave or contacting surface) are shown as
function of the angle in Figure 4-5 and Figure 4-6, respectively.
CHAPTER 4
Displacement X (mm)
0.8
Pin_x
0.7
0.6
0.5 Strip_x
0.4
0.3
0.2
Angle (degrees)
0.1
0 60 120 180 240 300 360
Figure 4-5 Displacement (x) along the Circular Edge of the Pin and the Strip
Displacement Y (mm)
0.10
0.08
0.06 Strip_y
0.04
Pin_y
0.02
0.00
-0.02
-0.04
Angle (degrees)
-0.06
0 60 120 180 240 300 360
Figure 4-6 The Displacement (y) along the Circular Edge of the Pin and the Strip
For the comparison, another solution is obtained by using the existing solid element available in SOL 400. This
element type is defined by PSOLID option only. The results are almost identical. Figure 4-7 compares of the
displacement contours obtained by MD Nastran SOL 400 with the advanced 3-D solid elements and the standard 3-D
solid elements (without PSLDN1 option). It shows that both results are extremely close.
(a) (b)
Figure 4-7 Displacement Contours Obtained by Two Different Solid Elements in SOL 400
CHAPTER 4 101

• Convergence control: While the nonlinearity is quite mild in this problem, it is suggested to use both
displacement and residual convergence check due to the nonlinearity introduced by contact. Also, the full
Newton-Raphson iteration scheme is recommended for all SOL 400 analyses because the degree of
nonlinearity may be significant.
• In this example, the body surface of the pin is defined as slave nodes for the contact search against the master
contact surface. Generally speaking, the contact body with finer mesh should be defined as slave contact
surface because it is easy to be detected when the slave nodes touch the master surface. Also, caution must be
used when choosing the BIAS value. Smaller BIAS value may be used to give better contact accuracy, but
may increase computation cost significantly if too small a value is applied.
Input File(s)
File Description
nug_04am.dat 3-D loaded pin with friction – advanced lower-order planar elements
nug_04an.dat 3-D loaded pin with friction – lower-order planar elements
nug_04bm.dat 3-D loaded pin with friction – advanced higher-order planar elements
nug_04bn.dat 3-D loaded pin with friction – higher-order planar elements
nug_04cm.dat 3-D loaded pin with friction – advanced higher-order hexahedral elements
nug_04cn.dat 3-D loaded pin with friction – higher-order hexahedral elements
Video
L1
R2
H θ
R1
t
F
2
L

Chapter 5: Bilinear Friction Model: Sliding Wedge
Bilinear Friction Model:

5 Sliding Wedge

Summary 103

Introduction 104


FEM Solutions 104

Modeling Tips 107

Input File(s) 107

Video 108
CHAPTER 5 103
Bilinear Friction Model: Sliding Wedge
Summary
Title Chapter 5: Bilinear Friction Model: Sliding Wedge
Contact features • Bilinear stick-slip friction behavior
• Friction along the contact surface
• Comparison of linear and quadratic elements
Geometry 1.0
4.0
gy
px 1.2
1.3
0.7
6.0 Y
1.0 X
Material properties E up = 2.06 10 Pa ,  up = 0.3 ,  up = 1 kg  m

7 3
Pa ,  low = 0.3 ,  low = 1 kg  m , K spring = 119.5 N/m

11 3
E low = 2.06 10
Boundary conditions All displacement components of the nodes in the lower face of the lower wedge are
fixed; u z = 0 m of two nodes on the upper wedge with contact between upper and lower
wedge
Applied loads Gravity load g y = – 764.5 N ; pressure load p x = 1250 Pa and – 693.375 Pa
Element type 3-D solid with 4 -node linear and 10-node parabolic tetrahedral elements
Contact properties Friction coefficient  = 0.3
FE results 1. Deformed configuration at the end of the second STEP
2. Plots of x-displacement of point A
x-displacement (m)
0.0012
0.0010
0.0008 Quadratic Elements
0.0006
Linear Elements
0.0004
0.0002
% of load
0.0000
0 50 100 150 200
-0.0002
-0.0004
-0.0006
CHAPTER 5
Introduction
This problem verifies and validates the behavior of the bilinear friction model. A more detailed description of the
bilinear friction model can be found in the Release Notes for MD Nastran. The fundamental control parameter of this
friction model is the so-called relative sliding displacement below which (elastic) sticking is simulated. This parameter
can be user-defined by specifying RVCNST on the BCPARA option. Otherwise, MD Nastran determines the default
value as a function of the average edge length of the elements in the contact bodies.
This example was originally proposed by NAFEMS as a 2-D large sliding contact and friction example. Here, we use
a modified version of the problem: namely 3-D instead of 2-D and an alternating load instead of a linearly increasing
load.
A large displacement is expected in this solution but the strains will be pretty small. Assuming the motion as rigid
body, it can be predicted analytically as shown in the NAFEMS documentation (NAFEMS Benchmark Tests for Finite
Element Modeling of Contact, Gapping and Sliding, 2001).
First, a gravity load is applied to the whole model. Then, a positive pressure p x is applied as such that point A will
have displacement u x = 1 m . The next step, a negative pressure is applied as such that point A will have displacement
u x = – 1 m . The last step is again an application of positive pressure p x . The applied pressure p x will be determined
analytically.
The analysis results are presented with linear and parabolic elements.
Analytical Solution
Assuming a rigid body motion and neglecting the loss of energy due to friction, the relation among the total force on
the upper wedge in the x- and y-direction ( F x and F y ), the friction coefficient (  ), the wedge angle (  , the total spring
stiffness ( K ) and the positive displacement ( u x ) of the upper wedge is:
F x  1 –  tan   + F y   + tan  
K = ------------------------------------------------------------------------------
-
u x  1 –  tan  
With tan  = 0.1 ,  = 0.3 , F x = 1500 N , F y = 3058 N (based on g y = – 764.5 N ) and u x = 1 m , the total spring stiffness
( K ) is 239 N/m . Thus, the applied p x that correlates with is 1250 Pa . This load is applied during the second step.
Alternatively, with the given value of K , tan  , and F y , F x = – 832.8 N results in a displacement of the upper wedge
( u x = – 1 m ). p x that correlates with this F y is F x = – 693.375 N . This pressure is applied in the third step. The fourth
step is again the introduction of p x = 1250 Pa .
FEM Solutions
A numerical solution has been obtained with MD Nastran’s SOL 400 for the element mesh shown in Figure 5-1. The
colored regions of the wedges have been identified as contact bodies. Contact body IDs 1 and 2 are identified as a set
of elements of upper and lower wedge, respectively as:
CHAPTER 5 105
BSURF 1 42 107 118 132 194 236 239
...
and
BSURF 2 1 2 3 4 5 6 7
...
Figure 5-1 Element Mesh applied in Target Solution with MD Nastran
Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other.
BCTABLE 0 1
SLAVE 1 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 2
BCTABLE 1 1
SLAVE 1 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 2
Thus, any deformable contact body is simply a collection of mutually exclusive elements and their associated nodes.
To activate contact with Coulomb friction, FTYPE must be set to 6 in BCPARA option (the only supported Coulomb
friction model). The contact separation option is based on relative stresses. It is done by setting IBSEP = 4.
Furthermore, for model with quadratic element, the genuine parabolic contact has to be set using LINQUAD = -1.
BCPARA 0
FTYPE 6 IBSEP 4 LINQUAD -1
3-D tetrahedral elements are used in this analysis.

PSOLID 1 1
PSOLID 2 2 +
The two material properties are isotropic and elastic with Young’s modulus and Poisson’s ratio defined as
MAT1 1 2.06+07 .3 1.
MAT1 2 2.06E+11 .3 1.
CHAPTER 5
The nonlinear procedure used for the analysis:

PARAM LRGDSIP 1
NLPARM 1 1 FNT UV
NLPARM 2 25 FNT UV
Here the FNT option is selected to update the stiffness matrix during every recycle using the Newton-Raphson iteration
strategy and the default convergence tolerance for displacement (relative to the incremental displacement) will be
used.
The simulation is eventually controlled by the case control section which consists of four STEPS.
STEP 1
LABEL = Gravity Load
...
STEP 2
LABEL = Px is 1250
...
STEP 3
LABEL = Px is -694
...
STEP 4
LABLE = Px is again 1250
...
The deformed structure plot (magnification factor 1.0) is shown in Figure 5-2. After the second step, as seen in
Figure 5-2, the upper wedge moves in the x-direction one meter as predicted analytically.
deformed
undeformed
ux = 1.0
Figure 5-2 Deformed Structure at the End of the Second Step (magnification factor = 1)
The displacement plot of point A, for linear and parabolic elements, is shown in Figure 5-3. It is clearly seen that the
upper wedge moves alternately from u x = 1 m to u x = – 1 m and then back to u x = 1 m as expected using the analytical
solution. The result of the linear element is nearly the same as that of the parabolic elements. As clearly seen from this
figure, during (linear) sticking contact, the displacement of the upper wedge varies linearly.
CHAPTER 5 107
x-displacement (m)
1.0
0.8
0.6
0.4
0.2 % of load
0.0
0 50 100 150 200 250 300 350 400
-0.2
-0.4
-0.6
-0.8
-1.0
x-displacement (m)
0.0012
0.0010
0.0008 Quadratic Elements
0.0006
Linear Elements
0.0004
0.0002
% of load
0.0000
0 50 100 150 200
-0.0002
-0.0004
-0.0006
Figure 5-3 Displacement Plot for Point A (Representing the Displacement of the Upper Wedge)
Modeling Tips
It is very important to have accurate coordinates for those points that are located on the both sides of the contact
interfaces. Failure in representing accurate smooth surfaces may lead to unexpected contact behavior. That is why the
coordinate of the grid points both for models with linear and parabolic elements are expressed in the extended format
of MD Nastran.
Input File(s)
File Description
nug_05a.dat Linear Elements
nug_05b.dat Quadratic Elements
CHAPTER 5
Video
Click on the image or caption below to view a streaming video of this problem; it lasts about 47 minutes and explains
how the steps are performed.
1.0
4.0
A
gy
px 1.2
1.3
0.7
6.0 Y
1.0 X

Chapter 6: Laminated Strip under Three-point Bending
Laminated Strip under

6 Three-point Bending

Summary 110

Introduction 111


FEM Solution 111

Modeling Tips 113

Input File(s) 113

Video 114
CHAPTER 6
Summary
Title Chapter 6: Laminated Strip under Three-point Bending
Geometry 2-D Shell (units: mm)
C
0o fiber direction 0.1 0o
0.1 90o
0.1 0o
y
10 0.4 90o
x
0.1 0o
10 15 15 10 0.1 90oo D
0.1 0
10 N/mm E
z C
1 all dimensions in mm
x E
A B
Material properties
E 1 = 100GPa  12 = 0.4 G 12 = 3GPa
E 2 = 5GPa G 13 = 2GPa
E 3 = 5GPa G 23 = 2GPa

Boundary conditions Three-point bending test
Applied loads Line load of 10N  m m
Element type • 2-D shell
• 3-D solid composite
FE results  11  13 u z Compared with NAFEMS solution
CHEXA
CQUAD4 CQUAD4 CHEXA
Quantity Units NAFEMS PCOMPLS
linear PSHLN1 PCOMPLS-L
-ASTN
 11 at E MPa 684 683 683 685 664
 13 at D MPa -4.1 -4.1 -4.1 -4.1 -4.2
u z at E mm -1.06 -1.06 -1.06 -1.06 -1.02

CHAPTER 6 111
Laminated Strip under Three-point Bending
Introduction
This problem demonstrates the ability to model composite laminated material both using shell and solid elements. A
laminated strip is subjected to a three-point bending test, due to symmetry only a quarter of the structure needs to be
modeled. Stresses and displacements are computed and compared to a reference solution.
Requested Solutions
The stresses and displacements of a composite laminated strip under three-point bending configuration are calculated
in MD Nastran. This test is recommended by the National Agency for Finite Element Methods and Standards (U.K.):
Test R0031/1 from NAFEMS publication R0031, “Composites Benchmarks”, February 1995.
FEM Solution
A numerical solution has been obtained with MD Nastran’s solution sequence 400 for the configuration shown in
Figure 6-1. The composite strip comprises seven lamina, with lamina thicknesses and orientation as shown in the
figure. Only one quarter of the structure is modeled using symmetry conditions along the mid span and center of the
longitudinal direction. Each lamina is modeled as one layer is the composite. For the model using shell elements, this
is done using the PCOMP entry
PCOMP 1 0. 0.
1 .00001 0. YES 1 .09999 0. YES
1 .1 90. YES 1 .1 0. YES
1 .4 90. YES 1 .1 0. YES
1 .1 90. YES 1 .09999 0. YES
1 .00001 0. YES
C
o
0.1 90
o
0.1 0
y
10 0.4 90
o
x
o
0.1 0o
10 15 15 10 0.1 90 D
o
0.1 0
10 N/mm E
z C
x E
A B
Figure 6-1 Laminated Strip in a Three-point Bending Configuration

CHAPTER 6
For the model using composite brick elements, this is done using the PCOMPLS entry. Please note that the layer
orientation is defined relative to the coordinate system defined in the CORDM field of this entry.
PCOMPLS 1 1 1
C8 SLCOMP L
9 1 .00001 0.
8 1 .09999 0.
7 1 .1 90.
6 1 .1 0.
5 1 .4 90.
4 1 .1 0.
3 1 .1 90.
2 1 .09999 0.
1 1 .00001 0.
For the model using solid shell elements this is done using the PCOMPLS entry
PCOMPLS 1 1 1
C8 SLCOMP ASTN
9 1 .00001 0.
8 1 .09999 0.
7 1 .1 90.
6 1 .1 0.
5 1 .4 90.
4 1 .1 0.
3 1 .1 90.
2 1 .09999 0.
1 1 .00001 0.
Note that in these models two very thin extra layers are added, they have the same properties as the layer they are
connected to. These two layers are added to calculate the stress mentioned in the reference table (Table 6-1) at the
correct position.
Table 6-1 Laminated Strip under Three-point Bending

CHEXA CHEXA
CQUAD4 CQUAD4 PCOMPLS PCOMPLS
Quantity Units NAFEMS linear PSHLN1
-ASTN -L
 11 at E MPa 684 683 683 685 664
 13 at D MPa -4.1 -4.1 -4.1 -4.1 -4.2
u z at E mm -1.06 -1.06 -1.06 -1.06 -1.02
The material is orthotropic, with the following properties:
E 1 = 100GPa  12 = 0.4 G 12 = 3GPa

E 2 = 5GPa  23 = 0.3 G 13 = 2GPa
E 3 = 5GPa  31 = 0.02 G 23 = 2GPa
For the model using the shell elements this is defined as

MAT8 1 100000. 5000. .4 3000. 3000. 2000. 1.-4
CHAPTER 6 113
Laminated Strip under Three-point Bending
And for the model using the solid composite elements this is defined as
MATORT 1 100000. 5000. 5000. .4 .3 .02 1.-4
3000. 2000. 2000.
-1
Two types of shell elements are analyzed. The default CQUAD4 and the CQUAD4 suitable for large deformations.
The latter is activated using the PSHLN1 entry
PSHLN1 1 NO +
+ C4 DCT L
For analysis of shell-like structure with composite material, the TSHEAR option on the NLMOPTS entry has to be given
to obtain a parabolic transverse shear distribution across the thickness of the element.
NLMOPTS TSHEAR TSHEAR
A line pressure of 10N  mm is applied, this pressure is translated to point loads on the finite element mesh.
Table 6-1 compares the results of the different models with the reference solution, the data is taken from the f06 file.
The stress at E is linearly interpolated from the centroid of the first two elements close to the symmetric line.
Modeling Tips
When modeling composite structures that support large deformation and nonlinear material behavior (activated with
the PSHLN1 or PCOMPLS entry) it is recommended to set the TSHEAR parameter on the NLMOPTS entry. This will
result in a more parabolic shear distribution through the thickness, and in the output of interlaminar stresses. When
using CHEXA elements for analysis of shell-like structure under bending deformation, it is recommended to use solid
shell elements instead of linear composite brick elements.
Input File(s)
File Description
nug_06n.dat Linear Elements
nug_06m.dat Linear Elements using PSHLN1 entry
nug_06c.dat Linear Composite Elements
nug_06d.dat Solid Shell Elements
CHAPTER 6
Video
C
o
0.1 90o
0.1 0
y
10 0.4 90o
x
o
0.1 0
10 15 15 10 0.1 90oo D
0.1 0
10 N/mm E
z C
x E
A B

Chapter7: Wrapped Thick Cylinder under Pressure and Thermal Loading
Wrapped Thick Cylinder under

7 Pressure and Thermal Loading

Summary 116

Introduction 117


FEM Solution 117

Input File(s) 118

Video 119
CHAPTER 7
Summary
Title Chapter 7: Wrapped Thick Cylinder under Pressure and Thermal Loading
Geometry • 2-D Shell (units: mm)
• Cylinder length= 200
1
• Cylinder radius: 2
ate
rial
ic m
inner side = 23 o t rop tion
or th orient
a
mid side = 25 27
outside = 27 y 23 25
z 200
x all dimensions in mm
z=0
Material properties • Inner Cylinder

–5
E = 210GPa  = 0.3  = 2.0  10  C
• Outer Cylinder
E 1 = 130GPa  12 = 0.25 G 12 = 10GPa  11 = 3.0  10 – 6  C
E 2 = 5GPa  13 = 0.25 G 13 = 10GPa  22 = 2.0  10 – 5  C
E 3 = 5GPa  23 = 0 G 23 = 5GPa  33 = 2.0  10 – 5  C

Boundary conditions Axial displacement zero at z = 0 .
Applied loads Pressure of 200MPa and temperature rise of 130C
Element type 2-D shell
FE results Hoop stress compared with NAFEMS solution
Wrapped Thick Cylinder under Pressure and Thermal Loading
CQUAD4 CQUAD4
Quantity Units NAFEMS linear PSHLN1
STEP 1
at r = 24 mm MPa 1483 1414 1414
at r = 26 mm MPa 822 875 875
STEP 2
at r = 24 mm MPa 1309 1236 1236
at r = 26 mm MPa 994 1053 1053
CHAPTER 7 117
Introduction
This problem demonstrates the ability to model pressure and thermal loading for composite laminated material. A
thick cylinder is loaded with both pressure and a temperature increase. Stresses are calculated and compared to a
reference solution.
Requested Solutions
The Hoop stress at the inner and outer cylinders is calculated under pressure loading and under both pressure loading
and thermal loading in MD Nastran. This test is recommended by the National Agency for Finite Element Methods
and Standards (U.K.): Test R0031/2 from NAFEMS publication R0031, “Composites Benchmarks”, February 1995
FEM Solution
A numerical solution has been obtained with MD Nastran’s SOL 400 for the configuration shown in Figure 7-1. The
cylinder consists of two layers with layer thickness and orientation as shown in Figure 7-1. The axial displacement is
set to zero at z = 0 . Only one eighth of the model is analyzed with the appropriate symmetry boundary conditions.
The two layers are modeled using the PCOMP entry, where the thickness of both layers is 2 mm
PCOMP 1 0. 0.
1 2. 0. YES 2 2. 0. YES
1
2 al
teri
i c ma
p
otro ation
or th orient
27
y 23 25
z 200
z=0
Figure 7-1 Wrapped Thick Cylinder under Pressure and Thermal Loading
Each lamina is modeled as one layer in the composite. The inner cylinder (layer 1) is isotropic and the outer cylinder
(layer 2) is orthotropic. The material properties for the inner cylinder are
E = 210GPA ,  = 0.3 ,  = 2.0  10 – 5  C

CHAPTER 7
and for the outer cylinder are

E 1 = 130GPa  12 = 0.25 G 12 = 10GPa  11 = 3.0  10 – 6  C
E 2 = 5GPa  13 = 0.25 G 13 = 10GPa  22 = 2.0  10 – 5  C
E 3 = 5GPa  23 = 0 G 23 = 5GPa  33 = 2.0  10 – 5  C
and are entered using the MAT1 and MAT8 entry, respectively.
Two types of shell elements are analyzed: the CQUAD4 default and the CQUAD4 suitable for large deformations. The
latter is activated using the PSHLN1 entry.
PSHLN1 1 NO +
+ C4 DCT L
The analysis is performed in two analyses steps. In the first step, a uniform pressure of 200MPa is applied on the
inside of the cylinder. In the second step, both this pressure and a temperature rise of 130C is applied.
Table 7-1 compares the Hoop stress in the inner and outer cylinders for the two examples for the two analyses steps
with the reference solution at r = 24mm and r = 26mm . The NAFEMS Hoop stress at r = 23mm and
r = 25mm are averaged to compare at r = 24mm for the inner cylinder and similar for r = 26mm for the outer
cylinder.
Table 7-1 Wrapped Thick Cylinder under Pressure and Thermal Loading
CQUAD4 CQUAD4
Quantity Hoop Stress Units NAFEMS Linear PSHLN1
STEP 1
at r = 24 mm MPa 1483 1414 1414
at r = 26 mm MPa 822 875 875
STEP 2
at r = 24 mm MPa 1309 1236 1236
at r = 26 mm MPa 994 1053 1053
Input File(s)
File Description
nug_07m.dat Linear Elements using PSHLN1 Entry
CHAPTER 7 119
Video
1
2 rial
ate
ic m
o t rop tion
a
or th orient
27
y 23 25
z 200
z=0

Chapter 8: Three-layer Sandwich Shell under Normal Pressure Loading
Three-layer Sandwich Shell

8 under Normal
Pressure Loading

Summary 121

Introduction 122


FEM Solution 122

Modeling Tips 124

Input File(s) 125

Video 125
CHAPTER 8 121
Three-layer Sandwich Shell under Normal Pressure Loading
Summary
Title Chapter 8: Three-layer Sandwich Shell under Normal Pressure Loading
Geometry • 2-D Shell (units: in) z
Length= 10 face sheet
Width = 10
uniform normal 0.028
pressure
Thickness = 0.806
core
C
10 0.750 x
A 0.028
10 face sheet
y
simply supported
on all four edges all dimensions in inches
Material properties • Face sheets
6 6
E 1 = 10  10 Psi  12 = 0.3  G 12 = 1.875  10 Psi 
6 6
E 2 = 4  10 Psi   13 = 0  G 13 = 1.875  10 Psi
6 6
 E 3 = 1  10 Psi    23 = 0  G 23 = 1.875  10 Psi
• Core
The values within
the parenthesis are
 E 1 = 10Psi    12 = 0   G 12 = 10Psi 
chosen to have a
 E 2 = 10Psi    13 = 0  G 13 = 3  10 Psi
4 complete 3-D
material model
4
 E 3 = 10Psi    23 = 0  G 23 = 1.2  10 Psi necessary for the
solid elements.

Boundary conditions Plate is simply supported fixed at four corners
Applied loads Pressure of 100Psi applied to the top face (most positive in the z-axis)
Element type 2-D shell, 3-D solid shell
FE results Stresses and displacements compared with NAFEMS solution
Three-layer Sandwich Shell Results
CQUAD4 CQUAD4 CHEXA
Quantity Units NAFEMS Linear PSHLN1 PCOMPLS
u z at C in -0.123 -0.123 -0.122 -0.122
 11 at C kpsi 34.45 34.029 34.212 33.932
 22 at C kpsi 13.93 13.294 13.167 13.406
 12 at E kpsi -5.07 -5.040 -5.006 -5.020

CHAPTER 8
Introduction
This problem demonstrates the ability to model pressure loading of a square composite three layer sandwich flat shell.
Stresses and displacements are calculated and compared to a reference solution.
Requested Solutions
Stresses and displacements are calculated at the surface of the composite three layer sandwich flat shell in MD Nastran.
This test is recommended by the National Agency for Finite Element Methods and Standards (NAFEMS): Test
R0031/3 from NAFEMS publication R0031, “Composites Benchmarks”, February 1995.
FEM Solution
A numerical solution has been obtained with MD Nastran’s SOL 400 for the configuration shown in Figure 8-1. The
plate consists of three layers, a core layer and two face sheets covering this layer. Thicknesses of the layers are shown
in Figure 8-1. Only one quarter of the part is analyzed with the appropriate symmetry boundary conditions, and the
two edges on the boundary of the plate are fixed. The three layers are modeled using the PCOMP entry, where the
thickness of both layers is 0.028 in.
PCOMP 1 0. 0.
1 .028 0. YES 2 .75 0. YES
1 .028 0. YES
face sheet
uniform normal 0.028
pressure
core
C
10 0.750 x
A 0.028
10 face sheet
y
simply supported
on all four edges all dimensions in inches
Figure 8-1 Three-layer Sandwich Shell under Normal Pressure Loading
Each lamina is modeled as one layer in the composite. The materials for the face sheets and core have the following
orthotropic properties:
CHAPTER 8 123
Face sheets
6 6
E 1 = 10  10 Psi  12 = 0.3  G 12 = 1.875  10 Psi 
6 6
E 2 = 4  10 Psi   13 = 0  G 13 = 1.875  10 Psi
6 6
 E 3 = 1  10 Psi    23 = 0  G 23 = 1.875  10 Psi
and the core
 E 1 = 10Psi    12 = 0   G 12 = 10Psi 
4
 E 2 = 10Psi    13 = 0  G 13 = 3  10 Psi
4
 E 3 = 10Psi    23 = 0  G 23 = 1.2  10 Psi
These properties are entered using the MAT8 entry.

Two types of shell elements are analyzed: the CQUAD4 default and the CQUAD4 suitable for large deformations. The
latter is activated using the PSHLN1 entry
PSHLN1 1 NO +
+ C4 DCT L
For modelling with solid shell elements, the standard CHEXA elements are used to define the element connectivity.
To activate the solid shell elements, PCOMPLS entry has to be used for assigning the property of the CHEXA.
PCOMPLS 1 -1
C8 SLCOMP ASTN
1 1 .028 0.
2 2 .75 0.
3 1 .028 0.
For shell-like structure with composite materials, the TSHEAR option on the NLMOPTS entry has to be given to obtain
a parabolic shear distribution for composite layers in shells. This is particularly important for this structure because
the inner core resists deformation in shear.
NLMOPTS TSHEAR TSHEAR
A uniform pressure of 100MPa is applied on the top surface of the shell.
Table 8-1 shows the comparison of the face sheet stresses and midspan displacement with the NAFEMS results.
CHAPTER 8
Table 8-1 Three-layer Sandwich Shell Results

CQUAD4 CQUAD4 CHEXA
Quantity Units NAFEMS Linear PSHLN1 PCOMPLS
u z at C in -0.123 -0.123 -0.122 -0.122
 11 at C kpsi 34.45 34.029 34.212 33.932
 22 at C kpsi 13.93 13.294 13.167 13.5406
 12 at E kpsi -5.07 -5.040 -5.006 -5.020
Figure 8-2 Deformed Shape of the Model with Solid Shell Elements
Modeling Tips
When modeling composite structures using shell elements that support large deformation and nonlinear material
behavior (activated with the PSHLN1 entry), it is recommended to set the TSHEAR parameter on the NLMOPTS entry.
This will result in a more parabolic shear distribution through the thickness, and in the output of interlaminar stresses.
CHAPTER 8 125
Input File(s)
File Description
nug_08m.dat Linear Elements using PSHLN1 Entry
nug_08d.dat Solid Shell Elements
Video

Chapter 9: Bird Strike On Prestressed Rotating Fan Blades
Bird Strike on Prestressed

9 Rotating Fan Blades

Summary 127

Introduction 128


Model Details 128

FEM Solution 129

Results 132

Modeling Tip 133

Input File(s) 134
CHAPTER 9 127
Bird Strike on Prestressed Rotating Fan Blades
Summary
Title Chapter 9: Bird Strike on Prestressed Rotating Fan Blades
Features Bird Strike On Prestressed Rotating Fan Blades
Geometry Units: inches
2
44.2
D = 1.8
t = 0.2
D = 27.2
6.24 0.0266 < t < 0.0403
D = 2.36
Material properties Fan: Piecewise linear plastic material (MATD024)

Bird: Elastic-plastic hydrodynamic material (MATD010)
Boundary conditions • Prestress analysis:
One end of blade is fully fixed.
1/3 and 1/2 span of rotor are fixed to x and y translational and rotational directions
• Impact analysis:
One end of blade is fixed to x, y and z translational directions.
1/3 and 1/2 points of rotor are fixed to x and y translational directions
Details are explained in FEM solutions section.
Applied loads • Prestress analysis:
Fan: 8000 rpm using RFORCE option (rotational static force)
• Impact analysis:
Fan: 8000 rpm using TIC3 option (rotational initial speed) and SPCD2 option
(enforced motion)
Bird: Initial velocity of 7692 inch/s (437 m.p.h.) using TIC option.
Details are explained in FEM solutions section.
Element type • Fan: 4-node shell element
• Bird: 8-node hexahedral element (Impact analysis only)
FE results t = 1.52 ms •Prestress analysis:
Plot of final stage of implicit run nastin - ASCII result
file for initial state values are included.
•Impact analysis:
Plot of each stage (t = 1.52 ms shown here)
CHAPTER 9
Introduction
Aerospace companies have performed bird strike test simulation to predict the impact-resistance properties of the
aircraft structure. This is an example of a bird (made by solid elements) impacting against rotating fan blades using a
sequential implicit-explicit technique. First, using the implicit solver, the initial condition (stress and displacement) on
the blades and rotor was calculated followed by transient loading of bird impact, which was simulated using the
explicit solver.
Requested Solutions
A numerical analysis was performed to demonstrate the pre-stressed fan blade out method. The rotational inertia
effects were taken into account in implicit analysis and the resulting stress, strain and displacements were computed.
Next, the results were added to the explicit analysis as initial condition.
Model Details
Materials
Fan: Piecewise linear plastic material (MATD024)
 = 4.14e-4 lbf/inch3-s2/inch,  = 0.35, E = 1.60E+7 psi
y (yield stress) = 138000 psi, ET (Tangent modulus) = 100000 psi
Plastic strain failure limit = 0.2
Bird: Elastic-plastic hydrodynamic material (MATD010)
 = 9E-5 lbf/inch3-s2/inch, G (Shear modulus) = 145 psi
y (yield stress) = 2.9 psi, ET (Tangent modulus) = 0.145 psi
Linear polynomial equation of state (EOSPOL
P = a  + a 2 + a 3 +  b + b  + b 2 + b 3   E
1 2 3 0 1 2 3 0
 =  –1
0
 = overall material density
 0 = reference density
E = specific internal energy pur unit mass

a1 = a2 = b1 = b2 = b3 = 0
a = 4.25x10 6 psi
1
CHAPTER 9 129
FEM Solution
Boundary Condition and Applied Load

Prestress Analysis (Implicit)
The rotational velocity of blades and rotor is 8000 rpm which is applied using RFORCE option (rotational static force)
in the prestress run. The end of the rotor is fully fixed. In addition, the bearings located at 1/3 and 1/2 of distance from
the front of rotor are fixed in x, y translational as well as x, y rotational directions using SPC1 option. The applied
loading and boundary conditions of prestress analysis are shown in Figure 9-1(a).
RFORCE 1 299999 -133.3330.0 0.0 1.
TABLED1 321
0. 1. .001 1. ENDT
SPC1 1 123456 300425 THRU 300443
SPC1 1 1245 400058
SPC1 1 1245 400115
Impact Analysis (Explicit)

The initial rotational velocity of 8000 rpm is applied to fan blades using the TIC3 entry as well as end of rotor using
the SPC2 entry (enforced motion). The bird impact velocity of 7692 inch/s (437 m.p.h.) is applied on all the grid points
of the bird model. The boundary conditions at the end of rotor is changed to constrain x, y and z translational directions
and the bearing locations of rotor are constrained in x and y translational directions. The applied loading and boundary
conditions of impact analysis are shown in Figure 9-1 (b).
TIC 1 1000001 3 7692.

...
SPCD2 1 GRID 1 7 80 -1.
TABLED1 80 +
+ 0.0 837.758 1. 837.758 ENDT
$ Displacement Constraints of Load Set : Disp1
SPC1 1 3 21 THRU 31
...
...
$ Initial angular velocity for rotor +fan blade
TIC3 1 299999 1.
-837.758
1 THRU 6384 300000 THRU 300018 300020 THRU
CHAPTER 9
8000 rp
rrpm
m
Fu
Fully
ully fixed
f xed
fi
Fixed (x,y direction)

(x,y rotation)
(a) Prestress model (implicit)
8000 rrprpm
pm 8000 rp
rrpm
m
(iniitiall speed)
(initial (enfo
(enforced
f rced speed))
Fixed (x,y,z direction)
Fixed (x,y direction)
437 mph
(b) Impact model (explicit)
Figure 9-1 Boundary Conditions and Applied Loads of the Fan And Bird
CHAPTER 9 131
FEM Model and Contact

The rotor, hub and fan blades are modeled by shell elements while the bird is modeled by solid elements.
Prestress Analysis (implicit)

By using the PRESTRS bulk data entry, a prestress analysis is carried out. The prestress simulation requires the
analysis to be run with double precision version of the implicit solver. Final deformations and stresses of elements are
written to a text file named “input_file_name”.dytr.nastin to provide initial conditions for rotor and fan blades
of the impact run. The definition of TSTEPNL is required in implicit run to determine the number of time steps and
their increment for higher fidelity of the solution.
TSTEPNL 1 5 1.-5 1 ADAPT 2 10
PRESTRS
Impact analysis (explicit):

The end time in transient run is defined by using 100 time steps at 0.4e-4 sec. for each increment. End time is the
product of these two entries. Notice here the Time Increment is only for the first step. The actual number of Time
Increments and the exact value of the Time Steps are determined by MD Nastran solver during the analysis. The time
step is a function of the smallest element dimension during the simulation.
The prestress results file is prestress_rotor.dytr.nastin. The name of this file was changed to
rotor.dytr.nastin due to the long file name. It includes the results for grid points, elements and is used as initial
condition for explicit transient run. The prestress file prestress_rotor.dytr.nastin includes all geometry
information such as grids, elements and the results. Therefore, the explicit model should include only the material
properties for the structure, the new boundary conditions as well as new data for the bird.
INCLUDE rotor.dytr.nastin
TSTEPNL 1 100 .4e-4 1 ADAPT 2 10
The file rotor.dytr.nastin contains an entry called ISTRSSH. This entry specifies the prestress condition of the
shell element as defined below (see the MD Nastran Quick Reference Guide for more details). These result values of
the prestress run are to be carried over to the impact run. When other elements types other than shells are used,
ISTRSBE, ISTRSTS, and ISTRSSO entries must be included in the nastin file.
ISTRSSH* 2275 1 5 5*
* *
* 0.000E+00 6.916E+03 7.371E+03 1.480E+02*
* 7.084E+03 -3.908E+01 1.150E+02 0.000E+00*
...
In this analysis, adaptive contact is defined between the bird and the fan blades. The BCBODY and BCPROP entries
are used to define a symmetric (M-S, S-M) contact bodies.
BCTABLE 1 2
SLAVE 8001 0. 0. 0.1 0. 0
0 0 0
0.1 YES
+
+
CHAPTER 9
+
MASTERS 1001
SLAVE 1001 0. 0. 0.1 0. 0
0 0 0
0.1 YES
+
+
+
MASTERS 8001
BCBODY 1001 3D DEFORM 1001 0
BCPROP 1001 1 2 3 4 5 6 7
...
Results
Prestress Run
The results of all increments are essentially the same which indicates that the implicit calculations are stable. The
results of the last increment were written to the file prestres_rotor.dytr.nastin.
Figure 9-2 Result Increment 5: written to the .nastin file

CHAPTER 9 133
Impact run
The prestress result variables have been initialized at the begin of the analysis (Time = 0)
t = 0 ms t = 1.00 ms
t = 1.52 ms t = 2.00 ms
t = 3.00 ms t = 4.00 ms
Figure 9-3 Element Mesh Applied in the MD Nastran Simulation
Modeling Tip
The default values for shell integration points in implicit and explicit analyses are different. There are three integration
points for implicit analysis and two integration points for explicit analysis. Therefore, the shell element type for the
implicit analysis has to be modified to be consistent with that of explicit simulation.
PSHELL1 1 1 BLT GAUSS 2
CHAPTER 9
Input File(s)
File Description
nug_9a.dat Impact analysis
nug_9b.dat Prestress model
nug_9c.dat Stresses and deformations of prestress model for input to
impact analysis
nug_9d.dat Data for bird
Chapter 10: Engine Gasket
10 Engine Gasket

Summary 136

Introduction 137


Model Details 137

FEM Solution 138

Modeling Tip 143

Input File(s) 144

Video 144
CHAPTER 10
Summary
Title Chapter 10: Engine Gasket
Features Glued contact, MPC’s for bolt modeling, Gasket material
Geometry
gasket ring
gasket body
Cylinder diameter: 24 mm . Engine block width, breadth and height: 93.1 mm , 70 mm and
15 mm . Cylinder head thickness: 3 mm . Bolt diameter: 8 mm . Bolt head diameter:
14 mm . Gasket ring thickness: 1 mm ; gasket body thickness: 0.9091 mm
Material properties Linear elastic material for the engine block, cylinder head and bolts,
5
Isotropic in-plane
E engine = E head = E bolt = 2.1 10 MPa  engine =  head =  bolt = 0.3
behavior of the gasket: E body = 120 MPa , E ring = 100 MPa ,  body =  ring = 0 . Transverse
shear moduli of the gasket: G body = 40 MPa , G ring = 35 MPa . Out-of-plane elastic-plastic
behavior of the gasket defined by loading and unloading curves.
Boundary conditions Symmetry conditions in ZX-plane: u y = 0 . Bottom of engine block fully clamped:
u x = u y = u z = 0 . Glued contact between gasket and cylinder head, gasket and engine
block, and bolts and cylinder head.
Applied loads Prescribed shortening of the bolts l = 0.175 mm .
Element type 3-D 8-node hexahedral and 3-D 6-node pentahedral solid elements
Contact properties Glued contact with extended tangential contact tolerance at sharp corners
FE results Bolt forces and stresses in the gasket
CHAPTER 10 137
Engine Gasket
Introduction
A gasket is assembled between an engine block and a cylinder head. The loading of the assembled structure consists
of pre-tensioning the bolts connecting the cylinder head and the engine block. Striking features in this analysis are the
MPCs used to load the bolts, the geometry and material description of the gasket, and the use of the contact algorithm
to establish contact constraints between the grids of the gasket and the cylinder head and the engine block and between
the grids of the bolts and the cylinder head.
Requested Solutions
A numerical analysis will be performed to find the forces in the bolts and the response of the gasket in terms of gasket
closure versus gasket pressure.
Model Details
The gasket actually consists of two parts: the so-called gasket ring and the gasket body. These parts have different
material properties and thicknesses. Assigning different material properties is straightforward, but modeling different
thicknesses would require different finite element meshes for the ring and the body. Since this is inefficient from a
modeling perspective, it is allowed to include both parts in one connected set of finite elements and to define the
thickness difference as an initial gap. In the numerical analysis, this implies that as long as the thickness reduction of
gasket element integration points is smaller than the initial gap, there will be no stress in the thickness direction. In
Figure 10-1, a detailed view of the actual versus the modeled gasket geometry is shown.
initial gap
magnitude
Figure 10-1 True Gasket Geometry (left) and Modeled Geometry (right)
The material behavior of a gasket is generally rather complex to characterize using conventional material models.
Instead, a special gasket material model is adopted, which de-couples the in-plane and thickness behavior. The
in-plane behavior is assumed to be linear and defined by Young’s modulus and Poisson’s ratio. The behavior in
thickness direction is nonlinear and defined by experimentally determined loading and unloading curves, where the
gasket pressure is measured as a function of the gasket closure. This gasket closure is given by the change in distance
between the top and the bottom face of the gasket. The loading and unloading curves for the gasket ring and the gasket
body are shown in Figure 10-2.
CHAPTER 10
Figure 10-2 Material Behavior in Thickness Direction for the Gasket Body and Ring
In order to apply pre-tensioning on the bolts, they are piece wise modeled by two parts, one upper and one lower part,
obtained by a fictitious cut. The grids of the lower and the upper part of this cross section are connected using MPC’s
to a so-called control grid. Calling the displacement of a grid in the lower part u lower , the displacement of a grid in the
upper part u up per and the displacement of the control grid u control , then the MPC reads:
u control = u lower – u upper
By assigning all the grids in the lower and upper part of the section of a bolt to the same control grid, one can easily
define the shortening of a bolt by prescribing u control . As a result, the total bolt force is found as the reaction force on
the control grid.
FEM Solution
The numerical solution has been obtained with MD Nastran’s SOL 400 for the element mesh shown in Figure 10-3
using 3-D 8-node hexahedral and 6-node pentahedral elements. Based on symmetry, only half of the structure is
modeled.
bolt cross section
bolt cross section
Figure 10-3 Element Mesh applied in the MD Nastran Simulation

CHAPTER 10 139
Engine Gasket
In total, four deformable contact bodies are used. The first deformable body consists of all elements of the gasket
including the gasket body and ring. The cylinder head defines the second deformable body. The third deformable body
contains the elements of the engine block. Finally, the fourth deformable body consists of the upper and lower parts
of the bolts. The deformable contact bodies are identified as 3-D bodies referring to the BSURF IDs 1, 2, 3 and 4:
BCBODY 1 3D DEFORM 1
BSURF 1 285 286 287 288 289 290 291
292 293 294 295 296 297 298 299
...
...
BSURF 2 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
...
...
BSURF 3 670 671 672 673 674 675 676
677 678 679 680 681 682 683 684
...
...
BSURF 4 967 968 969 970 971 972 973
974 975 976 977 978 979 980 981
...
...
In addition to the BCBODY option to define the deformable contact bodies, the BCTABLE option will be used to
indicate:
• which grids are to be treated as slave grids and which as master grids in the multipoint constraints for
deformable-deformable contact;
• glued contact between the gasket and the cylinder head;
• glued contact between the gasket and the engine block;
• glued contact between the bolts and the cylinder head.
Compared to the cylinder head and the engine block, the gasket has the finest mesh and is also relatively soft. In
general, it is recommended to use the grids of the contact body with the finest mesh as the slave grids in the MPCs
used to solve the contact problem. If the mesh density in the contact area is comparable, then the grids of the softest
body should be chosen as the slave grids. In the current simulation, grids of the gasket and the bolts are selected as
slave grids, which is done using the BCTABLE option. This option is also used to activate glued contact conditions, so
that both relative normal and tangential displacements in the contact areas are prohibited:
BCTABLE 1 3
SLAVE 1 0. 0. 0. 0. 1 0.
1 2 0
MASTERS 2
SLAVE 1 0. 0. 0. 0. 1 0.
1 0 0
MASTERS 3
SLAVE 4 0. 0. 0. 0. 1 0.
1 0 0
MASTERS 2
CHAPTER 10
Besides indicating the slave nodes and glued conditions, the first SLAVE MASTER combination also activates the
extended tangential contact tolerance. The reason to use this is motivated by the coarse mesh of the cylinder head (see
Figure 10-4) compared to the gasket. By activating the extended tangential contact tolerance, all grids at the top of the
gasket are found to be in contact with the cylinder head.
grid outside contact surface
Figure 10-4 Detail of the FE mesh to illustrate the delayed slide off option
In order to activate the full nonlinear formulation of the 3-D isotropic elements (cylinder head, engine block and bolts),
the nonlinear property extension of the PSOLID entry is used:
PSOLID 3 5 0
PSLDN1 3 5 1 +
+ C8 SOLI L
MAT1 5 210000. .3 1. 1.5-5
Where the isotropic material definition is straightforward, the gasket behavior needs more attention. Here, the MATG
entry is used. For the gasket body, the definition is:
PSOLID 1 2 0
PSLDN1 1 1 1 NO +
+ C8 SLCOMP L
MAT1 2 120. 60. 1. 5.-5
MATG 1 2 0 1 2
52. 72.
35. .090909
TABLES1 1
0. 0. .027 2.08 .054 8.32 .081 18.72
.108 33.28 .135 52. .175 56. ENDT
TABLES1 2
.1 0. .1225 5.04 .1375 14. .1525 27.44
.16 35.84 .1675 45.36 .175 56. ENDT
The PSLDN1 entry refers to the PSOLID with ID number 1 and activates the solid continuum composite element
formulation via the SLCOMP option. The material ID number 2 of the MATG entry refers to MAT1 ID number 2 to
define the in-plane (membrane) behavior of the gasket material. The loading curve is defined by the table with ID
number 1, while the unloading curve is defined by the table with ID number 2. In general, up to ten unloading curves
can be referred to, but in this example only one unloading curve is used. The onset of irreversible behavior of the gasket
material is defined by a yield pressure of 52 MPa (see also Figure 10-2). As soon as the corresponding gasket closure
CHAPTER 10 141
Engine Gasket
has been exceeded, the unloading behavior will be interpolated between the loading and the unloading curve. The
tensile modulus (in case the gasket would be loaded in tension) is set to 72 MPa and the transverse shear modulus to
35 MPa. The initial thickness difference between the gasket ring and gasket body is reflected by the initial gap of
0.090909 mm.
The control grids for the bolt pre-tensioning, 4083 and 4095, are defined by:
GRID 4083 -36.04921.31545 20.515 5
GRID 4095 36.0492 1.31545 20.515 6
CORD2R 5 -36.04921.31545 20.515 -36.0492-40.183220.515
5.44948 1.31545 20.515
CORD2R 6 36.0492 1.31545 20.515 36.0492 -40.183220.515
77.5479 1.31545 20.515
Using these control grids, the MPC entries are:

MPC 22 4084 1 1. 3924 1 -1.
4083 1 -1.
MPC 22 4085 1 1. 3930 1 -1.
4083 1 -1.
MPC 22 4086 1 1. 3936 1 -1.
4083 1 -1.
...
...
MPC 22 4104 3 1. 1966 3 -1.
4095 3 -1.
MPC 22 4105 3 1. 1972 3 -1.
4095 3 -1.
MPC 22 4106 3 1. 1978 3 -1.
4095 3 -1.
Alternatively, as of version MD 2010, the BOLT option can be used. Although the kinematic constraints involved are
the same, the BOLT option has the following advantages:
• the input format is more concise;
• the option is easier to use in a contact analysis.
When the MPC entries are used, the user defined MPC's may easily be conflicting with MPC's introduced by the
contact algorithm, thus causing the contact constraints to be skipped. On the other hand, when the elements at both
sides of the cross section are included in the same contact body, then the BOLT option causes the contact algorithm to
treat this cross section in a special way, Consequently, grid points at the boundary of the cross section can touch
another contact body, while grid points touching the body with the cross section can slide along this body, even when
the cross section has to be passed.
Using the same control grids as mentioned above, the input of the BOLT entries is:
BOLT 1 4083
TOP 3924 3930 3936 3942 3948 3954 3960
3966 3972 3978 3984
BOTTOM 4084 4085 4086 4087 4088 4089 4090
4091 4092 4093 4094
BOLT 2 4095
TOP 1918 1924 1930 1936 1942 1948 1954
1960 1966 1972 1978
BOTTOM 4096 4097 4098 4099 4100 4101 4102
4103 4104 4105 4106
CHAPTER 10
The SPCDs defining the shortening of the bolts are:

SPCD 1 4083 2 .175
SPCD 1 4095 2 .175
The nonlinear procedure used is defined via the NLPARM entry:

NLPARM 1 10 FNT 1 25 UPW YES
10
Here the FNT option is selected to update the stiffness matrix during every recycle using the full Newton-Raphson
iteration strategy. Convergence checking is performed based on displacements, forces, and work. For all criteria, the
default error tolerance is used. In order to avoid bi-sections, the field MAXDIV is set to 10.
Figure 10-5 shows a plot of the displacement magnitudes in the structure corresponding to the maximum pre-
tensioning of the bolts. The expected symmetry in the solution is clearly present.
Figure 10-5 Displacement Contours at Maximum Bolt Pre-tensioning
The values of the bolt force as a function of the bolt shortening are depicted in Figure 10-6 and clearly show a
nonlinear response. The bolt force is found as the reaction force on grid 4083.
CHAPTER 10 143
Engine Gasket
5000 Bolt Force (N)
4000
3000
2000
1000
Bolt Shortening (mm)
0
0.00 0.05 0.10 0.15 0.20
Figure 10-6 Bolt Force as a Function of the Bolt Shortening
Finally, Figure 10-7 displays the gasket pressure as a function of the gasket closure, both for the gasket ring and the
gasket body. As explained before, the gasket body has an initial gap which explains that the gasket pressure remains
zero until this gap is closed. The fact that the gasket pressure seems to already be nonzero for a gasket closer smaller
than the initial gap value (0.090909 mm) is due to the finite number of steps (10). Neither the gasket ring nor the gasket
body is loaded yet beyond the yield stress.
Figure 10-7 Gasket Pressure as a Function of the Gasket Closure
Modeling Tip
Contact Body Definition

Since the mesh of the engine block and the lower part of the bolts is a continuous mesh, the automated contact
algorithm will not be able to find a unique boundary description at the interface of the engine block and the bolts. This
is reflected by messages like:
warning: node 1407 belongs to bodies 3 4.

for the contact algorithm it will belong to body 3 only.
CHAPTER 10
Although, in the current example, this will not affect the results (there will be no contact detection between the engine
block and the bolts), it is generally not recommended. Instead, one should either make sure that the lower part of the
bolts are separated from the engine block or include only the upper part of the bolts in the contact body definition.
Input File(s)
File Description
nug_10.dat Engine Gasket with MPC option
nug_10_bolt.dat Engine Gasket with BOLT option
Video
bolt cross section
bolt cross section

Chapter 11: Elastic-plastic Collapse of a Cylindrical Pipe under External Rigid Body Loading
Elastic-plastic Collapse of a
11 Cylindrical Pipe under External
Rigid Body Loading

Summary 146

Introduction 147


FEM Solutions 147

Modeling Tips 152


Input File(s) 210
CHAPTER 11
Summary
Title Chapter 11: Elastic-Plastic Collapse of a Cylindrical Pipe under External Rigid
Body Loading
Contact features Rigid-deformable contact; Velocity controlled rigid bodies; Elastic perfectly plastic
material; Nonlinear shell elements with large strain plasticity
Geometry Pipe Length = 24”; Pipe Diameter = 8”; Pipe Thickness = 0.4”
+
Move Down
R=4
V = -2 in Rigid
Body 2
Pipe
Rigid Move Up
R=3
Body 1 V = 2 in
+
Material properties Elastic perfectly plastic material

6
E = 3.0 10 psi  = 0.3  y = 36000 psi
Analysis type Quasi-static analysis using elastic perfectly plastic material, geometric nonlinearity, and
nonlinear boundary conditions
Boundary conditions Both ends of pipe are constrained in all degrees of freedom
Applied loads Both rigid bodies are moving towards the pipe in y-direction with a velocity of 2 in/sec.
for duration of 1 second.
Element type 4-node nonlinear thick shell element
FE results Plot of y-displacement and total plastic strain contours
Die Load [Lbf ]
100000
80000
60000
40000 Force Y Top

Force Y Bottom
20000
0
0.0 0.5 1.0 1.5 2.0
Die Displacment [in]
CHAPTER 11 147
Elastic-plastic Collapse of a Cylindrical Pipe under External Rigid Body Loading
Introduction
A model of a cylindrical pipe is subjected to crushing as rigid bodies above and below the pipe move inward towards
each other. The model is created using 2-D nonlinear thick shell elements to model the pipe and rigid surfaces above
and below the pipe. The problem attempts to quantify whether the movement of the external structures cause the
plastic collapse of the pipe. Initial contact with the external structures is expected to cause elastic deformation of the
steel pipe. Additional incremental movement potentially subjects the structure to stresses beyond the proportional limit
of the material. The yield stress defines the onset of plastic strains that may initiate the collapse of the structure walls.
This exercise illustrates several SOL 400 capabilities including large displacement analysis, contact analysis between
rigid and deformable bodies, and large strain plasticity modeled with an elastic-perfectly plastic model.
Requested Solutions
The large displacement elastic-plastic contact analysis is carried out using MD Nastran SOL 400 for this rigid to
deformable problem. The application of the nonlinear thick shell element is demonstrated by using the nonlinear
extension PSHLN1 option for the regular PSHELL option. The following results from SOL 400 model are compared
with the results obtained from the Marc model.
• Contour plot for y-displacement
• Contour plot for total equivalent plastic strain
FEM Solutions
A numerical solution has been obtained with MD R2Nastran’s SOL 400 for a 3-D representation of the deformable
pipe structure and two semi-circular sections of rigid pipes sections. The details of finite element model, contact
simulation, material, load, boundary conditions, and solution procedure are discussed in this chapter.
Finite Element and Contact Model

The finite element mesh for the pipe contains 18 elements around the circumference and 18 elements along the length
for a total of 324 elements. MD Nastran CQUAD4 elements with material ID 1 and thickness 0.4 inches are selected
using the following PSHELL and PSHLN1 entries. The PSHLN1 entry enables SOL 400 to access the thick shell
elements with large strain capabilities. The finite element model used for this simulation is shown in Figure 11-1.
PSHELL 1 1 .4 1 1
PSHLN1 1 1 1 NO +
+ C4 DCT L
CHAPTER 11
Figure 11-1 Finite Element Model used with MD Nastran Simulation
In defining the contact model, the primary pipe section is modeled as a deformable body and the two external pipe
structures are modeled as rigid bodies. Elements comprising the deformable pipe structure are used to generate a
deformable contact body with ID 4 using the following BCBODY and BSURF entries. Contact body IDs 5 and 6 are
used to define the velocity controlled rigid bodies for the two semicircular sections of rigid pipes. The geometry
profiles of the rigid surfaces are defined using 3-D NURB surfaces that describe the true surface geometry and most
accurately represent the curved surfaces.
BSURF 4 1 2 3 4 5 6 7
...
BCBODY 5 3D RIGID 0 1 0
0 0. 0. 0. 0. 0. -2. 0.
RIGID 0 1 CONTACT_TOP
NURBS -13 10 4 4 50 50 0
-2. 8.1 -5.5 -2. 8.1 -4.66667
...
0 0. 0. 0. 0. 0. 2. 0.
RIGID 0 1 CONTACT_BOTTOM
NURBS -13 10 4 4 50 50 8
0. -7.1 -5.5 0. -7.1 -4.66667
...
Furthermore, the following BCTABLE entries identify how these bodies can touch each other. BCTABLE with ID 0 is
used to define the touching conditions at the start of the analysis. This is a mandatory option required in SOL 400 for
contact analysis and is flagged in the case control section through the optional BCONTACT = 0 option. The BCTABLE
with ID 1 is used to define the touching conditions for later increments in the analysis, and it is flagged using
BCONTACT = 1 in the case control section.
BCTABLE 0 2
SLAVE 4 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 5
SLAVE 4 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 6
CHAPTER 11 149
BCTABLE 1 2
SLAVE 4 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 5
SLAVE 4 0. 0. 0. 0. 0 0.
0 0 0
MASTERS 6
Material
The isotropic elastic and elastic-perfectly plastic material properties of the deformable body are defined using the
following MAT1 and MATEP options.
MAT1 1 3.+7 .3
MATEP 1 Perfect36000. Isotrop Addmean
NLMOPTS,LRGS,1

Both ends of the pipe are constrained in all degrees of freedom using the following entries. In addition to this, the top
and bottom rigid surfaces are given velocity vectors of –2 inches per second, and +2 inches per second, respectively
in the y-direction. This causes the upper structure to be pushed down onto the top of the pipe section and the lower
structure to be pushed up into the bottom of the pipe section at a rate of 2 inches per second for a total time of 1 second.
The velocities of these rigid bodies are defined in the BCBODY section.
SPCADD 2 1
FORCE 1 1 0 1.-16 1. 0. 0.
SPC1 1 123456 1 THRU 18
SPC1 1 123456 343 THRU 360
Solution Procedure
The nonlinear procedure used is defined through the following NLPARM entry:
NLPARM 1 100 PFNT 0 500 UPV NO
where 100 indicates the total number of increments; PFNT represents Pure Full Newton-Raphson Technique wherein
the stiffness is reformed at every iteration; KSTEP = 0 in conjunction with PFNT indicates that the program
automatically determines if the stiffness needs to be reformed after the previous load increment is completed and the
next load increment is commenced. 500 is the maximum number of allowed recycles for every increment and if this
were to be exceeded, the load step would be cut-back and the increment repeated. UPV indicates that convergence will
be checked on displacements (U) and residuals (P) and V stands for vector component which will do a maximum
component check. NO indicates that intermediate output will not be produced after every increment. The second line
of NLPARM is omitted here which implies that default convergence tolerances of 0.01 will be used for U and P
checking.
CHAPTER 11
Results
The contour of displacement in y-direction and total equivalent plastic strain in the pipe section from SOL 400
simulations are shown in Figure 11-2 and Figure 11-3, respectively. Similar plots from the Marc simulations are
shown in Figure 11-4 and Figure 11-5, respectively. It is clear from these figures that the predictions from the SOL
400 matches closely with the prediction from Marc.
Figure 11-2 Y-Displacement Contours from SOL 400 Model
Figure 11-3 Total Equivalent Plastic Strain Contours from SOL 400 Model
CHAPTER 11 151
Figure 11-4 Y-Displacement Contours from Marc Model
Figure 11-5 Total Equivalent Plastic Strain Contours from Marc Model
CHAPTER 11
Modeling Tips
• PSHLN1 entry in conjunction with regular PSHELL entry allows the users to make use of the thick shell
element which is capable of handling large strain elasto-plastic applications problems. Users should also make
use of the NLMOPTS,LRGS,1 option to flag the large strain behavior of these element.
• Adding the parameter,
PARAM,CDBMSG05,5
after the BEGIN BULK option will output a num-11m.t19 file that has the contact information available for
postprocessing in either Mentat or Patran. With this information, you can plot the normal contact force on the
rigid bodies (Die Forces) versus the Die Displacement as shown in Figure 11-6. The step shaped response is
due to the local collapsing of the curvature of the pipe elements. Using more elements would require smaller
step sizes.
Die Load [Lbf ]

100000
80000
60000
40000 Force Y Top

Force Y Bottom
20000
0
0.0 0.5 1.0 1.5 2.0
Die Displacment [in]
Figure 11-6 Die Load versus Die Displacement
• It is possible to make use of load controlled rigid body in place of the velocity controlled rigid body for this
problem. In such case, you should apply necessary displacement boundary condition at the control node of
rigid bodies to simulate its movement in y-direction.
CHAPTER 11 153
Specify the Model Units
a. Tools: Options
b. Select Units Manager
c. For Basic Units, specify the model units:
Length = mm; Mass = kg; Time = s; Temperature = kelvin, Force = N
d. Click OK
b c
d
CHAPTER 11
Create a Part for the Pipe
a. Assemble tab
b. Select Create Part
c. For Title, specify pipe
d. Click OK
e. Observe pipe in the Model Browser Tree
a
b
d
CHAPTER 11 155
Create Curves for the Pipe
a. Geometry tab: Curve/Arc

b. Select Arc
c. Select Circle
d. Select Dir-Radius
e. For X,Y,Z Input, enter -12,0,0
f. Click OK
g. For Circle,1 Radius, enter 4
h. Click OK
i. Fill
c
g
d
e
h
f
CHAPTER 11
Create Curves for the Pipe (continued)

b. Select Arc
c. Select Circle
d. Select Dir-Radius
e. For X,Y,Z Input, enter -7.2,0,0; click OK
f. For X,Y,Z Input, enter 7.2,0,0; click OK
g. For X,Y,Z Input, enter 1.2,0,0; click OK
g
CHAPTER 11 157
Create Mesh for the Pipe
a. Meshing tab
b. Select 2-3-4-Line Mesh
c. For Curves, select 2 curves
d. For On curve 1: enter 18
e. For On curve 2, enter 3
f. Leave On curve 3 and 4 blank
g. Click OK
d
e
f
g
CHAPTER 11
Create Mesh for the Pipe (continued)
a. Meshing tab
g. Click OK
d
e
f
g
CHAPTER 11 159
Create Mesh for the Pipe (continued)
a. Meshing tab
g. Click OK
d
e
f
g
CHAPTER 11
Merge Equivalent Nodes
a. Node/Elements tab
b. Select Equivalence
c. For Entities, select Select All
d. Click OK
d
CHAPTER 11 161
Merge Equivalent Nodes (continued)
a. Node/Elements tab
b. Check for any other coincident nodes by repeating the previous step.
c. Click OK
a
CHAPTER 11
Merge Equivalent Nodes (continued)
a. Quality tab
b. Select Fix Elements
c. Select Normal
d. For Element Verify Normals 1: Mode, select Show Normals
e. Select Select All
f. Click OK
g. For Element Verify Normals 1: Mode, select Hide Normals
h. Select Select All
i. Click OK
a
b
c
e f
i
h
CHAPTER 11 163
Save the Intermediate File
a. File tab
b. Select Save As
c. For File name: enter ch11.SimXpert
d. Click Save
c d
CHAPTER 11
Create a Part for the Upper-right Body
a. Assemble tab
c. For Title, specify upper_rigid
d. Click OK
e. Observe upper_rigid in the Model Browser Tree
a
b
d
CHAPTER 11 165
Create Surface for Upper-rigid Body (continued)

b. Select Arc
c. Select 3 Points
d. For X,Y,Z Input, enter -2,8.1 -5.524.1 -5.568.1.5
e. Click OK
f. Click OK
d
e
f
CHAPTER 11
a. Geometry tab:
b. Select Sweep
c. For X,Y,Z Input, enter 0 0 1
d. For Sweep Direction screen, enter Vector
e. For Axis, select Z
f. Click OK
e
f
CHAPTER 11 167
a. Geometry tab:
b. Select Sweep
c. For Entities screen select the CURVE/5
d. For Length of Sweep, enter 10
e. Click OK
c
d
e
CHAPTER 11
Create a Part for the Lower-rigid Body
a. Assemble tab
c. For Title, specify lower_rigid
d. Click OK
e. Observe lower_rigid in the Model Browser Tree
a
b
d
CHAPTER 11 169
Create Surface for Lower-rigid Body (continued)

b. Select Arc
c. Select 3 Points
d. For X,Y,Z Input, enter -5.5 -3 -4.1 -5.5 -6 -7.1 -5.5
e. Click OK
f. Click OK
d
e
f
CHAPTER 11
a. Geometry tab:
b. Select Sweep
c. For X,Y,Z Input, enter 0 0 1
d. For Sweep Direction screen, enter Vector
e. For Axis, select Z
f. Click OK
c
d
e
f
CHAPTER 11 171
Create Surface for Lower-rigid Body (continued)
a. Geometry tab:
b. Select Sweep
c. For Entities screen select the CURVE/5
d. For Length of Sweep, enter 10
e. Click OK
c
d
e
CHAPTER 11
a. Materials and Properties tab:

b. Select Isotropic
c. For Isotropic Material screen, select steel
d. For Young’ Modulus, enter 3e7
e. For Poisson’s Ratio, enter 0.3
f. Click Advanced
g. Click Add Constitutive Model, Elasto Plastic
d
e
g
CHAPTER 11 173
Define Material Data (continued)
a. Materials and Properties tab: Isotropic

b. Click Perfectly Plastic
c. For Initial Yield Stress, enter 36000
d. Click OK
d
CHAPTER 11
Define Property Data
a. Materials and Properties tab

b. Select Shell
c. For Name, specify pipe_prop
d. Select Entities pipe from Model Browser
e. For Material, specify steel
f. For Part Thickness, enter 0.4
g. Click OK
a
b
d d
e
f
g
CHAPTER 11 175

b. Select Shell
c. For Name, specify pipe_prop
d. Select Entities pipe from Model Browser
e. For Material, specify steel
f. For Part Thickness, enter 0.4
g. Click OK
a
b
d d
e
f
g
CHAPTER 11
a. Materials and Properties tab: Shell

b. Select Non Linear
c. For Membrane material, specify steel
d. For Bending material, specify steel
e. For Analysis type, specify IS
f. For Corner elements keyword, enter 4
g. For Element structural behavior, enter DCT
h. For Integration scheme, enter L
i. Click OK
b
c
d
e
f
g
h
i
CHAPTER 11 177
Define Contact Body for Pipe
a. LBCs tab
b. Select Deformable Body
c. For Name, specify deform_pipe
d. For Pick Entities, select pipe from Part in the Model Browser
e. Click OK
a b
d
d
e
CHAPTER 11
Define Contact Body for Upper-rigid Body
a. LBCs tab
b. Select Rigid Body
c. For Name, specify rigid_top
d. For Pick Entities, select SURFACE/1 (upper-rigid body)
e. Click Motion
c
d
e
CHAPTER 11 179
Define Contact Body for Upper-rigid Body (continued)
a. LBCs tab: Rigid Body

b. For Velocity, specify X: 0; Y: -2; Z: 0
c. Click Body
b
CHAPTER 11

b. For Inward Normals, click Reverse
c. Click Display
d. Click Preview
b c
d
CHAPTER 11 181

b. Click Animate
c. Verify rigid_top is moving down
d. Click Exit
b
d
c
CHAPTER 11
Define Contact Body for Lower-rigid Body
a. LBCs tab
b. Select Rigid Body
c. For Name, specify rigid_bottom
d. For Pick Entities, select SURFACE/2 (lower-rigid body)
e. Click Motion
c
d
e
CHAPTER 11 183
Define Contact Body for Lower-rigid Body (continued)

b. For Velocity, specify X: 0; Y: 2; Z: 0
c. Click Body
b
CHAPTER 11

b. For Inward Normals, click Reverse
c. Click Display
d. Click Preview
b c
d
CHAPTER 11 185

b. Click Animate
c. Verify rigid_bottom is moving up
d. Click Exit
b
d
c
CHAPTER 11
Define Contact Table
a. LBCs tab
b. Select Table
c. Click twice on T to disable self contact of the pipe
d. Click OK
d
CHAPTER 11 187
Define Boundary Conditions
a. LBCs tab
b. Select Fixed
c. For Name, specify fix
d. Select nodes at left and right edges of the pipe
e. Click OK
a
b
d d
CHAPTER 11
Create SimXpert Analysis File
a. Right click on FileSet

b. Select Create new Nastran job
c. For Job Name, enter pipe-crush
d. For Solution Type, select SOL 400
e. For Solver Input File, specify the fine name and its path
f. Unselect Create Default Layout
g. Click OK
a
b
e
f
g
CHAPTER 11 189
Create SimXpert Analysis File (continued)
a. Right click on Load Case

b. Select Create Global Loadcase
c. Click OK
a
b
c
CHAPTER 11
a. Right click on Loads/Boundaries

b. Select Select Contact Table
c. For Selected BCTable, enter BCTABLE_1
d. Click OK
b
c
d
CHAPTER 11 191
a. Right click on Load Cases

b. Select Create Loadcase
c. For Name (Title), enter subcase-1
d. Click OK
a
b
d
CHAPTER 11
a. Right click on Loadcase Control

b. Select Subcase Nonlinear Static Parameters
c. For Stiffness Update Method, select Pure Full Newton (PFNT)
d. For Maximum Iterations for each Load Inc, enter 500
e. Unselect Default Tolerance Setting
f. Check Displacement Error; for Displacement Tolerance, enter 0.01
g. Check Load Error; for Load Tolerance, enter 0.01
h. Check Vector Component Method
i. From the Intermediate Output Control pull down menu,
select Every computed load increment (YES)
j. Click Apply
k. Click Close
b
c
e
a
f
g
i
j
k
CHAPTER 11 193
a. Double click on Loadcase Control

b. Select Stepping Procedure Parameters
c. For Number of Steps, enter 100
d. Click Apply
e. Click Close
b
c
e
CHAPTER 11

b. Select Select Lbcs
c. Select fix from the Model Browser
d. Click OK
d
c
CHAPTER 11 195

c. Select BCTABLE_1 from the Model Browser
d. Click OK
d
c
CHAPTER 11
a. Right click on Output Request

b. Select Nodal Output Requests
c. Select Create Displacement Output Request
d. Click Suppress Print
e. Click OK
a
b
e
CHAPTER 11 197

c. Select Create Contact Output Request
e. Click OK
a
b
e
CHAPTER 11

b. Select Elemental Output Requests
c. Select Create Nonlinear Stress Output Request
e. Click OK
e
CHAPTER 11 199
a. Double click on Solver Control

c. Structural Damping Coefficient, select Large Disp and Follower Force
d. Click Apply
e. Creep Analysis Type, select Additive Plasticity for Large Strain Formulation
f. Click Apply
g. Click Close (not shown)
f
CHAPTER 11

b. Select Output File Properties
c. Nastran DB Options, select Master/DBALL
d. Binary Output, select OP2
e. Click Apply
f. Click Close (not shown)
b c
e
CHAPTER 11 201
a. File: Save
b. Select pipe-crush
c. Select Run
c
CHAPTER 11
Attach the SimXpert Analysis Results File
a. File tab
b. Select Attach Results
c. File path, enter *.Master
d. Attach Options: click Results or click Both to get both model and results data which
enables postprocessing without using model data from SimX database
e. Click OK
e
CHAPTER 11 203
Attach the SimXpert Analysis Results File (continued)
a. Results: Deformation
b. Deformation tab: Deformed display scaling, check True
c. Plot Data tab: Plot type select Deformation
d. Results entities: Results cases: select last increment
e. Results entities: Results type: select Displacements, Translational
f. Click Update
f
c e
d
CHAPTER 11
a. Animation tab
b. Results cases: select SC1:Step 1 (selects all increments)
c. Results entities: Results type: select Displacements, Translational
d. Click Update
d
c
b
CHAPTER 11 205
a. Animation tab
b. Click Pause icon to stop animation
a
CHAPTER 11
a. Results: Fringe
b. Animation tab
c. Results entities: Results cases: select SC1:Step 1 (selects all increments)
d. Results entities: Results type: select Nonlinear Strains, Plastic Strain
e. Fringe tab: Display settings tab: select Element edges
f. Label attributes, select color of labels
g. Click Update
c d
f
CHAPTER 11 207
a. Use shift + Right click on the mouse to rotate the model in SimXpert to view results in
various parts of the pipe
CHAPTER 11
a. Results: Fringe
b. Animation tab: click Pause icon to stop animation
c. Plot Data tab: Results type: Contact Status: select Normal contact force
d. Click Update
d
c
CHAPTER 11 209
a. Use shift + Right click on the mouse to rotate the model in SimXpert to view results in
various parts of the pipe
CHAPTER 11
Input File(s)
File Description
nug_11m.dat MD Nastran SOL 400 input
ch11.SimXpert SimXpert input file
ch11.bdf Associated MD Nastran SOL 400 input from SimXpert
Chapter 12: Thermal/Pressure Loaded Cylinders
Thermal/Pressure
12 Loaded Cylinders

Summary 212

Introduction 213

Required Solutions 213

FEM Solutions 213

Results 216


Input File(s) 219
CHAPTER 12
Summary
Title Chapter 12: Thermal/Pressure Loaded Cylinders
Contact features • Curved contact surfaces
Geometry and Two eccentric cylinders:
description t = 0.03 “
R = 0.32 “
R = 0.25 “
0.09 “
Material properties Inner cylinder: Isotropic elasto-plastic; E inner = 2.2 107 psi ;  in = 0.3 ,
–5
Thermal expansion coefficient = 1.85 10 1  F , Initial yielding stress: 9900 Psi; Piece-wise
linear and isotropic work hardening rule.
Outer cylinder: Isotropic elastic, Young’s modulus is temperature dependent, initial
value E outer = 1.27 107 psi ;  out = 0.3 , Thermal expansion coefficient = 1.85 10–5  F , no
plasticity.
Analysis type Quasi-static analysis; Material nonlinearity (softening by temperature and hardening by
plastic deformation); Geometric nonlinearity
Displacement Boundary Symmetric displacement constraint over the horizontal plane with one end of the
conditions and applied cylinders are fixed in the z-direction. Step 1: Thermal loading 50oF temperature change.
loads Step 2: Internal pressure loading; internal cylinder.
Element type 8-node linear elements
Contact properties Deformable-to-deformable body contact without friction
FE results Plot of stress/strain and displacement distribution after each step.
Displacement Contours after Step 2

CHAPTER 12 213
Thermal/Pressure Loaded Cylinders
Introduction
This application example evaluates the performance of an adaptive load stepping scheme in the applications of MD.
Nastran SOL 400 for the FE analysis. Due to the symmetry condition, half of the assembly is sufficient for the finite
element analysis. This example involves thermal load, contact, material, and geometrical nonlinearity under pressure
loading. The geometry and material descriptions are given in the above summary table. There are two load steps. The
first step is to apply the thermal load by specifying the temperature changes at each node of the two eccentric cylinders.
With the thermal loading along with the given boundary conditions, the stress and strain are generated due to uneven
thermal expansion of the two cylinders. In the second loading step, a pressure is applied at the inside of the inner
cylindrical surface. Due to this pressure, the smaller cylinder expands in diameter and eventually fills the gap between
the two cylinders when the outer surface of the small cylinder progressively touches the inner surface of the outside
cylinder.
Due to the strong nonlinearity, adaptive time stepping scheme is used. By the adaptive time stepping scheme, the step
size of each increment is adjusted at the end of step that just converged.
Required Solutions
SOL 400 is used for the FE analysis of this problem. The advanced HEX element defined by PSOLID entry pointing
to an auxiliary PSLDN1 entry is used. For the first loading step, the thermal strains and stresses of the two cylinders
are of the interests. For the second load step, the deformation and contact between two cylinders under pressure
loading are investigated. Due to the nonlinearity introduced by nonlinear material properties and contact, convergence
speed varies with the nonlinear deformation and changes of contact condition. In order to achieve fast and stable
analysis, the time step size is automatically adjusted according to the convergence condition. In the current version of
MD Nastran SOL 400, this is done by adding the NLAUTO option into the input data file. For comparison purposes,
one analysis with MSC.Marc version 2005 with the solid element of the same formulation as the element in SOL 400
and auto step scheme is also conducted.
FEM Solutions
The element, contact, material/geometry, solution algorithm, and convergence schemes parameters are explained in
this chapter.
The Advanced HEX Element

The FE model is shown in Figure 12-1. As mentioned earlier, two solutions are obtained. The first solution was
obtained by using the MD Nastran SOL 400 with the advanced HEX element, which is defined by the PSOLID and
PSLDN1 bulk data options as shown below, where (C8 SOLI L) defines the 3-D continuum solid element with linear
integration scheme.
PSOLID 1 1 0
PSLDN1 1 1 +
+ C8 SOLI L
CHAPTER 12
Figure 12-1 The FE Model for the Numerical Solution
Contact Parameters
As shown in Figure 12-1, the contact body named as cbody1 (shown in pink) represents the inner cylinder. The
contact body named as cbody2 defines the outside cylinder. The black arrows represent the pressure applied on the
inner surface of the small cylinder (cbody1). It should be noted that only half of the whole assembly is modeled due
to the symmetry condition.
In the input data file, the contact bodies are defined deformable contact bodies as below:
BSURF 1 1813 1814 1815 1816 1817 1818 1819
BSURF 2 1013 1014 1015 1016 1017 1018 1019
The BCTABLE bulk data entries shown below define the touch conditions between the bodies:
BCTABLE 0 1
SLAVE 1 0. 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0.
MASTERS 2
BCTABLE 1 1
SLAVE 1 0. 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0.
MASTERS 2
BCTABLE 2 1
SLAVE 1 0. 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0.
MASTERS 2
As shown above, BCTABLE with ID 0 is used to define the touch conditions at the start of the analysis. 0 identifies the
case number. This BCTABLE is mandatory for the contact analysis with SOL 400. Also, the options BCONTACT with
CHAPTER 12 215
ID 0 and BCPARA with ID 0 are all applied at the start of the analysis. For each load step, the touch condition can be
defined by BCTABLE, BCPARA, and BCONTACT option.
Both bodies in this analysis are isotropic in terms of thermal and mechanical properties. Body one represents the inner
cylinder, which is also elasto-plastic. The Young’s modulus, Poisson ratio, and thermal expansion coefficient are
defined by MAT1 bulk data option. The plasticity properties are defined by MATEP with TABLES1 option. Here,
TABLES1 is associated with MATEP to defined the strain hardening rule of the material with ID 1.
MAT1 1 2.2+7 .3 1. 1.85-5
TABLES1 1 2
0. 9900. 3.9-4 12500. 9.5-4 15200. .00295 17500.
.00615 20000. .05 25000. .1 28000. ENDT
Body two represents the outside cylinder. As shown below, this body has a temperature dependent Young’s modulus
(see TABLEM1).
MAT1 2 2.2+7 .3 1. 1.85-5
MATT1 2 2
TABLEM1 2
0. 2.2+7 50. 1.76+7 100. 1.54+7 ENDT
The thermal expansion coefficient of the two cylinder are the same which is 0.0000185 1/oF.

There are two loading sequences (or loading steps) in the analysis. In each loading sequence, the control parameters
are defined by the NLPARM and the NLAUTO option. The ID of the NLAUTO option is linked with the identification
number of the NLPARM option. This option must be used in conjunction with NLPARM. The NLAUTO options are
specified in the bulk data area. As shown below, load STEP ID 1 of SUBCASE ID 1 defines all necessary conditions
applied to the analysis for the first load step which includes bulk data options (TITLE, NLPARM, BCONTACT, SPC,
LOAD) and the requested output information. Particularly, it is necessary to note the analysis control options of
NLMOPTS and the LGDISP parameter. In this example, the NLMOPTS option defines LRGS to 1. It means that LARGE
STRAIN formulation is used. The LGDISP parameter indicates that geometric nonlinearity includes the stiffness of
follower forces.
NLPARM defines the parameters to control the time step and convergence schemes. In this example, PFNT means that
full Newton-Raphson method is adopted. The attempted total number of loading increments is set to 20. The maximum
iteration for each increment is set to 25. UP means the convergence scheme is set to check both the convergence of
displacements and residuals. In this loading sequence, both tolerances are set as 0.01. It is worth to note that a negative
value is set for the displacement check. The negative sign means the convergence check will be based on the
incremental displacement. And NO in the NLPARM option means that it is not required to output the analysis results
for intermediate loading steps, except the results at the end of the loading sequence. However, the total number of
loading increment may be changed according to the parameters set in NLAUTO option. In the first load step, the
deformation is relatively small. The desired number of iterations (1st field of the second line of NLAUTO option) is set
as 5. In the second load step, due to contact and large deformation, the desired number of iteration is set as 7. To set a
proper desired number of iterations is critical to achieve the solution with minimum computation time and adequate
CHAPTER 12
accuracy. Too large numbers may cause significant change of time step size between increments, which may cause the
solution to converge slowly or even diverging. If this happens, SOL 400 cuts the time step size back. As one of the
consequences, the analysis may need even longer computation time. To avoid this, it is recommended to set a
reasonably small value for the maximum ratio of incremental step size change between incremental steps (the 6th field
of the first line of the NLAUTO option). This parameter is set as 10 with desired number of iteration as 5 for load step
1. For the second load step, with consideration of the fact that contact and large deformation may occur, this parameter
is set as 1.2 with desired number of iterations as 7. This is particularly important in order to avoid penetration and also
to control the time step size with good balance of efficiency and accuracy.
SUBCASE 1
STEP 1
ANALYSIS = NLSTATICS
NLPARM = 1
BCONTACT = 1
SPC = 2
LOAD = 3
TEMPERATURE(LOAD) = 4
BOUTPUT (PRINT)=ALL
STEP 2
ANALYSIS = NLSTATICS
NLPARM = 2
BCONTACT = 2
SPC = 2
LOAD = 6
BEGIN BULK
NLMOPTS LRGS 1
PARAM LGDISP 1
NLPARM 1 20 PFNT 1 25 UP NO
-0.01 0.01 0 0
NLAUTO 1 0.05 1.0 0.1 10. 1.0e-5 0.2 999999
5 1 0 0 10 0 0 0.0
$
NLAUTO 2 0.05 1.0 0.1 1.2 1.0e-5 0.2 999999
7 1 0 0 10 0 0 0.0
-0.01 0.01
Results
Load Step One
The initial temperature of the whole assembly is set as zero (0). In the first load step, a temperature load is applied to
the inner cylinder and part of the outside cylinder (see Figure 12-2 - yellow color). Due to the thermal expansion
caused by the temperature load and the corresponding changes of the material properties, thermal strain and stress are
generated. Figure 12-3 shows the distribution of major principal stress and the equivalent stress at the end of this load
step. It is seen that the distribution of stress is uneven through the wall thickness of the outside cylinder. However, the
stress in the inner cylinder is quite uniformly distributed (see Figure 12-3(b)). This is because the inner cylinder has a
CHAPTER 12 217
uniform temperature load with minimum displacement boundary constraints. Therefore, it has nearly stress-free
thermal expansion. With the adaptive loading step scheme, the analysis of this loading sequence is completed in eight
incremental steps.
Figure 12-2 Temperature Loading
(a) Major Principal Thermal Stress (b) Equivalent Stress
Figure 12-3 Distributions
Load Step Two

This load step is to apply the pressure inside the inner cylinder. Due to the pressure loading, the inner cylinder expands
in diameter. At some point of loading, the gap between the two cylinders is closed. Figure 12-4 (a) shows the gap
between two cylinders at the beginning of this load step. Figure 12-4 (b) shows that the gap is completely closed after
the pressure is fully applied. Using the adaptive load step control, this load step is completed in 19 incremental steps.
So the total number of incremental steps for the analysis is 27 steps. The distribution of equivalent stress in the
deformed cylinders is shown in Figure 12-5. It is seen that the level of stress is higher in the inner cylinder. The lowest
stress occurs on the outside cylinder along its inner surface which is in contact with the outside surface of
CHAPTER 12
the inner cylinder. The lower level of stress is mainly because of the softening of material due to increased
temperature.
(a) (b)
Figure 12-4 Change of Contact Status Between the Two Cylinders
Figure 12-5 Equivalent Stress of the Deformed Cylinders After Pressure Loading
In addition to the analysis with MD Nastran SOL 400, the MSC.Marc 2005 version is also used to conduct the analysis
with the same type of element and material and boundary condition definition. The results are quite close as shown in
Figure 12-6(a) and Figure 12-6(b). The analysis by MSC.Marc takes 16 incremental steps for the first load step and
another 27 incremental steps for the pressure loading step.
CHAPTER 12 219
(a) MD Nastran SOL 400 (b) MSC.Marc

Figure 12-6 Displacement Contours of the Cylinders After Pressure Loading

Convergence control: While the nonlinearity is quite strong in the second load step, it is suggested to use both
displacement and residual convergence check due to the nonlinearity introduced by contact. Also, the full Newton-
Raphson iteration scheme is recommended for all SOL 400 analyses because the degree of nonlinearity is typically
significant.
Adaptive step size control: The NLAUTO option with NLPARM option provides the convenient interface for user to
control the analysis procedure. Proper setting of the control parameters is very important to obtain accurate results
without losing computational efficiency. A useful tip is to use loose control over the desired number of iteration but
use tighter control over the maximum ratio of time step change allowed after each converged step.
Contact control: In this example, the FE nodes of inner cylinder part are defined as slave contact nodes. This is due
to the consideration that, during the pressure loading process, the inner cylinder will expand and intend to touch the
inner surface of the outside cylinder. In this case, the nodes on the inner cylinder surface usually have much larger
incremental displacements at each increment.
Input File(s)
File Description
nug_12bm.dat Input data for MD Nastran SOL 400
mdug_12b3d.dat Input data for Marc
Chapter 13: Ball Joint Rubber Boot
13 Ball Joint Rubber Boot

Summary 221

Introduction 222


FEM Solution 223

Results 226

Modeling Tips 228

Input File(s) 228

Video 229
CHAPTER 13 221
Ball Joint Rubber Boot
Summary
Title Chapter 13: Ball Joint Rubber Boot
Contact features Load controlled rigid bodies and friction with viscoelastic relaxation
Geometry
+
r = 0.017557 m
r=0m
Clamp 2
Knuckle
CL
Original Shape of Boot
Deformed Shape of Boot

Stud
Clamp 1
R
Housing
Material properties Shear Modulus, G = 2.0 MPa - using time dependent and independent Mooney and
Ogden elastomeric material models
Boundary conditions Housing moves to seat clamp 1; stud and knuckle move to seat clamp 2.
Element types Axisymmetric 4-node quad element
FE results Verify the equivalence of the two elastomeric models and underscore the importance of
time effects of material properties in elastomers. Verify the deformed shape with actual
installation.
CL
R
CHAPTER 13
Introduction
In the design of ball joints for automotive applications, the major design concern is to prevent sealing boots from
leaking. Because most ball joint failures occur as a result of corrosion, contamination or dirt ingress, causing excessive
wear. Figure 13-1 shows some typical ball joint failure modes. In practice the stud of a ball joint is subjected to axial,
oscillatory and rotational loads. Currently, most designs of sealing boots are based on design engineer's experience,
experimental tests, and/or much more simplified FEA models. In this example, we will install the boot using a 2-D
axisymmetric FEA model whereby the boot is fitted onto the housing under the large clamp, and then the stud and
knuckle moved to fit the boot onto the shaft. The deformed profile of the boot is then compared to the actual boot.
Contamination in the Wear in labyrinth from

grease corrosion on the pin
Contamination at the
parting line.
Figure 13-1 Ball Joint Sealing Boot Failure: Excessive Wear in Labyrinth
MD Nastran is used to model the assembly process of the boot onto the housing and stud. Since the stiffness of the
housing, ball stud, knuckle and clamping rings is much higher than the rubber sealing boot, they are modeled with
rigid bodies. The simulation is performed as three different cases as explained below:
Cases A and B: The rubber-sealing boot material is modeled using Mooney-Rivlin (Case A) and Ogden (Case B)
material models and equivalent performance of both is studied.
Case C: Viscoelastic Relaxation follows the installation with Mooney as the material mode. A time
dependence of hyperelastic properties is taken into account where the viscoelasticity is represented
as linear perturbations over hyperelastic material capable of representing large strains. The
viscoelastic relaxation will drop the strain energy density by about 50% in a two hour time period.
CHAPTER 13 223
FEM Solution
The numerical solution has been obtained with MD Nastran's solution sequence 400. The details of finite element
models, contact simulations, material, load, boundary conditions, and solution procedure are discussed next.

An axisymmetric model of the Ball Joint rubber boot is used in the simulation. The rubber boot is meshed with 845
lower-order axisymmetric solid elements.
The bulk data file entries defining the axisymmetric properties of the CQUADX elements are as follows:
PLPLANE 1 1
PSHLN2,1,1
,C4,AXSOLID,L
Contact Models
The model has six contact bodies. The rubber boot is the deformable contact body while the housing, ball stud,
knuckle, ring small and ring large are represented as the rigid contact bodies. Each of the contact bodies is defined
through the BCBODY bulk data entry. Each rigid body is defined to contact the deformable rubber boot, and hence, six
contact pairs are defined through BCTABLE. In each contact pair, the contacting rigid body is defined as MASTER and
the deformable rubber boot is defined as SLAVE. The contact tolerance is zero and the bias factor is globally defined
for all contact pairs as 0.95. For simplicity, no friction has been included in the analysis. The BCPARA bulk data entry
is used to define the global bias factor.
Figure 13-2 Original Axisymmetric Model

CHAPTER 13
Material
Cases A and B:
The experimental data is fitted with a one term Mooney (commonly known as neo-Hookean) model. To demonstrate
the equivalence and accuracy of the implemented elastomer models in sol 400, both Mooney (Case A) and Ogden
(Case B) models have been used for the rubber boot. The models are made equivalent by ensuring that the bulk
modulus is the same for both models and taking care of the following:
µ1 = 2C10 and 1 = 2 and µ2 = 2C01 and 2 = -2
It is important to note that this equivalence relation holds only one way i.e. any neo-Hookean or Mooney model can
be represented by the Ogden model in general but not vice-versa. The bulk data entry used to define the material
properties in Case A is MATHE for both Mooney and Ogden models. The properties of Mooney and Ogden materials
have been input as follows:
MATHE 1 Mooney 0. 1.
1. 0.
0. 0.
0.
MATHE 1 Ogden 1. 0. 0. 0.
2. 2.
0. -2.
Case C:
In this case, along with the Mooney properties of Case A, a MATVE bulk data file entry is used to define the viscoelastic
properties. Here, Wdi (multiplier or scale factor for deviatoric behavior in Prony series) and Tdi (time constant for
deviatoric behavior in Prony series) need to be entered in the MATVE entry. They have been included in the input file
as follows:
MATHE 1 Mooney 0. 1.
1. 0.
0. 0.
0.
MATVE,1,Mooney,,,0.111188,0.205057,,
,0.130683,1.71947,0.0967089,23.7532,0.0822848,273.121,0.0965449,3107.79

All the rigid bodies are load controlled and are assembled using displacement boundary conditions.
Cases A and B:
The control node 977 of the housing is given an x-displacement of 0.00273451 in the first load case. The control node
976 of the stud is held fixed in the y-direction in the first load case and given a y-displacement of 0.0031074 in the
second load case. The control node 978 of knuckle is held stationary in the first load case and given a displacement -
0.0105098 in the second load case. The clamping rings, ring large with control node 974, ring small with control node
975 are held stationary in the y-direction throughout the analysis but are allowed to translate in the x-direction.
CHAPTER 13 225
Case C:
All the control node displacements are applied together in the first load step (as explained in the above case) which is
followed by a step of visco-elastic relaxation.
Solution Procedure
The assembly process for the different cases has been done as follows:
Cases A and B:
• In the first step, the housing is brought into place with the ball stud and knuckle held unassembled. A fixed
time stepping procedure using NLSTEP with 50 increments is used to assemble the knuckle. UPV residual
checking is used with KSTEP = -1 and the solution algorithm utilizes the full Newton-Raphson (PFNT) with
convergence check using the infinity norm (as opposed to the L-2 norm):
NLSTEP 1 1.0
general 25 1 10
fixed 50 0
mech UPV .01 .01
NLSTEP 2 1.0
general 25 1 10
fixed 50 0
mech UPV .01 .01
• In the second step, both the stud and the knuckle are brought into position with the housing held in place.
Again, a fixed time stepping procedure using NLSTEP with 50 increments is used to assemble the Knuckle.
UPV convergence checking is used with KSTEP = -1.
• Large displacement (PARAM, LGDISP, 2)
• Large Strain analysis with updated Lagrangian approach with multiplicative decomposition of deformation
gradient (NLMOPTS,LRGS,2)
Case C:
In this case, all three housing, knuckle, and stud are brought into place in the first load step. Here, the entire analysis
is done in real time. The first load step is of 2 seconds.Again, a fixed time stepping is used with 100 increments with
each increment representing a real time of 0.02 seconds. Again the convergence technique is PFNT and UPV
convergence checking is used with KSTEP = -1. The NLSTEP entry is as follows
NLSTEP 1 2.0
general 25 1 10
fixed 100 0
mech UPV .01 .01
In the second load step, there are no additional loads or boundary conditions applied and the system is held in place
through the contact conditions. The assembled system thus relaxes for the next 7200 seconds. This is easily
accomplished with the adaptive time stepping scheme activated using the NLSTEP entry. The ADAPT field is employed
CHAPTER 13
in the NLSTEP entry to achieve this. While options like PV convergence test method and PFNT technique with
KSTEP=-1 and convergence tolerance of 0.100 are specified in the MECH option of the NLSTEP entry, the ADAPT
option is used which specifies the following:
• Initial time step (=1.0e-3)
• Minimum time step as a fraction of total load step time (=1.0E-5)
• Maximum time step as a fraction of total load step time (=.10)
• Desired number of iterations (=10)
• Factor for increasing the time steps (=1.20)
• Output flag (=-1)
• Maximum number of increments in the current load case (=999999)
• Flag for damping (=0)
• Damping co-efficient (=.100E-03)
The NLSTEP entry is as follows:
NLSTEP 2 72000.0
GENERAL 25 0 10
ADAPT 1.0E-03 1.0E-5 .10 10 1.20 -1 999999
0 .100E-03 0 0 1 .100 1.2
MECH PV 0.00 .100 0.00 PFNT -1
Results
The installation of the boot onto the housing and stud is shown in Figure 13-3. The deformed shape is overlaid onto
the actual deformed boot geometry to validate the modeling techniques.
CL
Undeformed Deformed
R
Figure 13-3 Undeformed and Deformed Rubber Boot

CHAPTER 13 227
As expected, the knuckle force is identical for both the models as shown in Figure 13-4. In addition, the results agree
with Marc's results which have been taken as reference. Figure 13-5 shows the fall of the knuckle force due to the
subsequent relaxation associated with the viscoelastic effects. The fall is quite dramatic and consistent with the
material data. Also, it can be noticed that the SOL 400 solution is very close to the Marc reference results.
Axial Force (N)

80
70
60
50
40
Ogden (MD Sol 400)
30
Mooney (MD Sol 400)
20
Mooney (Marc)
10
0
0.000 0.002 0.004 0.006 0.008 0.010
Axial Displacement (m)
Figure 13-4 Comparison of Knuckle Force during Assembly
Axial Force (N)

80
Install
70 Mooney (MD Sol 400)
60
Mooney (Marc)
50
40
30
Relax
20
10
Time (sec)
0
0 2000 4000 6000 8000 10000
Figure 13-5 Insertion Force History

CHAPTER 13
Modeling Tips
Use of NLMOPTS,LRGS,2 and PARAM,LGDISP,2 must be included in the analysis. The KSTEP field in the NLSTEP
entry should be set to -1,especially for these kind of problems. Finally, for an efficient solution using the adaptive time
stepping scheme, the ADAPT option is used in the NLSTEP entry.
It must be noticed that additional laboratory tests (and corresponding curve fitting to get the Prony coefficients) would
need to be carried out to get the time dependence of the material properties. The need for the addition of time
dependent effects in an analysis requires judgment. In analyses involving both rolling resistance (important for
designing for fuel efficiency) or standing waves (tire blowout) in tires, viscous effects are important,; however, a
simple static loading to capture load-deflection curves does not require modeling of any time dependent effects. This
can save time and money to do the additional tests.
In general, adaptive load stepping is recommended to provide robust automatic control of the applied load even in the
presence of strong nonlinearities. In this case, however, the large amount of contact throughout loadcase one together
with the time-dependent aspects of loadcase two made fixed stepping the better option.
Input File(s)
File Description
nug_13a.dat Mooney model
nug_13b.dat Ogden model
nug_13c.dat Mooney model with viscoelastic properties
CHAPTER 13 229
Video
+
+
r = 0.017557 m
r=0m
Clamp 2
Knuckle
CL
Original Shape of Boot
Deformed Shape of Boot

Stud
Clamp 1
R
Housing

Chapter 14: Time NVH Analysis – Chassis Example
Time NVH Analysis –

14 Chassis Example

Summary 231

Introduction 232


Model Details Time NVH scheme 232

FEM Solution 233

Results 235

Modeling Tips 237

Input File(s) 238
CHAPTER 14 231
Time NVH Analysis – Chassis Example
Summary
Title Chapter 14: Time NVH Analysis – Chassis Example
Features A potentially nonlinear periodic transient dynamic response of a chassis sub-frame
analysis is followed by a fast Fourier transform to extract the modes and frequencies that
characterize the dynamic solution which is compared to traditional linear modal
analysis.
Geometry Units: mm
G L
W1= 993
W2= 1,182 W1 W2
L1= 1,518 A F
L2= 865
L3= 927
L1 L2 L3 L4
L4= 361
Size of rectangular hollow beam: 53x111 to 53x191 depending on locations.
Thickness of shell: 3.5
Material properties E = 2.10x10 5 N  mm

2
,  = 0.3 ,  = 7.89x10 – 9 ton  mm 3
Analysis type TIMNVH analysis (SOL 700)
Boundary conditions Free
Applied loads Vertical impulse load applied at point A
Element type 4-node shell element
FE results Transient response, FFT, mode shapes and frequencies
1.00E-01
1.00E-02
901581
1.00E-03 901641
901697
Amplitude
901865
902061
1.00E-04 902097
902580
902595
902609
1.00E-05 902797
902996
903063
1.00E-06
0.00E+00 2.00E+01 4.00E+01 6.00E+01 8.00E+01 1.00E+02 1.20E+02 1.40E+02 1.60E+02
Frequency (Hz)
L
K
J
I
F
H E
G D
C
B
A
CHAPTER 14
Introduction
This is an example of a virtual dynamic test. A chassis of a car was modeled and a vertical impulse loading was applied
at one of front corner points. Time histories were obtained at select chassis locations and they were translated to
frequency domain by applying Fast Fourier Transform (FFT) to extract mode shapes and frequencies for 12 sampling
points.
Requested Solutions
Acceleration time histories are obtained at 12 points and they are translated to a frequency domain. Dynamic properties
such as modal natural frequencies and mode shapes are then computed. The results are then compared with those of
Nastran SOL 103 for validation purposes.
Model Details Time NVH scheme

MD Nastran bdf Model (impulse loading)
SOL 700
Obtain Time-history Results

- Displacement
- Velocity
- Acceleration (default)
FFT
Time domain results -> Frequency domain results
Find and compare peaks
Extract dynamic properties:

Natural frequencies and Mode shapes
(f06 and modes.out files)
Yes
Is acceptable? Final dynamic properties
No
Add PARAM, S700NVH1

, TIMNAT and TIMSML cards
Use primary time history or FFT results
Re-run MD Nastran SOL 700
Figure 14-1 Flow Chart of TIMNVH Scheme

CHAPTER 14 233
FEM Solution
There are two models. The first model is the initial run to determine the rough dynamic properties of the structure and
second model is a re-run of the first job to find the accurate and final results using the previous time history results.
Applied Load and Selected Location for Time History

To compute the dynamic responses of the chassis, a vertical impulse load is applied at the front corner as shown in
Figure 14-2. Using FORCE and TABLED entries as shown below, a maximum of 0.01 tons impulse point loading is
applied to node 902517.
FORCE 3 902517 0 .01 0. 0. -1.
TABLED1 1
-10. 0. 0. 0. .001 1. .002 0.
10. 0. ENDT
The acceleration time histories at 12 points on the chassis are computed (see Figure 14-2) to obtain the modal
responses.
L
Load (ton) K
0.010
J
I
F
H E
0.005 G D
C
B
A
Time (ms)
0.000
0 2 4 6 8 10
Figure 14-2 Applied Impulse Loading and Nodes Selected for Getting the Acceleration Responses
Primary Job
The end time in transient run is defined by using 100 time steps at 0.4e-4 sec. for each increment. The end time is the
product of these two entries. Notice here, the time increment is only for the first step. The actual number of time
increments and the exact value of the time steps are determined by MD Nastran solver during the analysis. The time
step is a function of the smallest element dimension during the simulation.
TSTEPNL 1 100 .01 1 ADAPT 2 10
TIMNVH defines the Time NVH analysis as explained below.
TIMNVH, 1, , , 1.0, 1000., 3, 0.0005, 2,+

+, 0, 3, 1, 0.015, 0, 3, 13, .0030,+
CHAPTER 14
The range of natural frequencies to obtain is from 1.0 Hz to 1000 Hz and translational degrees of freedom for z-
direction is only considered (3). The sampling rate is 0.0005 seconds. The peaking criterion is two, which means that
a peak is selected if the amplitude of the number of increasing and decreasing points around a peak is equal or greater
than 2.
Acceleration is selected for the response (0) and translational eigenvectors are only requested as ASCII format (3).
Eigenvalues are normalized by 1.0 (1) and 0.015 is selected as CLOSE value which means if there are two modes which
distance is smaller than 0.015 Hz, it is assumed to be the same mode. ACII file format of natural frequencies and
eigenvalues are asked (0) and translational time histories of z-direction are requested (3). Frequency-amplitude data
of z-direction are requested (13) and a peak whose amplitude is less than 0.0030 times the maximum amplitude is
ignored (.0030)
+, 901581, 901641, 901697, 901865, 902061, 902097, , ,+
+, 902580, 902595, 902609, 902797, 902996, 903063
The grid points 901581, 901641, 901697, 901865, 902061, 902097, 902580, 902595, 902609, 902797, 902996 and
903063 are selected to obtain time history responses for Time NVH analysis.
TIMNVH,1, , , 1.0, 1000., 3,.0005, 2,+
+, 0, 3, 1, 0.015, 0, 3, 13, .0030,+
+, 901581, 901641, 901697, 901865, 902061, 902097, , ,+
+, 902580, 902595, 902609, 902797, 902996, 903063
Re-running Job
To find the accurate modal properties, a re-run is required using the previous time history data. Only three entries are
different from the initial job;
PARAM, S700NVH,
TIMNVH and
TIMNAT
The value of PARAM, S700NVH is assigned to 1 for using the previous time history binary data (binout0000). In
TIMNVH entry, the PEAK option (in the first line) is changed from 2 to –2, which will require defining the TIMNAT entry.
TIMNAT is used to specify the natural frequencies selected from amplitude-frequency plot from the initial run. The
natural frequencies close to 35, 43, 49, 101, and 108 Hz’s are obtained as the natural frequencies.
PARAM,S700NVH1,1
TIMNVH,1, , , 1.0, 1000., 3,.0005, -2,+
+, 0, 3, 1, 0.015, 0, 3, 13, .0030,+
+, 901581, 901641, 901697, 901865, 902061, 902097, , ,+
+, 902580, 902595, 902609, 902797, 902996, 903063
TIMNAT,1,35.,43.,49.,101.,108.
CHAPTER 14 235
Results
There are three result files from Time Domain NVH analysis.
• mode.out: Results for the natural frequencies and eigenvalues.
• ampl-freq- 00901865-3.txt: amplitude-frequency output of degree of freedom =3 at grid point 901865.
• time-hist- 00901865-3.txt: time history output of degree of freedom =3 at grid point 901865.
From the ampl-freq-*** files, the frequency-amplitude plots are shown in Figure 14-3. Using the plot, the modal
frequencies are specified in TIMNAT option to refine the dynamic property results.
1.00E-01
6
7
1 2
1.00E-02 3
901581
1.00E-03 901641
901697
Amplitude
901865
902061
1.00E-04 902097
902580
4 5 902595
902609
1.00E-05 902797
902996
903063
1.00E-06
0.00E+00 2.00E+01 4.00E+01 6.00E+01 8.00E+01 1.00E+02 1.20E+02 1.40E+02 1.60E+02
Frequency (Hz)
L
K
J
I
F
H E
G D
C
B
A
Figure 14-3 Frequency-Amplitude Plots At 12 Nodes
CHAPTER 14
1 2 3
36.017 43.952 52.506

35.000 43.000 49.000
4 5 6
67.428 84.722 101.969

- - 101.001
Mode # 7
SOL 103 Frequency Hz 111.016

SOL 700 Frequency Hz 108.001
Figure 14-4 Comparison of Mode Shapes and Frequencies for SOL 103 and SOL 700
The small peaks for modes 4 and 5 are barely observable in Figure 14-3 and arise because of the selection of the type
of impulse loading. These lateral modes exhibit a low participation when the impulse loading is vertical. For a certain
set of impulse loads, certain modes may not be excited and the FFT only picks up the excited modes that significantly
participate in the transient response.
Mode SOL103 SOL 700 Diff(%) Comparison

1 36.0170 35.0002 2.82% Vertical motion dominant
3 52.5065 49.0003 6.68% Lateral motion dominant
4 67.4281 Small peak - Lateral motion dominant
5 84.7220 Small peak - Lateral motion dominant
CHAPTER 14 237
Results show that even though the vertical mode shapes of modes 2 and 3 are similar, their amplitude and lateral modes
are quite different. The results are compared in Figure 14-5.
Vertical mode shape of mode 2 Vertical mode shape of mode 3

Figure 14-5 Comparison of Vertical Mode Shapes Between Mode 2 and 3
Sample Output
The final response from the FFT steps for the 12 sampling points are contained in a file called modes.out which
contains the eigenvalues (frequencies) and eigenvectors (mode shapes) in the form:
MODES 1 5
st
EI GV 1 mode { 1 3. 500018E+01 } Frequency
901581- 3. 32998498E- 02- 2. 49243337E- 04 7. 08997618E- 01
901641- 4. 29914555E- 02 7. 70991520E- 05- 1. 08571907E- 01
901697- 4. 15069142E- 02 2. 55256359E- 04- 6. 31611930E- 01
901865 4. 37855265E- 02- 1. 51550001E- 04- 4. 18557096E- 01
902061 7. 97601410E- 02 4. 34427876E- 04 5. 67705213E- 01
Sample 902097 8. 68013598E- 02 8. 02417982E- 03 1. 00000000E+00
Grid IDS 902580- 3. 38588683E- 02 2. 97715028E- 04 7. 28400224E- 01
902595- 4. 37831381E- 02 2. 30181446E- 04- 9. 77437006E- 02
902609- 4. 24521220E- 02- 1. 61168521E- 04- 6. 35288211E- 01
902797 4. 11242103E- 02- 3. 00773060E- 04- 4. 29582120E- 01
902996 7. 69986448E- 02 7. 40153667E- 04 5. 51699503E- 01
903063 8. 41026922E- 02- 3. 47784987E- 03 9. 82653769E- 01
x-component y-component z-component
eigenvector
Modeling Tips
To get more accurate data, options of TIMNVH and TSTEPNL entry could be changed. For example, increasing the end
time (defined as 1 second in this analysis) can result in higher resolution (the frequency increment in the frequency-
amplitude plot). The resolution is determined as:
1 1
------------------------------------------------------------------------------------------ = ------------------------------------- = 1 Hz
 sample end time - sample start time   1 sec – 0 sec 
CHAPTER 14
To increase the maximum frequency in the frequency-amplitude plots, the sampling rate which is defined as 0.015
seconds in this example decreases. The maximum frequency of this example is computed as:
1 1
------------------------------------------ = -------------------------------- = 133.33 Hz
1 1
---  sampling rate  ---  0.015 sec 
2 2
Input File(s)
File Description
nug_14a.dat Initial run to find rough dynamic properties
nug_14b.dat Re-run to compute accurate dynamic properties
nug_14c.dat SOL 103 model
Chapter 15: Tube Flaring
15 Tube Flaring

Summary 240

Introduction 241


FEM Solutions 241

Input File(s) 245
CHAPTER 15
Summary
Title Chapter 15: Tube Flaring
Features Deformable-deformable contact
Large elastic-plastic deformation
Geometry Axisymmetric
x=r
• Tube diameter = 8 inches
• Tube thickness = 0.3 inches y CL
• Tube length = 8 inches
• Tool apex angle = 30°
• Tool wall thickness = 0.6 inches x=r
• Tool length = sufficient to mode
the process y CL
Material properties Tube: Young’s modulus = 3.0e7 psi, initial yield stress = 3.6e4 psi, yield
stress at 0.1 equivalent plastic strain = 1.8e5 psi, Poisson’s ratio = 0.3
Tool: Young’s modulus = 4.0e7 psi, Poisson’s ratio = 0.3, no yielding
Boundary conditions The left end of the tube is prevented from moving in the axial direction but
is free to move in the radial direction.
Applied loads An edge load is applied to the right end of the tool (the end with a larger
diameter) to push the tool into the steel tube, then released
Element type 4-node axisymmetric elements
Contact properties Friction between the tool and the tube is ignored in the analysis
FE results 1. Plot of tube tip versus time.
2. Contours of von Mises stress at maximum load on deformed mesh
3. Contours of plastic strain on deformed mesh after load removal
0.5 Radial Displacement Point A (in)
0.4
0.3 A
0.2
x=r
0.1 y CL
Time (s)
0.0
0.0 0.5 1.0 1.5 2.0
CHAPTER 15 241
Tube Flaring
Introduction
A cone-shaped flaring tool is pushed into a cylindrical tube to permanently increase the diameter of the tube end. The
goal of the analysis is to determine whether the final shape of the tube, after the entire process, meets the objective.
The nonlinear nature of the problem, along with the irreversible characteristics, makes it impossible to know in
advance the load required to drive the tool into the tube. As a result, multiple runs through the analysis cycle may be
necessary to achieve the final objective of the analysis.
This problem demonstrates the use of MD Nastran SOL 400 to analyze a contact problem involving deformable-
deformable contact and large elastic-plastic deformations.
Requested Solutions
The requested solutions include the curve of the tube diameter at the right end as a function of loads and the deformed
shape of the tube and the tool along with the distributions of von Mises stresses and plastic strains.
FEM Solutions
A numerical solution has been obtained with MD Nastran’s SOL 400 for the element mesh (shown in Figure 15-1)
using axisymmetric elements.
x=r
Figure 15-1 Finite Element Mesh
There are two contact bodies. One is the tube and one is the tool. The two contact bodies with ID 3 and 4 are identified
as selected elements of the tube and the tools respectively as:
BSURF 3 109 110 111 112 113 114
115 116 117 118 119 120
...
and
BSURF 4 25 26 27 28 29 30 31
32 33 34 35 36 37 38 39
...
CHAPTER 15
BCTABLE 0 2
SLAVE 3 0.05 100. 0. 0. 0 0.
0 0 0
fbsh 0.8
MASTERS 3
SLAVE 4 0.05 100. 0. 0. 0 0.
0 0 0
fbsh 0.8
MASTERS 3
BCTABLE 1 2
SLAVE 3 0.05 100. 0. 0. 0 0.
0 0 0
fbsh 0.8
MASTERS 3
SLAVE 4 0.05 100. 0. 0. 0 0.
0 0 0
fbsh 0.8
MASTERS 3
Axisymmetric elements are defined with CQUADX along with PLPLANE and PSHLN2 entries:
PLPLANE 1 1
PSHLN2 1 1 1 +
+ C3 AXSOLID L +
+ C4 AXSOLID L +
+ C5 IPS L +
+ C6 AXSOLID Q +
+ C8 AXSOLID Q
$ Pset: "pshell.1" will be imported as: "plplane.1"
CQUADX 109 1 10 144 145 1
CQUADX 110 1 144 146 147 145
…
The Young’s modulus and Poisson’s ratios for the tube and the tool are defined as:
MAT1* 1 3.+7 1.15385+7 .3
* 1.
MAT1* 2 4.+7 1.53846+7 .3
* 1.
The yield stresses along with the hardening are defined respectively as:
MATEP 1 Table 36000. 1 Isotrop Addmean
TABLES1,1,2,,,,,,,+,
+,0.,36000.,0.1,180000.,ENDT,
The NLPARM entry is used to define the nonlinear analysis iteration strategy. There are two load steps: loading and
unloading. One hundred (100) uniform time increments are used to solve each load steps. The stiffness matrix will be
updated at each iteration (full Newton-Raphson iteration strategy).
NLPARM 1 100 PFNT 1 25 U YES
NLPARM 2 100 PFNT 1 25 U YES

CHAPTER 15 243
Tube Flaring
The tube diameter at the right end of the tube gradually increases during the analysis as the load increases and reaches
the maximum of 0.4316 inches. The final tube radial displacement after unloading is settled at 0.4093 inches. See
Figure 15-2 for the curve of tube diameter as a function of time (load). The entire analysis procedure can be repeated
with various load levels to achieve the desired final tube diameter. The curve is not smooth at the loading path because
of the discrete finite elements. It can be improved by refining the finite element meshes.
0.5 Radial Displacement Point A (in)
0.4
0.3 A
0.2
x=r
0.1 y CL
Time (s)
0.0
0.0 0.5 1.0 1.5 2.0
Figure 15-2 Curve of Tube Diameter as a Function of Time
The deformed mesh and the distribution of von Mises stress at the time the applied load reaches maximum are shown
in Figure 15-3. It can be observed that the stresses are concentrated in two areas: the tip of deflection where the tube
made contact with the tool and in the area where the tube is deformed.
CHAPTER 15
x=r
Figure 15-3 Deformed Mesh and Distribution of von Mises Stress at Maximum Load
The deformed shape of the tube and the tool along with the distribution of plastic strains at the end of the analysis are
shown in Figure 15-4.
x=r
Figure 15-4 Deformed Mesh and Distribution of Equivalent Plastic Strains at the End of Analysis
CHAPTER 15 245
Tube Flaring
Input File(s)
File Description
nug_15.dat Tube flaring input file.
Chapter 16: Cup Forming Simulation
16 Cup Forming Simulation

Summary 247

Introduction 248


FEM Solutions 248


Input File(s) 255

Video 255
CHAPTER 16 247
Cup Forming Simulation
Summary
Title Chapter 16: Cup Forming Simulation
Contact features 3-D Shell-Rigid contact
Velocity-Controlled Rigid bodies modeled using NURBS
Friction along deformable-rigid interfaces
Geometry 3-D shell elements (units: mm)
• Blank Radius= 90
• Shell Thickness = 1
Three Rigid Tools
• Punch
• Die
• Holder
Material properties Aluminium alloy with isotropic properties

E sheet = 70000N  mm 2 ,  sheet = 0.3 ,  yo = 191.1 N/mm2
Analysis type Quasi static analysis using

• elasto-plastic material with isotropic work-hardening
• reduced integration shell elements
• nonlinear boundary conditions
Displacement boundary Symmetry displacement constraints (quarter symmetry)
conditions
Element type 3-D shell
• 4-noded reduced integration elements
Contact Data Rigid punch moved up by 40 mm into the workpiece
Stationary die and holder with uniform gap of 1 mm between them
coefficient of friction  = 0.05
FE results 1. History plots of contact body forces for punch, die, and holder
2. Plot of equivalent plastic strains and equivalent stresses in the workpiece
3. Distribution of contact normal and friction forces on workpiece
Force (N)
25000
20000
15000 Die Force
10000
5000 Holder Force
0
0.0 0.2 0.4 0.6 0.8 1.0
-5000 Time (s)
-10000
-15000 Punch Force
-20000
CHAPTER 16
Introduction
A cylindrical cup drawing test is simulated with a circular punch and blank. The test is simulated for a 1 mm thick
aluminium sheet modeled by one-point shell elements and using an isotropic elasto-plastic material with work-
hardening. Only a quarter section of the cup is analyzed. A schematic view of the cup drawing process is shown in
Figure 16-1. The simulation demonstrates various capabilities available in MD Nastran SOL 400 to simulate large
strain processes including robust and efficient shell elements, large strain material and geometric nonlinearity, and
automated contact algorithms that can handle large amounts of sliding and friction.
R2
DIE
R4 t0
R0
R3
R1
HOLDER
PUNCH R1=50.0, R2=51.25, R3=9.53, R4=7.14
(Unit: mm) (Blank size: Ro = 90.0, to = 1.0)
Figure 16-1 Schematic for Cylindrical Cup Drawing Process
Requested Solutions
The contact forces on the rigid tools, workpiece, and the stress/plastic strain contours in the workpiece are of interest.
The availability of the large-strain shell elements in SOL 400 (by using suitable PSHLN1 extensions to the PSHELL
entry) are demonstrated. Analytical rigid tools that capture curved geometries accurately are modeled and friction
between the workpiece and these rigid tools is simulated. The solutions presented include:
• History plot of the contact forces acting on the rigid punch, die, and holder
• Contact normal forces and friction forces acting on the workpiece
• Plastic strain and equivalent stress contours in the workpiece
FEM Solutions
The contact, material/geometry, convergence and other parameters used for the cup drawing simulated herein are as
follows.
Contact Parameters
The contact bodies are shown in Figure 16-2. The first body is the deformable workpiece; the second, third and fourth
bodies are the rigid punch, rigid die, and rigid holder, respectively. The gap between the holder and die is 1 mm. All
CHAPTER 16 249
the rigid bodies are defined with analytical surfaces using the NURBS option. Friction coefficient is taken as 0.05 for
all surfaces.
BSURF 7 19 20 21 22 23 24 25
0 0. 0. 0. 0. 0. 0. 40.
RIGID 0 27 PUNCH
0 0. 0. 0. 0. 0. 0. 0.
RIGID 0 27 DIE
0 0. 0. 0. 0. 0. 0. 0.
RIGID 0 9 HOLDER
BCBODY with user ID 7 is identified as a three-dimensional deformable body with associated BSURF ID 7. BCBODY
with ID 1 is identified as the rigid punch. It is specified as a velocity controlled body and is moved with a Z velocity
of +40 mm per unit time (identified in red on the BCBODY definition above). BCBODY with ID 2 is identified as the
die and BCBODY with ID 3 is identified as the holder. These are specified as zero velocity bodies and are held
stationary through the analysis.
Figure 16-2 Contact Bodies used For Cup Drawing Simulation
The BCTABLE bulk data entries shown below identify the touching conditions between the bodies:
BCTABLE 1 3
SLAVE 7 0.0 50. 0.05 0. 0
0 0 0
FBSH 0.95
MASTERS 2
SLAVE 7 0.0 50. 0.05 0. 0
0 0 0
FBSH 0.95
CHAPTER 16
MASTERS 3
SLAVE 7 0.0 50. 0.05 0. 0
0 0 0
FBSH 0.95
MASTERS 1
BCTABLE with ID 1 is used in conjunction with the BCONTACT = 1 case control option to define the touching
conditions between the bodies in the forming step. Three sets of contact parameters are defined in the above table: the
first set for the workpiece-holder, the second set for the workpiece die, and the third set for the workpiece punch. The
contact parameters for all sets are identical in this problem though they can be varied for each set if needed. The
friction coefficient is defined as 0.05, the bias factor as 0.95, and the separation force as 50 N. The definition of a non-
default separation force bears more explanation - during the sheet forming process, especially at the early stages, nodes
tend to chatter (contact, separate, back into contact, etc.). Using the default separation force (maximum residual force
in the solution) allows a significant amount of chattering and leads to increased iterations and smaller steps. Specifying
a larger separation force reduces this chattering and reduces the number of iterations for the solution. It should be noted
that care should be taken in specifying the non-default separation force; it should not be so large that it prevents
physical phenomena like earing, etc.
The BCPARA bulk data entry defines the general contact parameters to be used in the analysis:
BCPARA 0
FTYPE 6 BIAS 9.5E-01
NLGLUE 1 FNTOL 5.E1
Note that ID 0 on the BCPARA option indicates that the parameters specified herein are applied right at the start of the
option. Important entries under BCPARA option include FTYPE = 6 (bilinear Coulomb friction), BIAS = 0.95
(distance tolerance bias), FNTOL = 50 (separation force). A program calculated default (1/4 of the shell thickness)
is used for the distance tolerance (ERROR) is not defined on the BCPARA option.
An isotropic elasto-plastic material with work-hardening is used for the workpiece. MAT1 is used to define the elastic
properties and MATEP in conjunction with TABLES1 is used to define the initial yield stress and work-hardening
properties:
MAT1 1 70000. .3 1.
$ Stress/Strain Curve : plas

TABLES1 1 2
0. 191.1 .0333333249.772 .0666667293.962 .1 327.244
......
It should be observed that a 2 is used in the third field of the TABLES1 option to indicate that the data corresponds to
stress vs. plastic strain (as opposed to stress vs. total strain). Only the first line of the work-hardening data is indicated
here. The plastic strains are specified up to 1.0 in the actual table. The following should be noted: For the large strain
problem being simulated herein, TABLES1 data is interpreted by the program as Cauchy stress versus true plastic
strain. Also, if the actual plastic strains in the analysis exceed the maximum value in the table, the work-hardening
slope calculated using the last two values of plastic strain is used for extrapolating.
CHAPTER 16 251
Reduced integration shell elements are used herein. They are identified by the PSHELL option in conjunction with the
PSHLN1 option.
$ Elements and Element Properties for region : shell
PSHELL 1 1 1. 1 1
PSHLN1,1,1
,c4,dct,lrih
where the MAT1 primary material is pointed to by MID1/MID2/MID3 entries of the PSHELL option, a shell thickness
of 1.0 is specified on the PSHELL option, the C4 field DCT of the PSHLN1 option indicates that thick 4 noded shell
elements are to be used and LRIH of the PSHLN1 option indicates that reduced integration elements are to be used.
These elements have three global displacements and three rotations as the nodal degrees of freedom. Bilinear
interpolation is used for the coordinates, displacements, and rotations. MITC4 shell geometry with the ANS (assumed
natural strain) method in conjunction with a physical stabilization scheme in used in the formulation of the reduced
integration element. These elements with a one-point quadrature scheme are able to undergo large rotations without
any artificial correction for warping. The large strain formulation for the element is flagged through the
PARAM,LGDISP,1 in conjunction with the NLMOPTS,LRGSTRN,1 bulk data entries. The former option indicates that
a large displacement analysis with follower force effects is to be conducted. The latter option indicates that additional
large strain parameters are to be flagged for the shell elements. Note that for large strain elasto-plastic applications
using elements pointed by the PSHLN1, PSLDN1, PSHLN2 entries, NLMOPTS,LRGSTRN,1 is a mandatory option.
As is customary for all Nastran shell elements, a material coordinate system is defined herein for each of the shell
elements. This orientation is defined through the THETA/MCID option on the CQUAD4 option:
CQUAD4 19 1 40 22 3 4 0
CQUAD4 20 1 41 23 22 40 0
In the current example, the basic coordinate system (ID 0 indicated in red on the CQUAD4 options above) is projected
onto the plane of the element. The resulting axes define the X-Y-Z orientation of the material coordinate system in the
elemental plane.
The nonlinear procedure used is defined through the NLPARM entry:
NLPARM 1 100 PFNT 0 30 U NO
where 100 indicates the total number of increments; PFNT represents Full Newton-Raphson Technique wherein the
stiffness is reformed at every iteration; KSTEP = 0 in conjunction with PFNT indicates that the program
next load increment is commenced. 30 is the maximum number of allowed recycles for every increment and. if this
were to be exceeded, the load step would be cut-back and the increment repeated. U indicates that convergence will
be checked on displacements (U). NO indicates that no intermediate output will be produced after every increment. The
second line of NLPARM is omitted here, which implies that default convergence tolerances of 0.01 will be used for U
checking. It should be noted that, by default, the PFNT checking used herein conducts displacement checking over
incremental displacements and is generally more stringent than FNT checking which conducts displacement checking
over weighted total displacements.
CHAPTER 16
Note that P checking (checking on residuals) has not been conducted in this example. The normal P check in SOL 400
compares the weighted residuals with the weighted external loads and checks that the tolerance (default = 0.01) is
satisfied. In this problem, external loads are absent since the punch imposes displacement boundary conditions on the
workpiece. Under these circumstances, SOL 400 normally checks residuals in the current iteration versus residuals in
previous iterations. However, due to frequent separations, residuals and displacements oscillate significantly and the
check of current weighted residuals versus previous weighted residuals causes a large number of unnecessary recycles.
Due to these reasons, displacement checking alone is conducted in this problem.

Some of the case control entries to conduct these analyses are highlighted as follows: SUBCASE 1 indicates the case
being considered and STEP 1 indicates the step being considered within the case. BCONTACT = 1 is used to indicate
the contact parameters for SUBCASE 1. NLPARM = 1 is used to flag the nonlinear procedure for SUBCASE 1. In
addition to regular output requests like DISPLACEMENTS, STRESSES, the option that is required for contact related
output in the F06 file is BOUTPUT. It should be noted that with the BOUTPUT option, one can obtain normal contact
forces, frictional forces, contact normal stress magnitudes and contact status for the contact nodes.
Results
The history plot of the rigid tool contact forces in the Z direction are presented in Figure 16-3. Two trends are
noteworthy: The contact forces are in equilibrium; i.e., the contact force exerted by the punch on the workpiece is in
equilibrium with the contact forces transferred by the workpiece to the holder and die. Note also that as the punch
pushes the blank upwards (+Z direction), the predominant tendency is for the sheet to contact the die. However,
portions of the sheet separate from the die and make intermittent contact with the holder.
In order to verify the accuracy of the SOL 400 solution, the total punch force obtained from SOL 400 is compared with
the corresponding solution obtained from MSC.Marc in Figure 16-4. It is seen that the history of the forces match quite
well and are within about 2% of each other.
Force (N)
25000
20000
15000 Die Force
10000
5000 Holder Force
0
0.0 0.2 0.4 0.6 0.8 1.0
-5000 Time (s)
-10000
-15000 Punch Force
-20000
Figure 16-3 History Plot of Contact Tool Forces in Z Direction during Cup Drawing Process
CHAPTER 16 253
30000 Total Punch Force (N)
25000
20000 SOL 400
Marc
15000
10000
5000
Time (s)
0
0.0 0.2 0.4 0.6 0.8 1.0
Figure 16-4 Comparison of Total Punch Force vs. Time for MSC.MARC and SOL 400
The equivalent plastic strain contours at the outermost fiber of the workpiece and the corresponding equivalent stress
contours at the end of the cup forming process are plotted in Figure 16-5. It is noted that maximum plastic strains are
of the order of 45% and the peak values occur along the die radius. The portion of the workpiece held between the die
and the holder is the most highly stressed. Also, the circumferential variation of the quantities is negligible, thereby
confirming the axisymmetric nature of the problem being simulated.
Figure 16-5 Equivalent Plastic Strains and Equivalent Stresses in Workpiece at End of Cup Forming
Process
The contact normal force and friction force from the center to the outer edge of the workpiece along a radial line of
nodes is plotted in Figure 16-6. It can be noted that the peak contact normal forces occur at the punch radius and the
next peak is at the die radius. Friction force are of the order of F n , where  is the friction coefficient = 0.05.
30000 Total Punch Force (N)
25000
20000 SOL 400
Marc
15000
10000
5000
Time (s)
0
0.0 0.2 0.4 0.6 0.8 1.0
Figure 16-6 Contact Normal Force and Friction Force as a function of Radial Coordinate for Workpiece
CHAPTER 16
F06 Output
A number of case control options (DISPLACEMENTS, SPCFORCES, STRESS, NLSTRESS, BOUTPUT) are used (see
nug_16is.dat). This, in conjunction with the YES or NO option for INTOUT on the NLPARM entry, allows
extensive output of relevant quantities in the F06 file:
• Contact normal forces, normal stresses and frictional forces at the contact nodes of the Workpiece are
produced via the BOUTPUT option. BOUTPUT = ALL produces output for all contact nodes. BOUTPUT
= N where N is a set number would restrict output to only those contact nodes that belong to set N.
BOUTPUT = NONE suppresses all contact related output in the F06 file.
• For the nonlinear output format (requested by NLSTRES), average values of the stress components, strain
components, equivalent stress, and equivalent plastic strain are produced for the top and bottom fibers. For
each layer, the integration point values are averaged over the number of integration points and presented in
the F06 file. For the one-point elements used herein, the average is the same as the gauss point value. It
should be noted that for the large-strain elasto-plastic problem simulated herein using the
NLMOPTS,LRGSTRN,1 option, the output stresses are the Cauchy stresses and the output strains are the
logarithmic strains.

• The PSHLN1 option in conjunction with the PSHELL option allows the users to flag the 3-D shell elements.
These elements perform well for large-displacement/large rotation/large strain applications. 3-noded or
4-noded shell topologies and thin-shell or thick-shell formulations can be chosen. 4-noded shell elements
flagged through the C4 field of PSHLN1 offer options of thick-shell full integration, thick-shell reduced
integration, and thin-shell full integration. Reduced integration 4-noded elements are chosen in the present
problem for efficiency and robustness purposes.
• For large strain elasto-plastic applications, use should be made of the NLMOPTS,LRGSTRN,1 option to flag
appropriate element behavior.
• In the present problem, the shell is supported between a die and holder. The uniform gap between the die and
holder matches the original thickness of the workpiece. Any increase in this thickness is prevented by the
rigid tools and normal stresses through the thickness would be introduced. This violates the plane stress
assumption for the shell element. For such double-sided applications, an alternate element to use is the solid
shell element. This element uses continuum element topology while offering the benefits of shell bending. It
can be flagged through the PSOLID option in conjunction with the C8, BEH=SLCOMP, INT=ASTN field on
the PSLDN1 option.
• For deformable-rigid body contact, an important consideration is the definition of the interior and exterior
sides of the rigid body. The rigid body should be aligned such that it’s exterior side is facing the contacting
deformable body. The interior side is the one formed by applying the right-hand rule along a rigid patch. If the
rigid body is incorrectly aligned, it needs to be flipped before running the analysis.
CHAPTER 16 255
Input File(s)
File Description
nug_16is.dat 3-D Shell Elements - PSHLN1 used along with PSHELL to flag nonlinear
reduced integration elements. Isotropic elasto-plastic material properties
Video

Chapter 17: Double-sided Contact
17 Double-sided Contact

Summary 257

Introduction 258


FEM Solutions 258

Results 262

Modeling Tips 262


Input File(s) 304
CHAPTER 17 257
Double-sided Contact
Summary
Title Chapter 17: Double Sided Contact
Contact features Deformable-deformable contact with bilinear friction, large strain plasticity, and work
hardening
Geometry 2-D Plane Strain assumptions Five at
1.0” each
1.5”
0.5”
0.5”
0.5”
1.5”
Material properties Elastic-plastic material with isotropic strain hardening. The stress-strain curve is defined
in the materials section. The material properties are:
6
E = 31.75 10 psi  = 0.268 psi  y = 80730 psi
Analysis type Quasi-static analysis using: elastic plastic material, geometric nonlinearity, and
nonlinear boundary conditions
Boundary conditions Nodes on left-hand side are constrained in x-direction and nodes on bottom side are
constrained in y-direction
Applied loads Nodes on the top side are given the imposed displacement of -0.6 inch in y-direction
Element type 4-node nonlinear plane strain element
FE results Deformed shapes at several steps, contours of von Mises stress, and total equivalent
plastic strain
Stress Contours Last Increment

CHAPTER 17
Introduction
This problem demonstrates MD Nastran’s ability to perform multibody contact analysis, incorporating automated
double-sided contact with friction between the contact surfaces for linear plane strain elements. For these types of
contact problems, it is not necessary to assign either body as a master or slave.
Requested Solutions
The large displacement elastic-plastic contact analysis is carried out using MD Nastran for a deformable-to-
deformable contact problem with friction. The application of the nonlinear plane strain element is demonstrated by
using the nonlinear extension PSHLN2 option along with the PLPLANE option. The following results from the MD
Nastran model are compared with the results obtained from the Marc model.
• Deformed shapes at steps 10, 20 and 30
• Contour plot for equivalent plastic strain
FEM Solutions
A numerical solution has been obtained with MD Nastran’s SOL 400 for a 2-D representation of the contact simulation
between two deformable bodies. The details of finite element model, contact simulation, material, load, boundary
conditions, and solution procedure are discussed below.
Finite Element and Contact Model

The finite element mesh for each of the two deformable bodies contains 60 elements and 79 nodes. MD Nastran’s 2-D
plane strain solid elements with material ID 1 are selected using the following PLPLANE and PSHLN2 entries. The
second line of the PSHLN2 option enables SOL 400 to access the 4-node plane strain elements using the regular
CQUAD4 elements. This element can be used for both linear and nonlinear applications. When used for linear
applications, the assumed strain formulation should be activated for this element using the
NLMOPTS,ASSM,ASSUMED bulk data entry to get good bending behavior. This assumed strain option should not be
used for the applications involving large strain plasticity as in the case of the present problem. The finite element
model used for this simulation is shown in Figure 17-1.
PLPLANE 1 1
PSHLN2 1 1 1
C4 PLSTRN L
CHAPTER 17 259
Figure 17-1 Finite Element Model used with MD Nastran Simulation
In defining the contact model, the elements comprising the deformable bodies are used to generate a deformable
contact bodies with ID 1 and 2 using the following BCBODY and BSURF entries. The friction factor of 0.07 is defined
for both these contact bodies.
BSURF 1 61 62 63 64 65 66 67
...
BSURF 2 1 2 3 4 5 6 7
...
Furthermore, the following BCTABLE entries identify how these bodies can touch each other. BCTABLE with ID 0 is
used to define the touching conditions at the start of the analysis. This is a mandatory option required in SOL 400 for
contact analysis and is flagged in the case control section through the optional BCONTACT = 0 option. The BCTABLE
with ID 1 is used to define the touching conditions for later increments in the analysis and is flagged using
BCONTACT = 1 in the case control section. The 0 defined for the first field (ISEARCH) of third data line of BCTABLE
indicates that double-sided contact will be used for this contact pair. With this double contact option, SOL 400 will
consider another contact pair for the analysis with body 1 as master and body 2 as slave in addition to the contact pair
defined in the BCTABLE option.
BCTABLE 0 1
SLAVE 1 0. 0. .07 0. 0 0.
0 0 0
FBSH 1.+20 0.9
MASTERS 2
BCTABLE 1 1
SLAVE 1 0. 0. .07 0. 0 0.
0 0 0
FBSH 1.+20 0.9
MASTERS 2
CHAPTER 17
The BCPARA bulk data entry shown defines the general contact parameters to be used in the analysis.
BCPARA 0
FTYPE 6 BIAS 0.9
The ID 0 on the BCPARA option indicates that the parameters specified herein are applied right at the start of the
option. Important entries under BCPARA option include FTYPE – the friction type and the BIAS - the distance
tolerance bias. As a general recommendation, BIAS is set to 0.9 (note that the default value of BIAS is 0.9). For the
frictional case, FTYPE is set to 6 (bilinear Coulomb model).
Material
The isotropic elastic and elastic-plastic material properties of the deformable bodies are defined using the following
MAT1 and MATEP options. The stress-strain curve for this material is defined in TABLES1 which is referred in MATEP
option. Figure 17-2 shows the stress-strain diagram defined in TABLES1.
MAT1 1 3.175+7 .268 7.4-4 5.13-6
MATEP 1 TABLE 1
TABLES1 1 2
* 0.000000000e+0 8.073000000e+4 1.000000000e-5 8.096400000e+4
...
* 7.000000000e-2 1.595880000e+5 2.200000000e-1 1.753830000e+5

* ENDT
200000 Stress (Psi)
150000
100000
Plastic Strain (1)

50000
0.00 0.05 0.10 0.15 0.20 0.25
Figure 17-2 Stress-Plastic Strain Curve of the Material
NLMOPTS,LRGS,1
CHAPTER 17 261

The loads and boundary conditions are applied using the following SPCD and SPC1 options. SPCD options are used
to impose the displacement of -0.6 inch for the nodes on the top side. The nodes on the left-hand side are constrained
in x-direction and nodes on the bottom side are constrained in y-direction. These constraints are defined using the
SPC1 options. Figure 17-3 shows the loads and boundary condition applied on the model.
SPCADD 2 3 4 5
$ Enforced Displacements for Load Set : yu0
SPCD 1 104 2 -.6 105 2 -.6
SPCD 1 106 2 -.6 107 2 -.6
SPCD 1 108 2 -.6 109 2 -.6
SPCD 1 130 2 -.6 131 2 -.6
SPCD 1 132 2 -.6 133 2 -.6
SPCD 1 134 2 -.6
$ Displacement Constraints of Load Set : x0
SPC1 5 1 35 40 45 50 55 61
67 73 79 80 86 92 98 104
$ Displacement Constraints of Load Set : y0
SPC1 3 2 25 26 27 28 29 30
51 52 53 54 55
$ Displacement Constraints of Load Set : yu0 (just to trigger s-set)
SPC1 4 2 104 105 106 107 108 109
130 131 132 133 134
Figure 17-3 Load and Boundary Conditions Shown on FE Mesh
Solution Procedure
NLPARM 1 30 PFNT 25 P YES
0.01
CHAPTER 17
where 30 indicates the total number of increments; PFNT represents Pure Full Newton-Raphson Technique wherein
the stiffness is reformed at every iteration; KSTEP = 0 in conjunction with PFNT indicates that the program
next load increment is commenced. 25 is the maximum number of allowed recycles for every increment. P indicates
that convergence will be checked on residuals (P). YES indicates that intermediate output will be produced after every
increment. The 0.01 defined in the second line of NLPARM indicates the convergence tolerances of 0.01 for
residual checking.
Results
The deformed shape at steps 10, 20, and 30 observed from both Marc and SOL 400 models are compared in
Figure 17-4. The equivalent plastic strain contours observed at step 30 from Marc and SOL 400 runs are presented in
Figure 17-5 and Figure 17-6. It is clearly observed from these pictures that, the predictions from SOL 400 matches
closely with the predictions from Marc.
Modeling Tips
• PSHLN2 entry in conjunction with regular PLPLANE entry allows the users to make use of the plane strain
elements using regular Nastran elements CQUAD4, CQUAD8, and CTRIA6. Users should make use of the
NLMOPTS,LRGS,1 option to flag the large strain behavior of these elements.
• The value of 0 for ISEARCH parameter in BCTABLE defines the double sided contact for this problem.
Assigning the value of 1 for ISEARCH parameter will define single sided contact for this problem, and this
will not work properly in this case. The nug_17w.dat input file shows this wrong way of contact definition
for this problem and Figure 17-7 shows how SOL 400 works in such situations.
CHAPTER 17 263
Marc - Step 10 SOL 400 - Step 10
Figure 17-4 Deformed Shape Plots at Steps 10, 20, and 30

CHAPTER 17
Figure 17-5 Plastic Strain Contour from Marc
Figure 17-6 Plastic Strain Contour from MD-Nastran SOL 400

CHAPTER 17 265
Figure 17-7 Penetration with Wrong Contact Definition

CHAPTER 17
Units
a. Tools: Options
b. Observe the User Options window
c. Select Units Manager
d. For Basic Units, specify the model units:
e. Length = m, Mass = kg, Time = s, Temperature = Kelvin, and Force = N
b
a
d
c e
CHAPTER 17 267
Create a Part for the body_lower
a. Assemble tab
c. For Title, enter body_lower
d. Click OK:
e. Observe body_lower in the Model Browser Tree
a
b
d
CHAPTER 17
Create Mesh for the body_lower
a. Meshing tab: 3-4 Point Mesh

b. Points: X,Y, Z Input: 0,-1.5,0;2,-1.5,0;2,0,0;0,0,0, click OK
X,Y, Z Input: 2,-1.5,0;5,-1.5,0;5,0,0;2,0,0, click OK
X,Y, Z Input: 0,0,0;2,0.0,0;1,1.5,0;0,1,0, click OK
c. For n1, enter 5
d. For n2, enter 4
e. For n3, enter 5
f. For n4, enter 4
g. Click OK
b
c b b
d
e
f
g b
CHAPTER 17 269
Merge Equivalent Nodes in the body_lower
a. Nodes/Elements tab: Equivalence

b. Entities: Select All
c. Click OK
d. Click OK
d
CHAPTER 17
Create a Part for the body_upper
a. Assemble tab
c. For Title, enter body_upper
d. Click OK:
e. Observe body_lower in the Model Browser Tree
a
b
d
CHAPTER 17 271
Copy Mesh from body_lower to body_upper
a. Tools: Transform
c. Select Reorient
c
CHAPTER 17
Copy Mesh from body_lower to body_upper (continued)
a. Pick: check Make Copy

b. Select Elements
c. Click All
d. Select Create Source LCS
e. Select XYZ
f. For X,Y,Z Coordinate: enter 0 0 0 1 0 0 0 1 0; click OK
g. Select Create Target LCS
h. Select XYZ
i. For X,Y,Z Coordinate: enter 5 1.5 0 4 1.5 0 5 0.5 0; click OK
j. Click Done
k. Click Exit
d
e
a
f
b
j k
CHAPTER 17 273
Create Stress-strain Curve from Excel File
a. Copy stress-strain data from Excel file mat_nug17.xls
a
CHAPTER 17
Create Stress-strain Curve from Excel File (continued)
a. Materials and Properties tab: Isotropic

b. Click Plastic Strain
c. Right click Row 1 Column 1
d. Select Paste Table
e. Click OK
e
CHAPTER 17 275
Create Material Properties
a. Fields/Tables tab: NastranBDF TABLES1

b. For Name enter Iso_1
c. For Young’s Modulus enter 3.175e7
d. For Poisson’s Ratio enter 0.268
e. For Density enter 0.00074
f. Click Advanced
c
d
e
f
CHAPTER 17
Create Material Properties (continued)
a. Right click Add Constitutive Model

b. Select Elasto Plastic
c. Click Stress-Strain Data
d. For Stress-Strain Data, select TABLE_1
e. Click OK
d
e
CHAPTER 17 277
Define Property Data for lower_body
a. Materials and Properties tab: Plane

b. For Name enter prop_body_lower
c. For Entities, select body_lower from Model Browser tree
d. Click Advanced
e. For Corner Element Keyword, select C4
f. Click OK
e d
g
CHAPTER 17
Define Property Data for upper_body
a. Materials and Properties tab: Plane

b. For Name enter prop_body_upper
c. For Entities, select body_upper from Model Browser tree
d. Click Advanced
e. For Corner Element Keyword, select C4
f. Click OK
e
d
g
CHAPTER 17 279
Define Contact Body for lower_body
a. LBCs tab: Deformable Body

b. For Name enter def_body_lower
c. For Type, select Deformable Surface
d. For Entities, select body_lower from Model Browser tree
e. For Friction Coefficient, enter 0.07
f. Click OK
g. Observe def_body_lower in the Model Browser Tree
b
c
d
e
b
g
CHAPTER 17
Define Contact Body for upper_body

b. For Name enter def_body_upper
c. For Type, select Deformable Surface
d. For Entities, select body_upper from Model Browser tree
f. Click OK
g. Observe def_body_upper in the Model Browser Tree
b
c
d
e
b
f
g
CHAPTER 17 281
a. LBCs tab: Table

b. Select Deactivate All
c. Set Touching Condition for body 1 to 2
d. For Distance Tolerance, enter 0
f. For Individual Contact Detection, select Double Sided
g. For Bias Factor, enter 0.9
h. Click OK
b
c
d
e
f
h
CHAPTER 17
a. LBCs tab: LBC

b. Select Pin
c. For Name, enter fix-x
d. For Entities, select nodes at left edges of the model
e. Draw box about nodes at left edges of the model
f. For Translation, select Tx
g. Click OK
d
f
e
CHAPTER 17 283
Define Boundary Conditions (continued)
a. LBCs tab: LBC

b. Select Pin
c. For Name, enter fix-y
d. For Entities, select nodes at left edges of the model
e. Draw box about nodes at left edges of the model
f. For Translation, select Ty
g. Click OK
e
CHAPTER 17
a. LBCs tab: LBC

b. Select General
c. For Name, enter disp-y
d. For Entities, select nodes at top edge of the model
e. Draw box about nodes at top edge of the model
f. For Translation, select Ty
g. For Ty, enter -0.6
h. Click OK
e
d
f g
h
CHAPTER 17 285
a. Right click FileSet

c. For Job Name, enter nug-17
d. For Solution Type, select SOL 400
e. For Solver Input File, specify the fine name and its path
g. Click OK
a
b
d
e
f
g
CHAPTER 17
a. Right click on Load Cases

c. Click OK
a
b
c
CHAPTER 17 287

Select Contact Table for Loads in Global Loadcase

c. For Selected BCTable, select BCTABLE_1
d. Click OK
d
CHAPTER 17
a. Right click on Loadcase Control

c. For Stiffness Update Method: select Pure Full Newton (PFNT)
d. Unselect Use Default Tolerance Setting
e.Click Load Error and for Load Tolerance, enter 0.01
f. For Intermediate Output Control, select Every computed load increment
(YES)
g. Click Apply
h. Click Close
b
c
f
g
h
CHAPTER 17 289
a. Double click on Loadcase Control

c. For Number of Steps: enter 30
d. Click Apply
e.Click Close
b
c
d
e
CHAPTER 17

c. For Selected Lbcs: using the Control Key and the Mouse, select fix-x, fix-y, disp-y
from the Model Browser tree
d. Click OK
c c
d
CHAPTER 17 291

b. Select Select Contact Tables
c. For Selected BC Table: select BCTABLE_1 from the Model Browser tree
d. Click OK
a c
c
b
d
CHAPTER 17

d. Check Suppress Print
e. Click OK
a
b
e
CHAPTER 17 293

e. Click OK
e
CHAPTER 17

c. For Large Displacement: select Large Disp. and Follower Force
d. Click Apply
e. For Large Strain Formulation: select Hypoelasticy and Additive Plasticity for
Large Strain Formulation
f. Click Apply
g. Click Close (not shown)
a
b
f
CHAPTER 17 295

b. Select Contact Detection Parameters
c. For Bias on Distance Tolerance, enter 0.9
d. Click Apply
e. Select Contact Friction Parameters
f. For Type: select Bilinear Coulomb
g. Click Apply
h. Click Close (not shown)
e
f
g
CHAPTER 17

c. For Nastran DB Options: select Master/DBALL
d. For Binary Output: select OP2
e. Click Apply
f. Click Close (not shown)
b c
e
CHAPTER 17 297
a. File: Save
b. Right click on nug-17
c. Select Run
d. After completion of job, select Save
e. File: New
e
a d
c
CHAPTER 17
a. Results tab: Deformations

b. For Deformed display scaling., select True
c. Plot Data: Plot type, select Deformation
d. For Results cases, select the last increment
e. For Results Type, select Displacements, Translational
f. Click Update
f
c e
d
CHAPTER 17 299
a. Click Animate
b. Results cases: select SC1:Step 1 (selects all increments)
c. Results entities: Results type: select Displacements, Translational
d. Click Update
d
c
a b
CHAPTER 17
a. Animation tab
a
b
CHAPTER 17 301
a. Results: Fringe
b. Click Animate
c. Results entities: Results cases: select SC1:Step 1 (selects all increments)
d. Results entities: Results type: select Contact Status
e. Fringe tab: Display settings tab: Element edge display,
Display, select Element edges
f. Label attributes, select color of labels
g. Click Update
d
b c
f
g
e
CHAPTER 17

CHAPTER 17 303
a. Results: Fringe
c. Plot Data tab: Results type: select Logarithmic Strains
d. Derivation: select von Mises
e. Click Update
e
d
c
CHAPTER 17
Input File(s)
File Description
nug_17.dat MD Nastran SOL 400 input
nug_17w.dat Same as nug_17.dat, but the contact is defined in a wrong way in BCTABLE
ch17.dat MD Nastran SOL 400 input for SimXpert
ch17.SimXpert Corresponding SimXpert input file
Chapter 18: Demonstration of Springback
18 Demonstration of Springback

Summary 306

Introduction 307

Reference Solution 307

FEM Solutions 307

Modeling Tips 310

Input File(s) 310

Video 311
CHAPTER 18
Summary
Title Chapter 18: Demonstration of Springback
Contact features Rigid-deformable contact, velocity driven rigid cylinder, load controlled rigid cylinder,
and release of a contact bodies
Geometry Rigid cylinder, D = 0.4375 in
A
Material properties 6
E = 10.6 10 psi  = 0.33  y = 4.29 10 psi
4
Elastic plastic material with work-hardening

Boundary conditions • Left side is constrained with u x = 0
• A spring is used to constrain the motion in the y-degree of freedom
• Contact between rigid cylinder and the deformable body
Applied loads Two types of load introduction will be used:
• Constant “velocity” vx = 0.1125 applied on the rigid body
• Control node ux = 0.1125 applied on the load controlled rigid body
Element type 2-D 4-node plane strain elements
Contact properties Friction coefficient =0.2
FE results Contour of equivalent stress at the end of forming, equivalent stress after the springback;
displacement history of point A.
X-Displacement (in) Point A
0.20
forming springback
0.15
0.10
MD Nastran Sol400
0.05 MSC.Marc
% of Load
0.00
0 50 100 150 200
CHAPTER 18 307
Demonstration of Springback
Introduction
Significant permanent deformation and large strains occur during the forming step by moving a cylindrical rigid body
into the metal structure. The metal structure springs back upon removal of the cylindrical rigid body using the contact
table definition.
Reference Solution
MSC.Marc 2005r3 will be used to create a reference solution.
FEM Solutions
The finite element model is shown in Figure 18-1. There are two contact bodies: one deformable and one rigid body.
BSURF 1 1 2 3 4 5 6 7
...
0 0. 0. 0. 1. 0.1125 0. 0.
RIGID 0 72 CYL
NURBS2D -7 4 50
.85875 .51775 .85875 .95525
...
The deformable contact body is simply a collection of mutually exclusive elements and their associated nodes. The
rigid cylindrical body is defined using 2-D NURBS line.
Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other. Since the master body
is a rigid one, this actually means that the deformable body is the slave one.
BCTABLE 0 1
SLAVE 1 0. 0. .2 0. 0 0.
0 0 0
MASTERS 4
BCTABLE 1 1
SLAVE 1 0. 0. .2 0. 0 0.
0 0 0
MASTERS 4
During the springback analysis, the contact forces on the deformable body due to the contact with the rigid body are
removed immediately. It is done using BCMOVE option. To prevent the two bodies cylinder reclaims contact, a new
BCTABLE has to be defined that does not include the cylinder.
BCMOVE 2 RELEASE 0
4
BCTABLE 2 1 1
The geometric nonlinear analysis is requested using the following LGDISP parameter. The large strain option is also
set in this model
PARAM LGDSIP 1
NLMOPTS LRGSTR 1
CHAPTER 18
To activate the friction behavior, the user should use the BCPARA option as follows:
BCPARA 0
FTYPE 6
Figure 18-1 Finite Element Mesh
Plane strain elements for large strain elastic-plastic analyses are chosen by the PSHLN2 entry referring to the
PLPLANE entry on the CQUAD4 option as shown below.
PLPLANE 1 1
PSHLN2 1 1 1
The material property is isotropic and elastic-plastic with hardening. The Young’s modulus, Poisson’s ratio, and
plasticity parameters are defined as follows:
MAT1 1 1.06+7 .33
MATEP 1 TABLE 1 ISOTROP ADDMEAN
TABLES1 1 2
* 0. 42900. 0.001733 43110.2
…
The nonlinear procedure used during the forming and springback are set using the following options:
NLPARM 1 30 PFNT U
NLPARM 2 1 PFNT U
Here the PFNT option is selected to update the stiffness matrix during every recycle using the Newton-Raphson
iteration strategy, and the default displacement convergence tolerances will be used.
The simulation process is controlled by the case control section. The first step is the forming process and the second
one is the springback analysis:
BCONTACT=0
SPC = 2
STEP 1
TITLE=Forming Step
NLPARM = 1
BCONTACT = 1
LOAD = 1
CHAPTER 18 309
STEP 2
TITLE=Springback Step
NLPARM = 2
BCONTACT = 2
BCONTACT=0 is meant to bring both bodies just in contact. Since there is no explicit external load applied in this
analysis, a dummy LOAD is introduced in the case control parameters.
The deformed structure plot (magnification factor 1.0) is shown in Figure 18-2 along with the von Misses stress
contour. The maximum stresses are located at the expected location.
UNDEFORMED
DEFORMED
Figure 18-2 Deformed Configuration with von Misses Stress Contour at the End of the Forming Step
The deformation after the springback analysis is shown in Figure 18-3. There is significant permanent deformation
during the forming process as obviously seen from this figure. The von Misses stresses of the residual stresses are also
plotted.
UNDEFORMED
DEFORMED
Figure 18-3 Deformed Configuration with von Misses Stress Contour After the Springback
CHAPTER 18
The displacement of point A is plotted versus time (percentage of load) in Figure 18-4 illustrating the elastic
springback upon unloading the structure. This behavior is compared with a reference plot obtained with MSC.Marc
2005r3. The result of MD Nastran matches the referenced one very nicely.
X-Displacement (in) Point A

0.20
forming springback
0.15
0.10
MD Nastran Sol400
0.05 MSC.Marc
% of Load
0.00
0 50 100 150 200
Figure 18-4 Displacement Plot for Point A During Forming and Springback Step
Modeling Tips
Force control applied via a control node associated with the rigid cylinder may be used instead of displacement (or
equivalently velocity) control. Using this technique, the release of the load requires less difficulty with the contact
table (please see nug_18b.dat). In terms of CPU time, removing the rigid body from contact table is more efficient
since there is no need to do contact manipulation (please see nug_18c.dat).
Input File(s)
File Description
nug_18a.dat “Velocity” driven rigid body
nug_18b.dat Load controlled rigid body without BCMOVE
nug_18c.dat Load controlled rigid body with BCMOVE
CHAPTER 18 311
Video
UNDEFORMED
DEFORMED

Chapter 19: 3-D Indentation and Rolling without Friction
3-D Indentation and Rolling

19 without Friction

Summary 313

Introduction 314


FEM Solution 314


Input File(s) 364
CHAPTER 19 313
3-D Indentation and Rolling without Friction
Summary
Title Chapter 19: 3-D Indentation and Rolling without Friction
Contact features • Deformable, and two rigids
• Load controlled motion
Geometry 3-D Solid (units: in) Body_1
• Block length = 20 Body_2
• Block height = 12 Body_3
• Block width = 10
• Cylinder diameter =10
• Cylinder width = 18
Material properties E block = 17.5Mpsi  block = 0.3  yield = 35kpsi

Elastic-plastic material
Analysis type Quasi-static analysis; two analyses steps are preformed
Boundary conditions Displacement constraints to prevent rigid body modes
Contact between block, cylinder and surface
Applied loads Load controlled motion of cylinder
Step 1 u z = – 6.25in
Step 2 u z = – 6.25in u x = 5in r y = 0.5rad
Element type 3-D solid
FE results Deformed structure plot comparing MD Nastran results with Marc
Total Eq. Plastic Strain

CHAPTER 19
Introduction
This problem demonstrates the ability to perform metal forming analyses. A rigid cylinder is pressed into an elastic-
plastic material and, in the second loading stage, it is rolled. Large plastic deformation is anticipated in this analysis.
Requested Solutions
To model this large plastic deformation, additive plasticity with mean normal return is used. This is activated in MD
Nastran using the NLMOPTS bulk data entry, nonlinear material options, and then choosing LRGSTRN,1. Together
with this option, nonlinear property extensions for the PSOLID entry should be used. This can be done by activating
the PSLDN1 bulk data entry and selecting the required properties.
FEM Solution
A numerical solution has been obtained with MD Nastran’s SOL 400 for the element mesh (Figure 19-1) using solid
elements (contact body ID 1). The dimensions of the workpiece are 20 x 10 x 12 inches. The radius of the cylinder is
10 inches, the width 18 inches, and the cylinder is placed on top of the workpiece at its center. The cylinder (contact
body ID 2) is modeled as a rigid using NURBS to define the surface. The plane which supports the workpiece is also
defined as a rigid (contact body ID 3).
BSURF 1 1 2 3 4 5 6 7
...
and
226 0. 0. 0. 1. 0. 0. 0.
RIGID 227 1 BODY_2
...
and
0 0. 0. 0. 1. 0. 0. 0.
RIGID 0 1 BODY_3
...
Thus, a deformable contact body is simply a collection of mutually exclusive elements and their associated nodes.
CHAPTER 19 315
Figure 19-1 Element Mesh applied in Target Solution with MD Nastran
BCTABLE 0 3
SLAVE 1 0. 0. 0. 0. 0
0 0 0
MASTERS 1
SLAVE 2 0. 0. .1 0. 0
0 0 0
MASTERS 1
SLAVE 3 0. 0. .1 0. 0
0 0 0
MASTERS 1
BCTABLE 1 3
SLAVE 1 0. 0. 0. 0. 0
0 0 0
MASTERS 1
SLAVE 2 0. 0. .1 0. 0
0 0 0
MASTERS 1
SLAVE 3 0. 0. .1 0. 0
0 0 0
MASTERS 1
BCTABLE 2 3
SLAVE 1 0. 0. 0. 0. 0
0 0 0
MASTERS 1
SLAVE 2 0. 0. 0. 0. 0
0 0 0
MASTERS 1
SLAVE 3 0. 0. 0. 0. 0
0 0 0
MASTERS 1
Solid elements suitable for large deformation analyses are chosen by the PSLDN1 entry referring to the PSOLID entry
on the CHEXA option as shown below.
PSOLID 1 1 0
PSLDN1 1 1 1 +
+ C8 SOLI L
CHAPTER 19
The material property for all the elements is elastic-plastic, with Young’s modulus, Poisson’s ratio, and initial yield
stress defined as
MAT1 1 1.75+7 .3
The rigid cylinder (contact body 2) is load controlled. This means that two nodes define the motion of the rigid. One
node defines the translational degrees of freedom and one node defines the rotational degrees of freedom. The motion
of the cylinder is first in the -z-direction, and, after this, it rolls around its y-axis in the x-direction. This motion is
prescribed by defining two analyses steps. Node 227 is for the translational motion, and node 226 for the rotational
motion. Note that in step 2, the cylinder rotates both around the y-axis and moves in the x-direction, making a rolling
movement.
SPCD 1 227 3 -6.25
SPCD 2 227 3 -6.25
SPCD 2 227 1 5.
SPCD 2 226 2 .5

0.01 0.01 0.01 10
0.01 0.01 0.01 10
Here PFNT is selected to update the stiffness matrix every recycle using the full Newton-Raphson iteration procedure.
Convergence checking is on displacements and forces. Note that MAXITER is set to 200 and MAXDIV is set to 10 to
avoid that bisections occur, since too many bisections may increase the overall solution time.
Two stages of the deformation are shown in Figure 19-2 and Figure 19-3. Figure 19-2 shows the deformation after the
first step where the cylinder has moved in the -z-direction. Figure 19-3 shows the deformation after the second step
when the cylinder also has rolled in the x-direction.
Figure 19-2 Deformed Structure Plot after the First Load Step.
CHAPTER 19 317
Figure 19-3 Deformed Structure Plot after the Second Load Step.
A comparison with MSC.Marc is made. Figure 19-4 shows a superposition of the deformed mesh of Nastran (black)
and the deformed mesh of Marc (purple).
Figure 19-4 Comparison of Deformed Structure Plot Of MD Nastran (black) and Marc (purple) after the
Second Load Step.
CHAPTER 19
a. Tools: Options
c. For Basic Units, specify the model units
Length = in; Mass = lb; Time = s; Temperature = rankin, Force = N
d. Click OK
b c
d
CHAPTER 19 319
Create Parts
a. Assemble tab
b. Parts, select Create Part
c. For Name, type Solid_Block
d. Click Apply
e For Name, type Rigid_Body1
f. Click Apply
g. For Name, type Rigid_Body2
h. Click OK
i. Right click Solid_Block; select Set Current
a
b
f i
h
CHAPTER 19
Create Surface
a. Geometry tab
b. Surface, select Filler
c. For Method, select Points
d. For Points, enter 0,0,0;20,0,0;20,10,0;0,10,0 (Hit the Enter key on the keyboard)
e Click Apply
f. Click Cancel
a
b
f e
CHAPTER 19 321
Create Mesh
a. Meshing tab
b. Automesh, select Surface
c. For Surface to mesh, select the surface
d. For Size, enter 2.5
e Click Apply
f. Click Cancel
a
b
f e
CHAPTER 19
Create 3-D Mesh
a. Meshing tab
b. FEM based, select Normal
c. For Shell Elements, select all elements created (draw a box around graphic)
d. For Distance, enter 12
e For Layers, enter 4
f. Click Apply
g. Click Cancel
h. Select FE Shaded with Edges
a
b
c
d
e
f g
h
CHAPTER 19 323
Delete Quads
a. Hide 3-D elements

b. Edit, select Delete
c. Pick window, select Elements
d. Select the quads displayed with a window (draw a box around graphic)
e Pick window, click Done
f. In Delete? window, click Yes
g. Pick window click Exit
h. Show 3-D elements
h
d
e g
f
CHAPTER 19
Create Surface
a. Right click Rigid_Body1; select Set Current

b. Geometry tab
c. Curve: select From Points
d. Create, select Polyline
e. Method, select 2 Points
f. For Points, enter -30,-30,0;50,-30,0 (Hit the Enter key on the keyboard)
g. Click Apply
h. Click Cancel
b
c
d
e
f
h g
a
CHAPTER 19 325
Create Circle
a. Geometry tab: Surface: select Normal

b. Width, enter 80 (Hit the Enter key on the keyboard)
c. Check Reverse direction
d. Select the curve
e. Click Apply
f. Click Cancel
b
d
d
CHAPTER 19
Create Surface
a. Right click Rigid_Body2; select Set Current

b. Geometry tab: Curve: select Arc
c. Method, select Direction-Radius
d. Radius: enter 10 (Hit the Enter key on the keyboard)
e. Select Axis Y
f. Check Create Circle
g. Enter Center Point: 10,14,22 (Hit the Enter key on the keyboard)
h. Enter Start Point: 0,0,0 (Hit the Enter key on the keyboard)
i. Click Apply
j. Click Cancel
To rotate your graphic to match the one shown below, click on the Rotate Icon, put the cursor
on the graphic, hold the left mouse button, and rotate the graphic for different views.
b
c
d
e
f
g
i h
CHAPTER 19 327
Create Cylinder
a. Geometry tab: Multi: select Sweep

b. Along, select Axis
c. Select Axis Y
d. Length Of Sweep, enter 18 (Hit the Enter key on the keyboard)
e. Entities: select the curve
f. Check Delete Entities to Sweep
g. Check Reverse Direction
h. Click Apply
i. Click Cancel
b
c
d
f
g
i h
e
CHAPTER 19
Create Control Nodes
a. Nodes/Elements tab
b. Create, select Node
c. Locations: enter 20,-1,15;10,9,22 (Hit the Enter key on the keyboard)
d. Click Apply
e. Click Cancel
a
b
e d
CHAPTER 19 329
Create Material

b. Material, select Isotropic
c. Name: enter Mat_1
d. Young’ Modulus: enter 1.75e7
e. Poisson’s Ratio, enter 0.3
f. Click Advanced and Add Constitutive Model
g. Click Elasto Plastic
h. Select Perfectly Plastic
i. Initial Yield Stress, enter 35000
j. Click Apply
k. Click Cancel
CHAPTER 19
a
b
f
g
j i
CHAPTER 19 331
Create Properties

b. 3D Properties, select Solid
c. Entities: select Solid_Block
d. Material: select Mat_1
e. Click Advanced
f. Select Non Linear
g. Corner elements keyword: HEXA, select C8
h. Element structural behaviour: HEXA, select SOLID
i. Integration scheme: HEXA, select L
j. Click Apply
k. Click Cancel
a
b
g
h
i
j k
CHAPTER 19
Define Contact Bodies
a. LBCs tab
b. Contact, click Deformable Contact Body icon
c. Name: enter Solid_Block
d. Type: select Deformable Solid
e. Pick Entities: select Solid_Block
f. Click Apply
g. Click Cancel
a
b
c
d
g f
CHAPTER 19 333
Define Contact Bodies (continued)
a. LBCs tab
b. Contact, click Rigid Contact Body icon
c. Name: enter Rigid_1
d. Type: select Rigid Surface
e. Pick Entities: select SURFACE/2
f. Click Body
g. Contact Condition: select No Symmetry Condition
h. Click Apply
i. Click Cancel
c
d
e
i h
CHAPTER 19
Define Contact Bodies
a. LBCs tab
b. Contact, click Rigid Contact Body icon
c. Name: enter Rigid_2
d. Type: select Rigid Surface
e. Pick Entities: select SURFACE/2
f. Click Body
g. Contact Condition: select No Symmetry Condition
h. Click Motion
i. Motion Control: select Load
j. First Control Node: select Node/227
Second Control Node: select Node/226
k. Click Apply
l. Click Cancel
c
d
e
f
g 226
h 227
i
j k
CHAPTER 19 335
a. LBCs tab
b. Contact, click Contact Table icon
c. Click Apply
d. Click Cancel
c d
CHAPTER 19
Create Constraints
a. LBCs tab
b. Constraints, click Pin
c. Name: enter spc1
d. Uncheck Ty and Tz
e. Entities: activate “pick nodes”
f. On the left edge of the block, select 25 nodes with a window
g. Click Apply
h. Click Cancel
e
d
e
f g
CHAPTER 19 337
Create Constraints (continued)
a. LBCs tab
c. Name: enter spc2
d. Uncheck Tx and Tz
e. Entities: activate “pick nodes”
f. On the left front corner of the block, select 5 nodes
g. Click Apply
h. Click Cancel
e
d
g h
CHAPTER 19
Create Constraints (continued)
a. LBCs tab
c. Name: enter spc3
d. Entities: activate “pick nodes”
e. On the left edge of the block, select 2 (226 and 227) control nodes
f. Click Apply
g. Click Cancel
f g
CHAPTER 19 339
Create Enforced Displacement
a. LBCs tab
b. Constraints, click General
c. Name: enter spcd1
d. Entities: select NODE/227
e. Uncheck Tx, Ty, Rx, Ry, and Rz
f. Tz: enter -6.5
g. Click Apply
h. Click Cancel
e
d
f
g h
CHAPTER 19
Create Enforced Displacement (continued)
a. LBCs tab
e. Uncheck Ty, Rx, Ry, and Rz
f. Tx: enter 5
g. Tz: enter -6.5
h. Click Apply
i. Click Cancel
f
e
g d
h i
CHAPTER 19 341
Create Enforced Displacement (continued)
a. LBCs tab
e. Uncheck Tx, Tz, Rx, Ry, and Rz
f. Ty: enter .5
g. Click Apply
h. Click Cancel
d d
e
f
e
g h
CHAPTER 19
Analysis Setup
a. Model Browser, right click FileSet

c. Solution Type: select SOL400
d. Solver Input File: select NewJob.bdf
e. Uncheck Create Default Layout
f. Click OK
a
b
c
d
e
f
CHAPTER 19 343
Analysis Setup (continued)
a. Model Browser, New Job, right click Load Cases

c. Uncheck Auto Select LBCs Set
d. Click OK
e. Model Browser, double click NewLoadcase
f. Name: enter Step1
g. Uncheck Auto Select LBCs Set
h. Click OK
i. Repeat the above procedure to create Step2
a e
b
c
g
d
h
i
CHAPTER 19
a. Model Browser, New Job, double click Solver Control

b. Click Analysis Options
c. Large Strain Formulation: select Hypoelasticity and Additive Plasticity w/Mean
Normal Return
d. Click Apply
e. Click Output File Properties
f. Nastran DB Options: select Master/DBALL
g. Click Apply
h. Click Close
g
d
h
CHAPTER 19 345
a. Step1, double click Load Step Control

b. Analysis Control, click Generic Control
c. Maximum Iterations for each Increment, enter 200
d. Click Apply
e. Click Convergence Criteria for Mechanical Analysis
f. Check Displacement Criteria; Tolerance for Displacement Criteria, enter
0.01
g. Check Load Criteria; Tolerance for Load Criteria, enter 0.01
h. Click Apply
b
c e f
g
h
CHAPTER 19
a. Analysis Control, click Stepping Control Parameters

b. Stepping Type: select Fixed
c. Number of Increments: enter 25
d. Click Apply
e. Click Close
b
a c
d
e
CHAPTER 19 347
a. Step2, double click Load Step Control

b. Analysis Control, click Generic Control
c. Maximum Iterations for each Increment, enter 200
d. Click Apply
e. Click Convergence Criteria for Mechanical Analysis
f. Check Displacement Criteria; Tolerance for Displacement Criteria, enter
0.01
g. Check Load Criteria; Tolerance for Load Criteria, enter 0.01
h. Click Apply
b
c e f
g
d
h
CHAPTER 19
a. Analysis Control, click Stepping Control Parameters

b. Stepping Type: select Fixed
c. Number of Increments: enter 25
d. Click Apply
e. Click Close
b
a c
d
e
CHAPTER 19 349
a. Step1, right click LbcContainer

b. Select LBCs
c. From the Model Browser, select spc1, spc2, spc3, and spcd1
d. Click OK
e. Right click LbcContainer, select Contact Table
f. Select BC Table: select BCTABLE_1 from the Model Browser
g. Click OK
a e
b
e
c f
d g
c
CHAPTER 19
a. Step2, right click LbcContainer

b. Select LBCs
c. From the Model Browser, select spc1, spc2, spc3, spcd2, and spcd3
d. Click OK
e. Right click LbcContainer, select Contact Table
f. Select BC Table: select BCTABLE_1 from the Model Browser
g. Click OK
a e
b
e
c
f
d
g
c f
c
CHAPTER 19 351
Requesting Output Parameters
a. Step1, right click Output Requests

e. Click OK
e
CHAPTER 19
Requesting Output Parameters (continued)

e. Click OK
e
CHAPTER 19 353

b. Select Elemental Output Request
c. Select Create Element Output Request
e. Click OK
e
CHAPTER 19

b. Select Elemental Output Request
e. Click OK
For Step2, repeat the Step1 procedure for Requesting Output Parameters.
CHAPTER 19 355
Run the Deck
a. Right click NewJob

b. Click Run
b
CHAPTER 19
Postprocessing
a. File: Attach Results

b. File Path: select MASTER
c. Attach Options: Results
d. Click OK
e
CHAPTER 19 357
Postprocessing (continued)
a. Results tab
b. Click Deformation
c. Plot Data tab
d. For Plot Type, select Fringe
e. Result cases, select Step1
f. Result type, select Displacements, Translational
g. Derivation, select Magnitude
h. Click Update
a
b
h
d g
e
f
CHAPTER 19
CHAPTER 19 359
a. For Plot Type, select Deformation

b. Click Update
b
a
CHAPTER 19
CHAPTER 19 361
a. Results tab
b. Click Deformation
c. Plot Data tab
d. For Plot Type, select Fringe
e. Result cases, select Step2
f. Result type, select Displacements, Translational
g. Derivation, select Magnitude
h. Click Update
a
b
h
d g
e
f
CHAPTER 19
CHAPTER 19 363
a. For Plot Type, select Deformation

b. Click Update
b
a
CHAPTER 19
Input File(s)
File Description
nug_19.dat Linear Elements using PSLDN1 Entry
Chapter 20: Composite Fracture and Delamination
Composite Fracture and

20 Delamination

Summary 366

Introduction 367

Requested Solution 369

FEM Solutions 369

Modeling Tips 371

Input File(s) 373

Video 373
CHAPTER 20
Summary
Title Chapter 20: Composite Fracture and Delamination
Features • VCCT based crack propagation
• Cohesive zone modeling
Geometry 6“
R = 0.5 “
1.1 “
0.078 “
0.6 “ 0.9 “ 0.9 “ 0.6 “

Initial Crack
Material properties • Isotropic elastic material:

E = 5000 ksi,  = 0.3
• Cohesive material for interface elements: Exponential model used
• Cohesive energy = 4.409 lb/in; critical opening displacement = 0.005 in
Boundary conditions Simply supported as shown in the diagram above
Applied loads Prescribed vertical displacement
Element type 4-node plane strain; 4-node interface
VCCT properties • Direct crack propagation by releasing glued contact.
• Crack growth resistance = 4.409 lb/in
FE results 1. Plot of deformed shape for VCCT model.
2. Plot of deformed shape for interface element model
3. Force-displacement curve at applied load.
250
Cohesive zone
VCCT
200
150
Reaction force
100
50
0
0 0.05 0.1 0.15 0.2
Vertical displacement
CHAPTER 20 367
Composite Fracture and Delamination
Introduction
This example models a honeycomb (core) structure with a face sheet between which exists an initial delamination. A
hole is drilled in the core part, where a prescribed displacement is applied to the face sheet in order to study the effect
of delamination of the face from the core.
A plane strain assumption has been used and, for simplicity, the same isotropic material is used for the two parts.
The delamination is modeled in two ways:
• With glued contact and crack growth using the VCCT option.
• With interface elements using a cohesive zone model.
Figure 20-1 illustrates the VCCT model. The face sheet is glued to the core. The center part of the face sheet is omitted
from the contact body and thus defines the initial cracks. The grid IDs defining the crack tips are shown in Figure 20-2.
Figure 20-1 Definition of Contact Bodies for the VCCT Model
The model using interface elements is shown in Figure 20-3. Here, we do not use contact; instead, there are interface
elements between the core and the face which share the grids from the existing meshes. The interface elements have
zero thickness, but they are shown with finite thickness in Figure 20-3 (the face part has been moved downwards for
better illustration).
For the VCCT model, a crack growth resistance is specified. The energy release rate is calculated for each crack at
each load level. When this energy release rate is larger than the crack growth resistance, the crack will grow. The
growth is accomplished by releasing the glued contact at the crack tip. The next grid along the interface is
automatically identified and a new calculation of the energy release rate is performed, and the check for growth
repeated. This continues at constant load until either the crack reaches a free boundary or the energy release rate is
below the crack growth resistance.
CHAPTER 20
grid 2381 grid 1136

Figure 20-2 Grids for VCCT definition.
Figure 20-3 Delamination Model with Bottom Part moved Downwards to Show the Location of the
Delamination Elements
CHAPTER 20 369
With the interface elements and the cohesive material model, the growth of the delamination occurs by increased
damage in the interface elements. Damage could occur at any point along the interface, but in this case, the largest
stresses occur where the initial delamination ends, so the largest damage will happen here. When the interface elements
have sustained full damage at all integration points, they no longer contribute to the stiffness of the structure.
Requested Solution
Requested results are the force-displacement curve of the point where the prescribed displacement is applied and the
amount of growth of the initial delamination.
FEM Solutions
MD Nastran’s SOL 400 has been used in the analysis.
The VCCT option is specified in the bulk data as:
VCCT 1 1 2
4.409
0
2381
VCCT 1 2 2
4.409
0
1136
The grid IDs 2381 and 1136 are located as shown in Figure 20-2
Plane strain elements are chosen by the PLPLANE entry on the CQUAD4 option as shown below.
PLPLANE 1 1
PSHLN2 1 1 1 +
+ C4 PLSTRN L +
The delamination elements are defined with the CIFQUAD entry, and the corresponding cohesive property and material
are defined as:
MCOHE 2 2 2
+ 4.409 .500E-02
PCOHE 2 2
where the exponential option is used for the cohesive material model.
The nonlinear iterative control is specified as:
NLSTEP 2 1. +
+ GENERAL 30 0 +
+ FIXED 100 1 +
+ MECH PV 0.01 PFNT
Fixed time stepping procedure with total time of 1 is used. Maximum 30 iterations are allowed for each increment.
Total 100 numbers of increments are used for fixed time stepping. Output for every single increment is written to the
result file. For convergence criterion load equilibrium error with vector component method (PV) is used. Convergence
tolerance of 0.01 is used. Pure Full Newton-Raphson Method is used (PFNT) as an iteration method.
CHAPTER 20
The deformed shape at the final load for the two cases is shown in Figure 20-4. It can be seen that the amount of growth
of the delamination is the same for the two models. The cohesive zone variant shows the “stretched” interface
elements. They are, at this point, fully damaged and do not contribute to the structural stiffness.
Figure 20-5 shows a plot of the reaction force versus the prescribed displacement. Here, we clearly see the difference
between the two approaches. For VCCT, the interface is rigid until crack growth occurs. The jumps in the reaction
force indicate when a new node is released. With a finer mesh, the curve would be smoother. The cohesive zone model
shows a different behavior. The initial stiffness is lower as a result of the properties of the cohesive material. Here the
interface layer is relatively soft, and the growth of the delamination is smooth. By adjusting the properties of the
cohesive material one can adjust the initial stiffness of the interface layer. Thus, the VCCT approach models the
interface as rigid while the interface element approach models an elastic interface with initially zero thickness.
The values used for the crack growth resistance and the cohesive energy are the same in the two model. This makes
sense since these quantities are related – both correspond to the energy needed to break the connection.
a) VCCT
b) Cohesive Zone
Figure 20-4 Deformed Shape at Final Load for the Two Models
CHAPTER 20 371
250
Cohesive zone
VCCT
200
150
Reaction force
100
50
0
0 0.05 0.1 0.15 0.2
Vertical displacement
Figure 20-5 Reaction Force vs. Vertical Displacement
Modeling Tips
Both models could be done with higher-order elements for increased accuracy. When glued contact is released in the
VCCT model, the midside grid is released whenever a corner grid is released. Hence, although this would give an
increased general accuracy of the solution, it would not improve the jagged nature of the force-displacement curve.
Some notes on mesh design. In the VCCT model, the meshes on both sides of the glued interface have matching nodes.
One of the two grids at the crack tip is identified in the VCCT input. It does not matter which one of the two that is
used. It is allowed to use nonmatching meshes for VCCT based crack growth. Figure 20-6 shows an example. Here,
the bottom part is glued to the top part (the bottom part is the touching side and the top part the touched side). In this
case, it is important that the grid of the touching part is chosen for the VCCT input. This is the grid that would be
released in case of crack growth. The touching part should be the part with a finer mesh density.
The current interface element model does not use contact. The interface elements and the other elements share nodes.
In order to allow a model with independent meshes, one can also use glued contact here. See Figure 20-7 for an
example. The interface elements are shown with finite thickness for clarity. The top part of the interface elements are
glued to the top part of the model and the bottom part of the interface elements to the bottom part. This way, all three
parts can be modeled independently. Similar to the VCCT example above, the touching body (in this case the interface
elements) should have a finer mesh density.
CHAPTER 20
crack tip grid

Figure 20-6 Example of Mesh for VCCT with Nonmatching Mesh Densities
Figure 20-7 Example of Mesh for Cohesive Zone Model with Nonmatching Mesh Densities
CHAPTER 20 373
Input File(s)
File Description
nug_20v.dat Model using the VCCT option
nug_20d.dat Model using delamination elements
nug_20d.bdf Model using delamination elements for video
nug_20d_start.SimXpert Starting model for SimXpert video
Video
6“
R = 0.5 “
1.1 “
0.078 “
0.6 “ 0.9 “ 0.9 “ 0.6 “

Initial Crack

Chapter 21: Occupant Safety and Airbag Deployment
Occupant Safety and

21 Airbag Deployment

Summary 375

Introduction 376


FEM Solution 376

Results 379


Input File(s) 418

Animation 418
CHAPTER 21 375
Occupant Safety and Airbag Deployment
Summary
Title Chapter 21: Occupant Safety and Airbag Deployment
Features Airbag Deployment with Occupant
Geometry Unit dimensions: mm, kg, ms, KN,
GPa, K, J
Material properties Car frame: Rigid

Airbag: Fabric (MATD034)
Density = 8.76E-07
Ea = 0.3; Eb = 0.2
nab= 0.2; Gab = 0.04
CSE = 1; EL = 0.06; PRL = 0.35
LRATIO = 0.1; DAMP = 0.4
Initial airbag gas: Density = 1.2E-9; Pressure = 0.000101; Temperature = 294.34
Gamma gas constant = 1.4; R gas = 286.98; CP gas = 1004
Inflator: Rigid
R gas inflator = 353.78; CP gas inflator = 1191
The Inflator Mass Flow Rate and the Temperature of the gas as a
function of time are defined by tables.
Dummy: Hybrid 3 - 50 (LSTC.H3.022908_Beta_Rigid.50th
Seatbelt: fabric (MATD034) and seatbelt material (MATDB01)
Analysis type Transient explicit dynamic analysis (SOL 700)
Boundary conditions Fixed except an airbag and a dummy
Applied loads Initial velocity 15 mm/ms to a dummy.
Prescribed Mass Flow Rate and Temperature of Inflator Gas
Element type 1-D beam element, 2-D shell element, 3-D solid element
FE results Plots of deformed shapes at various steps.
CHAPTER 21
Introduction
Automotive companies perform crash simulations including airbags and dummies to predict the forces that would be
exerted on the passenger. For people of average size, the airbag can be simulated using a uniform gas bag method
where a pre-determined pressure profile is applied inside the airbag surface. In some crash scenarios, such as Out-of-
Position (OOP), the passenger is already leaning forward at the time of airbag deployment, in which case the flow is
not uniform and the pressure method is not accurate. Instead, Full Gas Dynamic approach (CFD method) is used to
accurately simulate the gas jet, and its pressure distribution inside the bag. This crash example is based on the full gas
dynamic approach where an occupant dummy impacts the airbag.
Requested Solutions
A numerical analysis will be performed to predict the behavior of an airbag and an occupant dummy during crash
simulation.
FEM Solution
The units of this model are mm, kg, msec, KN, GPa, K, and J.TSTEPNL describes the number of time steps (20) and
time increment (2 msec) of the simulation. End time is the product of the two entries. Notice here that the time
increment is only for the first step, and in this analysis, it is overruled by the addition of an initial time step parameter:
PARAM, DYINISTEP, 1.E-7.
The actual number of time increments and the exact value of the time steps are determined by SOL 700 during the
analysis. The time step is a function of the smallest element dimension during the simulation.
TSTEPNL 1 20 2.
AIRBAG instructs SOL 700 to create an airbag using either the full gas dynamic (CFD) method or using a uniform gas
bag method. Here, the CFD method will be used. Inflow of gas into the airbag is defined by the entries following the
INFLATOR key word.
AIRBAG 3 7 ON
+ CFD 1 1.2E-9 20. 20. 20.
+ NONE
+ INITIAL0.000101 294.34 286.98 1004.
+ INFLATOR 9 1 2 1.
+ 353.78 1191.
+ GAS 2
+ 0.0 0.02897CONSTANT 1004.
+ GAS 4
+ 0.0 0.0235CONSTANT 1191.
MATD034 represents SOL 700 Material #34. It is used to model fabric material.
CHAPTER 21 377
For the airbag and the Seatbelt the following fabric materials are used respectively:
MATD034 2 8.76E-7 0.3 0.2
0.2
+ 0.04
1. 0.06 0.35 0.1 0.4
+ 3.
0.0 0.0 0.0
+
0.0 0.0 0.0
+ 1. 0.0 0.0
0.0 0.0 0.0 0.0
MATD034 292 1.E-6 2.9 2.9
+
+
+
The ends of the Seatbelt are modeled with Seatbelt elements (CBELT), Seatbelt property (PBELTD), and Seatbelt
material (MATDB01). The loading and unloading curves (force vs. strain) are defined in the following tables:
MATDB01 293 1.E-6 61 62 3.
TABLED1 61
+ 0.0 0.0 0.05 1.7
0.1 4.2 0.45 6.7
+ 0.5 7.6 1.00 8.2
ENDT
TABLED1 62
+ 0.0 0.0 1.00 8.2
ENDT
The dummy is modeled by using many element types and joints: CPENTA, CHEXA, RBJOINT, RBJSTIFF, CBAR,
CBEAM, HGSUPPR, CSPR, PSPRMAT, MAT1, MATRIG, and several of MATD0**.
EOSGAM defines the ideal gas inside the airbag.
EOSGAM 1 1.4 286.98
Bulk Data Entries that Define Contact Relations and Contact Bodies
BCTABLE defines Master-Slave as well as self contact.
BCTABLE 1 1
+ SLAVE 1 0.5
+
+ +
+ 2 3 5
+
+ 0.5 YES+
+ MASTERS 1
+ SLAVE 5 0.3
+
+ 0.3 SS2WAY
+
+ 2
CHAPTER 21
+ 20.
+ 1. 1. YES+
+ MASTERS 6
..
BCBODY is a bulk data entry that defines a flexible or rigid contact body in 2-D or 3-D. It could be specified with a
BSURF, BCBOX, BCPROP, or BCMATL entry.
..
Two types of entries are used to define 3-D contact bodies.
BPROP and BSURF define 3-D contact regions by element properties and a contact surface or body by element IDs,
respectively.
BCPROP 2 1 2 3 4 7
..
BSURF 6 1 THRU 2516
2527 THRU 10922
..
Using the BCTABLE and several BCBODY, BCSEG, and BCSURF entries, the following contacts are defined as:
Contact
Number Slave Master
1 Airbag Airbag
2 Pelvis Connection bones to legs
3 Neck ring Neck
4 Ribs Torso
5 Ribs Breast
6 Airbag Dummy upper parts
7 Seatbelt Torso - lower body - neck
8 Lower body Chair
9 Feet - hands Frame
10 Airbag Frame
Boundary conditions are specified for the car frame, and chair. Because the car frame is rigid, enforced motion entry
(SPCD2) is used.
$ Constraint for Frame chair floor
SPCD2 6 RIGID MR289 1 0 555 1.
SPCD2 6 RIGID MR289 2 0 555 1.
SPCD2 6 RIGID MR289 3 0 555 1.
SPCD2 6 RIGID MR289 5 0 555 1.
CHAPTER 21 379
SPCD2 6 RIGID MR289 6 0 555 1.

SPCD2 6 RIGID MR289 7 0 555 1.
TABLED1 555
+ 0. 0. 1000. 0. ENDT
Results
Figure 21-1 Occupant and Airbag at Various Positions

CHAPTER 21

In this example, a folded airbag and its interaction with a dummy with a seat belt are shown. Also, an animation of the
deformation of the airbag and the displacement of the dummy is shown.
To enter the MD Explicit Workspace:
a. Click MD Explicit
b. File: Save As
c. File name: airbag
d. Click Save
c d
CHAPTER 21 381
a. Tools: Options
c. Click Standard Units
d. Select the line with mm, kg, ms, ...
e. Click OK
f. Return to User Options screen and click OK
e
CHAPTER 21
Specify Input/Output
a. Tools: Options
b. Select Input/Output
c. Click Nastran Structures
d. Unselect Reduce Parts
e. Click Apply
f. Click GUI Options
g. Click Solver Card
h. Click OK
b d
a e
g
f
h
CHAPTER 21 383
Import the Airbag Model
a. File: Import
b. Select Nastran
c. Look in: AIRBAG
d. Select airbagconstant_new_spiral_simx.bdf
e. Click Open
b
c
d
e
CHAPTER 21
Import the Airbag Model
a. Tools: Transform
b. Select Rotate
c. R.Axis: For X, enter 0; for Y, enter 1; for Z, enter 0
d. For Angle, enter 90
e. Select Elements
f. Click All
g. Click Done
h. Click Exit
d
a
e
f
g h
CHAPTER 21 385
Check the Airbag Data

To rotate the airbag Rigid Wall.
a. Right click Rigidwall Planar_2

b. Click Properties
c. Modify WALL: For XP, enter -1.5; for ZP, enter 0; for NX, enter 1; for NZ, enter 0
d. Click Modify
a
b
c c c c
d
CHAPTER 21
Check the Airbag Data (continued)

To Change Damping Coefficient Fabric Material
a. Right click Material MATDO34

b. Click Properties
c. For DAMP, enter 0.4
d. Click Modify
a
b
d
CHAPTER 21 387
Import Dummy Model
a. File: Import
b. Select Nastran
c. Select LSTC.H3.022908_Beta_RigidFE.50th.dat
d. Click Open
d
CHAPTER 21
Import Car Frame Model
a. File: Import
b. Select Nastran
c. Select Body_Final.bdf
d. Click Open
e. Right click Model Views, select Right
d e
CHAPTER 21 389
Import Car Frame Model (continued)
a. View: Entity Display

b. Select Coordinate Frames Shown
c. Select Rigid Elements
d. Select Unreferenced Nodes Shown
a b
c
d
CHAPTER 21
Dummy Positioning
a. Safety: Positioner Panel

b. Select Parts by clicking Torso
c. Dummy Positioning: select Dummy H-Point
d. For H Point Location, change X to 560; change Y to -279.90; change Z to 55
e. For Rotation, change Y to 10; change Z to 180
b
d e
b
CHAPTER 21 391
Dummy Positioning (continued)
a. Component Positioning: For FullArm_UpDown_, change X to -10.00 (do once for each arm)
b. For lower_arm_right, change Z to -90.0
c. For lower_arm_left, change Z to -90.0
d. For neck_head, change Y to 7.0
a
b
c
d
CHAPTER 21
Dummy Positioning (continued)
a. Component Positioning: For Upper_leg_left, Curr. X = 5.00

b.For lower_leg_left, change to -21.0
c. For upper_leg_right, Curr. X = 10.00
d. For lower_leg_right, Curr. X = -32.00
e. For foot_right, change to 15.0
f. Click Exit
g. Right click Render, select FE Shaded
a
b
c
d
e
f
g
CHAPTER 21 393
Create Seat Belt

Plot dummy and chair only:
a. Right click LSTC.H3.022908_..., select Show Only

b.Right click PSHELL_2468_..., select Show
c. Tools: Options, Window
d. Color: Entity, select Edge Color, Gray
e. Click OK
f. Shift Right mouse, Screen Rotate
b
a
b
c
d
e
CHAPTER 21
Create Seat Belt (continued)

Create seat belt:
a. Safety: Route Seat Belt

b.Click Torso
c. Click Pelvis
d. Click Upper Leg Left
e. Click Done
f. Click Node 1
g. Click Node 2
h. Click Node 3
i. Click Done
j. Click Exit
b h
c
d g
j
e
i
CHAPTER 21 395
Check Seat Belt: Shell Property

Create seat belt:
a. Right click SeatBeltShellMaterial

b.Click Exit
c. Right click SeatBeltShellProperty
d. Double click MID
e. Select SeatBeltShellMaterial 290
f. Click OK
g. Click Modify
f
CHAPTER 21
Check Seat Belt: 1D Element Property

Create tables for seat belt load and unloading curves (Force vs. Strain):
a. Field/Tables: TABLED1
b. Click ADD six times to make six rows
c. Fill in X-Y values
d. Click Update
e. Click Create
f. Click Exit
g. Repeat a. through d. for the second table except for step b.
For step b., click ADD two times to make two rows
c
g
b
d
e f
CHAPTER 21 397
Check Seat Belt: 1D Element Property (continued)

Add tables for seat belt load and unloading curves (Force vs. Strain) to SeatBeltMaterial:
a. Right click SeatBeltMaterial

b.Double click LLCID
c. Select TABLED1_60_60
d. Click OK
e. Double click ULCID
f. Select TABLED1_61_601
g. Click OK; then click Modify
h. Right click SeatBeltProperty
i. Double click MID1
j. Select SeatBeltMateriaL 291
k. Click OK; then click Modify
CHAPTER 21
b e
c
f
d g
i
k
k
CHAPTER 21 399
Delete Imported Simulation Data and Some Incorrect

Contact Definitions
a. Under LSTC.H3.022908_Beta_RidigFE.50th.dat tree, right click Simulation; select Delete

b. Under LSTC.H3.022908_Beta_RidigFE.50th.dat tree, select DEFORM_5 through
BCTABLE (click and Shift click); right click and select Delete
c. Under eulerbagconstant new spiral simx.bdf tree, select BCPROP_1 through BCPROP
(click and Shift click); right click and select Delete
b c
CHAPTER 21
Check Duplicate ID’s
a. Tools: ID Management
b.Select Duplicate ID Manager
c. Click OK
c
CHAPTER 21 401
Create Contact Bodies

b. Name: Deform_2; click PSOLIDD_72_...; Ctrl click PSOLIDD_79_...; click Apply
c. Name: Deform_3; click PSOLIDD_49_...; Ctrl click PSOLIDD_50_...; click Apply
d. Name: Deform_4; click PSOLIDD_25_...; Ctrl click PSOLIDD_26_...;
Ctrl click PSOLIDD_28_...; Ctrl click PSOLIDD_29_...
Ctrl click PSOLIDD_268_...; Ctrl click PSOLIDD_269_...;
Click Apply
e. Name: Deform_5; click PSOLIDD_10_...; click Apply
c
b
b Pelvis c Axes
d e
e Ring Neck
d Ribs
CHAPTER 21
Create Contact Bodies (continued)
a. Name: Deform_6; click PSOLIDD_25_...; Ctrl click PSOLIDD_26_...;

click PSOLIDD_28_...; Ctrl click PSOLIDD_29_...;
click PSOLIDD_268_...; Ctrl click PSOLIDD_269_...; click Apply
b. Name: Deform_7; click PSOLIDD_65_...; click Apply
c. Name: Deform_8; click PSOLIDD_98_...; click Apply
d. Name: Deform_9; click PSOLIDD_263_...; click Apply
e. Name: Deform_10; click PSOLIDD_18_...; Ctrl click PSOLIDD_65_...;
Ctrl click PSOLIDD_269_...; click Apply
f. Name: Deform_11; click SeatBelt_Shell; click Apply
a b
b Torso
a Ribs Shoulder
c d
d Breast
c Plate Neck
e f
e Dummy f Seatbelt
CHAPTER 21 403
Create Contact Bodies (continued)
a. Name: Deform_12; click PSHELL_22468_...; click Apply

b. Name: Deform_13; click PSOLIDD_73_...; Ctrl click PSOLIDD_74_...;
c. Name: Deform_14; click PSHELL_2376_...; Ctrl click PSHELL_2377_...; click Apply
d. Name: Deform_15; click PSOLIDD_80_...; Ctrl click PSOLIDD_87_;
Ctrl click PSOLIDD_70_; Ctrl click PSOLIDD_71_; click Apply
e. Name: Deform_16; click PSOLIDD_65_...; Ctrl click PSOLIDD_72_...;
a b
a Chair b Lower Body
c d
d Hands Feet
c Frame
e
e Body
CHAPTER 21
Modify BCTABLE
a. Right click: BCTABLE_1; select Properties

b. # NGROUP = 10
c. Click # NGROUP
Group 0 : Airbag - Airbag (Imported) (not shown)
Group 1 : Pelvis - Leg Bones
d. Double click +c19 IDSLAV,1
e. Click and select Deform2_2; click OK
f. Click +c19 FRIC,1, enter 0.3
g. Click +c25 METHOD,1, select SS2WAY
h. Click +c27 SOFT,1, select 2
i. Click +c29 SFS,1, enter 1; click +c29 SFM,1, enter 1;
click +c29 AUTO,1, select Yes
j. Double click +c36 IDMA,1
k. Click and select Deform3_3; click OK
Continue with Groups 2 through 9 (see the following page)
l. Click Modify
CHAPTER 21 405
a
c b
e d f
k j
l
CHAPTER 21
Modify BCTABLE (continued)
Contact: Contact Table -> BCTABLE
Contact GROUP IDSLAVE FRIC Method SOFT SFS SFM AUTO IDMA
airbag 0 1 0.3 ss2way 2 1 1 yes 1
Pelvis 1 2 0.3 ss2way 2 5 5 yes 3

bones
Ring plate 2 5 0.45 ss2way 2 1 1 yes 8

neck
Ribs torso 3 4 0.3 ss2way 2 1 1 yes 7
Ribs 4 6 0.3 ss2way 2 1 1 yes 9

breast
Airbag 5 1 0.3 ss2way 2 1 1 yes 10

dummy
seatbelt 6 11 0.3 blanks 2 1 1 yes 16

dummy
Dummy 7 13 0.3 ss2way 2 1 1 yes 12

chair
Dummy 8 15 0.3 ss2way 2 1 1 yes 14

frame
Airbag 9 1 0.3 ss2way 2 1 1 yes 14

Frame
CHAPTER 21 407
Define SPCD2 for Chair-ground-frame
a. Fields/Tables: Tabled: TABLED1

b. Click Add twice to make two rows
c. In Row 1, for X, enter 0.; for Y, enter 0.0; in Row 2, for X, enter 1000.; for Y, enter 0.0
d. Click Create
e. Click Exit
d e
CHAPTER 21
Define SPCD2 for Chair-ground-frame (continued)
a. Click LBC, select Part BC, select B Presc Motion Rigid

b. Right click Part, select Material
c. Click [020] MAT_RIGID
d. Ctrl click PSHELL_2468_Body_Final.bdf,
PSHELL_2377_Body_Final.bdf,
PSHELL_2376_Body_Final.bdf
e. Click Done
f. Click D1, D2, D3, D5, D6, D7
g. Click SPCD2
h. Double click LCID
i. Click TABLED_62 62; click OK
j. Click Store
k. Click Exit
l. Click Exit
d
e f
h
g
i j k
CHAPTER 21 409
Initial Dummy Velocity
a. Right click LSTC.H3..., click Show Only

b. Click LBC, select Nodal BC, click Initial Transient Condition
c. Click Define App Region
d. Using the mouse, select the complete dummy in the window
e. Click XVEL, enter -15
f. Click Create
g. Click Exit2
d
c
f g
CHAPTER 21
a. In the Model Browser, right click eulerbagconsta.......

c. Click Solver Input File
d. For File name:, enter Chapter21
e. Click Save
f. Click OK
g. Observe that there is a Newjob in the Model Browser tree
a
b
g f
d e
CHAPTER 21 411
a. In the Model Browser under Newjob, right click Displacement Output Request
and click Delete
b. In the Model Browser under Newjob, right click Element Output Request
and click Delete
c. In the Model Browser under Newjob, right click Loadcase Control
and click Properties
d. For Ending Time:, enter 40
e. For Number of Time Steps:, enter 20
f. Click Apply
c
a
b
d
e
f
CHAPTER 21
Export the SimXpert Analysis File
a. In the Model Browser under Newjob, right click Newjob

b.Click Export
Analysis Deck Corrections

This step becomes obsolete as soon as the following CR’s are solved:
CR 1-136647181 : BCTABLE issues Airbag-Dummy
CR 1-192117741 : Incorrect numbering Seatbelt elements
Edit Chapter21.bdf and modify the following values:
Row 12 : BCONTACT = 1
1234567$1234567$1234567$1234567$1234567$1234567$1234567$
Row 39833 : CBELT 50001 2470 79297 80456 0 0.0
Row 39834 : CBELT 50002 2470 79267 80457 0 0.0
CHAPTER 21 413
Run MD Nastran Solver
a. Double click the desktop icon

b. For the input file, select Chapter21.bdf
c. Click Open
d. Click Run
b
a
d
CHAPTER 21
Access the MD Nastran Analysis Results File

Access the results by attaching the d3plot file.

b. Click File Path icon
c. Select Chapter21.dytr.d3plot
d. Click Open
e. Click OK
a
b
Note: If SimX can’t access the results, do the following:

File -> Save
File -> New
File –> Attach Results
Attach Options: BOTH
OK
CHAPTER 21 415
Access the MD Nastran Analysis Results File (continued)

Change the model visualization.
a. Right click Model Views; click Right

b. Right click on the vertical line (wall); click Hide
c. Right click Render; click FE Shaded with Edges
d. Click Hide Unreferenced nodes
c d
CHAPTER 21
Animate a Deformed Plot

Create a deformed plot with animation
a. Results: Deformation
b. To select all Result Cases, click ch21a.dytr
c. Result type: select Displacement Components
d. Click Deformation
e. For Deformed display scaling, select True
f. For Deformed shape, Render style, select Shaded
g. For Deformed shape, Edge color, select cyan
h. Click Plot Data
i. Click Animate
j. Click Update
j
c
i b
Updated (Deformed)
Original e
f
g
CHAPTER 21 417
Animate a Deformed Plot (continued)

Animation
a b
c d
e f
CHAPTER 21
Input File(s)
File Description
Chapter21.dat MD Nastran input file for airbag FSI
example
Body_Final.bdf Frame model
eulerbagconstant_new_spiral_simx.bdf Airbag model
LSTC.H3.022908_Beta_RigidFE.50th.dat Dummy model
Animation
Click on the figure below to play the animation, Esc to stop.
Figure 21-2 Deployment of Airbag Animation

Chapter 22: Multi-Compartment Side Curtain Airbag Deployment
Multi-compartment Side
22 Curtain Airbag Deployment

Summary 420

Introduction 421


Airbag Analysis Scheme 421

FEM Solution 421

Results 423

Input File(s) 424
CHAPTER 22
Summary
Title Chapter 22: Multi-compartment Side Curtain Airbag Deployment
Features Deploy Multi-compartment Side Curtain Airbag
Geometry Fix
Gas supply bag
Compartment
2m
= 0.75
gth
Len
Inflator
Material properties See Summary of Materials.

Analysis type Transient explicit dynamic analysis
Boundary conditions Fixed at brackets
Applied loads Prescribed pressure and temperature of inflator gas
Element type Airbag: 2-D triangular shell element
Airbag gas: 3-D solid element (automatically generated)
FE results
Heigh
t = 0.3
60 m
CHAPTER 22 421
Multi-compartment Side Curtain Airbag Deployment
Introduction
.The purpose of this example is to demonstrate the simulation of a multi-compartment airbag; a capability is introduced
in MD Nastran SOL 700 (SOL 700). AIRBAG, GRIA, and EOSGAM are added in Bulk Data entries to support the
capability.
Requested Solutions
The airbag has five compartments. These compartments are folded, and each compartment is connected to the gas
supply bag through a large hole. An inflator is modeled next to the gas supply bag. The gas jet is initiated from the
inflator and running into the gas supply bag. Fixed boundary conditions are applied to the brackets attached to the gas
supply bag. The simulation time is 0.04 seconds.
Airbag Analysis Scheme
MD Nastran SOL 700 Airbag Model (bdf)
SOL 700
Obtain Binary Results

- Deformation (AIRBAG)
- CFD result (GAS)
FEM Solution
The units of this model are kg for weight, meter for length, second for time, and Kelvin for temperature.
TSTEPNL describes the number of Time Steps (100) and Time Increment (0.0004 seconds) of the simulation. End time
is the product of the two entries. Notice here, the Time Increment is only for the first step. The actual number of Time
Increments and the exact value of the Time Steps are determined by SOL 700 during the analysis. The step size of the
output files is determined by the Time Increment as well.
TSTEPNL 1 100 .0004 1 ADAPT 2 10
CHAPTER 22
One inflator and five compartment AIRBAG entries are defined. An AIRBAG entry instructs SOL 700 to create an
airbag using either the CFD method (full gas dynamics) or using a uniform gasbag method. Here, the full gas dynamic
method is used for all airbag definitions. Inflow of gas into the airbag is defined by the entries following the INFLATOR
key word. Outflow is defined by adding LARGHOLE to the inflator which is connected to the five different compartment
airbag. Details of an AIRBAG entry are described below:
Airbag 1 is the definition of the inflator airbag.
The CFD option defines CFD related data. Gamma law equation of state is defined referring the EOSGAM 3 field.
AIRBAG 1 25 +
+ CFD 3 1.527 0.009 0.009 0.009 +
Using the INITIAL option, initial conditions of gas property inside an airbag are defined. Initial pressure is 101,325
N/m2, initial temperature is 293 K, initial gamma gas constant is 1.4 and initial R gas constant is 294 N·m2/s2/K.
+ INITIAL 101325. 293. 1.4 294. +
The INFLATOR option is used to define gas property from an inflator. Mass flow rate is defined referring a table data
(TABLED1). Temperature of inflowing gas is 350 K, a scale factor of available inflow area is 0.7, the gamma gas
constant of the inflator gas is 1.557, and the R gas constant of the inflator gas is 243 N·m2/s2/K.
+ INFLATOR1001 1 350. 0.7 +
+ 1.557 243. +
The LARGEHOLE option defines the compartment location where gas flows into. In the example below, the first field,
LARGHOLE 301 indicates that gas flows through surface 301 into the compartment with ID 2. A scale factor of inflow
area is 1.0, meaning that 100% of the gas flows in. Five LARGEHOLE‘s definitions are used to model the gas flow inside
the five airbag compartments.
+ LARGHOLE301 2 1.0 +
+ LARGHOLE302 3 1.0 +
+ LARGHOLE303 4 1.0 +
+ LARGHOLE304 5 1.0 +
+ LARGHOLE305 6 1.0
AIRBAG entries from 2 to 6 define the compartments in the airbag.
AIRBAG 2 35 +
+ CFD 3 1.527 0.011 0.011 0.011 +
+ INITIAL 101325. 293. 1.4 294.
EOSGAM defines the ideal gas inside the airbag. This entry is used for each airbag definition. The gamma law gas
equation of state is defined by EOSGAM. The pressure p is defined as:
 =   – 1   e
where  is a constant, e is specific internal energy per unit mass,  is overall material density. A  constant of 1.517
and R gas constant of 226.4 m2/s2/K are used in this model.
CHAPTER 22 423
Multi-compartment Side Curtain Airbag Deployment
EOSGAM 3 1.517 226.4

The GRIA entry defines the final unstretched configuration of a deployed bag. All ID’s of GRIA entries must be the
same as the ID’s of GRID entries.
GRIA 1 .0009375-.626128 .230000
...
Summary of Materials
Inflator airbag: fabric material (MATD034):
 density= 783 kg/m3
Ea (Young’s Modulus - longitudinal direction) = 2.6e+08
Eb (Young’s Modulus - transverse direction) = 2.6e+08
a (Poisson’s ratio - longitudinal direction) = .3
b (Poisson’s ratio – transverse direction) = .3
Compartment airbag: null material (MATD009):

 density= 783 kg/m3
E (Young’s Modulus) = 2.6e+08
 (Poisson’s ratio) = .3
Initial condition of airbag gas:

 density) = 1.527 kg/m3
Initial temperature = 293 K
Initial pressure = 101,325 N/m2
Initial gamma gas constant = 1.4
Initial R gas constant = 294 N·m2/s2/K
Results
There are two types of results files: ARC and d3plot. The ARC file is the original MSC.Dytran binary result file and
includes the results for the Euler elements (fluid). d3plot is the native LS-DYNA result file format.
CHAPTER 22
t=0 t=2
t=4 t=6
t=8 t = 10
t = 20 t = 30
Airbag Euler
Deformed Shape Adaptive Mesh
t = 40 Time (ms)
Figure 22-1 Deformed Shape Airbag and Adaptive Euler Mesh
Input File(s)
File Description
nug_22.dat MD Nastran input file for multi-compartment airbag FSI example
Chapter 23: Bolted Plates
23 Bolted Plates

Summary 426

Introduction 427


FEM Solutions 429

Modeling Tips 436

Input File(s) 436

Video 437
CHAPTER 23
Summary
Title Chapter 23: Bolted Plates
Contact features • Deformable-deformable contact
• No friction
Geometry Units: mm
Large plate 60x20x6
Small plate 20x20x2
Bolt hole radius = 5
Bolt shaft radius = 4
Bolt head radius = 6 Y
Z
Bolt head thickness = 2 Z X
X Y
Nut thickness = 2 1 4
Nut outer radius = 6
Material properties E plates = 210kN  mm 2 , E bolt = 21kN  mm 2 ,  plates =  bo lt = 0.3 ,  plates = 10 C

–5 –1
, Linear
elastic material
Boundary conditions Small plate is supported at one side. Normal contact conditions applied between the two
plates and between the large plate and the bolt, glued contact between the small plate and
the nut. Rigid rotation and translation of the plates is suppressed
Applied loads Load step 1: Bolt is fastened by pre-tension force F = 200N .
Load steps 2-4: Cyclic loading of plates. Two different cases:
• uniform pressure P = 0.125MPa
• thermal load, temperature increase T = 50C
Element type 3-D solid 8-node linear elements
FE results 1. Deformed shape and von Mises stress distribution
2. Plot of bolt forces
CHAPTER 23 427
Bolted Plates
Introduction
A small and a large steel plate are bolted together. Initially, the smaller plate is in full contact on one side with the
larger plate. The opposite side of the smaller plate is supported. Furthermore, the bolt head is touching the larger plate
and the nut is glued to the smaller plate. It is assumed that the material behavior for both the plates and the bolt is linear
elastic.
In the first load step, the bolt is fastened by applying a pre-tension force ( F = 200N ) to the bolt in the basic Z-direction.
In three subsequent load steps, the bolt is locked (that is, further shortening of the bolt is suppressed) and the plates
are subjected to cyclic loads. Two types of loads will be presented: a mechanical load that consists of a uniform
pressure equal to P = 0.125MPa applied to the larger plate and a thermal load in which temperature of the plates is
increased by T = 50C .
Two solutions, one involving a uniform pressure equal to P = 0.125MPa applied to the larger plate and one involving
a temperature increase by T = 50C of the two plates, are:
• Bolt shortening during fastening in the first load step
• Bolt forces during the loading cycle
• Bolt stresses
• Bolt modelling
• That the bolt force is largely unaffected by the applied pressure to the larger plate
• That the bolt force increases with increasing temperature of the plates, due to thermal expansion
The analysis results are presented with linear elements.
Bolt Modeling
In various engineering applications, it is necessary to define a pre-stress in, for example, bolts or rivets before applying
any other structural loading. A convenient way do this is via multi-point constraints. The idea is to split the element
mesh of the bolt across the shaft in two disjoint parts, such that duplicate grid points appear at the cut, and to connect
the duplicate nodes again by multi-point constraints (see Figure 23-1). The constraints are chosen such that an overlap
or a gap can be created between the two parts in a controllable way. If the motion of the parts is somehow constrained
in the direction in which the gap or overlap is created, then an overlap (a “shortening” of the bolt) will introduce a
tensile (pre-)stress in each of the parts and a gap (an “enlongation” of the bolt) will result in a compressive stress.
The multi-point constraints have one slave and two master grid points. The slaves are the grid points at the cut from
the bottom part of the bolt (see Figure 23-1). The first master grids are the corresponding grid points from the top part
of the bolt on the other side of the cut. The second master in the constraints is a unique third grid point, called the
control grid point of the bolt. This is often a free grid point (that is, not part of the element mesh) and is shared by all
multi-point constraints on the cut.
CHAPTER 23
top part top part Fcontrol
top grids mesh split F1,bot F2,bot

(first master) MPCs ucontrol
u1,bot u2,bot
(overlap) ucontrol
control grid
(second master) u1,top u2,top
bottom grids
(slave) F1,top F2,top
bottom part bottom part
undeformed deformed
Figure 23-1 Pre-stressing a Structure by Creating an Overlap Between the Top and the Bottom Part
Using Multi-Point Constraints.
The multi-point constraints impose the following constraint equations on the model:
u bo t – u t op – u control = 0 .
in which u bo t , u top and u control are the displacement degrees of freedom of a grid point from the bottom part, its
corresponding grid from the top part and the control grid point, respectively. It immediately follows from this equation
that u control is the displacement difference of the bottom and top grids and is equal to the size of the overlap or gap
between the parts. Hence, by enforcing the displacements of the control grid point, an overlap or gap of a particular
size can be created between the two parts.
It can be shown (see, for instance, MSC.Marc 2010 Volume A: Theory and User Information, Chapter 9, Section
“Overclosure Tying”), that if the multi-point constraints are set up as outlined above, the force on the control grid
point equals the sum of the forces on the grid points from the bottom part as well as minus the sum of the forces on
the grid points from the top part:
F control =  F bot = –  F top .
Hence, the force on the control grid point is the total force on the cross-section of the bolt. By applying a (pre-tension)
force to that grid point, the total force on the cross-section can be prescribed. Moreover, if the shortening of the bolt
is prescribed via an enforced displacement on the control grid point, then the reaction force on that grid point is equal
to the total force on the cross-section of the bolt.
Note that both types of boundary conditions on the control grid point can be combined in a single analysis as
demonstrated in this example. In the first load step, the pre-tension force will be applied to the control grid point of
the bolt. This results in a certain amount of shortening of the bolt. At the end of the first load step, the amount of
shortening is recorded and is kept constant in subsequent load steps, via a single point constraint on the control grid
point.
CHAPTER 23 429
Bolted Plates
Grid 1903
Bolt
Large Plate
Small plate
Nut
Figure 23-2 Element Mesh and Multi-Point Constraints applied in Target Solution with MD Nastran
Note: The gap between the top and bottom parts of the bolt in the picture on the right is purely for visualization
purposes. In reality, the gap is closed although the duplicate grids remain.
There are two ways to define the multi-point constraints for bolt modeling in the bulk data: each constraint can be
defined explicitly via the MPC option or the entire set of constraints can be defined via the BOLT option. The latter has
been designed specially for bolt modeling and has several advantages over explicit MPCs:
• Provides a much more concise input than explicit MPCs;
• Generates all the required multi-point constraints on all displacement and rotational degrees of freedom
automatically;
• Ensures continuity of the temperature field across the cut in the thermal passes of coupled analyses;
• Requires no special provisions in a contact analysis (see below).
FEM Solutions
A numerical solution has been obtained with MD Nastran’s SOL 400 for the element mesh shown in Figure 23-2 using
3-D solid linear elements. The bolt and the nut are assumed to be rigidly connected and are modeled as a single
physical body. To fasten the bolt, the element mesh of the bolt is split into two parts across the shaft and the 41 grid
point pairs on both sides of the cut are connected by multi-point constraints of the form discussed in the preceding
section. Grid ID 1903 acts as the control grid of the bolt.
Two versions of the input are considered. In the first version, the BOLT option is used to generate the multi-point
constraints on the cut. In the second version, the constraints are defined explicitly via the MPC option.
The BOLT option requires a bolt ID (5000), the ID of the control grid of the bolt (1903) and the grids at the cut from
the top and bottom parts of the bolt. The latter must be entered pair-wise in the TOP and BOTTOM section of the option:
the i-th TOP grid should correspond to the i-th BOTTOM grid.
BOLT 5000 1903
CHAPTER 23
TOP 1862 1863 1864 1865 1866 1867 1868

1869 1870 1871 1872 1873 1874 1875
1876 1877 1878 1879 1880 1881 1882
1883 1884 1885 1886 1887 1888 1889
1890 1891 1892 1893 1894 1895 1896
1897 1898 1899 1900 1901 1902
BOTTOM 341 353 365 377 389 401 413
425 437 449 461 473 485 497
1394 1406 1418 1430 1442 1454 1466
1478 1490 1502 1572 1584 1596 1608
1620 1632 1644 1656 1668 1680 1747
1759 1771 1783 1795 1807 1819
The equivalent input using explicit MPCs reads:

MPC 1 341 1 1.0 1862 1 -1.0
1903 1 -1.0
MPC 1 341 2 1.0 1862 2 -1.0
1903 2 -1.0
MPC 1 341 3 1.0 1862 3 -1.0
1903 3 -1.0
MPC 2 353 1 1.0 1863 1 -1.0
1903 1 -1.0
MPC 2 353 2 1.0 1863 2 -1.0
1903 2 -1.0
MPC 2 353 3 1.0 1863 3 -1.0
1903 3 -1.0
...
$
MPCADD 100 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31
32 33 34 35 36 37 38 39
40 41
Contact
The main problem with the use of explicit MPCs is that in a contact analysis, the constraints may conflict with the
multi-point constraints due to contact. Special provisions have to be made in the contact setup to avoid that the slave
grids of the MPCs can come in contact with other contact bodies. Furthermore, due to the cut in the mesh, it is difficult
for grid points of other contact bodies that touch the bolt surface, to slide across the cut from the bottom part of the
bolt to the top part or vice versa. The BOLT option addresses both issues, provided that the two parts of the bolt are in
the same contact body. Conflicts with contact constraints are avoided and grid points that touch the surface of the bolt
can slide without difficulties across the cut.
For the present model, the two methods are compared. To avoid problems in the MPC version between the explicit
MPCs and the contact constraints, the radius of the bolt shaft is slightly smaller than the radius of the holes in the plates,
such that contact between the shaft and plates will not occur.
The three physical components of the model (the two plates and the bolt with the nut) have been selected as contact
bodies. The contact bodies are identified as the set of elements in the respective components:
$ contact body: bolt and nut
BSURF 1 167 168 169 170 171 172 173
...
$ contact body: small plate
CHAPTER 23 431
Bolted Plates
BSURF 2 139 140 141 142 143 144 145

...
$ contact body: large plate
BSURF 3 1 2 3 4 5 6 7
...
The two parts of the bolt are in same contact body (ID=1).
The BCTABLE entries shown below identify the admissible contact combinations, select the slave and master body for
each combination, and set associated parameters. It is important to note that:
• The first contact body (bolt and nut) must be selected as the slave (or contacting) body. Since the contact
algorithm detects contact between the grid points at the surface of the slave (or contacting) body and the faces
of the elements at the surface of the master (or contacted) body, the body with the finer element mesh in the
contact region generally should be selected as the slave body and the body with the coarser mesh as the
master, as this results in “more points in contact” and thus a better description of the contact conditions than
with the opposite definition. The ISEARCH entry is set to 1 to force search order from the slave body to the
master.
• The bolt can touch the plates and the plates can touch each other.
• The IGLUE entry is set to 1 for contact between the nut and the smaller plate to activate glued contact
conditions (that is, no sliding and no separation) between these two contact bodies.
BCTABLE 0 3
SLAVE 1 0. 0. 0. 1
1 0 0
MASTERS 2
SLAVE 1 0. 0. 0. 0
1 0 0
MASTERS 3
SLAVE 2 0. 0. 0. 0
1 0 0
MASTERS 3
BCTABLE 1 3
SLAVE 1 0. 0. 0. 1
1 0 0
MASTERS 2
SLAVE 1 0. 0. 0. 0
1 0 0
MASTERS 3
SLAVE 2 0. 0. 0. 0
1 0 0
MASTERS 3
Materials and Properties

The 3-D solid elements with large strain capability available on MD Nastran SOL 400 are chosen by the PSOLID and
PSLDN1 entries on the CHEXA option as shown below.
$ plates
PSOLID* 1 1
PSLDN1* 1 1
$
$ bolt and nut
PSOLID* 2 2
PSLDN1* 2 2
CHAPTER 23
The large strain capability and assumed strain formulation (for improved bending behavior) for these elements are
activated via the NLMOPTS option.
NLMOPTS ASSM ASSUMED
LRGSTRN 1
The two materials are isotropic and elastic with Young’s modulus, Poisson’s ratio and thermal expansion defined as:
$ plates
MAT1* 1 2.100000E+05 3.000000E-01
* 1.000000E+00 1.000000E-05
$ bolt and nut
MAT1* 2 2.100000E+04 3.000000E-01
Loads, Boundary Conditions and Load Steps

The loading sequence consists of four load steps. In the first load step. The pre-tension force in the basic Z direction
is applied to the control grid point of the bolt via a FORCE option, as follows:
$ bolt-force
FORCE 1 1903 0 200. 0. 0. 1.
At the end of the load step, the shortening of the bolt due to the applied pre-tension force is recorded and kept constant
in subsequent load steps by a single-point constraint on the displacement of the control grid in the basic Z direction:
$ bolt-lock
SPC1 5 3 1903
Throughout the analysis, the displacements of the control grid in the basic X and Y directions are suppressed by a
single-point constraint:
$ bolt-xy
SPC1 4 12 1903
In all four load steps, the full load is applied in a single increment. The nonlinear procedure used in the load steps is:
+ .01 .01
+ 0
Here, the PFNT option is selected to activate the pure Newton-Raphson iteration strategy. Convergence of the non-
linear iteration process is checked on both displacements and forces, using tolerances equal to 0.01.
Results
The shortening of the bolt due to the pre-tension force applied in the first load step is listed in Table 23-1. The solution
obtained with an equivalent MSC.Marc 2005r3 model is included for reference. This shortening is recorded at the end
of the first load step and kept fixed in the subsequent load steps. It is apparent from this table that the MPC version
and the BOLT version produce identical results.
CHAPTER 23 433
Bolted Plates
Table 23-1 Bolt Shortening During Fastening in the First Load Step
MD Nastran
MD Nastran (MPC) (BOLT) MSC.Marc 2005r3
bolt shortening 0.0054 0.0054 0.0054
Pressure Load
The pressure load is applied in a cyclic fashion to the large plate in the final three load steps. The plate is loaded in
load steps 2 and 4 and unloaded in load step 3. The deformed structure plot (magnification factor 500) as well as the
equivalent von Mises stress distribution at the end of the final load step are shown in Figure 23-3. A plot of the bolt
force in the basic Z direction is depicted in Figure 23-4. Note that in the first load step, the bolt load is the externally
applied pre-tension force; whereas in subsequent load steps, the bolt load is the reaction force on the control grid point.
Figure 23-3 Deformed Structure Plot and von Mises Stress Distribution at Maximum Load Level Due to
the Pressure Load (magnification factor = 500)
CHAPTER 23
200 n n n
n
150
Bolt Force [N]
100
50
MSC.Marc 2005 r3
MD Nastran n
0
1 2 3 4
Load Step
Figure 23-4 Bolt Forces During Loading Cycle by Pressure Load.
In Figure 23-4, the MD Nastran solution (blue dots) is compared with the solution obtained by MSC.Marc 2005 r3
(the solid line). The good agreement between the two solutions is apparent.
This plot demonstrates the well-known fact that the bolt force is unaffected by the pressure applied to the plate. Due
to a slight bending of the larger plate under the pressure load, however, the bolt force is not exactly constant.
CHAPTER 23 435
Bolted Plates
Thermal Load
The thermal load is applied in a cyclic fashion to both plates. The plates are heated in load steps 2 and 4 and cooled
down in load step 3. The deformed structure plot (magnification factor 100) as well as the equivalent von Mises stress
distribution at the end of the final load step are shown in Figure 23-5. A plot of the bolt force in the basic Z direction
is shown in Figure 23-6. Again, the MD Nastran solution (blue dots) is compared with the solution obtained by
MSC.Marc 2005 r3 (the solid line) and the agreement of the two solutions is apparent.
Figure 23-5 Deformed Structure Plot and von Mises Stress Distribution at Maximum Load Level Due to
the Thermal Load (magnification factor = 100)
n n
300
250
200 n n
Bolt Force [N]
150
100
50
MSC.Marc 2005 r3
MD R2 Nastran n
0
1 2 3 4
Load Step
Figure 23-6 Bolt Forces During Loading Cycle by Thermal Load.

CHAPTER 23
In this load case, the bolt force increases with increasing temperature due to thermal expansion of the plates. It
decreases again to the pre-stress force after cooling down.
Modeling Tips
Multi-point constraints provide a convenient way to fasten bolts. Either the shortening of the bolt or the total force in
the cross-section of the bolt can be controlled via enforced displacements or forces on the control grid point of the bolt.
These two types of boundary conditions can be combined in one simulation in which the bolt is first pre-stressed and
then loaded by other mechanical or thermal loads.
The BOLT option provides a convenient way to generate the required multi-point constraints. It can be used
conveniently in a contact analysis, provided that the two parts of the bolt are in the same contact body.
Input File(s)
File Description
nug_23p_bolt.dat Bolt pre-tension followed by cyclic pressure load (BOLT version)
nug_23p.dat Bolt pre-tension followed by cyclic pressure load (MPC version)
nug_23t_bolt.dat Bolt pre-tension followed by cyclic thermal load (BOLT version)
nug_23t.dat Bolt pre-tension followed by cyclic thermal load (MPC version)
CHAPTER 23 437
Bolted Plates
Video
Units: mm
Large plate 60x20x6
Small plate 20x20x2
Bolt hole radius = 5
Bolt shaft radius = 4
Bolt head radius = 6 Y
Z
Bolt head thickness = 2 Z X
X Y
Nut thickness = 2 1 4
Nut outer radius = 6

Chapter 24: Friction Between Belt and Pulley
Friction Between Belt

24 and Pulley

Summary 439

Introduction 440



FEM Solutions 441

Modeling Tip 444

Input File(s) 446

Video 446
CHAPTER 24 439
Friction Between Belt and Pulley
Summary
Title Chapter 24: Friction Between Belt and Pulley
Contact features • (Slightly) changing contact area
• Deformable-deformable and deformable-rigid contact
• Friction between deformable bodies
Geometry 3-D (units: mm)
R
• Pulley outer radius = 0.55 ϕ
• Pulley inner radius = 0.25 r2
r1
• Out of plane pulley thickness = 0.3
• In plane belt thickness = 0.05
• Out of plane belt thickness = 0.2 y
• Initial angle spanned = /2 rad t
z x
F
Material properties 13 10
E pulley = 1.0 10 Pa E belt = 1.0 10 Pa  pulley =  belt = 0.3
Boundary conditions An 180o section of the pulley is modeled, which is clamped along the inner radius using
“glued” contact conditions. On both ends of the belt, load-controlled rigid bodies are
defined and connected to the belt using “glued” contact conditions. The forces F and R
are external and reaction forces on the control nodes. On the loaded control node we have
u x = u y = 0 , while on the other control node u x = u y = u z = 0 .
Applied loads Point load F y = – 1.0 105 N

Element type 3-D 20-node hexahedral solid elements
Contact properties Different coefficients of friction between belt and pulley:  = 0.05 ,  = 0.15 and
 = 0.25
FE results Reaction force for each value of the friction coefficient

CHAPTER 24
Introduction
A belt is positioned around a pulley such that a 90o section of the pulley is contacted. One end of the belt is fixed; the
other end is loaded by a tensile force with magnitude F = 1.0 105 . It is assumed that the material behavior for both the
belt and the pulley is linear elastic. Although this problem can be solved by a 2-D approximation, a full 3-D model is
chosen here in order to show the characteristic behavior of 3-D parabolic hexahedral elements in a contact analysis
involving friction. An analytical solution for the case with Coulomb friction is known.
Requested Solutions
Analyses will be carried out for three different values of the friction coefficient:  = 0.05 ,  = 0.15 , and  = 0.25 .
With a constant value of the applied load, the reaction force will decrease for increasing values of the friction
coefficient. This reaction force is the primary requested quantity, as this can be easily compared with an analytical
solution.
Analytical Solution
Assuming Coulomb friction between the belt and the pulley, the principle of rope friction according to the Euler-
Eytelwein formula provides a relation between the magnitude F of the applied force, the magnitude R of the reaction
force, the angle  spanned by the belt and the friction coefficient  between the belt and the pulley:
F
R = --------

e
With F = 1.0 105 and  = --- , the theoretical value of the magnitude of the reaction force R is listed in Table 24-1 for
2
various values of the friction coefficient  .
Table 24-1 Reaction Force for Various Values of the Friction Coefficient (Theory)
Friction Coefficient  Reaction Force R
0.05 9.2447x104
0.15 7.9008x104
0.25 6.7523x104
CHAPTER 24 441
FEM Solutions
Numerical solutions have been obtained with MD Nastran’s SOL 400 for the element mesh shown in Figure 24-1 using
3-D 20-node hexahedral elements. Assuming that the deformations of the pulley are small and localized around the
contact area, only an 180o section has been modeled. In total, there are five contact bodies: two deformable and three
rigid. The rigid bodies will be used to easily apply the boundary conditions (single point constraints and forces).
load controlled
rigid body
fixed rigid body;

glued contact
load controlled
rigid body
Figure 24-1 Element Mesh applied in MD Nastran Simulation
The first deformable body consists of all elements of the belt, where the second deformable body consists of all
elements of the pulley. The body number ID’s of the belt and the pulley are 1 and 2, respectively. These deformable
contact bodies are identified as 3-D bodies referring to the BSURF IDs 1 and 2:
BSURF 1 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31
32 33 34 35 36 37 38 39
40 41 42 43 44 45 46 47
48 49 50 51 52 53 54 55
56 57 58 59 60 61 62 63
64 65 66 67 68 69 70 71
72 73 74
BSURF 2 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89
90 91 92 93 94 95 96 97
98 99 100 101 102 103 104 105
106 107 108 109 110 111 112 113
114 115 116 117 118 119 120 121
122 123 124 125 126 127 128 129
130 131 132 133 134
CHAPTER 24
The first rigid body is a half cylinder described as a NURBS surface and will be used to clamp the grids on the inner
radius of the pulley. Its body ID number is 3 and it is identified as:
0 0. 0. 0. 1. 0. 0. 0.
RIGID 0 1 RIG-INNER
NURBS -7 13 4 4 50 50 0
.176777 -.176777 0. .324015 -.029538 0.
.237263 .222631 0. .0306021.24812 0.
...
The second and the third rigid bodies are load controlled rigid bodies. A load controlled rigid body is associated with
a control grid, which can be used to apply forces and/or single point constraints. In the current analysis, two flat load
controlled rigid bodies are used. They will be glued to both ends of the belt and their control grids will be used to
prevent a rigid body motion in the basic z-direction, to apply the external force on the belt and to transfer the belt load
to the fixed control grid. The load controlled rigid bodies are identified as:
0 0. 0. 0. 1. 0. 0. 0.
RIGID 526 1 RIG-R
NURBS -2 2 2 2 50 50 4
-.2 .6 .05 -.2 .55 .05
-.2 .6 .25 -.2 .55 .25
...
0 0. 0. 0. 1. 0. 0. 0.
RIGID 527 1 RIG-F
NURBS -2 2 2 2 50 50 4
.55 -.2 .05 .6 -.2 .05
.55 -.2 .25 .6 -.2 .25
...
Note that the control grids have the IDs 526 and 527.
The BCTABLE option will be used to indicate:
• which grids are to be treated as slave nodes and which as master grids in the multipoint constraints for
deformable-deformable contact;
• the friction coefficient between the belt and the pulley;
• glued contact between the pulley and the half cylinder;
• glued contact between the load controlled rigid bodies and the belt.
The entries of the BCTABLE option are defined as:
BCTABLE 1 4
SLAVE 1 0. 0. .05 0. 0 0.
1 0
MASTERS 2
SLAVE 1 0. 0. 0. 0. 1 0.
0 1 0
MASTERS 5
SLAVE 1 0. 0. 0. 0. 1 0.
0 1 0
MASTERS 4
SLAVE 2 0. 0. 0. 0. 1 0.
0 1 0
MASTERS 3
CHAPTER 24 443
The first SLAVE MASTERS combination indicates that the grids of deformable body 1 are treated as slave grids when
contact is established with body 2. The friction coefficient is set to 0.05.
The other SLAVE MASTERS combinations activate glued contact between the bodies with body ID numbers 1 and 5,
1 and 4, and 2 and 3, respectively.
The bilinear Coulomb friction model will be activated using the BCPARA option (FTYPE = 6); this option is also used
to indicate that the separation behavior is based on stresses (IBSEP = 4), which is necessary in a contact analysis
involving quadratic elements:
BCPARA 0 NBODIES 5 IBSEP 4 FTYPE 6
In order to activate the full nonlinear formulation of the 20 node hexahedral elements, the nonlinear property extension
of the PSOLID entry is used. For the materials defining the belt (material ID number 1) and the pulley (material ID
number 2), this results in:
MAT1 1 1.+9 .3 1.
MAT1 2 1.+13 .3 1.
PSOLID 1 1 0
PSLDN1 1
PSOLID 2 2 0
PSLDN1 2

NLPARM 1 1 FNT 1 25 UPW YES
1.e-4 1.e-4 1.e-4 10
Here the FNT option is selected to update the stiffness matrix during every recycle using the full Newton-Raphson
iteration strategy. Convergence checking is performed based on displacements, forces and work. The error tolerance
is set to 10-4 for all criteria. Note that the MAXDIV field is set to 10 to avoid that bisections occur, since too many
bisections may increase the overall solution time.
The obtained values of the reaction forces are listed in Table 24-2, together with the relative error compared to the
analytical solution. The numerical and analytical solutions turn out to be in good agreement.
Table 24-2 Numerical Solutions and Relative Errors

Friction Coefficient  Reaction Force R Error (%)
0.05 9.2314x104 0.14
0.15 7.9476x104 0.59
0.25 6.8448x104 1.37
CHAPTER 24
Modeling Tip
Convergence Behavior
A nonlinear analysis involving contact and friction may need several iterations to fulfil the convergence requirements.
In such inherently nonlinear analyses, it may be advantageous to increase the number of criteria needed to force a
bisection. As discussed above, this number (MAXDIV on the NLPARM option) has been set to 10 instead of the default
value 3. The tables below show the convergence behavior with the increased value (Table 24-3) and the default value
(Table 24-4). The increased value clearly reduces the overall number of Newton-Raphson iterations and thus the
analysis wall time. When looking at Table 24-3, iteration 9 reaches displacement, load and work errors which are
within the required tolerances. The extra iterations needed are caused by the fact that some grids of the belt which are
initially in contact with the pulley, separate because of tensile contact stresses. After separation of these grids, a new
solution with a smaller number of contact constraints has to be found.
Table 24-3 Convergence Behavior with MAXDIV=10 (

Load Factor Step Iteration Disp. Error Load Error Work Error
1.000 1 1 1.00E+00 1.70E-01 1.70E-01
1.000 1 2 7.76E+00 3.54E-01 1.58E+00
1.000 1 3 6.61E+02 2.31E+01 6.17E+02
1.000 1 4 2.12E+02 1.80E+02 1.30E+04
1.000 1 5 8.61E-02 2.78E+01 7.33E+00
1.000 1 6 3.12E-03 1.70E-01 4.67E-02
1.000 1 7 2.60E-04 4.31E-03 3.50E-03
1.000 1 8 7.87E-06 4.09E-05 1.34E-04
1.000 1 9 3.92E-06 9.30E-07 5.09E-05
1.000 1 10 3.39E+00 1.41E-02 4.30E+00
1.000 1 11 4.26E-02 2.05E-03 6.67E-01
1.000 1 12 2.42E-03 3.31E-02 3.33E-02
1.000 1 13 8.19E-06 2.26E-05 1.30E-04
1.000 1 14 4.93E-06 1.61E-06 6.57E-05
CHAPTER 24 445
Table 24-4 Convergence Behavior with MAXDIV=3 (

Load Factor Step Iteration Disp. Error Load Error Work Error
1.0000 1 1 1.00E+00 1.70E-01 1.70E-01
1.0000 1 2 7.76E+00 3.54E-01 1.58E+00
1.0000 1 3 6.61E+02 2.31E+01 6.17E+02
1.0000 1 4 2.12E+02 1.80E+02 1.30E+04
0.5000 1 1 1.00E+00 9.36E-02 9.36E-02
0.5000 1 2 8.06E+02 2.96E-01 3.12E+02
0.5000 1 3 5.62E+02 3.36E+01 6.19E+02
0.5000 1 4 8.37E+01 8.70E+01 1.92E+02
0.5000 1 5 3.27E-02 1.91E+00 8.84E-02
0.5000 1 6 8.88E-04 2.22E-02 2.19E-03
0.5000 1 7 1.27E-04 2.24E-04 2.84E-04
0.5000 1 8 2.93E-06 6.83E-06 8.15E-06
0.5000 1 9 1.94E+00 1.02E-02 2.71E-01
0.5000 1 10 2.89E-02 1.31E-03 6.47E-02
0.5000 1 11 3.25E-04 7.79E-03 5.95E-04
0.5000 1 12 2.44E-05 8.00E-06 5.31E-05
1.0000 2 1 5.60E-01 2.26E-01 1.27E-01
1.0000 2 2 1.25E+02 2.32E+02 7.04E+03
0.7500 2 1 1.25E+02 2.32E+02 7.04E+03
0.6250 2 1 1.25E+02 2.32E+02 7.04E+03
0.5625 2 1 1.25E+02 2.32E+02 7.04E+03
0.5312 2 1 3.86E-01 6.06E-01 3.32E-01
... ... ... ... ... ...
... ... ... ... ... ...
0.9688 16 3 4.10E-03 1.92E-02 6.62E-03
0.9688 16 4 7.84E-05 4.16E-04 1.37E-04
0.9688 16 5 9.70E-06 4.13E-06 1.67E-05
1.0000 17 1 3.58E-02 5.91E-03 2.16E-04
1.0000 17 2 4.49E+00 7.24E-01 6.56E+00
1.0000 17 3 3.37E-03 1.27E-02 5.40E-03
1.0000 17 4 6.27E-05 2.93E-04 1.08E-04
1.0000 17 5 7.94E-06 2.83E-06 1.34E-05
CHAPTER 24
Input File(s)
File Description
nug_24_1.dat Friction coefficient 0.05
Video
Figure 24-2 Video of the steps above

Chapter 25: Modal Analysis with Glued Contact
Modal Analysis with

25 Glued Contact

Summary 448

Introduction 449


FEM Solutions 449

Modeling Tips 454

Input File(s) 454

Video 454
CHAPTER 25
Summary
Title Chapter 25: Modal Analysis with Glued Contact
Contact features • Glued Contact between two bodies with dissimilar meshes
• Stress Free Projection
• Contact tolerance bias factor = 0.0
Geometry • Shroud outside diameter = 0.46 m t
• Hub diameter = 0.26 m
• Width = 0.12 m
d2 d1
• Shroud thickness = 0.02 m
Material properties E = 210 10 Pa ,  = 0.3 ,  = 7850kg  m 3

9

Analysis type Modal analysis using SOL 103
Boundary conditions • Free-Free
• Glued contact between vanes and shroud
Applied loads None
Element type • 8-node hexahedral elements
• 10-node tetrahedral elements
FE results Natural frequencies and mode shapes
Mode Shape 7 @ 1,130 Hz Mode Shape 8 @ 1,131 Hz
Mode Shape 9 @ 1,168 Hz Mode Shape 10 @1,774 Hz

CHAPTER 25 449
Modal Analysis with Glued Contact
Introduction
The shrouded vanes shown in Figure 25-1, consisting of twelve vanes with a central hub and an outer shroud, uses
contact to join dissimilar meshes during a modal analysis. The hub and vanes contain higher-order tetrahedral elements
while the shroud has linear hexahedral elements. The glued contact parameters preclude separation after initial contact
and change the original coordinates of the nodes in contact to insure stress free contact between the dissimilar meshes.
Figure 25-1 Shrouded Vanes Model
Requested Solutions
The modal analysis assumes free-free boundary conditions and returns ten natural frequencies and their associated
mode shapes of which the lowest six correspond to rigid body motion.
FEM Solutions
An eigenvalue analysis has been performed with MD Nastran’s SOL 103 for the element mesh shown in Figure 25-2.
The vanes and the hub are modeled using higher order tetrahedral elements while the shroud is modeled using linear
hexahedral elements. Contact body ID 1 is identified as all the elements making the vanes and hub whereas contact
body ID 2 is identified as the elements making the shroud respectively as:
BSURF 1 10000 10001 10002 10003 10004 10005 10006
...
and
BSURF 2 100000 100001 100002 100003 100004 100005 100006
...
CHAPTER 25
Figure 25-2 FEA Mesh for the Shrouded Vanes Model
The BCTABLE entries shown below identify that these bodies are glued to each other:
BCTABLE 0 1
SLAVE 2 0. 0. 0. 0. 1
1 1 0
MASTERS 1
BCTABLE 1 1
SLAVE 2 0. 0. 0. 0. 1
1 1 0
MASTERS 1
The BCTABLE option shows that contact body ID 2, the shroud, has been selected as the touching body, the SLAVE,
whereas contact body ID 1, the vanes, has been selected as the touched body, the MASTERS. This selection is due to
the fact the average element size for the vanes in the contact area is slightly larger than that of the shroud as shown in
Figure 25-3. The IGLUE parameter of the BCTABLE option activates the glue option. The JGLUE parameter is turned
off to ensure that no nodes separate once in contact. Additionally, the ICOORD parameter is turned on to modify the
coordinates of the nodes in contact to ensure stress-free initial contact.
The BCPARA entries activate the quadratic contact option and indicate that a bias factor of 0 (actually a small nonzero
number of 1 x 10-16) has been selected:
IBSEP 2 BIAS 1.-16
CHAPTER 25 451
Figure 25-3 Relative Element Size Between the Shroud and Vanes in the Contact Area
The vanes and the shroud are both modeled using the same material. The material properties are isotropic and elastic
with Young’s modulus, Poisson’s ratio, and density defined as
$ Referenced Material Records
$ Material Record : inner_mat
$ Description of Material :
MAT1 1 2.1+11 .3 7.85+3
$ Material Record : outer_mat
MAT1 2 2.1+11 .3 7.85+3
The Lanczos procedure is selected for the real eigenvalue problem using the METHOD and EIGRL entries in which ten
modes are desired:
METHOD=13
...
EIGRL,13,,,10
The obtained modes are listed in Table 25-1. The first six modes are rigid body modes. Mode shapes 7 to 10 are shown
in Figure 25-4.
Table 25-1 Obtained Modes and Frequencies

Mode Frequency (Hz)
1 6.911939E-04
2 6.290693E-04
3 4.908829E-04
4 4.434468E-04
5 2.943299E-04
6 7.051053E-05
CHAPTER 25
Table 25-1 Obtained Modes and Frequencies (continued)

Mode Frequency (Hz)
7 1.130332E+03
8 1.131441E+03
9 1.168441E+03
10 1.774218E+03
Mode Shape 7 @ 1,130 Hz Mode Shape 8 @ 1,131 Hz
Mode Shape 9 @ 1,168 Hz Mode Shape 10 @1,774 Hz
Figure 25-4 Mode Shapes and Corresponding Frequencies

CHAPTER 25 453
To check the efficacy of gluing dissimilar messes on natural frequencies, Test 53 (Selected Benchmarks for Natural
Frequency Analysis, Abbassian, F, Dawswell, D J, and Knowles, N C, NAFEMS Ref R0015, 1987) was performed on
glued mesh below.
Title Simply-Supported Solid Annular Plate, Axisymmetric Vibration

Contact features Glued Contact between two bodies with dissimilar meshes
Stress Free Projection
Geometry and Mesh
Geometry A θ
R
A
o
Z α = 10
4.2 m
0.6 m
1.6 m
Gluing
Surface
Mesh
Material properties E = 200 10 Pa ,  = 0.3 ,  = 8000kg  m 3

9

Analysis type Modal analysis using SOL 103
Boundary conditions u = 0 for all nodes on axial planes of symmetry. u z = 0 along section AA
Element type 10-node tetrahedral elements, 20-node hexahedral elements
FE results
fref = 18.583 Hz fref = 140.15 Hz fref = 224.16 Hz
fMD = 18.666 Hz fMD = 140.03 Hz fMD = 224.56 Hz
z z r
R R R
Flexural Flexural Extensional
Mode 1 Mode 2 Mode 3
fref = 358.29 Hz fref = 629.19 Hz

fMD = 362.71 Hz fMD = 658.97 Hz
z z
R R
Flexural Flexural
Mode 4 Mode 5
CHAPTER 25
Modeling Tips
Glued contact with no separation ensures that nodes do not separate once in contact. Stress-free initial contact modifies
the coordinates of the nodes in contact to close any gaps between the two bodies. Quadratic contact allows midside
nodes to participate in the glued contact. Insuring that the dissimilar meshes join properly requires there are no
artificial stresses induced by nodes slightly off the contact surface, and the displacement field is completely continuous
across the contact surface.
This technique of “gluing” dissimilar meshes together facilitates faster model building by not requiring the meshes to
be contiguous across all nodes. Furthermore, as in this application example, joining different element types assists
modeling flexibility.
Input File(s)
File Description
nug_25_1.dat Linear Hexahedral and Parabolic Tetrahedral Elements
nug_25_2.dat Glued Annular Plates NAFEMS Test #53
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately two minutes and

Chapter 26: Interference Fit Contact
26 Interference Fit Contact

Summary 456

Introduction 457



FEM Solution 458

Modeling Tips 460

Input File(s) 460

Video 461
CHAPTER 26
Summary
Title Chapter 26: Interference Fit Contact
Contact features Deformable-deformable contact
Contact interference
Geometry • Valve insert inside radius, a = 15.5 mm
• Valve insert outside radius, b + h = 20 + 0.05 mm
• Cylinder head valve insert opening radius, b = 20 mm
a
b+h
CL
Material properties E head = 224 kN/mm

2
E seat = 125 kN/mm
2
 hea d = 0.26  s eat = 0.25

Boundary conditions • Some nodes on the periphery of the cylinder head are fixed
• Contact between cylinder head and valve insert includes an initial interference fit
Applied loads None
Element type 10-node tetrahedron elements
Contact properties Coefficient of friction  = 0.15 with an interference shrink of 0.050 mm.
FE results Plots of radial and hoop stresses versus radial distance from valve center
Radius (mm)
15 16 17 18 19 20 21 249166
0 246621 246815
A B 247999 B
246823 247587
-100 Radial Stress 248815
246622 A 246615
Radial Stress FEA
-200
248830 249221
Hoop Stress FEA
X Y, r
-300 Hoop Stress 246821 246816
Z
248019 248604
-400
246619 246617
-500 Stress (MPa) 248024 246820 248039
CHAPTER 26 457
Interference Fit Contact
Introduction
The interference fitting of a valve insert into a cylinder head recess is to be simulated. The general arrangement is
shown in Figure 26-1. The compressive interference between the valve insert external radius and the cylinder head
valve recess opening is 0.05 mm. Only a portion of the relatively stiff cylinder head is modeled. An approximate
analytical solution for the stress in the valve insert can be found from a deformation analysis of thick-walled cylinders
subject to symmetric external loading.
Figure 26-1 Valve Insert Fitted into Cylinder Head
A single solution is sought and the average hoop and radial stresses in the valve insert are compared to a thick cylinder
solution assuming the cylinder head is rigid. Comparison plots include average hoop and radial stresses plotted along
the radial distance from the value center for the predicted and analytic solutions.
Analytical Solution
An estimate for the hoop and radial stresses in the valve insert can be obtained from the analytical solution of a two-
dimensional plane stress (axial stress assumed to be zero) thick walled cylinder with prescribed displacement on its
external radius. The analytical solution assumes the cylinder head is rigid and the radial displacement of the insert at
its external radius is equal to the interference fit.
The thick walled cylinder solution only varies with radius, r , where the radial displacement, u , becomes the solution
C
of d  --1- d  ur  = 0 or u  r  = C 1 r + -----2- . The stresses are then determined from the radial displacement as,
dr r dr r
E C
-  1 +  C 1 –  1 –   -----2-
 rr = -------------------
2 r
1 –  
subjected to the boundary conditions, u  b  = h = – 0.05 mm and  rr  a  = 0 .
E C
-  1 +  C 1 +  1 –   -----2-
  = -------------------
2 r
1 –  
CHAPTER 26
This yields the analytic solutions of
– bh  1 +  a 2 +  1 –  r 2-
u  r  = --------- ------------------------------------------------------
r  1 +  a 2 +  1 –  b 2
– Ebh a2
 rr = ----------------------------------------------------------
- 1 – ----
-
  1 + v a 2 +  1 –  b 2  r2
– Ebh 2
- 1 + a-----
  = ----------------------------------------------------------
  1 + v a 2 +  1 –  b 2  r2
FEM Solution
A numerical solution has been obtained with MD Nastran's SOL 400 for the element mesh (shown in Figure 26-2)
using higher order tetrahedron elements. The contours show the two contact bodies defined in this analysis.
Figure 26-2 FEA Model for Interference Fit
Contact body id 1 is identified by the element property IDs 1 and 3 for the cylinder head while contact body ID 4 is
identified by the element property ID 2 for the valve insert as:
BCPROP 1 1 3
...
and
BCPROP 4 2
...
Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other:
BBCTABLE 0 1
SLAVE 4 0.3 0. .0 0. 0 0.
1 1 0
MASTERS 1
CHAPTER 26 459
BCTABLE 1 1
SLAVE 4 0. 0. .15 0.050 0 0.
1 0 0
MASTERS 1
Additionally, BCTABLE ID 1 shows the coefficient of friction to be 0.15 and the interference closure to be 0.05 mm.
BCTABLE ID 1 is referenced in the BCONTACT entry of the STEP case control command:
STEP 1
BCONTACT=1
SUBTITLE=FRETTAGE
NLPARM = 1
SPC = 2
LOAD = 10
Although there are no forces applied in this problem, a dummy LOAD = n case control is required for SOL 400.
Figure 26-3 plots the FEA and analytical solutions for the hoop and radial stresses in the valve insert against the radius
from the valve center. An arbitrary cross-section (high noon position of Figure 26-1) of the valve insert along the free
surface was chosen to pick the FEA stresses. The results of the analytical and FEA solutions are in general agreement.
Radius (mm)
15 16 17 18 19 20 21 249166
0 246621 246815
A B 247999 B
246823 247587
-100 Radial Stress 248815
246622 A 246615
Radial Stress FEA
-200
248830 249221
Hoop Stress FEA
X Y, r
-300 Hoop Stress 246821 246816
Z
248019 248604
-400
246619 246617
-500 Stress (MPa) 248024 246820 248039
Figure 26-3 Hoop and Radius Stress versus Radius From Valve Center
Several factors may have contributed to the difference in results. The analytical solution assumes a perfectly shaped
insert with prescribed displacements on the outside radius. On the other hand, the portion of the cylinder head that is
modeled using FEA is a nonsymmetric deformable body, which makes the FEA results slightly nonuniform across the
circumference as shown in Figure 26-4. The valve insert is in contact with the cylinder head not only across the insert's
cylindrical surface but across its bottom surface as well. In addition, the shape of the cross-section of the valve seat
disc has a slant edge on its top free surface.
CHAPTER 26
Figure 26-4 Slightly Nonuniform Hoop Stress in Valve Insert
Modeling Tips
This application example holds the insert in position by contact and friction. Take out friction, and the insert may (or
may not) pop out - in which case, the best thing is to add some soft springs, or a very small amount of friction to hold
it in place in the axial direction. Using the parabolic tetrahedral elements allows for good contact detection of the
cylindrical surface which yields a very smooth contact condition between the two bodies.
If the interference distance is small compared to the element size, the default contact tolerances will probably be ok;
however, it is possible that the interference fit will end up larger than the contact distance tolerance and contact will
be missed (one reason for a spotty stress plot). The remedy is to specify a distance tolerance equal to the interference
fit for the contact pair in the table, as well as a bias of 0.99 in general.
Input File(s)
File Description
nug_26s4.dat Parabolic Tetrahedral Elements With Friction
CHAPTER 26 461
Video
a
b+h
CL

Chapter 27: Large Sliding Analysis of a Buckle
Large Sliding Contact Analysis

27 of a Buckle

Summary 463

Introduction 464

Modeling Details 464

Solution Procedure 467

Results 469

Modeling Tips 472

Input File(s) 473

Video 473
CHAPTER 27 463
Large Sliding Contact Analysis of a Buckle
Summary
Title Chapter 27: Large Sliding Contact Analysis of a Buckle
Features Deformable-deformable contact, bilinear, Coulomb friction model, Hookean, isotropic
elastic material, adaptive time stepping, solid elements with assumed strain formulation
Geometry
Y 168 mm
X
Z
y
mm metr
247 Sym
Half
Material properties E = 10GPa ,  = 0.4
Analysis characteristics Quasi-static analysis using: adaptive time stepping and geometric nonlinearity due to
large displacement
Boundary conditions Sliding, frictional contact with: ends fixed for second contact body and contact between
the two deformable bodies with  = 0.1
Applied loads Prescribed displacements for the end nodes of the first contact body with two load cases:
insertion (clipping) and removal of the buckle
Element type 8-node solid element with assumed strain formulation
FE results 1. History plot of y-displacements for specific nodes
2. Normal and frictional contact force comparison of Nastran and Marc
3. Load displacement curves comparison between the frictional and frictionless cases
Fx Fx
1000 Fx (N)
500
0.5 1.0 1.5
0
Time (s)
-500 Frictionless
Frictional
-1000
-1500
Insert Remove
-2000
Fx Fx
CHAPTER 27
Introduction
This problem demonstrates the ability of MD Nastran SOL 400 to do a frictional contact problem. An ostensibly
simple geometry poses a substantial challenge for the contact algorithm due to the large sliding involved between the
two deformable bodies. Sudden changes in the motion path pose a challenge to the ability of the contact algorithm to
correctly place the node on the contact surface while respecting the various geometric details in the problem.
Due to large bending stresses in the deformed configuration, assumed strain formulation is used with the 8-node
hexahedral elements. The material is elastic and the original geometry without residual stresses is recovered upon the
complete removal of the loading.
From elementary strength of materials analysis, the tip deflection for beam bending can be written as:
 = PL 3   3EI 
where P is the applied load, L is the length of the beam, I is the moment of inertia and E is the Young’s modulus.
The normal stress along the beam cross section varies in the thickness direction as:
 xx = M t  I
where M is the moment and  t is the thickness coordinate. It must be noted that the above solution only holds for small
displacements and uniform cross section.
Modeling Details
A numerical solution has been obtained with MD Nastran’s SOL 400 for a 3-D representation of a belt buckle with a
deformable-to-deformable contact between the two pieces of the buckle. The details of finite element model, contact
simulation, material, load, boundary conditions, and solution procedure are discussed below.
The case control section of the input contains the following options for nonlinear analysis:
SUBCASE 1
STEP 1
TITLE=Insertion (Clipping)
ANALYSIS = NLSTATIC
NLPARM = 1
BCONTACT = 1
SPC = 2
LOAD = 1
DISPLACEMENT(PLOT,SORT1,REAL)=ALL
SPCFORCES(PLOT,SORT1,REAL)=ALL
STRESS(PLOT,SORT1,REAL,VONMISES,BILIN)=ALL
NLSTRESS(PLOT,SORT1)=ALL
STEP 2
TITLE=Removal
ANALYSIS = NLSTATIC
NLPARM = 2
BCONTACT = 2
SPC = 6
LOAD = 2
SPCFORCES(PLOT,SORT1,REAL)=ALL
NLSTRESS(PLOT,SORT1)=ALL
CHAPTER 27 465
The analysis contains a single subcase with two steps. The two steps comprise of individual load sequences consisting
of insertion (clipping) and removal of the belt buckle. Each step has a definition of convergence control option via
NLPARM, contact table and parameters via BCONTACT, applied displacements (or single point constraints) via SPC
and the displacements and stress results for the .f06 (output) file. A zoomed-in view of the cross section of the model
shown in Figure 27-1 consists of an outer piece modeled as body 2, the buckle, while the inner piece is modeled as
body 1, the insert.
Figure 27-1 Geometry and a Zoomed-in View of a Belt Buckle
Large displacement effects are included in the nonlinear analysis using the option:
PARAM LGDISP 1
While the assumed strain formulation is flagged using the option:

NLMOPTS,ASSM,assumed
The NLMOPTS field triggers the assumed strain formulation which provides a better bending behavior of the
continuum elements. This alleviates the difficulty associated with spuriously large shear stresses induced due to
bending moment. The LGDISP field indicated the use of large displacement, large rotation kinematics of the element.
This is adequate when the analysis consists of Hookean elastic material; however, incase of large deformation
plasticity or other inelastic models, the LRGSTRN parameter should be used in the NLMOPTS option (for more details
on its usage, please refer to : Chapter 3: 3-D Sheet Metal Forming of this manual).
Element Modeling
Besides the standard options to define the element connectivity and grid coordinate location, the bulk data section
contains various options which are especially important to do nonlinear analysis. The nonlinear extensions to
CHAPTER 27
lower-order solid element, CHEXA can be activated by using the PSLDN1 property option to the regular PSOLID
property option in the manner shown below:
PSOLID 1 1 0
PSLDN1 1 1 1 +
+ C4 SOLI L +
The PLSLDN1 option allows the element to be used in both large displacement and large strain analysis and has no
restrictions on the kinematics of deformation unlike the regular CHEXA elements with only PSOLID property entry.
The standard CHEXA elements are more suitable for large rotations but small strain analysis due to their linear
formulation in co-rotational system. While the difference may be small or even negligible in elastic analysis, use of
any inelastic material model would certainly require the use of these options.
Modeling Contact
The BCPARA defines the number of bodies in contact with maximum number of contact entities (e.g., patches), nodes
on the periphery of the contact surfaces and contact parameters like friction type (in this case – node based, bilinear
Coulomb model), friction coefficient, bias factor, and type of contact procedure used.
BCPARA 0ERROR 0.005BIAS 0.99FTYPE 6
It must be mentioned that the contact procedure being used (flagged via ISPLIT flag) is iterative penetration checking
procedure and must always be used for robustness in a quasi-static analysis.
Friction has been flagged via the FTYPE field where a 6 denotes the bilinear, Coulomb model. The friction coefficient
is 0.1 and is included in contact body definition with BCBODY option or the contact tables using the BCTABLE option.
Another significant point is the use of BIAS in frictional problems. The bias factor measures the non-dimensionalized
distance on both sides of the contact surface which is used to make a decision if the node is in contact or not, based on
whether the node falls within this band defined by contact zone tolerance. Ideally, it should be 1.0 or as close to it.
However, due to the possibility of excessive iterations in case of even very slight penetration, the bias is kept as zero
or, in other words, a slight penetration is accepted. While a bias of zero works well for nonfrictional problems, it can
be a detriment for frictional problems which require the bias to be set as close to one as possible in order to avoid a
fictitious tangential force on the node which can cause non convergence of the solution. Finally, the ERROR parameter
denotes the contact zone tolerance. The default value is about 1/20th of the smallest element size for a solid element.
In this case, it has been chosen to be an even smaller value of 0.005.
To identify how the contact bodies can touch each other, the BCTABLE option is used. BCTABLE with ID 0 is used to
define the touching conditions at the start of the analysis. This is a mandatory option required in SOL 400 for contact
analysis and it is flagged in the case control section through the optional BCONTACT = 0 option. The BCTABLE with
ID 1 is used to define the touching conditions for later increments in the analysis, and it is flagged using BCONTACT
= 1 in the case control section. Also, the SLAVE-MASTER combination defines that the nodes for body 1 are nodes
belonging to the slave body. This, in literature, is referred by various terminologies as either contacting body nodes or
tied nodes (imagining the situation of multi-point constraints). The nodes belonging to body 2 are said to belong to the
master body which are also referred to as the contacted body nodes or the retained nodes (imagining the situation of
multi-point constraints)
BCTABLE 0 1
SLAVE 2 0. 0. .1 0. 0
0 0 0
MASTERS 1
CHAPTER 27 467
BCTABLE 1 1
SLAVE 2 0. 0. .1 0. 0
0 0 0
MASTERS 1
The definition of the contact bodies (defined as body 1 and 2 in Figure 27-1) consists of the bulk data entries. The
BCBODY option defines the deformable body including the body ID, dimensionality, type of body, type of contact
constraints and friction etc. while the BSURF identifies the elements forming a part of the deformable body as:
BSURF 2 50000 50001 50002 50003 50004 50005 50006
50007 50008 50009 50010 50011 50012 50013 50014
50015 50016 50017 50018 50019 50020 50021 50022
50023 50024 50025 50026 50027 50028 50029 50030
… (list of element forming this body)
Material Modeling
The isotropic, Hookean elastic material properties of the deformable body are defined using the following MAT1
option as follows:
MAT1 1 10000. 0.4 Isotropi
The Young’s modulus is taken to be 10 GPa with a Poisson’s ratio of 0.4.

The displacements for body 2 are fixed at the end in the following manner:
$ Displacement Constraints of Load Set : right_fixed_xyz
SPC1 5 123 100056 THRU 100074
SPC1 5 123 100446 THRU 100464
The loading involves application of displacement controlled boundary conditions as follows:

SPCADD 2 1 8 5
$ Enforced Displacements for Load Set : case1_left_xyz
$ Dummy Force Required to Activate the Following Enforced Displacements
FORCE 1 50084 0. .57735 .57735 .57735
SPCD 1 50084 1 85. 50085 1 85.
A total X displacement of 85 mm is applied to body 1. The application of the loads or displacements is such that the
total load applied at the end of the loading sequence is given in the input.
Solution Procedure
NLPARM 1 20 FNT 50 UV ALL
0.01
NLAUTO 1 .01 1. .1 1.2 1.-5 .5 0
10 0
FNT represents Full Newton-Raphson technique wherein the stiffness is reformed at every iteration; KSTEP (field
after FNT) is left blank and in conjunction with FNT, it indicates that the program will determine if the stiffness needs
CHAPTER 27
to be reformed between the end of the load step and the start of next load increment. Fifty (50) is the maximum number
of allowed recycles for every increment and, if this were to be exceeded, the load step would be cut-back and the
increment repeated. UV indicates that the maximum norm of vector component of the incremental displacements will
be checked for convergence. ALL indicates that intermediate output will be produced after every increment. The
second line of NLPARM indicates that a tolerance of 0.01 will be used for displacement based convergence checking.
NLAUTO defines the parameters in the adaptive load stepping scheme. The initial load step is 1% of the total load. It
must be noted that, for many problems including plasticity of complicated contact conditions in the early stages of the
analysis, this must be a very small percentage (typically 0.5%). The smallest and largest ratio between the steps is 0.1
and 1.2, respectively, while the minimum value of the step is 10 – 5 . Finally, the desired number of recycles is kept at
ten which is the default in SOL 400. If this number is chosen to be very small, then the step size is cut to a smaller size
for convergence to be achieved and there will be larger number of steps. If this number is very large, then the load step
will allow more iterations for convergence in the same step.
The number of increments is provided in the third field of the NLPARM option. It is also worth noting that removing
the NLAUTO option results in a constant load step procedure with a total of 20 load increments per step (thus, a total
of 40 for the analysis).
Alternately another nonlinear procedure used is defined through the following NLSTEP entry like:
NLSTEP 1 1. +
+ ADAPT 1.00E-2 1.E-5 0.10 1.2 0 999999 +
+ 0 0.0002 +
+ MECH PV 0.1 PFNT
Adaptive time procedure with total time of 1 is used. Initial time step of 0.01 is used as fraction of total time. It means
the initial load step is 1% of the total load. It must be noted that, for many problems including plasticity of complicated
contact conditions in the early stages of the analysis, this must be a very small percentage (typically 0.5%). The
maximum number of recycles allowed for each increment are 10 and minimum is 1. The desired number of recycles
per increment is 4. If this number is chosen to be very small, then the step size is cut to a smaller size for convergence
to be achieved and there will be larger number of steps. If this number is very large, then the load step will allow more
iterations for convergence in the same step.The smallest and largest ratio between the steps is 0.1 and 1.2, respectively,
while the minimum value of the step is 1E-5. Output is written to result file for every single increment.
CHAPTER 27 469
Results
Figure 27-2 shows the sequence of the analysis with a close-up view of the buckle. It can be seen that the clip slides
on top of the protrusion of the static frame without any penetration. It is quite remarkable that even with the large
motion as well as large sliding contact per load increment between the two deformable contact bodies, the analysis
shows a robust behavior.
A vector plot of the comparison of normal and frictional contact forces with the Marc results is presented in
Figure 27-3 and Figure 27-4, respectively. The contact forces for SOL 400 and Marc agree very well in both
magnitude and direction.
Figure 27-2 Various Stages of Insertion of the Clip

CHAPTER 27
(a) SOL 400 (b) Marc
Figure 27-3 Comparison of Contact Normal Forces
(a) SOL 400 (b) Marc

Figure 27-4 Comparison of Contact Frictional Forces
Next, the load displacement for the frictional and frictionless cases are compared in Figure 27-5. Only the X direction
forces are plotted versus time. It is always recommended to perform a frictionless analysis (nug_27f.dat)
whenever possible to aid in the understanding of the affect of adding friction. As expected, for the frictionless case,
the load displacement curve is symmetric about the center line (between the insertion and removal steps). Deformed
geometry is shown at various peaks of the curve and, as intuition would suggest, the peak forces correspond to the
point of maximum bending. Addition of the non-conservative friction forces destroys the symmetry and the peak
insertion force increases compared to the peak force in removal. The removal of the clip generates less pull-out force
compared to the push-in force. Also, the insertion force starts reducing due to frictional forces aiding the motion as
opposed to resisting the motion as the sliding switches from the convex part to the concave part of the contact surface.
CHAPTER 27 471
Fx Fx
1000 Fx (N)
500
0.5 1.0 1.5
0
Time (s)
-500 Frictionless
Frictional
-1000
-1500
Insert Remove
-2000
Fx Fx
Figure 27-5 Load Displacement Curve for the Frictional and Frictionless Cases
Checking the finite element analysis with a hand calculation assists both in understanding the FEM as well as the
E t
physics of the simulation. Solving elementary equations mentioned earlier for the bending stress yields,  = --3- -----------
2
-
2 L
where  is the tip displacement shown in Figure 27-6 during the insertion of the clip.
Inc: 17
Time: 4.250e-001
4.213e+002
0 mm
3.368e+002 L=8
2.524e+002
1.679e+002
δ = 20 mm
8.349e+001
-9.664e-001
2ζ t = 6 mm
-8.542e+001
-1.699e+002
-2.543e+002
-3.388e+002
-4.232e+002 Y
Z X
lcase1
Comp 11 of Stress 1
Figure 27-6 Verify FEM with Simple Calculation
Performing the calculation of the bending stress at the outer fibers of the thinnest section gives,
3 E  2 t 
2
3  10x10 9  N  m    20mm   6mm  2
- =  4.69 x10 8 ------  ------------------ =  469 ----------- .
N m N
 =  --- -------------------- =  --- ----------------------------------------------------------------------------------- 2  10 3 mm
The value of  469N   mm 2 
2 L2 2  80mm 
2
m mm
2
agrees closely to the corresponding bending stresses in Figure 27-6 of  423N   mm 2  . As expected, the linear solution
presents an upper-bound to the actual stresses.
CHAPTER 27
Modeling Tips
The two most important aspects in the analysis comprise of the inclusion of assumed strain enhancements to the
standard element formulation and the choice of contact and time stepping scheme parameters use of adaptive load
stepping scheme, and its associated parameters. The former is important due to presence of bending stresses in the
structure which can manifest themselves as (sometimes large) spurious shear stresses. This is a purely numerical
artifact due to the standard, displacement based finite element chosen which can be ameliorated by the use of an
assumed strain enhancement to the standard element.
Among the numerical parameters affecting the convergence of the job, the two most important parameters for this kind
of analysis are the contact bias and maximum number of recycles for the adaptive stepping scheme.
In contact analysis with friction, it is important to use a high bias (preferably 0.99) for frictional problems for improved
convergent results. In many cases (although, not in this problem, nug_27b.dat), it can decrease the number of
iterations as well.
Next is the contact zone tolerance. Typically, a default value is 1/20th the smallest length of solid element. If the
contact zone is too big, then there could be a loss of accuracy due to acceptance of penetrated nodes or large amount
of recycling due to contact nodes separating. However, reducing the contact zone tolerance may not always yield the
reduction in the number of iterations. In fact, in certain problems where there are not many separations expected,
reducing to a very small number can even increase the number of iterations due to contact detection and scaling of
incremental displacements in the iterative penetration checking algorithm in contact.
It is also worth noting that the adaptive load stepping improves the speed and accuracy of the analysis quite
significantly for this problem due to its intelligent choice of time steps based on the convergence parameters. This
adequately demonstrates the strength of the adaptive stepping in tough problems where the smart algorithm adjusts the
increment size based on the kinematics of deformation, contact constraints, and convergence rates rather than the fixed
time stepping where the only alternative is to cut down the existing increment size in case of non convergence in the
specified number of recycles.
It is also noted that a very high or very low number of desired number of recycles can either invoke an excessive
number of iterations or induce cutbacks during the analysis. For example, decreasing the desired number of recycles
to may increase the number of increments. Due to a large amount of sliding and significant contact nonlinearity, a large
number of recycles, in general, are expected for most increments. Therefore, a high number of desired recycles proved
to be useful in this particular example. However, in problems with milder material and/or contact nonlinearities where
only a few iterations per increment are expected, a smaller number of desired recycles can yield faster results. This
difference can result in notable savings of the computing time for large jobs.
Flat rigid surfaces can be glued to the ends of the buckle and insert to control the insertion and extraction of the insert
in and out of the buckle. The advantage of this modeling technique is that the total insertion and extraction force
component, Fx, can be easily determined as shown in Figure 27-5, since all of the forces acting on rigid bodies are
resolved to a single force and moment vector acting at the position of the rigid bodies.
Finally, since the buckle has a plane of symmetry, it is cost effective to only model the half of the model say above this
plane of symmetry.
Note: For contact problems, artificial damping can improve the speed of convergence and stability of the
analysis as seen in nug_27c.dat.
CHAPTER 27 473
Input File(s)
File Description
mug_27.dat Marc input for fixed time
nug_27.dat MD Nastran input for fixed time stepping
MD Nastran input with adaptive time stepping with bias = 0.99, contact zone tolerance = 0.0
nug_27a.dat
(default), desired number of recycles = 20 (default = 10)
MD Nastran input with adaptive time stepping bias = 0.0 (default), contact zone tolerance =
nug_27b.dat
0.005, desired number of recycles = 20 (default = 10)
MD Nastran input with adaptive time stepping bias = 0.99, contact zone tolerance = 0.005,
nug_27c.dat
desired number of recycles = 20
nug_27b.bdf Input file similar to nug_27b.dat above with half symmetry use in the video
nug_27_star MD Nastran input with adaptive time stepping bias = 0.99, contact zone tolerance = 0.005,
t.SimXpert desired number of recycles = 20
Video
Y 168 mm
X
Z
y
mm metr
247 Sym
Half

Chapter 28: Model Airplane Analysis
Model Airplane
28 Engine Analysis

Summary 475

Introduction 476

Required Solution 476

FEM Solution 476

Input File(s) 484

Video 485
CHAPTER 28 475
Model Airplane Engine Analysis
Summary
Title Chapter 28: Model Airplane Engine Analysis
Contact features • Deformable-deformable contact - glue contact; Segment - Segment Contact
• Gasket material
• Bolt modeling with BOLT entry
Geometry
66
Units: mm
33
82
Eq. Stress At Pressure
Material properties • Linear elastic material (Steel) for the engine block, plug, and bolts:
E = 2.1  10 5 MPa ,  = 0.3
• Linear elastic material (aluminium) for the cylinder head:
E = 7.0  10 4 MPa ,  = 0.3
• Isotropic in-plane behavior or the gasket body:
E = 120MPa , G = 60MPs
• Isotropic in-plane behavior of the gasket body:

E = 100MPa , G = 50MPa
• Out-of-plane pressure-over closure curves are used for the gasket body and gasket ring
using loading and unloading curves.
Boundary conditions Some nodes on the outer boundaries on the engine block are constrained in all directions
Applied loads Step 1: Enforces displacement of 0.25 mm on the bolts using BOLT.
Step 2: Pressure load of 16 MPa
Element type • 4-node tetrahedron elements
• 8-node CHEXA to model the gasket
Contact properties • Glue contact, segment to segment contact
• Extended tangential contact tolerance at sharp corners
FE results • Displacement of the engine model, Load history chart for bolt
• Contact pressure and forces on the gasket
CHAPTER 28
Introduction
The model airplane engine analysis consists of a cylinder head, a engine block, a gasket, bolts, and a plug. The gasket
is assembled between the head and the block. The problems demonstrates how the solution sequence 400 of MD
Nastran can be used for a typical analysis for engine involving the nonlinear pressure-over closure relationship of the
gasket material and bolt pre-tension load. Glued contact is used to establish contact between the different parts of this
engine model.
Required Solution
The nonlinear analysis involving large displacement and gasket nonlinearity is carried for the model airplane engine
to find the forces in the bolts and contact forces in the gasket.
FEM Solution
MD Nastran’s nonlinear solution sequence SOL 400 is used to analyze the engine model under the bolt and pressure
loads in two steps. The details of finite element models, contact simulations, material, load, boundary conditions, and
solution procedure are discussed in the following sections.
Finite Element Model

The finite element model used for the 3-D solid approach is shown in Figure 28-1. The model consists of 88293
CTETRA element and 468 CHEXA elements. MD Nastran’s 4-node tetrahedral elements are used for block using the
following PSOLID and PSLDN1 options. Head, bolts, and plug are also models with 4-node tetrahedral elements.
PSOLID 1 1 0
PSLDN1 1 1
Figure 28-1 Finite Element Model for Model Airplane Engine

CHAPTER 28 477
Using the following PSOLID and PSLDN1 options, the gasket body is modeled using MD Nastran’s 8-node hexahedral
gasket elements. Here, the gasket material is referred to by the material ID 5.
PSOLID 5 3 0
PSLDN1 5 3 1
C8 SLCOMP L
The gasket ring is also modeled in a similar way using the different material ID 6.
PSOLID 5 6 0
PSLDN1 5 6 1
C8 SLCOMP L
Contact Model
For the contact definition, various parts of the model airplane engine are defined as deformable contact bodies. the
following BCBODY and BSURF entries show the contact body definition for the gasket.
BCBODY 1 3D DEFORM 4 0 0
BSURF 4 70172 THRU 70639
The contact bodies for other parts of the model as also defined in a similar way. Figure 28-2 presents the details of
different contact bodies defined for the model airplane engine.
Zoomed view of contact parts

without head and block
Figure 28-2 Details of the Different Contact Bodies
The following BCTABLE entries identify how the contact bodies can touch each other. The BCTABLE with ID 1 is used
to define contact conditions at the first step of the analysis. Since there is no difference in the contacts in Second Step
the same BCTABLE with ID 1 is used to define the contact conditions for second step in the analysis, and it is flagged
using the option BCONTACT = 2 in the case control section. Glued contact is used for all the six contact pairs defined
CHAPTER 28
in the BCTABLE option. Delayed sliding is enabled for the contact pairs involving gasket by choosing the value 2 for
the field ICOORD.
BCTABLE 1 6
SLAVE 1 0.0 0.0 0.0 1
1 2 0
MASTERS 4
SLAVE 1 0.0 0.0 0.0 1
1 2 0
MASTERS 5
SLAVE 2 0.0 0.0 0.0 1
1 0 0
MASTERS 4
SLAVE 2 0.0 0.0 0.0 1
1 0 0
MASTERS 5
SLAVE 3 0.0 0.0 0.0 1
1 0 0
MASTERS 4
SLAVE 4 0.0 0.0 0.0 1
1 0 0
MASTERS 5
Material
The linear isotropic elastic properties of the steel and aluminium materials are defined using the following MAT entries.
Steel properties are used for block, bolts and plug and aluminium properties are used for cylinder head.
MAT1 1 210000. .3 7.86-6 1.-5
MAT1 2 70000. .3 2.7-6 2.4-5
The in-plane membrane properties of gasket body (ID 3) and gasket ring (ID 4) materials are defined using the
following MAT1 entries. The nonlinear pressure-over closure relation for the gasket body (ID 3) and gasket ring (ID
5) are defined using the following MATG entries.
MAT1 3 120. 60. 9.99E-7 5.E-5
MAT1 4 100. 50. 1.99E-6 0.0001
MATG 5 3 0 1 2
52. 72.
35. 0.05
MATG 6 4 0 3 4
42. 64.
35. 0.0
Figure 28-3 shows the pressure-over closure properties for the gasket materials. The following TABLES1 entries
(referred in the MATG entries) are used to define these nonlinear gasket properties.
$ Displacement Dependent Table : body_loading
TABLES1 1 +
+ 0.0 0.0 0.027 2.08 0.054 8.32 0.081 18.72+
+ 0.108 33.28 0.135 52. 0.175 56. ENDT
$ Displacement Dependent Table : body_unloading
TABLES1 2 +
+ 0.1 0.0 0.1225 5.04 0.1375 14. 0.1525 27.44+
+ 0.16 35.84 0.1675 45.36 0.175 56. ENDT
$ Displacement Dependent Table : ring_loading
TABLES1 3 +
+ 0.0 0.0 0.026 1.68 0.052 6.72 0.078 15.12+
+ 0.104 26.88 0.13 42. 0.18 48. ENDT
$ Displacement Dependent Table : ring_unloading
TABLES1 4 +
+ 0.12 0.0 0.138 4.32 0.15 12. 0.162 23.52+
+ 0.168 30.72 0.174 38.88 0.18 48. ENDT
CHAPTER 28 479
Gasket Pressure (MPa)

60
Body
Loading Curve Body
50 Unloading Curve Body Ring
Loading Curve Ring
40
Unloading Curve Ring
30
20
10
0
0.00 0.05 0.10 0.15 0.20
Gasket Closure (mm)
Figure 28-3 Pressure-over Closure Relations for Gasket Materials

The analysis for the model airplane engine is carried out in two steps. In the first step, a pre-tension load is applied on
bolts. In the second step, a pressure load is applied in the part of head and gasket. Some nodes on the outer boundaries
on the block are constrained in all directions. Figure 28-4 shows these boundary conditions applied in both Steps 1
and 2.
Figure 28-4 Constraints used in Steps 1 and 2

CHAPTER 28
The following data in case control section of the input file defines the load and boundary conditions at the two different
steps of the analysis. The bulk data entries SPCD, SPC1, and PLOAD4 are used to define the boundary condition and
loads in these steps. Bolt pretension loading is simulated using BOLT.
In order to define Pre-Stress in Bolts, Bolt modeling is carried out using BOLT entry. BOLT
consists of combination of two pairs, TOP and BOTTOM nodes set. The key idea is to split the
element mesh of the bolt across the shaft in two disjoint parts, such that duplicate grid points
appear at the cut, and to create an overlap or gap between the two parts via multi-point
constraints. If the motion of these parts is somehow constrained in the direction in which the
gap or overlap is created, then an overlap (shortening) will introduce a tensile (pre-) stress
in each of the parts and a gap (elongation) will result in a compressive stress. This technique
is more elaborated in Chapter 23: Bolted Plates.
However the internal MPC equations are generated between the TOP and BOTTOM nodes to
a free node which is also called as Control node. The BOLT entry for Bolt_1 is defined as
follows:
BOLT 89847 38083
TOP 38271 38272 38273 38274 38275 38276 38277+
+ 38278 38279 38280 38281 38282 38283 38284+
+ 38285 38286 38287 38288 38289 38290 38291+
+ 38292 38293 38294 38295 38296 38297 38298+
+ 38299 38300 38301 38302 38303 38304 38305+
+ 38306 38307
BOTTOM 22467 22459 22466 22470 22481 22817 22460+
+ 22463 22461 22814 22813 22478 22474 22462+
+ 22341 22816 22480 22458 22477 22473 22464+
+ 22475 22465 22472 22471 22275 21642 22476+
+ 22482 21643 22469 22479 22468 21644 22815+
+ 21641 21640
Here 89847 indicates the BOLT ID; 38083 indicates the Control node ID; TOP indicates the set of node IDs and BOTTOM
indicates the bottom node IDs. Similarly the remaining 3 bolts are defined as follows:
BOLT 89848 38007
TOP 38308 38309 38310 38311 38312 38313 38314+
+ 38315 38316 38317 38318 38319 38320 38321+
+ 38322 38323 38324 38325 38326 38327 38328+
+ 38329 38330 38331 38332 38333 38334 38335+
+ 38336 38337 38338 38339 38340 38341 38342+
+ 38343 38344
BOTTOM 20192 20191 20194 21827 20202 22544 20195+
+ 21825 21828 20184 20186 20187 20838 20207+
+ 21826 20185 20196 20188 20189 20183 21829+
+ 20205 19867 20199 20197 20201 19870 19869+
+ 20193 20190 19868 20203 20198 20200 20204+
+ 19871 20206
BOLT 89849 38084

TOP 38345 38346 38347 38348 38349 38350 38351+
+ 38352 38353 38354 38355 38356 38357 38358+
+ 38359 38360 38361 38362 38363 38364 38365+
+ 38366 38367 38368 38369 38370 38371 38372+
+ 38373 38374 38375 38376 38377 38378 38379+
+ 38380 38381
BOTTOM 20324 20318 20320 20321 20309 20310 20307+
+ 20322 19721 20311 20325 20304 22009 21808+
+ 20308 20305 20312 20313 20315 20316 20319+
+ 20327 20317 22008 20328 20326 20306 20323+
CHAPTER 28 481
+ 22451 19722 22007 19723 22006 22005 19720+

+ 20314 19719
BOLT 89850 38085

TOP 38382 38383 38384 38385 38386 38387 38388+
+ 38389 38390 38391 38392 38393 38394 38395+
+ 38396 38397 38398 38399 38400 38401 38402+
+ 38403 38404 38405 38406 38407 38408 38409+
+ 38410 38411 38412 38413 38414 38415 38416+
+ 38417 38418
BOTTOM 21071 21069 21068 21080 21078 21076 21077+
+ 21089 21074 21066 21073 21086 21401 21400+
+ 21065 21067 21398 21075 21087 22540 21088+
+ 22539 21070 22541 21072 21395 21082 21079+
+ 22542 21083 21399 21081 21085 21084 21326+
+ 22543 21397
The SPCD data is used for applying the imposed displacement of 0.25 mm in the vertical direction in Steps 1 and 2 at
the controlled nodes for bolts. The lateral displacements at these four control nodes are constrained.
STEP 1
$! Step name : Bolt_Preload
SPC = 30
LOAD = 31
BCONTACT = 1
ANALYSIS = NLSTAT
NLSTEP = 2
STEP 2
$! Step name : Static_Pressure
SPC = 31
LOAD = 32
BCONTACT = 1
ANALYSIS = NLSTAT
NLSTEP = 3
...
SPCD 31 38083 3 0.25
SPC1 31 3 38083
SPCD 31 38007 3 0.25
SPC1 31 3 38007
SPCD 31 38084 3 0.25
SPC1 31 3 38084
SPCD 31 38085 3 0.25
SPC1 31 3 38085
...
SPC1 9 123 987
SPC1 9 123 2453 THRU 2465
...
PLOAD4 1 85127 16. 24238 23579
...
PLOAD4 2 55616 16. 15870 15071
...
Solution Procedure
The nonlinear procedure for the Step 1 is defined through the following NLSTEP entry with ID 2.
NLSTEP specifies the convergence criteria, step size control between coupled loops and step/iteration control for each
physics loop in MD Nastran SOL 400. NLSTEP entry is represented as follows:
NLSTEP 2 1.
GENERAL 50
FIXED 10 1
MECH P 0.01 PFNT
CHAPTER 28
Here, 1. Indicate the total Time for the Load case; GENERAL indicates the keyword for parameters used for overall
analysis; 50 indicates the maximum number of iterations per increment; FIXED indicates the fixed stepping is to be
used; 10 indicate the number of increments for fixed stepping; 1 indicates interval for output. Every increment will be
saved for output; MECH indicate the keyword for parameters for mechanical analysis; P indicates the load convergence
criteria; 0.01 indicates convergence tolerance for load; PFNT indicates the Modified Full Newton Raphson Technique
for updating stiffness matrix. The fields MAXQN, MAXLS, and MAXBIS are set to zero to disable the Quasi Newton, line
search, and bisection techniques in the iterative process.
Similar NLSTEP option with ID 3 is used for Step 2.
NLSTEP 3 1.
GENERAL 50
FIXED 10 1
MECH P 0.01 PFNT
Segment to Segment Contact method is activated using BCPARA. Here METHOD indicates the Global Contact type;
SEGSMALL indicates the Small Segment-to-Segment Contact. If, in BCTABLE, there are multiple GLUE with different
“SLAVE” entries, then NLGLUE, 1 must be used.
BCPARA 0 METHOD SEGSMALL NLGLUE 1
Results
The variation of the bolt forces at grid points 38007,38083,38084 and 38085 as a function of the bolt shortening is
shown in Figure 28-5. This clearly shows a nonlinear response. The normal contact forces in gasket are shown in
Figure 28-6.
Figure 28-5 Bolt Force as a Function of Bolt Shortening

CHAPTER 28 483
Figure 28-6 Normal Contact Forces in Gasket
The displacement contours of the engine model in y-direction at Steps 1 and 2 are shown in Figure 28-7 and
Figure 28-8.
The pressure-closure output for the gasket element 70582 is presented here from the f06 output file at the end of Step
2. It is observed that the pressure for this gasket element exceeded the yield pressure of 52 MPa and this result in a
plastic closure of 0.12 mm.
ELEMENT ID PLY ID INT. PT. ID PRESSURE CLOSURE PLASTIC CLOSURE
70582 1 1 7.805712E+01 1.997745E-01 1.200000E-01
2 8.207688E+01 2.024191E-01 1.200000E-01
3 7.722001E+01 1.992237E-01 1.200000E-01
4 8.107123E+01 2.017574E-01 1.200000E-01
Figure 28-7 Displacement Contours in y-direction at Step 1

CHAPTER 28
Figure 28-8 Displacement Contours in y-direction at Step 2
Figure 28-9 Von Mises Stress Contours for Node-Segment and Seg-Seg method
Input File(s)
File Description
nug_28m.bdf MD Nastran SOL 400 input for model airplane engine
CHAPTER 28 485
Video
66
Units: mm
33
82
Eq. Stress At Pressure

Chapter 29: Rapid Road Response Optimization of a Camaro Model using Automatic External Superelement
Optimization
Rapid Road Response

Optimization of a Camaro
29 Model using Automatic
External Superelement
Optimization

Summary 487

Introduction 488

 Optimization Solutions 490

Modeling Tip 495

Input File(s) 496
CHAPTER 29 487
Rapid Road Response Optimization of a Camaro Model using Automatic External Superelement
Summary
Title Chapter 29: Rapid Road Response Optimization of a Camaro Model using Automatic
External Superelement Optimization, AESO
Features • Grids 23K
• Total degrees of freedom 137K
• Degrees of freedom in residual 7K
• Elements 37K
• Subcases 2
• Frequencies 3
Geometry
Material properties Mild Steel (E = 2x107 Psi, nu = 0.28, rho = 7.835x10-5 lbf-s2/in4)
Analysis type Modal/Direct Frequency Analysis
Boundary conditions See the asm file, aeso9.asm, containing boundary connection data
Element type CQUAD4, CTRI3, CROD
Loads Random inputs applied on left and right suspension, including cross-correlation (see
Figure 29-2)
FE results
5.0E -0 3
4.0E -0 3
S u m m ed A c celeratio
3.0E -0 3
S UM Init
S um fina l
2.0E -0 3
1.0E -0 3
0.0 E +0 0
4 6 8 10 12 14
F req u en cy (H z )
CHAPTER 29
Introduction
The purpose of the example is to illustrate how to run an Automatic External Superelement Optimization, AESO, job
and to demonstrate significant performance gain can be achieved with AESO. Learn more about the capability, consult
MD Nastran Design Sensitifity and Optimization User’s Guide. It is assumed that the reader is experienced in
performing modal frequency analysis. The discussion of the analysis modeling is kept to minimum.
The Camaro model is provided by General Motor Corp (Figure 29-1). Random inputs are applied on left and right
suspension, including cross-correlation (Figure 29-2). The road response optimization task is solved by varying spring
constants of the engine mount to achieve maximum ride comfort. Both a regular (or a single shot) optimization run
and an AESO run are performed. The efficiency and accuracy of the solutions are compared between two approaches.
Figure 29-1 Camaro Model
1.60E-02
1.20E-02
Input Spectra
LEFT SUSP
8.00E-03
RIGHT SUSP
REAL L/R
4.00E-03
IMAG L/R
0.00E+00
4 6 8 10 12 14
-4.00E-03
Frequency
Figure 29-2 Input Load Power Spectra

CHAPTER 29 489
Requested Solutions
The task will be solved in three design scenarios that are described in detail in the Optimization Solution section. Each
of three cases is solved by a single run approach and the AESO run approach. Then, the results and performance data
are compared between two approaches. It has been observed that the single shot run may fail with signal = 11 message
in the log file when design cycle is greater than 1 due to some modeling issue. However, this behavior does not show
up in the AESO runs. In this document, the results from good single shot runs will be presented but the input file is
not included.
The AESO approach should demonstrate that
• accurate and very efficient solution can be obtained
• the reduced model allows to perform re-analyses and/or optimization tasks many times rapidly
• much larger performance gain is achieved with Analysis=DFREQ
CHAPTER 29
Optimization Solutions
Case A
This design case is to minimize the sum of RMS acceleration at driver’s seat and passenger’s seat while limiting the
PSD response at steering column by varying nine spring constants of the engine mount. Listing 1 shows the required
design model set up for Case A.
Listing 1 Design model set up for Case A
...
DESOBJ = 1020
DESSUB = 101
...
BEGIN BULK
$ design model set up
DESVAR 11 K5307 1.0 0.01 3.0
......
DESVAR 24 K5018 1.0 0.01 3.0
DVCREL1 5307 CELAS2 5307 K
11 1246.3
......
24 1120.
FREQ1 4 6.0 0.1 60
$ LHS - Acceleration at Driver's seat
DRESP1 1033 ACC1033 RMSaccl 3 620 1033
$ RHS - Acceleration at Passenger's seat
$
$ sum of RMS accelerations at Driver's and Passenger's seats
DRESP2 1020 sumrms 1020
dresp1 1033 2033
DEQATN 1020 object(driver,pass) = driver + pass
$
DRESP1 9105 ACC9005 PSDACCL 620 3 MAX 9005
DCONSTR 101 9105 2.5e-3
DOPTPRM DESMAX 20 P1 1 P2 15 conv1 5.e-3
Each AESO job requires two separate runs: an AESO creation run and an AESO assembly run.
To activate an AESO creation run, you need to add the following user input to a regular optimization job (bold face in
Listing 2): 1) an FMS ASSIGN statement that specifies the file name for the assembly run that will be generated from
the AESO creation run and 2) a keyword on DOPTPRM entry, autose = 1 that activates an AESO creation run.
CHAPTER 29 491
Listing 2 Required user inputs for activating AESO creation run
assign aeso='test9_2.dat'
.....
begin bulk
doptprm desmax 5 p1 1 P2 15
delx 0.2 delp 0.8 autose 1
After the creation run is complete, search for the user information message 9181 in the f06 file that indicates a
successful run.
^^^
^^^ USER INFORMATION MESSAGE 9181 (FEA)
^^^ THE JOB IS TERMINATED FOR AN AUTO EXTERNAL CREATION RUN
^^^
The input file for the assembly run (aeso9_2.dat) is automatically generated from the creation run. Its Bulk Data
section contains the residual model (or the design model) while the Control Section is the identical copy from the
original optimization job. Some special contents in an assembly run are shown in bold face in Listing 3. The FMS
ASSIGN statement references the Nastran Master database file and the DBLOCATE statement identifies the data block
that contains various boundary matrices. The INCLUDE statement includes an assembly file that include boundary
connection data. Notice that the AUTOSE = 1 request on the DOPTPRM entry added for the creation run has been
changed to AUTOSE = 0.
Listing 3 Special contents in an assembly file
nastran buffsize= 65537

nastran rseqcont=1
assign se1= './test9.MASTER'
dblocate datablk(EXTDB) logical=se1, CONVERT(SEID=1)
SOL 200
CEND
......
BEGIN BULK
include './test9.asm'
DOPTPRM DESMAX 5 P1 1 P2 15
DELX 0.2 DELP 0.8 AUTOSE 0
Figure 29-3 shows that the sum of RMS is reduced from the initial value of 0.154 to the final of 0.130 by the road
response optimization. Table 29-1 compares the accuracy of the results and performance in terms of Clock time
between the regular approach and the AESO approach and clearly shows that the AESO is able to obtain the same final
design but with one fifth of the time spent by a single shot run.
CHAPTER 29
5.0E -0 3
4.0E -0 3
S u m m ed A c celeratio
3.0E -0 3
S UM Init
S um final
2.0E -0 3
1.0E -0 3
0.0 E +0 0
4 6 8 10 12 14
F req u en cy (H z )
Figure 29-3 Sum of RMS Reduced from 0.154 to 0.130
Table 29-1 Results and Performance Data for Case A

Initial Final Init. Max Init. Max # Design Clock Time
Case A OBJ OBJ Const Const Cycle (Minute)
Single Shot Run 0.1534 0.0639 0.1329 -0.2102 9 37
AESO Creation 5
Run
AESO Assembly 0.1534 0.0639 0.1319 -0.2102 9 1
Run
ASEO Total 6
Performance 6
Ratio
CHAPTER 29 493
Case B
This case minimizes the RMS acceleration at Driver’s seat and maintains frequency dependent limits on PSD
acceleration at driver’s seat by varying nine spring constants of the engine mount. Listing 4 shows the required design
model set up for Case B.
Listing 4 Design Model Set up for Case B
...
DESPBJ = 1033
DESSUB = 101
...
BEGIN BULK
$ design model set up
$ Desin model set up

$
DESVAR 11 K5307 1.0 0.01 3.0
......
DESVAR 24 K5018 1.0 0.01 3.0
11 1246.3
......
24 1120.
$ LHS - Driver's seat to floor (Response for Objective to be minimized)
DRESP1 1133 ACC1033 PSDACCL 620 3 1033
DCONSTR 101 1133 1133
DOPTPRM DESMAX 20 P1 1 P2 15 conv1 5.e-3
TABLED1 1133
0.0 1.0e03 6.0 1.0e-3 7.0 1.7e-3 8.0 1.7e-3
12.0 2.0e-4 endt
Notice that in Case B, the design objective now is to minimize an RMS acceleration at Driver's seat while limiting
maintaining the frequency dependent limits on the PSD acceleration at Driver seat. The rest of the analysis model is
kept the same. Therefore, the outputs from the creation run for Case A can be reused here except replacing the
objective and constraints for Case A (Listing 1) with that for Case B formulation (Listing 4).
Figure 29-4 shows that the RMS acceleration at Driver's seat is reduced from the initial of 0.071 to the final of 0.058.
Table 29-2 compares the accuracy of the results and performance dat between the regular approach and the AESO
approach. Again, AESO achieves the same final design as the single shot run. Since no creation run is required because
it can reuse the results from the Case A's creation run, the speed up by the AESO run vs. a single shot run for Case B
is a factor of 33.
CHAPTER 29
3.0E-03
P asse n g er A cce lera
2.5E-03
2.0E-03
2033 Init
1.5E-03
2033 Final
1.0E-03
5.0E-04
0.0E+00
4 6 8 10 12 14
Frequency (Hz)
Figure 29-4 RMS Reduced from 0.071 to 0.058
Table 29-2 Results and Performance Data for Case B

Initial Final Init. Max Final Max # Design Clock Time
Case B OBJ OBJ Const Const Cycle (Minute)
Single Shot Run 0.0713 0.0586 0.2855 -0.0025 14 33
AESO Creation 0
Run
AESO Assembly 0.0713 0.0584 0.2855 -0.0201 9 1
Run
ASEO Total 1
Performance 33
Ratio
Case C
This case is exactly the same as Case A except the frequency response is solved by the Direct Frequency Analysis
Solver. Specifically, the ANALYSIS=MFREQ Case Control command in Case A is replaces by ANALYSIS=DFREQ
command in Case C.
Therefore, the same discussions presented for Case A can be directly applied here. Table 3 compares the results and
performance data between a single shot run and shows the relationship to Case C. Again, the final design from AESO
agrees well with that from a single shot run. However, the performance gain by AESO is a factor of 40.
CHAPTER 29 495
In fact, the assembly run could be run directly by assessing the database file and asm file and the assembly run file
generated from the creation run for Case A since these files are identical if ANALYSIS=MFREQ or ANALYSIS=DFREQ.
Therefore, the performance gain would be a factor of 244 (i.e. 244=244/1) assuming the time spent by the assembly
run for Case B is still five minutes.
Table 29-3 Results and Performance Data for Case C

Initial Final Init. Max Init. Max # Design Clock Time
Case A OBJ OBJ Const Const Cycle (Minute)
Single Shot Run 0.1535 0.1327 -0.0631 -0.2073 9 244
AESO Creation 5
Run
AESO Assembly 0.1534 0.1327 -0.0636 -0.2062 9 1
Run
ASEO Total 6
Performance 40
Ratio
Modeling Tip
This section provides some guideline or modeling tips for performing AESO tasks:
• Only database option is supported in AESO. No op2 or punch option is supported.
• The nondesigned part is treated as a single part component and can not be further partitioned.
• The performance gain achieved by an AESO job depends on the size of the analysis model, the ratio of the
design model size vs. the analysis model size and number of boundary points shared by designed part and
nondesigned part. A general rule of thumb is that the relative ratio should be less than 10%. The smaller the
ratio, the more performance gain can be achieved.
• The UIM 7824 from the creation run lists the size of your analysis model and design model (in terms of
number of the grid points). DRATIO may be adjusted for a larger or smaller residual model.
• Submit the AESO creation run with SCR=NO option to store the Nastran database. An assembly run does not
require that option.
• It is recommended to use Matrix domain based domain decomposition (domain solver acms(partopt=dof) for
large scale normal modes or model frequency tasks, say the total number of degrees of freedom is half million
or higher.
CHAPTER 29
• ASSIGN AESO=’fn’ is required in the creation to define a file name of the assembly file. Directly assigning
the original job name to filename should be avoided. A good practice is to add some suffix to the original file
name such as myjob_2nd.dat where myjob is the original file name.
• General guidelines or limitations to the manual External Superelement analysis also apply to AESO.
• Refer to the MD Release Guide for more guidelines and limitations.
Input File(s)
Case A
File Description
nug_29.dat BDF for an AESO run of Road Response Optimization
Case B
File Description
nug_29b.dat BDF for an AESO run of Road Response Optimization.
Case C
File Description
nug_29c.dat BDF for an AESO run of Road Response Optimization
Chapter 30: Paper Feeding Example
30 Paper Feeding Example

Summary 498

Introduction 499


FEM Solution 499

Results 503

Input File(s) 503
CHAPTER 30
Summary
Title Chapter 30: Paper Feeding Example
Geometry
Material properties See Summary of Materials

Boundary conditions • Fixed at each pinch and drive.
• Fixed at the center point of each guide.
Applied loads 1. Angular velocity to each pinch.
2. Translational force to each pinch for deleting a gap between a pinch and driver.
3. Gravitational acceleration.
Element type 0-D concentrated mass element
1-D spring and damper element
2-D shell element
3-D solid element
Contact properties
FE results
t = 0 sec t = 0.1 sec
t = 0.2 sec t = 0.3 sec
t = 0.4 sec
CHAPTER 30 499
Paper Feeding Example
Introduction
The paper feeding analysis is done to predict the paper jamming and capacity of the printer. In this example, angular
velocities are applied on five rollers to feed the paper in the printer. There are 31 contact body definitions to simulate
the paper feeding process. Total time of simulation is 0.4 seconds.
Requested Solutions
A numerical analysis will be performed to find the printer behavior. The angular velocity of each drive and pinch is
defined such that a 1500 mm/s circumferential velocity is created. The rotational velocities are applied sequentially at
center node of the drive starting from drive 1 through drive 5 by defining Tables and SPCD. Gravity is also taken into
account. To push a drive to the paper, a load is applied at the center of each driver.
FEM Solution
The printer consists of 21 parts as shown in Figure 30-1.
entrance drive_1
paper upper guide_1
upper guide_4 upper guide_5
pinch_4 pinch_5
upper guide_3
pinch_1
pinch_3 lower guide_5
lower guide_1
drive_5
pinch_2 lower guide_4
drive_2 guide_2 drive_4
drive_3 lower guide_3

Figure 30-1 Analysis Model
Using the BCTABLE and several CBODY and BCSUFT entries, the following 31 contacts are defined.
Contact Contact
Number Slave Master Number Slave Master
1 (self contact) paper paper 17 paper entrance
2 paper drive_1 18 paper lower guide_1
3 drive_1 pinch_1 19 paper upper guide_1
CHAPTER 30
Contact Contact
Number Slave Master Number Slave Master
4 pinch_1 drive_1 20 paper guide_2
5 paper drive_2 21 paper lower guide_3
6 drive_2 pinch_2 22 paper upper guide_3
7 pinch_2 drive_2 23 paper lower guide_4
8 paper drive_3 24 paper upper guide_4
9 drive_3 pinch_3 25 paper lower guide_5
10 pinch_3 drive_3 26 paper upper guide_5
11 paper drive_4 27 paper pinch_1
12 drive_4 pinch_4 28 paper pinch_2
13 pinch_4 drive_4 29 paper pinch_3
14 paper drive_5 30 paper pinch_4
15 drive_5 pinch_5 31 paper pinch_5
16 pinch_5 drive_5
TSTEPNL describes the number of Time Steps (100) and Time Increment (0.004 sec.) of the simulation. End time is
the product of the two entries. Notice here the Time Increment is only for the first step. The actual number of Time
TSTEPNL 1 100 .004 1 ADAPT 2 10
The enforced angular velocities are applied to all pinches and drivers. The nodes, located on the circumference of each
drive and pinch, are rigidly connected to the center node using RBE2 entry. Each enforced angular velocity is defined
to have the same circumferential velocity (1500 mm/sec.) at the tip of drivers and pinches using SPCD2. The angular
velocities vary depending on the diameter of drivers and pinches. The boundary conditions are applied only to pinches.
A combination of spring and damper elements, CDAMP1D and CELAS1D, connect the fixed node and the center node
of pinches. To close the gap between all the drives and the pinches, two vertical forces are applied, in opposite
directions by using a combination of FORCE and Table entries. The magnitude of the load is predefined at each drive
location. The boundary condition and enforced motion at each pinch are shown as Figure 30-2.
In the cases of the drive_1 and dirver_5, their diameters are 25 and 15 mm, respectively. The angular velocity of
drive_1 is applied as 120 radian/sec. (25/2×120 = 1500 mm/sec.). And 225 radian/sec. is applied to driver_5.
The example below shows how to define the boundary conditions and the enforced angular velocity of pinch_1.
CHAPTER 30 501
Various angular velocities are

applied to get 1500 mm/sec
RBE2 circumferential velocity.
Translational force is applied
Damper Spring
Figure 30-2 Boundary Condition And Enforced Angular Velocity At Pinch
Node 21002 is fully fixed and connected to the center node 21001 using CELAS1D and CDAMP1D. The coefficients
of the spring and damper are 4.9 N/mm and 196 N·sec /mm, respectively. Node 21001, the center node of the pinch_1,
is fixed except in the y-direction to which a spring and a damper are connected.
PELAS 18 4.9
CELAS1D 21001 18 21001 2 21002 2
PDAMP 19 196.
CDAMP1D 21002 19 21001 2 21002 2
$
SPC1 8 13456 21001
SPC1 1 123456 21002
The circumference nodes are connected to the center node 21001 rigidly using RBE2.
RBE2 55003 21001 123456 1001 1002 1003 1004 1005
1006 1007 1008 1009 1010 1011 1012 1013
...
At the center node, angular velocity 120 is applied to negative z angular direction. And, at the same node, translational
force is applied as well.
TLOAD1 19 20 VELO 1
LSEQ 1 20 21
SPCD 21 21001 6 -120.
FORCE 4 21001 0 9800. 0. 1. 0.
Paper - Linear elastic material:
E (Young’s Modulus) = 3e+6 N/mm2

 density= 8.4e-7 kg/m3
CHAPTER 30
Rubber 1 - Linear elastic material:
E (Young’s Modulus) = 1e+4. N/mm2

Rubber 2 - Linear elastic material:

Pinch and driver - Linear elastic material:

Entrance and guide - Linear elastic material:
E (Young’s Modulus) = 3.e+5. N/mm2

 density= 7.86e-6 kg/m3
CHAPTER 30 503
Results
t = 0 sec t = 0.1 sec
t = 0.2 sec t = 0.3 sec
t = 0.4 sec
Figure 30-3 Paper at Various Positions
Input File(s)
File Description
nug_30.dat MD Nastran input file for printer feeding example
Chapter 31: Wheel Drop Test
31 Wheel Drop Test

Summary 505

Introduction 506


FEM Solution 506

Results 510

Input File(s) 510
CHAPTER 31 505
Wheel Drop Test
Summary
Title Chapter 31: Wheel Drop Test
Geometry
Impact block: 375 mm ×125 mm ×100 mm

Tire: Outer diameter = 635 mm
Width = 260 mm
Material properties See Summary of Materials

Boundary conditions • Fixed condition at the center of wheel.
• Constraining to y- and z-direction
Applied loads Translational velocity applied to the impact block
Element type 2-D shell element
3-D solid element
Contact properties
FE results
CHAPTER 31
Introduction
This is an example of a wheel drop test as required in automotive industry to comply with government regulations. In
this test a rigid block of 540 Kg is dropped at 13° on a wheel. The drop velocity is 2052.8 mm/seconds. Several
contacts are defined to predict the interaction between wheel, tire and the rigid block.
The 13° impact test is one of the requirements mandated by JWL (Japan Light Wheel Alloy). JWL is a set of standards
defined by the Japanese Government to ensure the vehicle's safety for aluminum road wheels. Every wheel must pass
the 13° drop test to meet government regulations before it is introduced in the market. These standards are generally
accepted worldwide for most road conditions.
The main purpose of test is to predict the stability of the vehicle when the tire hits a curb. The joint or the interface
area of the spoke and the rim is an important structural area where it usually experiences high stress concentration. An
acceptable wheel design is when there are no separation of tire and wheel (air leak) and acceptable range of stress and
strain values during the droptest.
This test has become even more important due to the recent trend of a larger and wider wheel with low profile tire
combination. The reason is that there is lower air volume than the standard OE (Original Equipment) and therefore the
inner rim section is subjected to higher stress levels.
Requested Solutions
A numerical analysis will be performed to find the behavior of a wheel and tire. The rigid block drops from 15 mm
above the tire and wheel at 13 degrees. The impact velocity of the block is 2052.8 mm/seconds.
FEM Solution
The original test setup uses a 540 kg rigid block that is dropped at 230 mm height. However, in order to reduce the
analysis time, a small gap of 15 mm is used between the wheel and the block while the initial velocity of the block is
adjusted to 2052.8 mm/sec. The original test set up and analysis model are compared in Figure 31-1.
Four Contacts are defined between:
1. Rigid block and tire
2. Rigid block and wheel
3. Tire and wheel
4. Self contact of tire
Total time of simulation is 0.04 seconds.

CHAPTER 31 507
Wheel Drop Test
230 mm
2052.8 mm/sec
15 mm
13°
(a) 13 degree impact test (b) Analysis model

o
Figure 31-1 13 Impact Test and Analysis Model
TSTEPNL describes the number of Time Steps (100) and Time Increment (4.e-4 sec) of the simulation. End time is the
product of the two entries. Notice here the Time Increment is only for the first step. The actual number of Time
TSTEPNL 1 100 4.-4 1 ADAPT 2 10
Two different boundary conditions are applied. First, the fixed boundary condition is applied at the center of the wheel
as shown in Figure 31-2. Second, the impact block is restrained in translation directions except to move vertically in
the x-direction. The two boundary conditions are defined below.
SPC1 1 123456 864 874 875 876 882 883
...
SPC1 3 23 60001 THRU 60108
...
Red part is fixed
Figure 31-2 Boundary Condition of Wheel

CHAPTER 31
The initial velocity applied to the impact block is defined by TIC option.
TIC 2 60001 1 -2052.8
...
The material of the tire is rubber composite and its definition needs special attention. The tire consists of seven shell
and seven solid properties as shown in Figure 31-3. Each shell property is defined by PCOMP entry that describes a
composite material laminates. The shell composite properties use orthotropic materials defined by MAT8 and the solid
properties use a rubber material model defined by MATD027. The examples are described as below.
PCOMP 310 0. 0.
301 .5 90. YES
...
PSOLID 250 250 0
...
MATD027 250 1.1-9 .49 4167. .1938
0.
...
MAT8 301 199700. 4400. .148 4400. 1.1-9
...
To model the internal pressure of the tire, the PLOAD4 entry is used to apply 1 N/mm2. The pressure at the cross section
of tire is shown in Figure 31-3.
PLOAD4 4 232401 1. 200105 210101
...
Figure 31-3 Tire Cross Section and Internal Pressure
The Hourglass Suppression Method is used to prevent hourglass behavior of the tire by using HGSUPPR entries.
HGSUPPR, 200, SOLID, 200, 1, , , , 0.040
, , , 0
...
CHAPTER 31 509
Wheel Drop Test
Impact block - Rigid material:
E (Young’s Modulus) = 2.1e+5 N/mm2
 density= 1.152e-7 tonne/mm3
Wheel: Elasto-Plastic material
E (Young’s Modulus) = 7.e+4. N/mm2
 density= 2.7e-9 tonne/mm3
y (yield stress) =250 N/mm2
ET (tangent plastic modulus) = 200 N/mm2
 pu (ultimate plastic strain) = .15
Tire: Composite materials

Details are explained in FEM solution section
CHAPTER 31
Results
The results show plastic strains only on the wheel.
Figure 31-4 Equivalent Stress Contours in Wheel
Input File(s)
File Description
nug_31.dat MD Nastran input file for wheel impact test example
Chapter 32: Pick-up Truck Frontal Crash
32 Pick-up Truck Frontal Crash

Summary 512

Introduction 513


FEM Solution 513

Results 515

Input File(s) 515
CHAPTER 32
Summary
Title Chapter 32: Pick-up Truck Frontal Crash
Geometry Width= 1,954 mm
Length= 5,454 mm
Height= 1,841 mm
Material properties Three different material types are used:

• Elastic material: MAT1
• Elasto-plastic material: MATD024
• Rigid material: MATD020
Almost all structures are made by elasto-plastic material
E (Young’s modulus) = 2.1e+5. N/mm2
 (density) = 7.89e-9 tonne/mm3
 pu (ultimate plastic strain) = .9

Boundary conditions Fixed condition of the rigid wall
Applied loads Initial velocity of 5000 mm/sec. defined for the pick-up truck
Element type • 1-D beam element
• 2-D shell element
• 3-D solid element
FE results t = 90 ms
CHAPTER 32 513
Pick-up Truck Frontal Crash
Introduction
Auto companies perform crash tests simulation to increase safety of the vehicles and comply with government
regulations such as those of FMVSS (Federal Motor Vehicle Safety Standards). This is an example of a pick-up truck
frontal crash at 15 m/s (34 m.p.h.) against a rigid wall. To model the simulation, contact was defined between the truck
and the rigid wall to predict the stress and deformations of the structure.
Requested Solutions
A numerical analysis will be performed to find the behavior of a pick-up truck during crash simulation.
FEM Solution
Three contacts are defined in the simulation:
1. The truck and rigid wall surface
2. The truck tires and the ground surface
3. Self contact for the truck to avoid penetration among various components
SET is an executive control entry in SOL 700 that defines a set that contains some grid points. The set will later be
referred by the CSPOT entry in the bulk entry section.
SET 990009 = 105843 105655
..
TSTEPNL describes the number of Time Steps (10) and Time Increment (9.e-3 sec.) of the simulation. End time is the
product of the two entries. Notice here, the Time Increment is only for the first step. The actual number of Time
TSTEPNL 20 10 9e-3 1 5
To define a 3-D contact region, BCPROP and PSURF are used. BCPROP and PSURF specify a contact body by
element properties and element IDs, respectively.
BCPROP 1 1 2 3 4 10 11 12
..
BSURF 5 5 6 7 8 9 10 11
..
Concentrated masses are defined by CONM2 entry.
CONM2 1990624 91344 1e-06
Rigid nodes which are attached to a reference node are defined by RBE2 entry.
RBE2 5 104247 123456 104272 104614 104615 105038 105039
..
Applied forces and motions in the model are gravitational force and the initial velocity on the truck.
CHAPTER 32
GRAV defines acceleration vectors for gravity or other acceleration loading.
GRAV 3 0 9806. 0. 0. -1.

Initial velocity of the pick-up truck is given. All nodes of the truck have an initial velocity specified by the TIC entry.
TIC defines values for the initial conditions of variables used in structural transient analysis. Both displacement and
velocity values may be specified at independent degrees of freedom.
TIC 1 1 1 15000.
Boundary conditions are limited to the rigid wall and ground. All nodes of the rigid wall and the ground have been
constrained in all the degree of freedom.
SPC1 1 123456 990803 THRU 991384
Spot weld definition is used at several points. CSPOT is used to define spot-weld with several types of failure criteria.
Normal force criterion at failure (1.e+8 N) is applied to the spot weld entry. The number of a specific SET defined in
the executive control section is referred in the entry.
CSPOT 990009 990009
1e+08
..
MATD20M is used to merge MATD020 rigid bodies into one assembly for SOL 700 only.
MATD20M 181 180 221 182 183

..
RBJOINT defines a Joint between two rigid bodies. This entry supports 14 different types of rigid joint. This analysis
has two different types of rigid joint. REVOLUTE type describes the revolute joint type which allows only axial rotation
with other degrees of freedom fixed. UNIVERS type describes the universal joint type which allows all rotational
degrees of freedom with all translational degrees of freedom fixed.
CHAPTER 32 515
Pick-up Truck Frontal Crash
Results
t = 0 ms t = 25 ms
t = 50 ms t = 75 ms
t = 90 ms
Figure 32-1 Deformation History
Input File(s)
File Description
nug_32a.dat MD Nastran main analysis input file
nug_32b.dat Pick-up truck model file
nug_32c.dat Definition of rigid connection file
Chapter 33: Beams: Composite Materials and Open Cross Sections
Beams: Composite Materials

33 and Open Cross Sections

Summary - Composite Beam 517

Introduction 518


FEM Solution 519

Modeling Tips 520

Input File(s) 521

Summary - VKI and VAM Beam Formulations 522

Introduction 523
 Solution Requirements 523

FEM Solution 524

Input File(s) 525
CHAPTER 33 517
Beams: Composite Materials and Open Cross Sections
Summary - Composite Beam

Title Chapter 33: Composite Beam
Geometry Straight Cantilever Beam with load (Fy or Fz) applied at Free-End
Y, Ye
Fy
Fz
Z, Ze X, Xe
Element coordinate (Xe, Ye, Ze) coincides with Basic Coordinate (X,Y,Z)
Material properties • Linear elastic orthotropic material using MAT8

• Assumptions: E33 = 0.8E22; 13= 23= 12
• Theta on PCOMP/PCOMPG specifies the angle between X-axis of material coordinate
and X-axis of element coordinate.
Analysis type Linear static analysis
Boundary conditions Cantilever configuration
Applied loads Bending
Element type CBEAM3
FE results • Converted PBEAM3 from PBMSECT
• Stress recovery - screened based on max failure index
• bdf file for FE mesh of cross section shown here
X Y
CHAPTER 33
Introduction
Composite materials have found increasing applications in many applications and slender structures like rotor blades
or high-aspect-ratio wings may be modeled in one-dimension as a 1-D beam provided the complex cross sectional
properties (ultimately represented as a 2-D finite element mesh) can be captured properly. Here, a new way for
composite beam analysis is introduced. The Variational Asymptotic Method (VAM) computes the properties of a
beam’s arbitrary cross section containing composite materials. VAM, the mathematical basis of VABS, splits a general
3-D nonlinear elasticity problem for a beam-like structure into a two-dimensional (2-D) linear cross-sectional analysis
and a 1-D nonlinear beam analysis. For details on VAM, refer to Yu, W., Volovoi, V., Hodges, D. and Hong, X.
“Validation of the Variational Asymptotic Beam Sectional Analysis (VABS)”, AIAA Journal, Vol. 40, No. 10, 2002
(available at http://www.ae.gatech.edu/people/dhodges/papers/AIAAJ2002.pdf). VAM’s key benefit lies in the ability
to model a beam made of composite material with only 1-D elements, namely CBEAM3.
In general, the solution requires the layup of composite material and the description of this general or arbitrary cross
section. PCOMP entries are used to provide the composite layup and PBMSECT entry is utilized to describe the profile
of cross section and the link to the composite layup via PCOMP. An example is shown as follows:
$
$ Composite case
PBMSECT 32 1 OP 0.015
OUTP=101,C=101,brp=103,c(1)=[201,pt=(15,34)]
pcomp 101 -0.1 5000. hill 0.0
501 0.05 0.0 501 0.05 90.0
501 0.05 -45.0 501 0.05 45.0
501 0.05 0.0
pcomp 201 5000. tsai 0.0 SYM
501 0.05 -45.0 501 0.05 45.0
501 0.05 0.0
$MAT1 501 3.6 .3
mat8,501,2.0e7,2.0e6,.35,1.0e6,1.0e6,1.0e6,0.0,+
+,0.0,0.0,0.0,2.3e5, 1.95e5, 13000., 32000., 12000.
The theta field on PCOMP is utilized to specify the angle between the X-axis of the material coordinate and the X-axis
of the element coordinate. A cutout of the FEM mesh at the intersect of OUTP=101 and BRP=103 illustrates the ply
layup shown in Figure 33-1.
CHAPTER 33 519
PCOMP 201 -45, 45, 0, 0, 45, -45
X Y P
0 C
45 O
-45 M
P
90 1
P 0 0
C 0
O 45 1
M -45
P
90
1
0 0
1
Figure 33-1 Intersection of Ply Layups 101 and 201
FEM Solution
The converted PBEAM3 for PBMSECT,32 is as follows:
*** USER INFORMATION MESSAGE 4379 (IFP9B)

THE USER SUPPLIED PBMSECT BULK DATA ENTRIES ARE REPLACED BY THE FOLLOWING PBEAM3 ENTRIES.
CONVERSION METHOD FOR PBARL/PBEAML - .
PBEAM3 32 0 4.7202E+00 8.3059E+01 2.9578E+01 -1.5664E+01 3.2316E+01 0.0000E+00
1.8014E+01 4.2136E+00 1.7100E+01 -2.7858E+00 3.8881E+00 -3.5404E+00 4.7202E+00 2.6994E+00
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00
1.2253E+08 -2.1160E+05 8.1193E+04 -2.4761E+06 -3.7193E+06 7.9049E+06 -2.1160E+05 2.1792E+06
-1.7859E+06 1.9780E+07 5,4643E+05 -3.5845E+05 8.1193E+04 -1.7859E+06 2.7228E+07 1.7190E+07
2.9835E+04 2.1407E+06 -2.4761E+06 1.9780E+07 1.7190E+07 2.2332E+08 5.8182E+06 -1.2186E+06
-3.7193E+06 5.4643E+05 2.9835E+04 5.8182E+06 2.1349E+09 -4.0706E+08 8.9040E+06 -3.5845E+05
2.1407E+06 -1.2186E+06 -4.0706E+08 7.5602E+08
Note that the MID field of above PBEAM3 has value of 0 which is a flag for using the Timoshenko 6 x 6 matrix stored
from the seventh line of PBEAM3. Timoshenko 6 x 6 matrix includes cross sectional and material properties. The
cross-sectional shape and the FE mesh is shown in Figure 33-2. The coordinate shown in the figure matches with
element coordinate.
CHAPTER 33
X Y
Figure 33-2 Cross-sectional Shape and the Corresponding FE Mesh
Full cross sectional stress recovery can be performed with PARAM,ARBMSS,YES in bulk data and FORCE=setid in
case control. The stresses screened based on maximum failure index is shown as follows:
1 VAB ALGORITHM USING CORE OF PBMSECT MARCH 6, 2007 MD NASTRAN 3/ 6/07 PAGE 14
TRANSVERSE TIP LOAD
0 SUBCASE 1
S T R E S S E S I N L A Y E R E D C O M P O S I T E E L E M E N T S ( BEAM3 )
ELEMENT GRID PLY D I R E C T S T R E S S E S FAILURE MAXIMUM STRENGTH

ID ID ID NORMAL-1 NORMAL-2 NORMAL-3 SHEAR-12 SHEAR-23 SHEAR-13 THEORY FAIL. INDEX RATIO
FLAG
2 302 2 2.468E+01 1.601E+01 2.670E+00 2.323E+01 4.991E-01 3.724E+00 TSIA-WU 7.161E-04 4.035E+02
102 2 1.685E+01 1.619E+01 -7.230E-01 1.993E+01 -1.377E-01 -5.572E-01 TSAI-WU 7.258E-04 4.470E+02
1301 2 1.588E+01 1.594E+01 -7.167E-01 1.938e+-1 -1.162e-01 -5.280e-01 TSAI-WU 7.193E-04 4.569E+02
Modeling Tips
CBEAM3 is considered a straight beam if PID points to PBMSECT ID. The third point is ignored during the formation
of element matrices. During data recovery, the stresses for the third point are computed based on the forces recovered
which may not be correct.
PARAM,ARBMSTYP,TIMOSHEN must be present to access VAM for composite beam.
CHAPTER 33 521
Input File(s)
File Description
Vabcore1.dat Composite beam with MAT1.
CHAPTER 33
Summary - VKI and VAM Beam Formulations

Title Chapter 33: VKI and VAM Beam Formulations
Geometry
Straight Cantilever Beam with load (Fy or Fz) applied at Free-End
Y, Ye
Fy 0.04
Z
X Y 0.5
Fz 1.0
Z, Ze X, Xe
Element coordinate (Xe, Ye, Ze) coincides with Basic Coordinate (X,Y,Z)
Material properties Linear elastic isotropic material

Analysis type Linear static analysis
Boundary conditions Cantilever configuration
Applied loads Bending load with forces applied at free end
Element type CBEAM, CBEAM3
FE results • Converted PBEAM/PBEAM3 from PBMSECT
• bdf file for FE mesh of cross section
• Stress recovery - screened based on max failure index
X Y
Results Isotropic with VKI Isotropic with Composite with

VAM MAT1 using VAM
Disp at free end 49.987 49.974 49.977
Smax at fixed end 74974 74956 75351

CHAPTER 33 523
Introduction
In MD Nastran, there are two formulations to compute sectional properties. Both formulations use the finite element
method. The first one is named after its third party vender, VKI, which solves a series of equations (see documentation
of PBMSECT in Quick Look Guide) to obtain sectional properties. The other formulation is Variational Asymptotic
Method (VAM), see attached for details on VAM Theory. While VKI formulation is for isotropic material only, VAM
is capable to compute beam sectional properties for isotropic and composite material.
PBMSECT bulk data entry is utilized to describe the shape of I section and PARAM,ARBMSTYP is used to control the
selection of formulation. Note that default value for PARAM,ARBMSTYP select VKI formulation to compute sectional
properties of arbitrary cross section with isotropic material. However, PARAM,ARBMSTYP,TIMISHEN must be present
in the bulk data section if PBMSECT entry with Core and/or Layer keywords exists in the file.
$ to select VAM
PARAM,ARBMSTYPE,TIMOSHEN
.
$.......2.......3.......4.......5.......6.......7.......8.......9.......10.....
$ Section profile
$
$ 1 -- 2 -- 3
|
|
$ 4 -- 5 -- 5
$
point 1 -0.50 0.23
point 2 0.00 0.23
point 3 0.50 0.23
point 4 -0.50 -0.23
point 5 0.00 -0.23
point 6 0.50 -0.23
$
$.......2.......3.......4.......5.......6.......7.......8.......9.......10.....
SET1 101 1 2 5 6
SET1 201 2 3
SET1 102 5 4
$
$ Ply properties
$.......2.......3.......4.......5.......6.......7.......8.......9.......10.....
$MAT8 501 20.59e6 1.42e6 0.42 0.89e6 0.89e6 0.89e6
$MAT1 501 1.+7 .3
$
$ isotropic case using T keyword
PBMSECT 31 1 OP +
OUTP=101,t=0.04,BRP(1)=201,BRP(3)=102
$
$ isotropic case using C and MAT1
PBMSECT 32 OP +
OUTP=101,CORE=301,CORE(1)=[101,PT=(1,2)],CORE(2)=[202,PT=(5,6)],+
BRP(1)=201,CORE(3)=[201,PT=(2,3)], +
BRP(3)=102,CORE(3)=[102,PT=(5,4)]
CHAPTER 33
FEM Solution
The converted BEAM for PBMSECT,31 from VKI is as follows:
*** USER INFORMATION MESSAGE 4379 (IFP9A)

THE USER SUPPLIED PBEAML/PBMSECT BULK DATA ENTRIES ARE REPLACED BY THE FOLLOWING PBEAM ENTRIES.
CONVERSION METHOD FOR PBARL/PBEAML - FINITE ELEMENT METHOD.
PBEAM3 31 1 9.6800E-02 4.4896E-03 6.6689E-03 -8.0299E-19 5.2448E-05 0.0000E+00
2.5000E-01 5.0000E-01 2.5000E-01 -5.0000E-01 -2.5000E-01 -5.0000E-01 -2.5000E-01 5.0000E-01
1.5197E-01 6.9769E-01 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 3.6170E-04 3.6170E-04
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 4.1043E-11 7.5134E-10 4.1043E-11 7.5134E-10
The converted BEAM/PBEAM3 for PBMSECT,31 and 32 from VAM is as follows:
*** USER INFORMATION MESSAGE 4379 (IFP9A)

THE USER SUPPLIED PBEAML/PBMSECT BULK DATA ENTRIES ARE REPLACED BY THE FOLLOWING PBEAM ENTRIES.
CONVERSION METHOD FOR PBARL/PBEAML - FINITE ELEMENT METHOD.
PBEAM3 31 1 9.6800E-02 4.4902E-03 6.6696E-03 0.0000E+00 5.5566E-05 0.0000E+00
2.5000E-01 5.0000E-01 2.5000E-01 -5.0000E-01 -2.5000E-01 -5.0000E-01 -2.5000E-01 5.0000E-01
1.5346E-01 7.0201E-01 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 3.5121E-04 3.4121E-04
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
*** USER INFORMATION MESSAGE 4379 (IFP9B)
THE USER SUPPLIED PBMSECT BULK DATA ENTRIES ARE REPLACED BY THE FOLLOWING PBEAM3 ENTRIES.
CONVERSION METHOD FOR PBARL/PBEAML - .
PBEAM3 32 0 9.6800E-02 4.4902E-03 6.6696E-03 0.0000E+00 5.5566E-05 0.0000E+00
2.5000E-01 5.0000E-01 2.5000E-01 -5.0000E-01 -2.5000E-01 -5.0000E-01 -2.5000E-01 5.0000E-01
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00
9.6800E+05 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 2.6041E+05
-5.9944E-04 1.5708E-04 0.0000E+00 0.0000E+00 0.0000E+00 -5.9944E-04 5.6910E+04 -7.1497E-05
0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00 4.4898E+04 0.0000E+00 0.0000E+00 0.0000E+00
0.0000E+00 0.0000E+00 0.0000E+00 6.6693E+04
Note that the MID field of above PBEAM3 has value of 0 which is a flag for using the Timoshenko 6 x 6 matrix stored
from the seventh line of PBEAM3. Timoshenko 6 x 6 matrix includes cross-sectional and material properties. The
cross-sectional shape and the FE mesh is shown in Figure 33-3.
X Y
Figure 33-3 Cross sectional Shape and the Corresponding FE Mesh

CHAPTER 33 525
Regular beam stresses at extreme point from different formulation is shown in following table.
Composite with
Results Isotropic with VKI Isotropic with VAM MAT1 using VAM
Disp at free end 49.987 49.974 49.977
Smax at fixed end 74974 74956 75351
Input File(s)
File Description
nug_33a.dat Isotropic and Composite beam with MAT1 using VAM
nug_33b.dat Isotropic beam using VKI
Chapter 34: Topology Optimization MBB Beam and Torsion
Topology Optimization MBB

34 Beam and Torsion

Summary - Beam 527

Introduction 528


Modeling Tips 531

Summary - Torsion 533

Introduction 534


Modeling Tips 539
 Input File(s) 540
CHAPTER 34 527
Topology Optimization MBB Beam and Torsion
Summary - Beam
Title Chapter 34: Topology Optimization MBB Beam and Torsion
Topology optimization • Compliance minimization
features • Mass target
• Checkerboard free
• Minimum member size control
• Mirror symmetry constraints
Geometry Units: m P = 200.0 N
12 x 2 x 0.01 Plate
(Symmetry) (Mesh 4800 Elements)
Material properties Young’s Modulus = 2x105 MPa, Poisson’s ratio = 0.3

Analysis type Static analysis
Boundary conditions Supported on rollers at one point and fixed support at another point.
Applied loads A concentrated force = 100.0 N (half model)
Element type 4-node liner QUAD elements
Topology result Material distribution
)
P = 200.0 N
CHAPTER 34
Introduction
An MBB beam example (a half model shown in Figure 34-1) is used to demonstrate (a) basic MD Nastran topology
optimization capabilities without manufacturing constraints, (b) minimum member size control, and (c) mirror
symmetry constraints. The structural compliance (i.e., total strain energy) is minimized with a mass target 0.5 (i.e.,
50% material savings). The loading and boundary conditions are shown in Figure 34-1. The structure is modeled with
4800 CQUAD4 elements.
P = 100.0 N
Figure 34-1 MBB Beam
This MBB beam is well accepted by academic and industry for topology optimization validation.
Design Model Description
Objective: Minimize compliance

Topology design region: PSHELL
Constraints: Mass target = 0.5 (i.e., mass savings 50%)
(a) Minimum member size control and/or
(b) Mirror symmetry constraints

• A distinct design can be obtained by MD Nastran topology optimization with checkerboard free algorithm (as
default)
• The minimum member size is mainly used to control the size of members in topology optimal designs.
Preventing thin members enhances the simplicity of the design and, hence, its manufacturability. Minimum
member size is more like quality control than quantity control.
• By using symmetry constraints in topology optimization, a symmetric design can be obtained regardless of
the boundary conditions or loads.
CHAPTER 34 529
Optimization Solution
Basic compliance minimization
The input data for this example related to topology optimization model is given in Listing 1. A TOPVAR =1 Bulk Data
entry is used to define a topological design region. XINIT=0.5 on the TOPVAR entry matches the mass target
constraint so that the initial design is feasible. The rest values on the TOPVAR entry are default values that are
recommended for general topology optimization applications. Type one design responses DRESP1 = 1 and 2 identify
compliance and fractional mass, respectively. DCONSTR= 1 specifies the mass target. DESOBJ=1 in Case Control
Command selects DRESP1=1 entry to be used as a design objective (minimization as default) and DESGLB selects the
design constraint DCONSTR= 1 to be applied in this topology optimization task.
Listing 1 Input File for MBB Beam
DESOBJ = 1
DESGLB = 1
SUBCASE 1
$ Subcase name : Default
SUBTITLE=Default
SPC = 2
LOAD = 2
ANALYSIS = STATICS
BEGIN BULK
DCONSTR 1 2 .5
TOPVAR, 1 , Tshel, Pshell, , , , , 1
DRESP1 1 COMPL COMP
DRESP1 2 FRMASS FRMASS
Figure 34-2 shows the topology optimized result that is smoothed and remeshed by using Patran. This optimal design
is very clear without any checkerboard effect. It is noticed that there are some small members.
Figure 34-2 MBB Beam Topology Design
Minimum Member Size Control

The MBB beam (shown in Figure 34-1) is used here to demonstrate the minimum member size control capability.
CHAPTER 34
The input data for this example related to topology optimization with “minimum member size” is given in Listing 2.
The minimum member size value is defined by the TDMIN = 0.5 parameter on the DOPTPRM entry and corresponds
to the length of 10 elements.
Listing 2 Input File for MBB Beam with Minimum Member Size
DESOBJ = 1
DESGLB = 1
SUBCASE 1
SUBTITLE=Default
SPC = 2
LOAD = 2
ANALYSIS = STATICS
BEGIN BULK
DOPTPRM, TDMIN, 0.5
DCONSTR 1 2 .5
DRESP1 1 COMPL COMP
The Figure 34-3shows the topology optimized result with “minimum member size” TDMIN=0.5. Compared the design
shown in Figure 34-2, this design with “minimum member size” is obviously much simpler and there are no tiny
members at all.
Figure 34-3 MBB Beam Topology Design with “Minimum Member Size”
Mirror Symmetric Constraints

Since the loads applied on the MBB beam are not symmetric, the topology optimized designs Figures 34-2 and 34-3
are not symmetric. The MBB beam is employed again to demonstrate the mirror symmetric constraint capability that
enforces the design to be symmetric about a given plane.
To apply symmetric constraints on designed properties, users need to create a reference coordinate system using a
rectangular coordinate system CORD1R or CORD2R. In this example, grid 10001 (location x=3, y=1, and z=0) is
defined as the origin. Grid 10002 (x=3, y=1, and z=1) lies on the z-axis, and grid 1003 (x=4, y=1, and z=0) lies in the
x-z plane. CORD1R CID=1 defines a reference coordinate system. A continuation line “SYM” enforces the property
PSHELL=1 to be symmetric about the planes YZ and ZX in the reference coordinate system CID=1. In addition, a
minimum member size TDMIN=0.15 is applied. The input data for this example is given in Listing 3.
CHAPTER 34 531
Listing 3 Input File for MBB Beam with Mirror Symmetry Constraints
DESOBJ = 1
DESGLB = 1
SUBCASE 1
SUBTITLE=Default
SPC = 2
LOAD = 2
ANALYSIS = STATICS
BEGIN BULK
CORD1R 1 10001 10002 10003
GRID 10001 3. 1. 0.0
GRID 10002 3. 1. 1.0
GRID 10003 4. 1. 0.0
, SYM , 1 , YZ , ZX
, TDMIN, 0.15
DRESP1 1 COMPL COMP
DCONSTR 1 2 .5
Figure 34-3 shows the topology optimal result with symmetric constraints and minimum member size.
Figure 34-4 MBB Beam with Symmetric Constraints and Minimum Member Size
Modeling Tips
The quality of the results of a topology optimization task is a strong function of how the problem is posed in MD
Nastran. This section contains a number of tips:
• A DRESP1=COMP is introduced to define the compliance of structures for topology optimizations. The
response is usually used as an objective to maximize structural stiffness in static analysis problems.
• A DRESP1=FRMASS is introduced to define the mass fraction of topology designed elements. The
DRESP1=WEIGHT is the total weight of all structural and nonstructural mass. For topology optimization tasks,
a DRESP1=FRMASS response is recommended to define a mass reduction target in a design constraint.
CHAPTER 34
• The POWER field on the TOPVAR entry has a large influence on the solution of topology optimization
problems. A lower POWER often produces a solution that contains large “grey” areas (area with intermediate
densities 0.3 – 0.7). A higher value produces more distinct black and white (solid and void) designs. However,
near singularities often occur when a high POWER is selected.
• A TCHECK parameter on DOPTPRM is used to turn on/off the checkerboard free algorithm. This default
normally results in a better design for general finite element mesh. However, if high order elements and/or a
coarser mesh is used, turning off the filtering algorithm may produce a better result.
• The TDMIN parameter is mainly used to control the degree of simplicity in terms of manufacturing
considerations. It is common to see some members with smaller size than TDMIN at the final design since the
small members have contributions to the objective. Minimum member size is more like quality control than
quantity control. It is in general recommended that TDMIN should not be less than the length of 3 elements.
• Maximum design cycle DESMAX=30 (as default) is often required to produce a reasonable result. More design
cycles may be required to achieve a clear 0/1 material distribution, particularly when manufacturability
constraints are used.
• There are many solutions to a topology optimization: one global and many local minimization. It is not
unusual to see different solutions to the same problem with the same discretization by using different
optimization solvers or the same optimization solver with different starting values of design variables.
• In a multiple subcase problem, a DRSPAN Case Control Command can be used to construct a weighting
function via a DRESP2 or DRESP3. For example, a static and normal mode combined problem, the objective
can be defined as
c1 0
obj = weight1  ----- + weight2  -----
 c 0   1
where weight1 and weight2 are two weighting factors. c 1 is the calculated compliance and 1 is the calculated
eigenvalue via DRESP1 definition. c 0 and 0 are the initial value of these responses.
• To obtain a rib pattern by topology optimization, a core non-designable shell element thickness must be
defined together with two designable above and below the core thicknesses. That is, add two designable
elements for each regular element.
• If some elements are disconnected on the final topology design proposal, the mass target may be too small to
fill the design space.
CHAPTER 34 533
Summary - Torsion
Title Chapter 34: A Torsion Beam
Topology optimization • Compliance minimization
features • Mass target
• Checkerboard free
• Minimum member size control
• Mirror symmetry constraints
Geometry
P = 1000
+
P = 1000
+
Z
Units: m
Length = 16 and width = 4 and height = 4
Material properties Young’s Modulus = 2.1x105MPa, Poisson’s ratio = 0.3, density = 1.0
Analysis type Static analysis
Boundary conditions Cantilever
Applied loads A pair of twisting forces = 1000.0 N at the free end
Element type 8-node HEXA elements
)
CHAPTER 34
Introduction
A torsion beam is used here to demonstrate the extrusion and casting constraints. Figure 34-5 shows the FEM model
of the torsion beam. A pair of twisting forces is applied on one end while the other end is fixed. 2048 CHEXA elements
are used for this model. The objective is to minimize the structural compliance with mass target of 0.3 (i.e., 70%
material savings).
P = 1000
+
P = 1000
+
Z
Units: m
Length = 16 and width = 4 and height = 4
Figure 34-5 Torsion Beam
This torsion beam is utilized to show MD Nastran topology optimization extrusion and casting constraint capabilities.
Objective: Minimize compliance

Topology design region: PSOLID
Constraints: Mass target = 0.3 (i.e., mass savings 70%)
(a) Extrusion constraints
(b) Casting constraints with one or two dies
Three solutions demonstrate:

• By using extrusion constraints in topology optimization, a constant cross-section design along the given
extrusion direction can be obtained regardless of the boundary conditions or loads.
• The use of casting constraints can prevent hollow profiles in topology optimization so that the die can slide in
a given direction. One or two die options are available for selection.
• Some combined manufacturing constraints are allowed in topology optimization to achieve design goal.
CHAPTER 34 535
Extrusion Constraints With One Die
If is often to see some topology optimized designs can contain cavities that are not achievable or require a high cost
manufacturing process. For example, the result from the torsion beam without manufacturing constraints is shown in
Figure 34-6. Clearly, this topology design proposal is not achievable by casting.
Figure 34-6 Torsion Beam without Manufacturing Constraints
The extrusion constraints enforce a constant cross-section design along the given extrusion direction. The input data
related to imposing an extrusion constraint along the z-axis in the basic coordinate system (as the default option) is
given in Listing 4.
Listing 4 Input File for Torsion Beam with Extrusion
DESOBJ = 1
DESGLB = 1
SUBCASE 1
SUBTITLE=Default
ANALYSIS = STATICS
SPC = 2
LOAD = 2
BEGIN BULK
DRESP1 2 Frmass FRMASS
CHAPTER 34
DRESP1 1 COMPL COMP

DCONSTR 1 2 .3
TOPVAR, 1 , TSOLID, PSOLID, .3, , , , 1
, EXT , , Z
PSOLID 1 1 0
Figure 34-7 shows the topology optimized result with extrusion constraints. It is obvious that the design has a constant
cross-section along the z-axis.
Figure 34-7 Torsion Beam with Extrusion Constraints in Z-Axis
Casting Constraints with One Die

A torsion beam (shown in Figure 34-5 is used here to demonstrate the combination of one die casting
manufacturability constraints and mirror symmetric constraints.
The casting constraints with one die option enforce that the material can only be added to the region by “filling up” in
the given draw direction from the bottom (or, stated another way, that voids extend from the top surface and do not
reappear in the die direction). To apply casting constraints and symmetric constraints on designed properties, a
reference coordinate system CID=1 is defined by using a rectangular coordinate system CORD1R. A CAST
continuation line defines casting constraints in the Y direction and one die is a default option. Another SYM
continuation line defines symmetric constraints about the YZ plane. The input data related to the topology
optimization model is given in Listing 5.
CHAPTER 34 537
Listing 5 Input File for Torsion with One Die
DESOBJ = 1
DESGLB = 1
SUBCASE 1
SUBTITLE=Default
ANALYSIS = STATICS
SPC = 2
LOAD = 2
BEGIN BULK
DRESP1 1 COMPL COMP
DCONSTR 1 2 .3
CORD1R 1 5 167 7
PSOLID 1 1 0
TOPVAR, 1 , TSOLID, PSOLID, .3, , , , 1
, CAST, 1 , Y, , YES
, SYM, 1 , YZ
Figure 34-8 shows the topology optimized result with one die casting constraints. It is observed that the design
material is added by “filling up” in the Y direction from the bottom. In addition, the design is symmetric about the YZ
plane in the reference coordinate system CID=1.
Figure 34-8 Torsion Beam with One Die Casting Constraints in Y Direction
CHAPTER 34
Casting Constraints with Two Dies

A torsion beam (shown in Figure 34-5 is also used here to demonstrate two die casting manufacturability constraints.
The input for two die casting constraints is similar to the one die option in Example 5. Here, the difference is that 2
are selected for the DIE field on the TOPVAR entry. The input data related to imposing two die casting constraints is
given in Listing 6.
Listing 6 Input File for Torsion with Two Dies
DESOBJ = 1
DESGLB = 1
SUBCASE 1
SUBTITLE=Default
ANALYSIS = STATICS
SPC = 2
LOAD = 2
BEGIN BULK
DRESP1 1 COMPL COMP
DCONSTR 1 2 .3
CORD1R 1 5 167 7
PSOLID 1 1 0
TOPVAR, 1 , TSOLID, PSOLID, , , , , 1

, CAST, 1 , Y, 2, YES
, SYM , 1 , YZ
PSOLID 1 1 0
Figure 34-9 shows the topology optimized result with two die casting constraints. It is observed that the design
material grows from the splitting plane in opposite directions along the y-axis specified in the reference coordinate
system CID=1. The splitting plane is determined by optimization and in this case corresponds to the
CHAPTER 34 539
Figure 34-9 Torsion Beam with Two Die Casting Constraints in Y-Axis
Modeling Tips
• It is recommended that a base line topology optimization job (without any manufacturability constraints) be
carried out before a topology optimization solution with manufacturability constraints. Benefits are:
a. a topology optimization without restriction may result in a better design
b. the design proposal from the no restriction run may give some hints for imposing manufacturability
constraints.
• Topology optimization with manufacturability constraints often needs more material to fill the design space.
Therefore, the design with manufacturability constraints usually requires a relatively bigger mass target (less
material savings) than the one without manufacturability constraints.
• The casting constraints may have difficulty dealing with a design model that has one or more non-smoothed
boundary surfaces to be designed. It is recommended to use smooth surfaces for topology designed boundary
surfaces.
CHAPTER 34
Input File(s)
File Description
nug_34a.dat Basic compliance minimization
nug_34b.dat Minimum member size
nug_34c.dat Mirror symmetry constraints
nug_34d.dat Extrusion constraints
nug_34e.dat One die casting constraints
nug_34f.dat Casting constraints with two dies
Chapter 35: Engine Mount Topology Optimization
Engine Mount Topology

35 Optimization

Summary 542

Introduction 543


Optimization Solution 544

Modeling Tips 547

Input File(s) 547
CHAPTER 35
Summary
Title Chapter 35: Engine Mount Topology Optimization
Topology optimization • Averaged compliance minimization
features • Multiple TOPVAR entries
• Multiple load cases
• Displacement constraints
Geometry
Front Mount Beam
Link
Front Mount Beam
Trunnion
Front Mount Ring
Thrust Strut
Material properties Young’s Modulus = 2.05x105 MPa, Poisson’s ratio = 0.3

Boundary conditions Supported on rollers at one point and fixed support at another point.
Applied loads 14 load cases (forces)
Element type HEXA, PENTA, TETRA, and RBE3
)
CHAPTER 35 543
Engine Mount Topology Optimization
Introduction
The main goal is to minimize the compliance of the engine-front-mount-beam (shown in Figure 35-1) with mass target
0.3 (material savings 70%) and displacements within a range (-0.6, 0.6) at selected 5 grids. The analysis model has 14
load cases. The finite element model is shown in Figure 35-2. There are 62306 HEXA elements, 703 PENTA elements,
31 TETRA elements, and 5 RBE3 elements.
Link
Front Mount Beam
Trunnion
Front Mount Ring
Thrust Strut
Figure 35-1 Front-Mount-Beam
Front Mount Beam
Figure 35-2 Front-Mount-Beam FE Model

CHAPTER 35
Objective: Minimize averaged compliance

Topology design region: PSOLID = 1, 2, 3, 8, 9, and 10
Constraints: Constraints: Mass target = 0.3 (i.e., mass savings 70%)
Displacements at grid points 76095, 76096, 76419, 76420,
and 76421 for all 14 load cases within the range (-6.0, 6.0)
This solutions demonstrates:

• The averaged compliance can be used for topology optimization problems with multiple load case to achieve
an efficient design concept.
• Multiple topological design parts are allowed.
• Displacement constrains can be well treated in topology optimization.
The input data related to the topology optimization model is given in Listing 7.
The TOPVAR entries define five topological design parts with XINIT (initial design)=0.3 that matches the mass target
so the initial design is feasible (reduce CPU time spent on optimizer).
In order for a structural response to be used either as an objective or a constraint, it first must be identified on a DRESPi
Bulk Data entry. The DRESP1 entries 200-213, for example, identify the compliance. DRSPAN and SET Case Control
Commands are then used to select one compliance DRESP1 entry for each subcase that are used in DRESP2=1000
response. The equation response DRESP2=1000 with the attribute FUNC=AVG spans all subcases to calculate averaged
compliance of the structure. A DESOBJ Case Control Command selects DRESP2=1000 to be an objective.
DRESP1=500 defines a fractional mass response. This mass target is imposed by the upper bound on the DCONSTR=50
entry. As always, fractional mass constraints should be applied at the global level in a design optimization by using
DESGLB. Separate DRESP1 entries 1 -5 identify displacements responses at gird points. There responses are
constrained by the bounds set using a corresponding set of DCONSTR entries.
Listing 7 Input File for Engine Mount
analysis=statics
set 1 = 200
set 2 = 201
set 3 = 202
set 4 = 203
set 5 = 204
set 6 = 205
set 7 = 206
set 8 = 207
set 9 = 208
CHAPTER 35 545
set 10 = 209
set 11 = 210
set 12 = 211
set 13 = 212
set 14 = 213
DESOBJ = 1000
DESGLB = 50
DESSUB = 1
$ Direct Text Input for Global Case Control Data
$ ==================================================================
$ ==================================================================
SUBCASE 1
LOAD = 1
DRSPAN = 1
SUBCASE 2
LOAD = 2
DRSPAN = 2
SUBCASE 3
LOAD = 3
DRSPAN = 3
SUBCASE 4
LOAD = 4
DRSPAN = 4
SUBCASE 5
LOAD = 5
DRSPAN = 5
SUBCASE 6
LOAD = 6
DRSPAN = 6
SUBCASE 7
LOAD = 7
DRSPAN = 7
SUBCASE 8
LOAD = 8
DRSPAN = 8
SUBCASE 9
LOAD = 9
DRSPAN = 9
SUBCASE 10
LOAD = 10
DRSPAN = 10
SUBCASE 11
LOAD = 11
DRSPAN = 11
SUBCASE 12
LOAD = 12
DRSPAN = 12
SUBCASE 13
LOAD = 13
DRSPAN = 13
SUBCASE 14
LOAD = 14
DRSPAN = 14
$ ===================================================================
CHAPTER 35
BEGIN BULK
$ *******************************************************************
$ Written by : MSC/NASTRAN
$ Version : 4.51
$ Translator : MSC/NASTRAN
$ From Model : D:\users\mulf\bmwroll\fmb.mod
$ Date :
$ *******************************************************************
$
$234567812345678123456781234567812345678
$DCONSTR 1 20 6. 6.1
$23456781234567812345678123456781234567812345678123456781234567812345678
$DCONADD 1 15 16 17 18 19 21 22
$ 23 24 25 50
DCONSTR 1 1 -6. 6.0
DCONSTR 1 2 -6. 6.0
DCONSTR 1 3 -6. 6.0
DCONSTR 1 4 -6. 6.0
DCONSTR 1 5 -6. 6.0
DCONSTR 50 50 .3
TOPVAR, 1 , psolid, Psolid, .3, , , , 1
TOPVAR, 2 , psolid2, Psolid, .3, , , , 2
$234567812345678123456781234567812345678123456781234567812345678
DRESP1 50 w FRMASS
DRESP1 1 d disp 123 76095
DRESP1 2 d1 disp 123 76096
DRESP1 3 d2 disp 123 76419
DRESP1 4 d3 disp 123 76420
DRESP1 5 d4 disp 123 76421
$234567812345678123456781234567812345678123456781234567812345678
DRESP1, 200, COMP1, COMP
$234567812345678123456781234567812345678123456781234567812345678
DRESP2 1000 COMPL AVG
DRESP1 200 201 202 203 204 205 206
207 208 209 210 211 212 213
CHAPTER 35 547
A topology result shown in Figure 35-3 is obtained by MD Nastran. The topology optimization design proposal is
smoothed by Patran.
Figure 35-3 Front-Mount-Beam Topology Optimization Proposal
Modeling Tips
• If multiple mass targets (multiple DRESP1=FRMASS) are used, it is recommended each TOPVAR's initial
value XINIT matches its corresponding mass target.
Input File(s)
File Description
nug_35.dat Minimize averaged compliance/displacement constraints
Chapter 36: Wheel Topology Optimization
36 Wheel Topology Optimization

Summary 549

Introduction 550


Modeling Tips 552

Input File(s) 552
CHAPTER 36 549
Wheel Topology Optimization
Summary
Title Chapter 36: Wheel Topology Optimization
Topology optimization Cyclical symmetry constraints
features
Geometry
Material properties Young’s Modulus = 1.0x107 Pa, Poisson’s ratio = 0.3, density = 1.0
Boundary conditions Fixed at some points
Applied loads Force = 1000.0 N in direction of gravity
Element type HEXA, RBE3
)
550 MD User’s Guide - Application Examples
CHAPTER 36
Introduction
A wheel model shown in Figure 36-1 is used to demonstrate MD Nastran topology optimization cyclical symmetry
capabilities. The wheel is modeled with six-sided solid elements (118156 CHEXA). The wheel outer layers and bolts
are nondesignable. One load case is considered. The structural compliance is minimized (i.e., minimize the total strain
energy of the structure) with a mass target 0.1 (i.e., remove 90% of the material). Although the load is not cyclically
symmetric about the Y-axis, the design is required to be cyclically symmetric about the Y-axis with five segments.
Figure 36-1 Wheel FE Model
Objective: Minimize averaged compliance

Topology design region: PSOLID (blue)
Constraints: Constraints: Mass target = 0.1 (i.e., mass savings 90%)
The design is forced to be cyclical symmetry about the Y-
axis with five segments.
This solutions demonstrates:

• By using cyclical symmetry constraints in topology optimization, a rotational symmetric design can be
obtained regardless of the boundary conditions or loads.
• CASI solver provides a major speed up for large 3-D problems in static analysis.
CHAPTER 36 551
Wheel Topology Optimization
The input data for this example related to topology optimization model is given in Listing 8. The coordinate system
(CORD2R = 1) is created to be used to specify cyclical symmetric constraints. The field CS (cyclical symmetric axis)
on the SYM line is Y-axis with NCS (number of cyclical symmetric segments) = 5. It is noticed that SMETHOD=
ELEMENT is used to select CASI iterative solver. The CASI iterative solver released in MD R1 Nastran can provide a
major speedup in the solution of large static analyses.
Listing 8 Input File for Wheel
DESOBJ = 10
DESGLB = 1
ANALYSIS = STATICS
SMETHOD = ELEMENT
SUBCASE 1
SPC = 2
LOAD = 2
BEGIN BULK
CORD2R 1 10.512 33.3312 12.9921 -22.209833.3312 4.88385
28.388 33.3313 -19.7297
DCONSTR 1 2 .1
TOPVAR 1 PSOLID PSOLID .1 2
SYM 1 Y 5
DRESP1 2 FRM FRMASS
DRESP1 10 COMP COMP
Figure 36-2 shows the topology optimized result that is smoothed by using MD Patran. It is noticed that cyclical
symmetry is obtained even though the loading is not cyclically symmetric.
Figure 36-2 Wheel Topology Design

CHAPTER 36
Modeling Tips
• CASI solver is limited to compliance minimization topology optimization problem only.
• The cyclical symmetry constraints can also be used for rotational parts <60°. In addition, the starting surface
must be XY plane for cyclical symmetric CS=X, YZ plane for CS=Y; ZX plane for CS=Z, respectively. The
cyclical symmetric segment (NCS) must also be defined in 360 for this case. For example, a 90° rotational
part has three segments, NCS must be set to NCS=12 in 360°.
Input File(s)
File Description
nug_36.dat Cyclical symmetry constraints
Chapter 37: Local Adaptive Meshing
37 Local Adaptive Meshing

Summary 554

Introduction 555


Mesh Refinement Process Definition 557

Material Modeling 558

Loading and Boundary Conditions 558


Results 559

Modeling Tips 563

Video 564
CHAPTER 37
Summary
Title Chapter 37: Local Adaptive Meshing
Features • 2-D structure mesh refinement
• Region to be refined defined by property identifier
• Mesh adaptivity criterion based on error indicator
• Free-Free structure
Geometry
H = 0.4 m
d = 0.2 m
s = 0.02 m
σmax
F = 280 N
F d H F
σnominal
Material properties E = 69GPa ,  = 0.33 ,  = 3200kg/m

3
Analysis characteristics Linear static analysis using local adaptive meshing functionality
Boundary conditions Automatic inertia relief (INREL = -2)
Applied loads Tensile axial loading acting on the shortest edge of the plate (F = 280 N)
Element type 4-node, 3-node 2-D elements (QUAD4/TRIA3)
FE results 1. Stress at the most critical point for each refinement cycle
2. Stress concentration factor to compare with theoretical results
Stress Concentration
2.5
σmax Theoretical (2.157)
Kt=
σnominal Numerical
2.0
Refinement Cycle
1.5
0 1 2 3 4 5 6 7
CHAPTER 37 555
Local Adaptive Meshing
Introduction
This problem demonstrates the ability of the mesh refinement capability to converge on the correct solution in terms
of stress distribution. A very simple structure has been considered to enable a comparison between theoretical and
numerical results.
F
Theory, based on net section, states that if the nominal stress  nom = --------------------- is defined as the stress acting on the net
 H – d s
section (defined as the section that results from the difference between the width of the plate and the diameter of the

hole), then the stress concentration factor due to the presence of the hole is k t = -----------
max
- , where  max is the actual stress
 nom
at the critical point. The stress concentration factor can be calculated from the empirical relationship shown in
Figure 37-1.
Kt
3.0 2 3
⎛ d ⎞ ⎛ d ⎞ ⎛ d ⎞
kt = 2 + 0.284 ⋅ ⎜1 − ⎟ − 0.600 ⋅ ⎜1 − ⎟ + 1.320 ⋅ ⎜1 − ⎟
⎝ H ⎠ ⎝ H ⎠ ⎝ H ⎠
2.5
2.0
1.5
d
H
1.0
0.00 0.25 0.50 0.75 1.00
Figure 37-1 Graphical Representation of Stress Concentration Factor versus d/H
The theoretical results and input data are shown in Table 37-1.
Table 37-1 Input Data and Theoretical Results

Applied Stress
Load Concentration Nominal Maximum
(N) Geometrical Data (m) Factor Stress (Pa) Stress (Pa)
F H d s kt  nom  max
280.0 0.4 0.2 0.02 2.157 70000.0 150990.0

CHAPTER 37
Modeling Details
A numerical solution has been obtained with MD Nastran’s solution sequence 101 for a 2-D representation of a free-
free plate with a hole in its central region. The details of finite element model, contact simulation, material, load,
boundary conditions and solution procedure are discussed below.
Figure 37-2 Initial Finite Element Model with Zoom in the Critical Region
The initial finite element model consists of:
M O D E L S U M M A R Y
NUMBER OF GRID POINTS = 964

NUMBER OF CQUAD4 ELEMENTS = 872
NUMBER OF CTRIA3 ELEMENTS = 12
The case control section of the input contains the typical entries for a linear static analysis. The only command that
has been added to activate the mesh refinement is HADAPT. This, in turn, specifies the use of the bulk data entries,
HADAPTL and HADACRI that control all the refinement process (see next section for details):
ECHO = NONE
HADAPT = 1
PARAM POST 0
PARAM,INREL,-2
SUBCASE 1
TITLE=First mesh
LOAD = 2
Furthermore, the INREL parameter has been included with a value of ‘-2’ to activate the automatic inertia relief
process. It is needed (automatic or manual) because the structure is in free-free conditions (unrestrained). The output
request for displacement has been considered only to check the congruency of the deformation while the stress output
is what we really need for comparison with the theoretical results.
The Bulk Data Section contains the standard options for a linear static analysis plus the specific option for mesh
refinement control.
CHAPTER 37 557
Mesh Refinement Process Definition

The following options have been added to the standard linear static analysis Bulk Data section to define the mesh
refinement process:
$----------------------------------------------------------------------
$ C A R D S F O R R E F I N E M E N T
$---1---$---2---$---3---$---4---$---5---$---6---$---7---$---8---$---9---
HADAPTL 1 7 1 PROP 2 1
+
HADACRI 1 1 0.9
$----------------------------------------------------------------------
The HADAPTL option specifies the local adaptive mesh refinement control parameters. In particular, referring to the
specific name associated to each field in the MD Nastran Quick Reference Guide, the process has been defined in this
way:
• REPEAT = 7 (5th field): maximum number of refinement cycles executed before the process is stopped
• CRITID = 1 (6th field): associated HADACRI option identifier
• WHEREMET = PROP (7th field): method used to specify the mesh refinement region subjected to the adaptivity
criteria referenced in the associated HADACRI. PROP means that all the elements associated to a specific
property option are considered by the refinement process
• WHEREID = 2 (8th field): Identifier of the mesh refinement region subjected to the selected adaptivity criteria.
Considering the WHEREMET value and the elements used in the finite element model, all the elements
associated to PSHELL which identifier is 2 will be involved in the refinement process
• SNAPMETH =1 (9th field): Method to project, snap, or relax new grid points on mid-edge or mid-face during
the refinement process. The selected value allows the projection onto a smooth approximation of the analysis
domain boundary interpolated from the mesh boundary.
• MAXLEVEL = default (2nd field in the second physical option for HADAPTL): Maximum refinement level
allowed for each individual element in the mesh. No elements will be refined to a level higher than the
specified value. The default value is equal to that one defined in the REPEAT field.
The HADACRI option specifies the mesh adaptivity criterion and the corresponding parameters. In this case, the
method based on a scalar error indicator has been chosen (TYPE = 1 in the 3rd field). According to this criterion a
scalar error indicator Ee is computed in the finite element mesh and an element ‘e’ will be refined if:
2
Ee
-1
--------------------------------
N
1
F 1  ----  E f
2
N
f= 1
where N is the total number of elements in the element set to which it belongs and F 1 is the value specified in the 4th
field of this option (in the specific case F 1 = 0.9 ). Note that the elemental error indicator is computed using the grid
point stresses following the procedure utilized by the ELSDCON Case Control command.
CHAPTER 37
Material Modeling
Isotropic elastic material properties of the deformable body are defined using the following MAT1 option as follows:
MAT1 1 6.9+10 .33 3200.
The Young’s modulus is taken to be 6.9 GPa with a Poisson’s ratio of 0.33. Mass density ( = 3200 Kg/mm3) has
also been specified to support the inertia relief process. Note that the results are not affected by the value included
in this field.

No boundary conditions have been defined because the structure is not constrained.
The loading involves application of concentrated forces (to simulate uniform load distribution) at the nodes located on
the shortest edges of the plate:
$ Loads for Load Case : Case_2
LOAD 2 1. 1. 1 1. 3 1. 4
1. 5
$ Nodal Forces of Load Set : TENSILE_FORCE_Central_NEG
FORCE 1 252 0 20. -1. 0. 0.
FORCE 1 253 0 20. -1. 0. 0.
FORCE 1 254 0 20. -1. 0. 0.
FORCE 1 255 0 20. -1. 0. 0.
FORCE 1 256 0 20. -1. 0. 0.
FORCE 1 257 0 20. -1. 0. 0.
FORCE 1 258 0 20. -1. 0. 0.
FORCE 1 735 0 20. -1. 0. 0.
FORCE 1 736 0 20. -1. 0. 0.
FORCE 1 737 0 20. -1. 0. 0.
FORCE 1 738 0 20. -1. 0. 0.
FORCE 1 739 0 20. -1. 0. 0.
FORCE 1 740 0 20. -1. 0. 0.
$ Nodal Forces of Load Set : TENSILE_FORCE_Central_POS
FORCE 3 504 0 20. 1. 0. 0.
FORCE 3 505 0 20. 1. 0. 0.
FORCE 3 506 0 20. 1. 0. 0.
FORCE 3 507 0 20. 1. 0. 0.
FORCE 3 508 0 20. 1. 0. 0.
FORCE 3 509 0 20. 1. 0. 0.
FORCE 3 510 0 20. 1. 0. 0.
FORCE 3 959 0 20. 1. 0. 0.
FORCE 3 960 0 20. 1. 0. 0.
FORCE 3 961 0 20. 1. 0. 0.
FORCE 3 962 0 20. 1. 0. 0.
FORCE 3 963 0 20. 1. 0. 0.
FORCE 3 964 0 20. 1. 0. 0.
$ Nodal Forces of Load Set : TENSILE_FORCE_Ends_POS
FORCE 4 503 0 10. 1. 0. 0.
FORCE 4 958 0 10. 1. 0. 0.
$ Nodal Forces of Load Set : TENSILE_FORCE_Ends_NEG
FORCE 5 251 0 10. -1. 0. 0.
FORCE 5 734 0 10. -1. 0. 0.
CHAPTER 37 559
Solution Procedure
According to the HADAPTL and HADACRI control options, the refinement process starts with a preliminary calculation
(CYCLE = 0 or ANALYSIS number 1) using the initial finite element model. Then, the refinement process starts and
continues up to a number of cycles equal to REPEAT (3rd field in HADAPTL). During these cycles, each element
involved will be refined up to MAXLEVEL value (2nd field in the second physical option in HADAPTL).
As result of each refinement cycle the following files will be generated (xxxx.bdf is the generic name of the input
file and):
• xxxx.n.bdf – It contains the grid points, the elements and the MPC options related to the refined mesh
created at the specific refinement cycle
• xxxx.n.xdb – It contains the model and the results for the specific refinement cycle.
where n is the number of the generic refinement cycle.
Furthermore, the standard files xxxx.log, xxxx.f04, xxxx.f06 are generated. In the last one, it is possible to read
some information about the refinement process show in the example below:
^^^------------------------------------------------------
^^^GLOBAL NUMBER OF ELEMENTS: 1096
^^^AVERAGE ERROR INDICATOR: 1.766260E+03
^^^CHANGE IN AVERAGE ERROR INDICATOR: 5.402161E-01 %
^^^------------------------------------------------------
^^^* * * E N D O F A N A L Y S I S #: 2 * * *
^^^------------------------------------------------------
by which it is possible to verify how it is proceeding and when the specific cycle is finished.
Results
The first result to analyze is the way in which the finite element mesh is changed during the refinement cycles. In the
figure below all the refined models are summarized. Note that the MPC relationships used to establish the congruency
between regions with different meshes are not displayed to make the images clearer.
CHAPTER 37
Refinement Cycle 1
Refinement Cycle 2
Refinement Cycle 3
Refinement Cycle 4
Refinement Cycle 5
Refinement Cycle 6
Refinement Cycle 7
Figure 37-3 Refined Finite Element Models

CHAPTER 37 561
Looking at the refined meshes obtained in the subsequent cycles, it can be seen how important it is to activate a
projection onto a smooth approximation of the analysis domain boundary from the mesh boundary (SNAPMTHD field
in HADAPTL option). In fact, it avoids the creation of kinks that create two problems:
• Driving the refinement process around the geometrical singularities
• Generating stress concentration in the singular regions
Displacement output has been required only to verify the correctness of the solution in terms of deformed structure.
The use of PARAM.INREL,-2 enables a meaningful deformed structure in the case of free-free boundary conditions
(Figure 37-4). The deformation seems to be congruent with the applied loads.
Figure 37-4 Deformed Structure
Also, the stress distribution is as we expect.
Figure 37-5 von Mises Stress Distribution Relative to the Last Refinement Cycle
The stress level in the critical point is compared with the theoretical one and the relative stress concentration factor is
calculated. The resulting data are summarized in the following table together with other general information related
to refinement effects on mesh size and error indicator.
The error percentages are calculated according to the following relationship:

Calculated value – Theoretical value
Error% = ----------------------------------------------------------------------------------------------------------  100
Theoretical value
while, as already mentioned, the stress concentration factor is calculated as:

 max
k t = -----------
-
 nom
CHAPTER 37
Referring to Table 37-1, the theoretical values for maximum stress and stress concentration factor are:
Maximum Stress = 150990 N/m2

Nominal Stress = 70000 N/m2
Stress Concentration Factor = 2.157
Table 37-2 Results Comparison

Maximum Stress
Global Average Stress
Refinement von Mises Concentration
Number of Error Concentration
Cycle elements Indicator
Stress
Factor
Factor Error
(N/mm2) (%)
0 880 - 115461.46 1.649 -23.53
1 1100 1756.77 130292.07 1.861 -13.71
2 1568 1766.26 137223.50 1.960 -9.12
3 2900 1582.74 141407.04 2.020 -6.35
4 6476 1211.11 145797-84 2.083 -3.44
5 16326 838.27 148861.35 2.127 -1.41
6 41060 530.66 150535.57 2.151 -0.30
7 98996 338.77 150545.23 2.151 -0.29
Two important considerations can be seen in Table 37-2:

• The evaluated stress concentration factor is close to the theoretical one. The relative error is about 0.3%.
• The differences between two subsequent maximum stresses decreases increasing the refinement level
(Figure 37-6).
CHAPTER 37 563
Stress Concentration
2.5
σmax Theoretical (2.157)
Kt=
σnominal Numerical
2.0
Refinement Cycle
1.5
0 1 2 3 4 5 6 7
Figure 37-6 Theoretical/Numerical Stress Concentration Factor Comparison
Modeling Tips
Some suggestions can be helpful to define the best refinement process:
The refinement can be limited using the field MAXLEVEL in the HADAPTL option. None of the elements in the mesh
will be refined to a level larger than MAXLEVEL. Limiting this process is necessary to avoid run-away refinement. In
this example, the default value (MAXLEVEL = REPEAT) has been used not only to test the right convergence towards
the theoretical stress but also the limited improvement introduced in the latest refinement cycles.
Kinks (e.g., sharp internal corners that lack C 1 continuity) should be avoided in order to limit their influence:
• on the refinement process (if they exist, the refinement is concentrated around the geometrical singularities)
• on results (avoiding kinks prevents fictitious stress singularities)
Kinks can be controlled defining SNAPMTHD = 1 in the HADAPTL option. In this example, the relaxation/projection
method has been activated for the grid points created by the procedure; to verify its positive effect, change SNAPMTHD
from 1 to 0 and see how the refinement process behaves. The refined meshes are concentrated along the geometrical
singularities (sharp corners or kinks of a polygonal hole) and the results (the maximum value always increases) will
continue to subdivide elements near the kinks.
CHAPTER 37
Setting SNAPMTHD = 1 ensures the geometry of the hole is correctly represented during the refinement process. By
creating a cylindrical coordinate system at the center of the hole, all the grid points that have been generated on the
boundary are all at R = 0.1 m, exactly the radius of the circle (the error is on the fifth decimal digit). It confirms the
need to use the SNAPMTHD = 1 relaxation/projection procedure.
Input File(s)
File Description
nug_37.dat MD Nastran input file for local adaptive meshing example
nug_37.bdf MD Nastran input file for local adaptive meshing example used in video
nug37.SimXpert MD Nastran input file for local adaptive meshing example
Video
H = 0.4 m
d = 0.2 m
s = 0.02 m
σmax
F = 280 N
F d H F
σnominal

Chapter 38: Landing Gear
38 Landing Gear

Summary 566

Introduction 567


FEM Solution 567

Results 574

Modeling Tips 577

Input File(s) 577

Video 578
CHAPTER 38
Summary
Title Chapter 38: Landing Gear
Contact features • Frictionless Deformable-Deformable Contact
• Glued Contact for non-matching meshes
Geometry
DRAG STRUT UPPER CYLINDER
GAS SPRING
SIDE STRUT
SIDE STRUT PIVOT
DRAG STRUT PIVOT UPPER LINK SPACER

UPPER TORQUE LINK
UPPER LINK PIVOT
APEX SPACER
AXLE
TORSION LINK APEX PIVOT
LOWER TORQUE LINK
INNER CYLINDER
LOWER LINK SPACER
Material properties Young’s Modulus = 3.0x107 Psi, Poisson’s ratio = 0.3

Boundary conditions Pinned Connections with/without Glued Contact SOL 400
)
P I N NE D C O N NE C T I O N S
Element types HEXA, TETRA, BAR

FE results Verify the contact conditions (GLUE and nonGLUE)
CHAPTER 38 567
Landing Gear
Introduction
This test case demonstrates contact analysis using MD Nastran. Two types of contact conditions between components
are considered:
• glue contact
• nonglue contact
In the first one, the contact is maintained for all the analysis after it occurs. In other words, nodes in contact are not
allowed to separate whereas, in the second one, separation can change depending on the loading conditions.
Large displacement/rotation and nonlinear materials are not taken into account in this example.
The numerical analysis is performed to demonstrate the behaviors of the 3-D surface contact solution into MD Nastran.
In particular, the simultaneous presence of glue, nonglue surface contact is considered. The deformed structure, the
satisfaction of the relative motion between components, and the stresses in the contact regions are considered as result
of the analysis.
FEM Solution
FEM solutions have been obtained with MD Nastran’s solution sequence 400. The details of finite element models,
contact simulations, material, load, boundary conditions, and solution procedure are discussed.

The structure consists of different components that have been modeled independently taking into account that
matching meshes are not needed in the contact regions.
Due to geometrical behaviors:
• The pins and the spacers have been modeled by 8-node HEXA elements
• 4-node TETRA elements have been used to model the remaining components. Note that fine meshes have
been used for these components in order to avoid the rigidity of such kind of element associated with this type
of element.
For the axle, two BAR elements have been used. In this way the proper load has been applied in the middle grid point.
No LGDISP parameter has been defined and therefore no geometrical nonlinearity is considered.
CHAPTER 38
Contact Models
In defining the contact regions for the structure, the components are modeled as deformable bodies. In particular, 15
contact bodies have been defined by specific BCBODY and BCSURF entries (each couple of options has been defined
using the same identifier). Note that each of them has been defined considering all the elements belonging to the
specific components.
Table 38-1 Contact Body General Information

BCBODY/BSU Component Name Elements
1 Drag Strut 217804 - 237802
2 Drag Strut Pivot 159301 - 160572
3 Gas Spring 160575 - 161534
4 Inner Cylinder 200218 - 217803
5 Lower Link Pivot 157797 - 158596
6 Lower Torque Link 277629 - 297917
7 Side Strut 237803 - 257846
8 Side Strut Pivot 159717 - 160332
9 Torsion Link Ape Pivot 158597 - 159300
10 Upper Cylinder 161663 - 200217
11 Upper Link Pivot 156997 - 157796
12 Upper Torque Link 257847 - 277628
13 Lower Link Spacer 161551 - 161582
14 Upper Link Spacer 161599 - 161630
15 Apex Spacer 161647 - 161662
Each contact body has been defined in the same way so, as an example, one set of options is used to define one of them
that has been listed:
$ Deform Body Contact LBC set: lower_link_spacer
BCBODY 13 3D DEFORM 13 0 -1
BSURF 13 161551 161552 161553 161554 161555 161556 161557
161558 161559 161560 161561 161562 161563 161564 161565
161566 161567 161568 161569 161570 161571 161572 161573
161574 161575 161576 161577 161578 161579 161580 161581
161582
In the above BCBODY option, the 3-D (third field) elements mentioned in the BSURF which identifier is 13 (look at
the fifth field) define the contact body number 13. Furthermore:
• The fourth field defines the general behavior of the contact body. In this case, it is a deformable contact body
• The null value in the sixth field means that symmetric penetration or double side contact check is considered.
The contact is verified symmetrically and both the contact surfaces are checked for penetration and, also, if
we need to define a MASTER and a SLAVE in any case.
CHAPTER 38 569
Landing Gear
• The empty seventh field forces a null friction coefficient. It means that no tangential forces are generated
when the contact condition occurs, unless these bodies are glued together.
• The negative value in the eighth field allows activating the analytic option for a deformable body. It is used in
this case because the part of each component involved in the contact process is cylindrical and therefore is
simple to represent it analytically. In this way, the contact is represented in the best way.
After the definition of the contact bodies, each couple of bodies that could be in contact must be defined in the
BCTABLE option. In this entry, one of the contact bodies is defined as the MASTER while the other one is the SLAVE.
The contact behaviors are completely defined. An example of the option format used in this case is listed below:
BCTABLE 1 19
SLAVE 1 4.-2 0. 0. 0. 1
0 0 0
FBSH 1.+20 0. 0.
MASTERS 2
SLAVE 2 4.-2 0. 0. 0. 1
0 0 0
FBSH 1.+20 0. 0.
MASTERS 10
SLAVE 3 4.-2 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0.
MASTERS 4
SLAVE 3 4.-2 0. 0. 0. 1
0 0 0
FBSH 1.+20 0. 0.
MASTERS 10
...
...
SLAVE 12 4.-2 0. 0. 0. 1
0 0 0
FBSH 1.+20 0. 0.
MASTERS 14
SLAVE 12 4.-2 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0.
MASTERS 15
It can be checked how the nineteen contact regions (look at the fifth field of the above BCTABLE option) are defined
in the same. The only difference is in the eighth field of the option where the SLAVE option is defined. In fact, we can
see a unit or null value. If a unit value is defined, the two contact surfaces must be glued. It means that the glue option
is activated and all the degrees of freedom of the nodes are tied in case of deformable-deformable contact once the
node comes in contact. In general, if the unit value is defined, all degrees of freedom are MPCd in the deformable-
deformable contact once the grids have come in contact. To turn on the general SOL 400 contact algorithm the entry:
BCPARA, 0, NLGLUE,1
is used. It should be taken into account that if, in SOL 400 on the BCTABLE, there are multiple GLUE and nonGLUE
entries associated with different SLAVE entries, then, the above option must be used. It is the case in this example.
A null value activates the standard contact conditions. It means that a SLAVE node can move only over the MASTER
contact surface when it comes in contact (except if glued). In this case, if the general load condition leads to the
separation of the contact bodies, the slave node start again to move without constraints. Note that in this entry different
CHAPTER 38
contact parameters (the distance below which the node is considered in contact, friction coefficient, separation force,
stress friction limit, contact tolerance bias, etc…) can be defined for each contact region.
The BCTABLE entry is activated by BCONTACT option in the Case Control section. Note that in this case, a
BCONTACT = 0, defined above the subcase level activates the corresponding BCPARA,0 and BCTABLE,0 entries
defined in the Bulk Data Section. It allows to initially identify contacting bodies. Note that in SOL 400, a
BCONTACT = 0 is allowed above all subcases but is not required. Any of the contact Bulk Data entries that allow a 0
and have a 0 value ID field are automatically sensed by SOL 400 with or without a BCONTACT = 0 command. The
contact regions are summarized in the table below.
Table 38-2 Contact Body General Information (ID in Parenthesis)

SLAVE Component MASTER Component
Number (BCBODY ID) (BCBODY ID) GLUE
1 Drag Strut (1) Drag Strut Pivot (2) YES
2 Drag Strut Pivot (2) Upper Cylinder (10) YES
3 Gas Spring (3) Inner Cylinder (4) -
4 Gas Spring (3) Upper Cylinder (10) YES
5 Inner Cylinder (4) Lower Link Pivot (5) -
6 Inner Cylinder (4) Upper Cylinder (10) -
7 Inner Cylinder (4) Lower Link Spacer (13) -
8 Lower Link Pivot (5) Lower Torque Link (6) YES
9 Lower Torque Link (6) Torsion Link Apex Pivot YES
10 Lower Torque Link (6) Lower Link Spacer (13) YES
11 Lower Torque Link (6) Apex Spacer (15) YES
12 Side Strut (7) Side Strut Pivot (8) YES
13 Side Strut Pivot (8) Upper Cylinder (10) YES
14 Torsion Link Apex Pivot Upper Torque Link (12) -
15 Upper Cylinder (10) Upper Link Pivot (11) -
16 Upper Cylinder (10) Upper Link Spacer (14) -
17 Upper Link Pivot (11) Upper Torque Link (12) YES
18 Upper Torque Link (12) Upper Link Spacer (14) YES
19 Upper Torque Link (12) Apex Spacer (15) -
CHAPTER 38 571
Landing Gear
a b c
DRAG STRUT DRAG STRUT PIVOT GAS SPRING

DRAG STRUT PIVOT UPPER CYLINDER UPPER CYLINDER
d e f
LOWER LINK PIVOT LOWER TORQUE LINK LOWER TORQUE LINK

LOWER TORQUE LINK TORSION LINK APEX PIVOT LINK LOWER SPACER
Figure 38-1 Glued Contact Regions Panels a-e, Nonglued Contact Panel f
Looking at the behaviors of the defined contact regions, it can be checked that:
• The gas spring is attached in its upper end to an internal surface of the UPPER cylinder. This system can
move along their common axis according to the non-glued contact regions defined between them and the
INNER cylinder.
• The torsion link apex pivot is rigidly connected to the LOWER torque link while a nonglued contact region is
defined between the first body contact and the UPPER torque link. Also, the APEX SPACER is in the same
contact condition. Considering the null friction coefficient, this modeling solution allows to avoid any
singularity maintaining the relative rotational motion between the two links.
• The rigid link pivot is rigidly connected to the LOWER torque link but it is connected by nonglued contact
region with the INNER CYLINDER. It is the same modeling solution than the above one.
• The two struts are rigidly connected to the UPPER cylinder.
• The two torque links (UPPER and LOWER) can rotate around the axes of the two pivots that connect each of
them respectively with the UPPER and the INNER cylinders.
CHAPTER 38
Figure 38-2 Possible Relative Motion Between the Different Components
Material
The isotropic elastic material properties of the steel used for all the components have been defined by the
following MAT1.
MAT1 1 3.+7 .3 7.3-4
Nonlinear behaviors of the material are not considered.

The set of boundary conditions (SPC = 2) defined in the model simulates hinges between some components and the
ground. In particular, they are positioned in the upper ends of the:
Drag Strut
Side Strut
Upper Cylinder
The following options are used to define this boundary condition:
SPCADD 2 1
...
SPC1 1 123 108520 108521 313468 313469 313470 313471
The braking load condition is considered. It consists of:
• Concentrated forces and moments applied to the middle point of the axle. They define three different loads
acting on this component:
CHAPTER 38 573
Landing Gear
Brake drag
FORCE 1 314410 0 60000. -1. 0. 0.

MOMENT 3 314410 0 0. .57735 .57735 .57735
Brake side moment
FORCE 4 314410 0 0. .57735 .57735 .57735

MOMENT 5 314410 0 1.335+6 0. 1. 0.
Brake vertical
FORCE 6 314410 0 140000. 0. 0. 1.

MOMENT 7 314410 0 0. .57735 .57735 .57735
Z
FX MY FZ
X Z Z
X X
Y Y Y
Figure 38-3 Pressure Load Applied to the Axle
• Breaking Pressure in the inner part of the Upper Cylinder (Load sets from 8 to 11)
PLOAD4 11 164669 1190.4 33161 7479

PLOAD4 11 164864 1190.4 33236 7156
PLOAD4 11 166091 1190.4 55196 49965
...
PLOAD4 10 199542 1190.4 54157 106392
PLOAD4 10 199546 1190.4 105944 106130
Figure 38-4 Pressure Load Applied to the Axle

CHAPTER 38
All these loads are combined by LOAD Bulk data entry to define the applied static load condition
LOAD 2 1. 1. 1 1. 3 1. 4
1. 5 1. 6 1. 7 1. 8
1. 9 1. 10 1. 11
Solution Procedure
In the present analysis, contact is the only nonlinearity. It means that the provided load condition generates small
displacements and only the stresses are in the linear elastic part of the stress-strain curve of the material. As
consequence, no geometrical and material nonlinearity are taken in account. Furthermore, looking at the geometries,
the contact conditions seems to be not so complicated, It simplifies the approach to be used in the analysis.
First of all no STEP is defined under the SUBCASE level.
BCONTACT = 0
SUBCASE 1
BCONTACT = 1
SPC = 2
LOAD = 2
DISPLACEMENT(plot)=ALL
$ SPCFORCES(SORT1,REAL)=ALL
STRESS(plot)=ALL
BOUTPUT(SORT1,REAL)=ALL
NLPARM = 1
The nonlinear procedure is defined through the following NLPARM entry with ID 1.
NLPARM 1 1 FNT PV YES
Here:
• Only one increment is considered.
• FNT represents the Full Newton-Raphson Technique wherein the stiffness is reformed at every iteration.
• PV indicates that convergence will be checked on vector component (V) of the residuals (P). In this V method,
convergence checking is performed on the maximum vector component of all components in the model.
• YES indicates that intermediate output is produced after every increment.
Results
No results to compare are available for this test case so what has been obtained by the calculation will be checked from
a qualitative viewpoint. The maximum total displacement occurs in the bottom part of the inner cylinder, close to the
axle (where the concentrated loads are applied).
CHAPTER 38 575
Landing Gear
Figure 38-5 Undeformed and Scaled Deformed Structure
To check how the contact is working it is possible to take advantage of a procedure that in MD R2 Nastran allows
storing all the contact results into the database. In fact it is not possible to obtain these data into XDB
(PARAM,POST,0) or OUTPUT2 (PARAM,POST,-1) postprocessing files while adding the keyword:
scr = post
in the Nastran command line, all the results, including the contact ones, are stored into the database. They are retrieved
into MD Patran selecting:
Action  Access Results

Object  Attach Entities
Method  Result Entities or Both
in the Results Window.

The following results can be displayed for contact regions
Contact Status
Friction contact force, Magnitude
Normal contact force, Magnitude
Contact force, Friction
Contact force, Normal
Contact stress, Friction 1
Contact stress, Friction 2
Contact stress, Normal
It is possible to understand which components are in contact displaying the Contact Status output. As first example
some of the contact regions belonging to the lower and upper torque links will be considered.
Looking at the Contact Status Contours in Figure 38-7 and taking into account the contact regions behaviors (as
summarized in Figure 38-6) we can say that:
• Both the contact bodies regions (MASTER and SLAVES) are highlighted.
CHAPTER 38
• The contact status in the UPPER TORQUE LINK-TORSION LINK APEX PIVOT nonglued contact
region put in evidence how the deformation of the structure determines the contact only in a limited part of
the bodies.
• A good contact modeling is recognized by a congruent representation of the Contact Status output in the
MASTER and SLAVE contact bodies. In particular in case of glued contact a continuous contact status contour
should be displayed. A different representation could highlights problems in the geometries of the contact
bodies.
UPPER LINK PIVOT

- SLAVE in contact region with UPPER TORQUE LINK (GLUED)
- MASTER in contact region with UPPER CYLINDER
833(572548(/,1.
$3(;63$&(5
0$67(5LQERWKWKH*/8('FRQWDFWUHJLRQV
/2:(572548(/,1.
7256,21/,1.$3(;3,927
6/$9(LQFRQWDFWUHJLRQZLWK833(572548(/,1.
0$67(5LQFRQWDFWUHJLRQZLWK/2:(572548(/,1.*/8('
Figure 38-6 Upper and Lower Torque Links Connections
$3(;63$&(5
121*/8(' 7256,21/,1.$3(;3,927
0$67(56/$9(
/2:(572548(/,1.
0$67(56/$9(
833(572548(/,1. */8('
Figure 38-7 First Contact Status Contour Plot Example
A nonclear situation is displayed for the nonglued contact between UPPER TORQUE LINK and TORSION APEX
PIVOT. In fact, the contact status is differently represented in the corresponding contact regions of the two
components. Probably, the combined effects of the deformation and the different element types in the two components
determine it.
CHAPTER 38 577
Landing Gear
Differently, in case of nonglued contact regions defined in the UPPER CYLINDER-UPPER LINK PIVOT
connection the contact status seems to be represented correctly (see Figure 38-8). In fact, there is a complete
congruency between the two regions that are in contact.
833(5&</,1'(5
121*/8('
0$67(56/$9(
833(5/,1.3,927
Figure 38-8 Second Contact Status Contour Plot Example
Modeling Tips
Important behaviors of this example are the definition of glued and nonglued contact regions and the effects of contact
geometries to obtain good results. Contact is only verified in a qualitative viewpoint by the analysis of the Contact
Status output.
The following are some guidelines and tips for modeling this benchmark:
• The geometry of a contact surface should be defined property in order to avoid problems when it touches
another surface contact.
• The density of the mesh affects the results in the contact region in particular in case of contact surfaces with
nonplanar shape and in which different types of elements are used.
• Use the Contact Status output to check if the contact is working properly (use scr=post in the Nastran
command line to obtain this kind of output).
Input File(s)
File Description
nug_38.dat MD Nastran SOL 400 input for the landing gear model
CHAPTER 38
Video

Chapter 39: Brake Squeal Analysis
39 Brake Squeal Analysis

Summary 580

Introduction 581


Results 586

Modeling Tips 588

Input File(s) 588

Reference 588

Video 588
CHAPTER 39
Summary
Title Chapter 39: Brake Squeal Analysis
Contact features Contact friction induced dynamic instability leading to brake squeal
Geometry Units: mm, kg, sec R = 144
Back_Plate
Insulator
Model Courtesy of Pad
Dr. Lin Jun Seng of TRW Rotor

Automotive
X Y
t = 20
Material properties • Back plate E = 2.07x108 kg/(mm-sec2),  = 0.28,  = 7.82x10-6 kg/mm3

• Insulator: E = 2.07x108 kg/(mm-sec2),  = 0.28,  = 7.82x10-6 kg/mm3
• Pad: Anisotropic Organic Material
• Rotor: E = 1.25x108 kg/(mm-sec2),  = 0.24,  = 7.2x10-6 kg/mm3
Boundary conditions • Constraints to simulate caliper guided brake pad motion
• Contact between the two deformable bodies with µ = user selected
Applied loads Piston pressure normal to pad surface
Element types 8-node solid element HEXA and PENTA
FE results The unstable mode at
1.953 Hz in the analysis
when  = 0.3.
CHAPTER 39 581
Brake Squeal Analysis
Introduction
Brake squeal is the unpleasant high frequency vibrations (2000 to 10000 Hz) that occur in disk brake systems.
Application of the brakes causes an increase in line pressure which results in the caliper piston (s) to push the pads
against the spinning rotor. A valuable review paper by Kinkaid et al. (Kinkaid 2003) provide a comprehensive review
and bibliography of research on disc brake squeal. The high pitch noise or squeal occurs when a specific combination
of piston pressure, friction and damping effects cause two stable modes to merge or coalesce into a single unstable
mode.
The solution to preventing modal coalescence is to modify the design. This would include, but is not limited to,
material changes, design changes and the addition or modification of present damping components. However the
analysis of disk brake systems has been challenging due to the complexity of the structure, material properties and
loading environment.
Brake squeal analysis models require not only the typical FEM mesh of the components (pads and rotor at a minimum),
but also the representation of the contact/frictional connection between the pad and rotor. This contact/friction is
represented by an unsymmetric stiffness matrix. Previously in Nastran there were restrictions imposed by this method
that included:
• The meshed contact area between the rotor and pad must be congruent
• Separation is not allowed; full contact is maintained
• The contact matrix is supplied as a DMIG generated outside of the normal FEM calculations
• Each contact condition involving the friction coefficient and loading (magnitude and pattern) required a
unique DMIG
Typically, the generation of the DMIG entries required days to weeks of analysis time. Interested users are directed to
Section 5.3 of the Advanced Dynamic Analysis Users Guide for a description on manual generation of the
contact/friction connection DMIG entries.
The introduction of the brake squeal analysis capability in this release has eliminated all of the previous restrictions.
In addition, the user now has the capability to examine various combinations of friction values, loading, and contact
definitions in a single execution. Further, the system matrices can include, at user request, differential stiffness due to
preloading, large displacement effects and full nonlinear property definitions. No longer is the brake squeal analysis
limited to a string of single shot runs or multiple restarts. This example features the following: 3-D deformable-
deformable contact with friction, multiple SUBCASE/STEP analysis, user selectable complex solution domain - real
or modal space, choice of complex Lanczos or Hessenberg solver, and full user control of contact parameters.
Modeling Details
Brake squeal analysis is activated in MD Nastran's Advanced Nonlinear solution sequence (SOL 400) with the Bulk
Data entry BSQUEAL. The BSQUEAL entry is selectable within the Case Control section at the SUBCASE level. With
the analysis chaining capability complex eigenvalues can be computed at user selected load factors.
CHAPTER 39
The case control loading and modal extraction requests are shown in the listing that follows. This example
demonstrates the extraction of complex modes at specific piston load points
SUBCASE 100
$
SUBTITLE = Nonlinear static analysis
SPC = 2
METHOD = 100 $ Modal Approach
CMETHOD = 200
AUTOSPC(noprint) = YES
RESVEC = NO
$
STEP 1
LABEL = Nonlinear Static Step
NLPARM = 2 $ Ten load increments
BCONTACT = 1
BOUTPUT = NONE $ No contact surface output
SPC = 2
LOAD = 200
$
$ STEPs for complex eigenvalue extraction
$
STEP 2
LABEL = Brake Squeal modes at 20% piston load 0.3 friction coeff
ANALYSIS=MCEIG
BSQUEAL = 900
NLIC STEP 1 LOADFAC 0.2
$
STEP 3
ANALYSIS=MCEIG
BSQUEAL = 900
$
STEP 4
ANALYSIS=MCEIG
BSQUEAL = 900
BEGIN BULK
...
The analysis contains a single SUBCASE with four STEPs. Step 1 performs the nonlinear loading in 10 steps. Contact
bodies are selected with the BCONTACT where the contact friction values are defined on the Bulk Data BCTABLE.
This step performs a normal nonlinear 3-D contact analysis that allows separation of the contact surfaces.
Steps 2 through 4 perform a complex eigenvalue extraction at selected load points. The methods used to extract the
modes are defined above all the STEP definitions. Activation is done with the ANALYSIS=MFREQ entry which requires
a normal modes and complex modes selection which in this example is above all STEP definitions. The user has access
to all of the MD Nastran modern modal methods: Lanczos, complex Lanczos, and Hessenberg.
Load steps selected for complex mode extraction is defined by the NLIC entry. This entry selects the loading STEP and
the load increment - LOADFAC. The allowable values for LOADFAC are determined by the INC value defined on the
CHAPTER 39 583
Bulk Data NLPARM entry. The BSQUEAL entry is also present to select the variables such as friction value to be used
in generating the contact stiffness matrix between the pad and rotor. As the example shows, complex modes are
extracted for a defined friction value of 0.3 at piston loads of 20, 50, and 80 percent of the maximum. This then allows,
in one execution, monitoring the complex modes for possible coalesce of two modes which signals the onset of brake
squeal.
Modeling Contact
Contact is easily defined in MD Nastran. The Bulk Data pair BCBODY/BSURF to designate the type of contact body
(deformable) and the elements comprising the contact body. The contact algorithms locate the element faces that will
potentially participate in contact surfaces. There is no need for user effort to limit the elements listed on the BSURF
entry to aid the contact algorithms. For example, all of the elements in the rotor are selected in BCBODY/BSURF 4 of
the larger model, and there is no need to painstaking pick only those elements that might contact the pads; similarly
for the pads.
The contact bodies for this example model are shown in Figure 39-1. Note that the elements defining the contact body
can be groups of discontinuous elements as shown by the brake pads.
bsurf-4
bsurf-5
bsurf-6
X Y
Figure 39-1 Contact Bodies
Additional contact bodies are permitted. With disk brake systems, other components would be (but not limited to) the
caliper, pistons, guide pins, and steering knuckle. The BCTABLE collects the contact bodies and assigns various
parameters related to the surface contact. In the example below, there are four contact bodies. Contact between the
pads and pistons are defined as glued contact - integer 1 in field 8. Glued contact also has the feature of eliminating
the requirement of matching mesh gridpoints between the bodies. Pad and rotor contact is defined as full nonlinear
contact with a frictional value of 0.3.
If the contact surfaces are a mixture on glued (pistons to pads) and full nonlinear contact (pads to rotor) the BCPARAM
entry is also required.
BCPARA 0 nlglue 1
CHAPTER 39
This ensures that a contact body that participate in glued and full nonlinear contact will maintain the full nonlinear
contact status in all STEPs.
$ Contact bodies (see BCBODY/BSURF) - all deformable
$ BODY 4 - Rotor
$ BODY 5 - Outer pad
$ BODY 6 - Inner pad
$ Body ID Fric Glued
$-------2-------3-------4-------5-------6-------7-------8-------9-------0-------
BCTABLE 0 2
SLAVE 6 0. 0. 0.3 0. 0 0.
2 2 0
MASTERS 4
SLAVE 5 0. 0. 0.3 0. 0 0.
2 2 0
MASTERS 4
BCTABLE 1 2
SLAVE 6 0. 0. 0.3 0. 0 0.
2 2 0
MASTERS 4
SLAVE 5 0. 0. 0.3 0. 0 0.
2 2 0
MASTERS 4
BCTABLE 2 2
SLAVE 6 0. 0. 0.4 0. 0 0.
2 2 0
MASTERS 4
SLAVE 5 0. 0. 0.4 0. 0 0.
2 2 0
MASTERS 4
BCTABLE 3 2
SLAVE 6 0. 0. 0.5 0. 0 0.
2 2 0
MASTERS 4
SLAVE 5 0. 0. 0.5 0. 0 0.
2 2 0
MASTERS 4
...
$
$ Rotor deformable contact body
$
BSURF 4 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
...(rest of elements omitted)
$ Outer pad deformable contact body
$
BSURF 5 24400 24401 24402 24403 24404 24405 24406
24407 24408 24409 24410 24411 24412 24413 24414
$
$ Inner pad deformable contact body
$
BSURF 6 20704 20705 20706 20707 20708 20709 20710
20711 20712 20713 20714 20715 20716 20717 20718
BCTABLE with ID 0 is used to define the touching conditions at the start of the analysis. This is a mandatory option
required in SOL 400 for contact analysis, and it is flagged in the case control section through the optional BCONTACT
= 0 option. The BCTABLE with ID 1 is used to define the touching conditions for later increments in the analysis, and
it is flagged using BCONTACT = 1 in the case control section. Also, the SLAVE-MASTER combination defines that the
nodes for body 1 are nodes belonging to the slave body. This in literature is referred by various terminologies as either
CHAPTER 39 585
contacting body nodes or tied nodes (imagining the situation of multi-point constraints). The nodes belonging to body
2 are said to belong to the master body which are also referred to as the contacted body nodes or the retained nodes
(imagining the situation of multi-point constraints)
The definition of the contact bodies (defined as Rotor and Pads in Figure 39-1 above) as stated above use the
BCBODY/BSURF Bulk Data pair. The BCBODY options define the deformable body including the body ID,
dimensionality, type of body, type of contact constraints and friction, etc. BSURF identifies the elements forming a
part of the deformable body and includes the convenient THRU option when listing the element ID's.
Brake Squeal Parameters

The BSQUEAL Bulk Data entry supplies information specific for forming the brake squeal analysis.
$ ID OMETH AVSTIF
BSQUEAL 900 0.5 1.e+5
0.0 0.0 1.0 0.0 0.0 0.0
AVSTIF is the average stiffness on a per unit basis between the pad and disk. This variable is under user control instead
of a hidden predefined value. This stiffness is used in forming the penalty contact stiffness between the pad and rotor.
Thus AVSTIF has a direct influence over the overall stability of the model and the values of the brake squeal modes.
The default value is 1.0E+4 however it is advised that until the user is comfortable with the calculated results, several
additional brake squeal runs be performed using alternate AVSTIF values.
Evaluation of the proper value for AVSTIF (or if the default is appropriate) can be easily accomplished with the STEP
command. As the BSQUEAL is called from the Case Control section, a series of STEPs can be defined each calling a
BSQUEAL Bulk Data entry with a unique AVSTIF.
The second line of data defines the rotational axis of the rotor; all reference from the basic rectangular coordinate
system. The first three values define the cosines of the rotation axis. The second three values represent a point on the
rotation axis. As the rotor spins about the Z direction, only the Z cosine is supplied. Any point coordinate on the Z axis
would be acceptable for the three values as the rotor straddles the Z=0.0 plane.

The displacements for the pads simulate the guidance of the brake caliper system. This is best described in Figure 39-2.
Figure 39-2 Displacement Constraints

CHAPTER 39
Pressure is applied to the backside of each brake pad. This is best described in Figure 39-3.
Figure 39-3 Piston Pressure on Brake Pads
Solution Procedure
NLPARM 2 FNT PV YES
FNT represents Full Newton Raphson technique wherein the stiffness is reformed at every iteration. KSTEP (field after
FNT) is left blank, and in conjunction with FNT, it indicates that stiffness needs to be reformed between the end of the
load step and the start of next load increment. The maximum number of allowed recycles for every increment is left
at the default of 25. If more than 25 recycles is exceeded, the load step would be cut-back and the increment repeated.
PV indicates that the maximum norm of vector component of the incremental loads will be checked for convergence.
YES indicates that intermediate output will be produced after every increment. The second line of NLPARM is not
defined indicating that default tolerances will be used for convergence checking.
The number of increments is provided in the 3rd field of the NLPARM option. The default is 10 and this ties back to
the allowable values for LOADFAC on the NLIC entry.
Results
Figure 39-4 shows the displacement (contours and physical shape) of the brake pads due to the pressure load at 100%
magnitude. The undeformed shape is represented by the unshaded wireframe. This information is available for each
load increment (10 as NINC was defaulted to 10.)
CHAPTER 39 587
Figure 39-4 Displaced Shape at 100% Load
Figure 39-5 is an example of the modal shape of the first unstable complex mode when is 0.3. The mode shapes are
available for every complex mode calculated at each STEP where the BSQUEAL is present.
Figure 39-5 First Unstable Complex Mode Shape at 1953 Hz
The SUBCASE/STEP combination provides the user with the powerful capability to evaluate multiple combinations
of friction, load patterns, and contact properties. In Table 39-1 a simple comparison between two friction values has
been summarized.
Table 39-1 Summary of First Unstable Mode Results

First Unstable First Unstable
Mode Frequency Damping Mode Frequency Damping
Piston Load Hz Coefficient Hz coefficient
 = 0.30  = 0.50
10% 1914.56 -0.014863 1914.90 -0.027065
20% 1914.55 -0.014855 1914.89 -0.027062
50% 1914.50 -0.014833 1914.84 -0.027052
100% 1914.42 -0.014796 1914.77 -0.027007
CHAPTER 39
Modeling Tips
Start with the smaller demonstration model (small_brake_squeal.dat). This model can be run locally on a PC
machine and runs fast. Data generation is reasonable even with a large number of output requests, then migrate to the
larger model.
Input File(s)
File Description
nug_39a.dat Simple brake squeal model. Runs fast and users encouraged to evaluate analysis
procedures/selections with this model.
nug_39b.dat This is the large brake squeal model shown in the figures. Although it runs relatively fast it can
generate vast amounts of data, particularly if the print or punch options are chosen.
Reference
Kinkaid, N. M. O’Reilly, O. M. Papadopoulos, P. (2003) Automotive disc brake squeal. Journal of Sound and
Vibration 267, 105-166.
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately four minutes
and explains how the steps are performed.
Units: mm, kg, sec R = 144

Back_Plate
Insulator
Pad
Rotor
X Y
t = 20

Chapter 40: Multiple Bird-strikes on Box Structure
Multiple Bird-strikes on
40 Box Structure

Summary 590

Introduction 591

FEM Solution 593


Results 651

Input File(s) 655
CHAPTER 40
Summary
Title Chapter 40: Multiple Bird-strikes on Box Structure
Features • Multi Material Euler
• General Lagrangian-Eulerian Coupling
• Failed Coupling Surface
Geometry
Bird 2
Bird 1
Structure
Outer Euler Zone

Inner Euler Zone
Material properties
Material Titanium Air Bird 1 Bird 2
Density (kg/m3) 4527 1.1848 930 930
Bulk Modulus (Pa) 1.03e11 2.2e9 2.2e9
Poisson’s ratio 0.314
Yield strength (Pa) 1.38e8
Gamma 1.4
Thickness (m) 0.0015
Radius (m) 0.25
Length (m) 0.25
Mass (kg) 0.36 0.285
Initial Velocity (m/s) 150 200
Fail (Eq. Plastic Strain) 0.1
Analysis characteristics Explicit Transient Dynamic (SOL 700)

Boundary conditions • Plate Structure fixed at ends
• Outer flow on the boundary of outer Euler zone.
Element types • Multi Lagrange: 4-node shell element
• Euler: 8-node hex element which is generated automatically using Mesh entry
FE results 1. Failure at primary structure followed by impact on secondary structure
2. Time history of total z-force on the coupling surface
CHAPTER 40 591
Multiple Bird-strikes on Box Structure
Introduction
Bird strike on a box structure is a typical problem in aircraft industries. The box structure simulates the leading edge
of lifting surfaces, e.g. wing, vertical, and horizontal stabilizers. The box can be simplified to consist of a curve leading
edge panel and a front spar. The acceptable design criteria for bird strike are that the leading edge panel may fail but
the front spar strength may not degrade to a certain level.
In this example, two cylindrical panels are concentric. Two birds strike the upper panel. One bird strikes in horizontal
direction and the second one vertically. The second bird will perforate the first panel and impact the second one. The
birds are modeled as cylindrical slugs of jelly. The plate is constrained in such a way that the edges can only move in
radial direction.
Bird 2 Bird 1
150 m/s
200 m/s
60o
Figure 40-1 Initial Situations
The properties and initial conditions of the plate and birds are as follows:
Plate Ambient B Bird 1 Bird 2

Material Titanium Air Jelly Jelly
Density (kg/m3) 4527 1.1848 930 930
Bulk modulus (Pa) 1.03e11 2.2e9 2.2e9
Poisson’s ratio 0.314
Yield stress (Pa) 1.38e8
Gamma 1.4
Thickness (m) 0.0015
Radius (m) 0.25
CHAPTER 40
Plate Ambient B Bird 1 Bird 2

Length (m) 0.25
Mass (kg) 0.36 0.285
Initial velocity (m/s) 150 200
Fail (equiv. Plas. Strain) 0.1
SOL 700 Model
Each curved plate is modeled using 33x16 BLT-shells. The boundary conditions applied at the edges of the plate are
defined within a cylindrical coordinate system, where the local z-axis is aligned with the length axis of the plate. The
cylindrical system is defined using a CORD2C entry. To create a closed surface, required by COUPLING option, the
two plates are connected with dummy quad elements.
The two birds and air are modeled using Multi Material Eulerian (FV) elements, also known as MMHYDRO. The
location of the bird in the Euler domain is defined using TICEUL option.
The material for the birds and air are modeled using EOSPOL and EOSGAM, respectively.
To allow the bird perforating the first plate and impact the second one, several modeling techniques can be used. One
of them is using two Eulerian domains and two coupling surfaces. Both the Eulerian domains and the coupling surfaces
have to be logically different. Each coupling surface associates with one Eulerian domain.
In this model, the two coupling surfaces share the same physical space. By specifying that one domain is covered
outside and the other inside, the Eulerian domain represents the correct physical space. The two Eulerian domains
cannot interact with each other except through coupling surfaces. When coupling surfaces share the same shell
elements with some or all shells failing, then the material can flow from one Eulerian domain into another one. The
interaction between the Eulerian domains is activated using COUP1INT option and PARAM, FASTCOUP, INPLANE,
FAIL. The rest of the Euler domain is filled with air. Please notice that when the effect of air is neglected, then the rest
of the Eulerian domain should be filled with void. It will speed up the analysis.
The first domain is associated with a coupling surface that is INSIDE covered. Therefore, it cannot be adaptive and is
defined using MESH,, BOX option. The second domain is adaptive and defined using MESH,, ADAPT. The ADAPT
option will let SOL 700 create and update the Eulerian domain to minimize memory allocation and consequently
reduced CPU time. The default Eulerian boundary condition is set to that only outflow is allowed using FLOWDEF
option. In this case, a bird that reaches the free face boundary will flow out of the domain. The initial velocity of the
birds is defined using TICVAL option.
The finite element model of the upper and lower plates, the Eulerian domains and the initialization of the birds are
shown in the Figure 40-2. The dummy quad elements used to create closed coupling surfaces are not shown in
Figure 40-1.
CHAPTER 40 593
FEM Solution
Figure 40-2 Euler Domains
Input File:
SOL 700 is an executive control that activates an explicit nonlinear transient analysis:
SOL 700,NLTRAN stop=1
Case control cards for problem time, loads, and initial conditions:
$ Direct Text Input for Executive Control

CEND
TITLE = Multiple BIRD STRIKE on BOX Structure
SUBCASE 1
$ Subcase name: Default
SUBTITLE=Default
TSTEPNL = 1
SPC = 1
IC = 1
TSTEPNL is a SOL 700 bulk data entry which describes the number of time steps (10) and time increment (0.0015
seconds) of the simulation. The total time is the product of the two entries. Notice here the time increment is only for
the first step. The actual number of time increments and the exact value of the time steps is determined by SOL 700
during the analysis. The time step is a function of the smallest element dimension during the simulation.
$------- BULK DATA SECTION -------

BEGIN BULK
TSTEPNL 1 10 0.0015 1
CHAPTER 40
Define the Initial, the Minimum and the Safety factor of the time step:
PARAM*, DYINISTEP, 1e-7

PARAM*, DYMINSTEP, 1e-8
DYPARAM, STEPFCTL, 0.9
Define coupling surface that can fail and Multi material overflow array to store material data. In a problem where more
than 10% of the elements have more than one material, the default value of FMULTI(0.1) must be increased.
DYPARAM, FASTCOUP, INPLANE, FAIL

DYPARAM, FMULTI, 0.2
Define Output results request for every 0.00015 s and time history output request for coupling surfaces:
DYPARAM, LSDYNA, BINARY, D3PLOT, .00015

DYTIMHS,, .000001,,,,,,,+
+, CPLSOUT
Euler domain 1:
Define an Euler mesh with 50x28x44 elements reference to PEULER1 (=1):
$ domain 1
$
MESH, 1, BOX,,,,,,,+
+,-0.26,-0.015,-0.05,0.50,0.28,0.44,,,+
+, 50, 28, 44,,,, EULER, 1
Define FSI coupling surface from elements listed in the BSURF entry (covering inside):
$ COUPLING SURFACE 1
$
COUPLE , 1 , 1 , INSIDE , ON , ON , , , , +
+ , , , , , , , , , +
+ , , 1
$
BSURF , 1 , 7393 , THRU , 8448 , 13729 , THRU , 14048 , 14577 , +
+ , THRU , 15236
Define Eulerian element properties with reference to TICEUL1 (=11).
PEULER1 , 1 , , MMHYDRO , 11
The initial conditions of these elements are defined in geometric regions.

CHAPTER 40 595
Define Regions with shapes, material, initial values and level indicators:
$ Allocation of material to geometric regions.

$ --------------------------------------------
TICEUL1 , 11 , 11
TICREG , 1 , 11 , CYLINDER , 1 , 3 , 1 , 3
TICREG , 2 , 11 , CYLINDER , 2 , 5 , 2 , 2
TICREG , 3 , 11 , SPHERE , 4 , 4 , 5 , 1
Define region shapes:
CYLINDR , 1 , , .13 , .125 , .2252 , .17 , .125 , .2944 ,

+
+ , .035
CYLINDR , 2 , , -.1381 , .125 , .26 , -.2381 , .125 , .26
, +
+ .035
SPHERE , 4 , , -.1381 , .125 , .26 , 1000
Define Initial values of the birds and the air:
TICVAL, 1 , , XVEL , -75 , ZVEL , -129.9

TICVAL, 2 , , XVEL , 200
TICVAL, 5 , , SIE , 2.1388E5 , DENSITY , 1.1848
Define Eulerian materials for the birds and the environment (air):
$--------Material Bird ------------------------------------

MATDEUL , 3 , 930 , 3
EOSPOL , 3 , 2.2e9
MATDEUL , 5 , 930 , 5
EOSPOL , 5 , 2.2e9
$ -------- Material Air id =4
MATDEUL , 4 , 1.1848 , 4
EOSG , 4 , 1.4
Euler domain 2:
Define an adaptive Euler mesh reference to PEULER1 (=6):
$-----------------------------Domain 2--------------------------
----
$
MESH , 2 , ADAPT , 0.01 , 0.01 , 0.01 , , , , +
+ , -0.26 , -0.015 , -0.05 , , , , , , +
+ , , , , , , , EULER , 6
CHAPTER 40
Define FSI coupling surface from elements listed in the BSURF entry (covering outside):
$===Coupling Surface 2
$
COUPLE , 2 , 2 , OUTSIDE , , , , , , +
+ , , , , , , , , , +
+ , , 2
$
BSURF , 2 , 7393 , THRU , 8448 , 13729 , THRU , 14048 , 14577
, +
Domain 2 has only 1 region with air.
TICEUL1,12,12
TICREG,11,12,SPHERE,7,4,5,1.0
SPHERE,7,,0.0,0.0,0.0,500.0
Interaction between the coupling surfaces 1 and 2:

Define interaction between coupling surface 2 and 1:
$ coupling interaction
$
COUPINT,2,2,1
Define default Eulerian flow boundary condition:
$ Flow boundary
$ -------------------------------------------------------------
FLOWDEF , 1 , , MMHYDRO , , , , , , +
+ , FLOW , OUT
Define cylindrical coordinate system:
$ --------------------
CORD2C , 1 , , 0.0 , 0.0 , 0.0 , 0.0 , 0.25 , 0.0 , +
+ , 0.0 , 0.125 , 0.25
Define properties of the panels:
PSHELL1 , 2 , 2 , Blt , Gauss , 3 , .83333

, Mid , , +
+ , .0015
$
MATD024 , 2 , 4527 , 1.150e11 , .314 , 1.38e8 , , 0.1
CHAPTER 40 597
Define properties of dummy elements to close the coupling surfaces.
PSHELL,3,999,1.E-3
PSHELL,4,999,1.E-3
$
MATD009,999,1.E-20
CHAPTER 40

When aircraft are landing or taking off, they sometimes have difficulties with bird swarms. An impact of several birds
striking at a high velocity can cause severe damage to the structure of the aircraft. So, we are going to consider a
situation where two birds strike a curves titanium plate at an arbitrary time. Bird 1 hits the plate perpendicularly; bird
2 hits the plate on the lower side at an angle of 25° (Figure 40-3). The birds are modeled as cylindrical jelly masses
with the following specifications:
Bird 1 Bird 2
Material: Jelly Jelly
Density: r = 930 kg/m3 r = 930 kg/m3
Speed of Sound: c = 1483 m/s c = 1483 m/s
Mass: m2 = .360 kg m2 = .285 kg
Velocity: v1 = 150 m/s v2 = 200 m/s
The plate is constrained on the edges in all directions.
Figure 40-3 Birdstrike

CHAPTER 40 599
Create a New Database

Enter the MD Explicit Workspace.
b. Tools: Options
d. Select Basic Units (m, kg, s, ...)
e. Select GUI Options; check Solver Card
f. Click OK
g. Click Apply
c d
e f g
CHAPTER 40
Create Curve 1
a. Geometry: Curve
b. Polyline Spline window: Create: select Spline
c. Polyline Spline window, Entities: select Pick
d. For Entities: X,Y,Z Coordinate, enter 0.2165 0 0.125; click OK
e. For Entities: X,Y,Z Coordinate, enter 0.2165 0.25 0.125; click OK
f. Click Apply
b
d c
e
e
CHAPTER 40 601
Create Curve 2
a. For Entities: X,Y,Z Coordinate, enter 0.2165 0 0.001; click OK

b. For Entities: X,Y,Z Coordinate, enter 0.2165 0.25 0.001; click OK
c. Click Apply
d. Click OK
d c
b a
b
CHAPTER 40
Create Surface1
a. Geometry: Revolve
b. Revolve Axis: Along, select Vector
c. For Locations: X,Y,Z Coordinate, enter 0 0 0; click OK (not shown)
d. For Locations: X,Y,Z Coordinate, enter 0 0 1; click OK (not shown)
e. For Locations: X,Y,Z Coordinate, enter 1 0 0; click OK
f. Click OK
g. Revolve Curves: Entities, select CURVE/1
h. For Angle Of Spin (Degrees): enter -120; click OK
g
CHAPTER 40 603
Create Surface2
a. Geometry: Revolve
b. Revolve Axis: Along, select Vector
c. For Locations: X,Y,Z Coordinate, enter 0 0 -0.124; click OK (not shown)
d. For Locations: X,Y,Z Coordinate, enter 0 0 1; click OK (not shown)
e. For Locations: X,Y,Z Coordinate, enter 1 0 0; click OK
f. Revolve Curves: Entities, select CURVE/2
g. For Angle Of Spin (Degrees): enter -120; click OK
h. Observe results
e
h
f
g
CHAPTER 40
Create Part2
Create surfaces 3, 4, 5, and 6
a. Assemble: Create Part

b. For Title: enter PART_2
c. For ID: enter 2; click OK
d. Observe in the Model Browser tree: PART_2
e. Surface: Filler
f. For Curves: pick CURVE/3; click OK
g. For Curves: pick CURVE/7; click OK (not shown)
h. Click Apply
i. Observe results
a e
b
c
h
f
f
i
d
CHAPTER 40 605
Create Surfaces 4, 5, and 6
a. For Curves: pick CURVE/4; click OK

b. For Curves: pick CURVE/8; click OK
c. Click Apply
d. For Curves: pick CURVE/5; click OK
e. For Curves: pick CURVE/9; click OK
f. Click Apply
g. For Curves: pick CURVE/6; click OK (not shown)
h. For Curves: pick CURVE/10; click OK
i. Click Apply
c f h
i
d
a e
b
CHAPTER 40
Show Labels PART_1
a. Right click in the Main Window

b. Select Render
c. Select Geometry WireFrame
d. In the Model Browser: right chick PART_1
e. Select Set Current
f. In the Model Browser: right chick PART_1
g. Select Show Only
h. Under Tools: select Identify
i. In the Pick window, select Curves
j. In the Pick window, select Surfaces
k. In the Pick window, select Select
l. In the Pick window, click All
m. In the Pick window, click Done (not shown)
n. In the Pick window, click Exit (not shown)
h
b
c
a
i
j
k
l
f
d
e
CHAPTER 40 607
Seed PART_1
a. Meshing: Seed
b. Type: Number of Elements, enter 20
c. Entity: Curves, pick Curve/3, Curve/4, Curve/7, and Curve/8
d. Click Apply
e. Entity: Curves, pick Clear
f. Type: Number of Elements, enter 40
g. Entity: Curves, pick Curve/5, Curve/6, Curve/9, (not shown) and Curve/10
h. Click Apply
i. Click OK
e
b f g
d i h
c
c
CHAPTER 40
Surface PART_1
a. Meshing: Surface
b. Element Type: Mesh Type, select Quad Dominant
c. Surface to mesh: pick Surface/1 and Surface/2
d. Element property: Add to part: PART_1
e. Click Apply
f. Click OK
c
b
f e
CHAPTER 40 609
Seed PART_2
a. In the Model Browser: right chick PART_2

b. Select Set Current (not shown)
c. In the Model Browser: right chick PART_2
d. Select Show Only (not shown)
e. Under Tools: select Identify (not shown)
f. In the Pick window, select Curves and Surfaces
g. In the Pick window, select Select
h. In the Pick window, click All
i. In the Pick window, click Done
j. In the Pick window, click Exit
k. Entity: Curves, pick Clear
l. Type: Number of Elements, enter 20 (not shown)
m. Entity: Curves, pick Curve/12 (not shown), Curve/14, Curve/16, and
Curve/18; click Apply
n. Entity: Curves, pick Clear
o. Type: Number of Elements, enter 40 (not shown)
p. Entity: Curves, pick Curve/20, Curve/22, Curve/24,
and Curve/26; click Apply
q. Type: Number of Elements, enter 5
r. Entity: Curves, pick Curve/13 (not shown), Curve/17,
Curve/19, Curve/21, Curve/23, Curve/25, and Curve/23;
click Apply
s. Click OK
f k n
q m
g
h
i j
p
s r
a c
CHAPTER 40
Surface PART_2
a. Meshing: Seed
b. For Mesh type:, enter Tria Only
c. For Surface to mesh, pick Surface/3, Surface/4, Surface/5, and Surface/6
d. Add to part:, enter PART_2
e. Click Apply
f. Click OK
b
c
f e
CHAPTER 40 611
Merge Nodes Surface 1 - 6
a. In the Model Browser, right click PART_2

b. Select Show All (not shown)
c. Nodes/Elements: Equivalence
d. For Entities, select All Nodes
e. For Merging Option, select Merge Nodes
f. For Merging tolerance, enter 1.e-5
g. Select Keep Lower ID
h. Select Delete merged unreferenced nodes
i. Click OK
j.Click OK
d
a e
f
g
h
i
j
CHAPTER 40
Shell Materials
a. Materials: MAT[024] MAT_PIECEWISE_LINEAR_PLASTICITY (not shown)

b. For Name: enter MATD024_1
c. For MID, enter 1
d. For RHO, enter 4527
e. For E, enter 1.15E11
f. For PR, enter 0.314
g. For SIGY, enter 1.38E8
h. For FAIL, enter 0.1
i. Click Create
j. Materials: MAT[020] MAT_RIGID (not shown)
k. For Name: enter MATD020_2
l. For MID, enter 2
m. For RHO, enter 7856
n. For E, enter 2.1e+011
o. For PR, enter 0.3
p. Click Create
b
c d e g
f h
k
n o
l m
p
CHAPTER 40 613
Shell Properties
a. Element Properties: 2D, select PSHELL1

b. For Name: enter PSHELL_1
c. For Card, enter PSHELL1
d. For PID, enter 1
e. For MID, double click, select Select
f. For Entity Selection, select MATD024_1; click OK
g. For T1, enter 0.0015
h. Click Create
i. Materials: MAT[020] MAT_RIGID (not shown)
j. For Name: enter PSHELL_2
k. For Card, enter PSHELL2
l. For PID, enter 2
m. For MID, double click, select Select (not shown)
n. For Entity Selection, select MATD020_2; click OK (not shown)
o. For T1, enter 0.0015
p. Click Create
b
c
d
e
f g
j
k l
o
p
CHAPTER 40
Shell Properties Change Region
a. Right click PART_1, select Show Only

b. Right click PSHELL_1, select Properties
c. Click Change Region
d. Screen select All Elements
e. Click Done
f. Click Modify
g. Repeat steps a through f for PART_2
b
e
a
f
g
CHAPTER 40 615
Euler Properties
a. Element Properties: EOS, select [12] EOS Ideal Gas

b. For Name: enter EOSGAM_1
c. For PID, enter 1
d. For GAMMA, enter 1.4
e. Click Create
f. Element Properties: EOS, select [01] EOS Linear Polynomial
g. For Name: enter EOSPOL_2
h. For PID, enter 2
i. For A, enter 2.2E9
j. Click Create
a
b
c d
e
f
g
h i
j
CHAPTER 40
Euler Materials
Air material
a. Materials: Eulerian, select Eulerian Material

b. For Name: enter MATDEUL_3
c. For MID, enter 3
d. For RHO, enter 1.1848
e. Double click EID, select Select (not shown)
f. For Entity Selection, select EOSGAM_1; click OK
g. Click Create
b
c d e
f
CHAPTER 40 617
Euler Materials
Bird material
a. Materials: Eulerian, select Eulerian Material

b. For Name: enter MATDEUL_4
c. For MID, enter 4
d. For RHO, enter 930
e. Double click EID, select Select (not shown)
f. For Entity Selection, select EOSPOL_2; click OK
g. Click Create
b
c d e
f
CHAPTER 40
Create Mesh
Creation of Mesh 1 (modeling Outside Box Euler)
a. LBCs: Eulerian, select Mesh

b. For Name: enter Mesh_1
c. For TYPE, select BOX
d. For X0, enter -0.26, for Y0, enter -0.015, for Z0, enter -0.05
e. For DX, enter 0.5, for DY, enter 0.28, for DZ, enter 0.44
f. For NX, enter 50, for NY, enter 28, for NZ, enter 44
g. For Prop, select Euler
h. Click Create
i. Observe that Mesh_1 has been added
b
c
d e g
f
i
CHAPTER 40 619
Create Mesh (continued)

Creation of Mesh 2 (modeling Inside Box Euler)
a. LBCs: Eulerian, select Mesh

b. For Name: enter Mesh_2
d. For X0, enter -0.26, for Y0, enter -0.015, for Z0, enter -0.01
e. For DX, enter 0.5, for DY, enter 0.28, for DZ, enter 0.27
f. For NX, enter 50, for NY, enter 28, for NZ, enter 27
g. For Prop, select Euler
h. Click Create
i. Observe that Mesh_2 has been added
j. In the Model Tree Browser, right click Mesh_1, select Show All
b
c
d e
g
f
j
CHAPTER 40
Create Cylinders
Create Cylinder 1
a. LBCs: Couple, select Cylinder (not shown)

b. From the Pick Window: select XYZ
c. For X,Y,Z Coordinate, enter -0.1381 0.125 0.26; click OK
d. For X,Y,Z Coordinate, enter -0.2381 0.125 0.26; click OK
e. For ID: enter 1
f. For Name: enter Cylinder_1
g. For Radius, enter 0.035
h. Click Modify
i. Observe that Cylinder_2 has been added
e f
g
h i
CHAPTER 40 621
Create Cylinders
Create Cylinder 2
a. LBCs: Couple, select Cylinder (not shown)

c. For X,Y,Z Coordinate, enter 0.13 0.125 0.2252; click OK
d. For X,Y,Z Coordinate, enter 0.17 0.125 0.2944; click OK
e. For ID: enter 2
f. For Name: enter Cylinder_2
g. For Radius, enter 0.035
h. Click Modify
i.Observe that Cylinder_2 has been added
e f
g
i
h
CHAPTER 40
Create Sphere (Initial Euler Condition)
a. LBCs: Couple, select Cylinder, select Sphere (not shown)

c. For X,Y,Z Coordinate, enter 0 0 0; click OK
d. For ID: enter 3
e. For Name: enter Sphere_3
f. For Radius, enter 1.
g. Click Modify
h. Observe that Sphere_3 has been added
d e
f
h
CHAPTER 40 623
Initial Euler Values

Air initial values
a. LBCs: TIC
b. Click TICVAL
c. For ID: enter 1
d. For Name: enter TICVAL_1
e. For Method, select NORMAL
f. For Density, enter 1.1848
g. For SIE, enter 13880.
h. Click Modify
i. Observe that TICVAL_1 has been added
c d
e g
f
h
i
CHAPTER 40
Initial Euler Values (Continued)

Bird 1 initial values
a. LBCs: TIC
b. Click TICVAL
c. For ID: enter 2
f. For XVEL, enter 200
g. Click Modify
h. Observe that TICVAL_2 has been added
c d
e f
g
h
CHAPTER 40 625
Initial Euler Values (Continued)

Bird 2 initial values
a. LBCs: TIC
b. Click TICVAL
c. For ID: enter 2
f. For XVEL, enter -75.
g. For ZVEL, enter -129.9
h. Click Modify
i. Observe that TICVAL_3 has been added
c d
e f g
i
CHAPTER 40
Initial Euler Regions

Air initial region
a. LBCs: TIC
b. Click TICREG
c. For ID: enter 1
d. For Name: enter TICREG_1
e. Double click VID
f. In the Entity Selection window, select Sphere_3; click OK
g. Double click MID
h.In the Entity Selection window, select MATDEUL_3; click OK
i. Double click TICID
j. In the Entity Selection window, select TICVAL_1; click OK
k. Click Modify
l. Observe that TICREG_1 has been added
c d
e g i
k
h j
f l
CHAPTER 40 627
Initial Euler Regions (Continued)

Bird 1 initial region
a. LBCs: TIC
b. Click TICREG
c. For ID: enter 2
e. Double click VID
f. In the Entity Selection window, select Cylinder_1; click OK
g. Double click MID
k. Click Modify
c d
e g i
k
f
h j
l
CHAPTER 40
Initial Euler Regions (Continued)

Bird 2 initial region
a. LBCs: TIC
b. Click TICREG
c. For ID: enter 3
e. Double click VID
f. In the Entity Selection window, select Cylinder_2; click OK
g. Double click MID
k. Click Modify
c d
e g i
k
f h
j
l
CHAPTER 40 629
Initial Euler Condition MESH_1
a. LBCs: TIC
b. Click TICEUL1
c. For ID: enter 1
d. For Name: enter TICEUL1_1
e. For NREG, enter 3
f. Click Modify
g. Observe that TICEUL1_1 has been added
h. In the Model Browser tree, right click TICEU1L_1
i. Select Properties
j. Double click TSID1
k. In the Entity Selection window, select TICREG_1; click OK
l. Double click TSID2
m. In the Entity Selection window, select TICREG_2; click OK
n. Double click TSID3
p. In the Entity Selection window, select TICREG_3; click OK
q. Click Modify
a
c d
b
e
f
j
l
n
h
i p
k
m
o
CHAPTER 40
Initial Euler Condition MESH_2
a. LBCs: TIC
b. Click TICEUL1
c. For ID: enter 2
d. For Name: enter TICEU1_2
f. Click Modify
g. Observe that TICEUL1_2 has been added
h. In the Model Browser tree, right click TICEUL1_2
i. Select Property
j. Double click TSID1
k. In the Entity Selection window, select TICREG_1; click OK
l. Click Modify
a c d
b
e
f
j
l
h i
k
CHAPTER 40 631
Initial Euler Properties MESH_1
a. Element properties: 3D
b. Click PEULER1
c. For Name: enter PEULER1_3
d. For Type: select MMHYDRO
e. Double click SID
f. In the Entity Selection window, select TICEUL1_1; click OK
g. Click Modify
h. Observe that PEULER1_3 has been added
a c
e
b
d
g
f
CHAPTER 40
Initial Euler Properties MESH_2
a. Element Properties: 3D
b. Click PEULER1
c. For Name: enter PEULER1_4
d. For Type: select MMHYDRO
e. Double click SID
f. In the Entity Selection window, select TICEUL1_2; click OK
g. Click Create
a
c
d e
g
b
f
CHAPTER 40 633
Add Euler Property to MESH_1 and MESH_2
a. Element Properties: 3D
b. Select Properties
c. Double click PID
d. In the Entity Selection window, select PEULER1_3; click OK
e. Click Modify
f. In the Model Browser tree, right click Mesh_2
g. Select Properties
h. Double click PID
i. In the Entity Selection window, select PEULER1_4; click OK
j. Click Modify
b d
c
i
g h
j
CHAPTER 40
Coupling Surfaces - Coupling Interaction

Coupling Surface 1
a. LBCs: Couple, select COUPLE (not shown)

b. From the Pick Window: select Shells for BSURF
c. Select All; click Done
d. For ID: enter 1
e. For Name: enter COUPLE_1
f. For COVER, select INSIDE
g. For both REVERSE and CHECK, select On
h. Double click MESHID
i. In the Entity Selection window, select MESH_1; click OK
j. Click Modify
k. Observe that COUPLE_1 has been added
d e
f g
h
j
i k
CHAPTER 40 635
Coupling Surfaces - Coupling Interaction (Continued)

Coupling Surface 2
a. LBCs: Couple, select COUPLE (not shown)

b. From the Pick Window: select Shells for BSURF
c. Select All; click Done
d. For ID: enter 2
e. For Name: enter COUPLE_2
f. For COVER, select OUTSIDE
g. For both REVERSE and CHECK, select On
h. Double click MESHID
i. In the Entity Selection window, select MESH_2; click OK
j. Click Modify
k. Observe that COUPLE_2 has been added
d e
f g
h
j
i k
CHAPTER 40
Coupling Surfaces - Coupling Interaction (Continued)

Coupling interaction
a. LBCs: Couple, select COUPINT (not shown)

b. For ID: enter 1
c. For Name: enter COUPINT_1
d. Double click CID1
e. In the Entity Selection window, select COUPLE_1; click OK
f. Double click CID2
g. In the Entity Selection window, select COUPLE_2; click OK
h. Click Modify
i. Observe that COUPINT_1 has been added
b c
d f
e g
i
CHAPTER 40 637
Parameters
Define result frequency output
a. Job Parameter: DYPARAM_BINARY_option

b. For Name: enter DYPARAM_BINARY_option_1
c. For SID: enter 1
d. For DT_D3PLOT: enter 0.00015
e. Click Create
f. Click Exit
g. Observe that DYPARAM_BINARY_option_1 has been added
b c
d
g
e f
CHAPTER 40
Parameters (Continued)
Define initial time step
a. Job Parameter: PARAM

b. For Name: enter PARAM_2
c. For SID: enter 2
d. For N: enter DYINISTEP
e. For V1: enter 5.E-7
f. Click Create
g. Click Exit
h. Observe that PARAM_2 has been added
b c
d e
f g
h
CHAPTER 40 639
Parameters (Continued)
Define parameter to activate coupling interaction
a. Job Parameter: DYPARAM

b. For Name: enter DYPARAM_1
c. For SID: enter 2
d. For F1: enter FASTCOUP
e. For F2: enter INPLANE
f. For F3: enter FAIL
g. Click Create
h. Click Exit
i. Observe that DYPARAM_1 has been added
b
c
d e f
g h
i
CHAPTER 40
Create New Nastran Job
a. In the Model Browser Tree, right click FileSet

b. Select Create New Nastran Job
a
b
CHAPTER 40 641
Create New Nastran Job (Continued)

Delete default Output Request to prevent excessive output Archive files
a. In the Model Browser Tree: Simulations: NewJob: Load Cases; DefaultLoadCase: Output Requests:
right click Displacement Output Request
b. Click Delete
c. Click Yes
d. the Model Browser Tree: Simulations: Load Cases; DefaultLoadCase: Output Requests:
right click Element Stress Output Request (not shown)
e. Click Delete (not shown)
f. Click Yes
a
b
f
CHAPTER 40
Simulations
Solver Control
a. In the Model Browser Tree: Simulations: NewJob: Load Cases; Solver Control:
right click Properties (not shown)
b. Select Solution 700 Parameters
c. Deactivate Large Displacement
d. Deactivate Follower Forces
e. Click Apply
f. Click Close
b
c
d
e
f
CHAPTER 40 643
Simulations (Continued)
Define End Time and Output frequency for Loadcase Control
a. In the Model Browser Tree: Simulations: NewJob: Load Cases; DefaultLoadCase: Loadcase Control
right click Properties (not shown)
c. For Ending Time: enter 0.0015
d. For Number of Time Steps: 10
e. Click Apply
f. Click Close
b c
a d
e
f
CHAPTER 40
Simulations (Continued)
Running New Nastran Job
a. In the Model Browser Tree: right click NewJob

b. Click Run
b
CHAPTER 40 645
Postprocessing
Start SimXpert: New Project

b. File Path: select newjob.dytr.d3plot
c. Attach Options, select Both
d. Click Apply
e. Repeat steps a through d for newjob.dytr_Euler_FV1_0.ARC (not shown)
f. Repeat steps a through d for newjob.dytr_Euler_FV2_0.ARC
a f
f
b
c
d
CHAPTER 40
Postprocessing (Continued)
Displacement
a. FileSet: Part: newjob

b. Select Show Only
c. Results: Deformation
d. State plot property editor: Results cases: select Time 0.0015016
e. State plot property editor: Result type: click Deformation Components
f. State plot property editor: click Deformation
g. State plot property editor: Deformed Display scaling: select True
h. Click Update
a
c
g h
CHAPTER 40 647
Fringe Stresses
a. Results: Fringe
b. State plot property editor: Results cases: select Time 0.0015016
c. State plot property editor: Results cases: select Stress Components
d. State plot property editor: click Fringe
e. State plot property editor: Element edge display: select Element edges
f. Click Update
e
f
CHAPTER 40
IsoSurface Bird 1 (MESH_1)
a. StatePlot: right click Deform 01

b. Select Hide
c. StatePlot: right click Fringe 01
d. Select Hide
e. FileSet: Part: right click NEWJOB.DYTR_EULER_FV1_0.ARC
f. Select Show Only
g. Results: Iso-Surface
h. State plot property editor: Result cases: select ...FV1_cycle744
i. State plot property editor: Result type: select FMAT4
j. State plot property editor: click IsoSurface
k. State plot property editor: Target entities: select All elements
l. Click Update
a
e
b c
f
d
h i
l
k
CHAPTER 40 649
IsoSurface Bird 2 (MESH_2)
a. FileSet: Part: right click NEWJOB.DYTR_EULER_FV2_0.ARC

b. Select Show Only
c. Results: Iso-Surface
d. State plot property editor: Plot attribute: select IsoSurf 02
e. State plot property editor: Result cases: select ...FV1_cycle744
f. State plot property editor: Result type: select FMAT4
g. State plot property editor: click IsoSurface
h. State plot property editor: Target entities: select All elements
i. Click Update
a
c
f
e
i
h
CHAPTER 40
IsoSurfaces Deformations
CHAPTER 40 651
Results
In this simulation, the time history of total z-force on the coupling surface is requested as shown in Figure 40-4. This
force is the sum of all z-forces on the nodes that belong to both the upper and the lower plate.
From Figure 40-4, it is obvious that there are three large impact forces occurring on the plate. The first one is when
the first bird impacts the upper plate, which is subject to a significant damage. The second one is when the second bird
impacts the upper plate. The last peak is caused by the first bird impacting the lower plate.
Snapshots of the motion of the two birds and the deformation of the plates are shown in Figure 40-5 at various time
steps of the simulation. Figure 40-5a is the initial condition. Figure 40-5b is at the moment when the first bird
penetrates the upper plate and second bird touches the plate.
This corresponds with the first peak in the time history plot shown in Figure 40-4. Figure 40-5c is at the moment when
the second bird penetrates the upper plate. It corresponds with the second peak of the time history plot. Figure 40-5d
is at the moment when the second bird has left the plate and the first bird penetrates the lower plate. This corresponds
with the third peak in the time history plot.
Figure 40-4 Time History of Total Z-force on Coupling Surface

CHAPTER 40
Figure 40-5 Deformation of Plates

CHAPTER 40 653
Abbreviated SOL 700 Input File
SOL 700,NLTRAN STOP=1

CEND
TITLE = Multiple bird strike using Multi-Material-FVSurfer
IC = 1
SPC = 1
TSTEPNL=1
$
BEGIN BULK
PARAM*,DYINISTEP,1e-7
PARAM*,DYMINSTEP,1e-8
DYPARAM,FASTCOUP,INPLANE,FAIL
DYPARAM,FMULTI,0.2
Dyparam,stepfctl,0.9
DYPARAM,LSDYNA,BINARY,D3PLOT,.00015
DYTIMHS,,.000001,,,,,,,+
+,CPLSOUT
$
TSTEPNL, 1, 10, .00015, 1
$
$ Include model + SPC
INCLUDE examp4_9_bs.bdf
$
$ domain 1
$
MESH,1,BOX,,,,,,,+
+,-0.26,-0.015,-0.05,0.50,0.28,0.44,,,+
+,50,28,44,,,,EULER,1
$
$ COUPLING SURFACE 1
$
COUPLE, 1, INSIDE, ON, ON, , , , , +
+, , , , , , , , , +
+, 1
$
BSURF, 1, 7393, THRU, 8448, 13729, THRU, 14048, 14577, +
+, THRU, 15236
$
$ Flow boundary, property, material and equation of state data.
$ -------------------------------------------------------------
FLOWDEF, 1, MMHYDRO, , , , , , +
+, FLOW, OUT
$
PEULER1, 1, , MMHYDRO, 11
PEULER1, 6, ,MMHYDRO, 12
EOSGAM,4,1.4
$
$--------Material Bird ------------------------------------
MATDEUL, 3, 930, 3
EOSPOL, 3, 2.2e9
MATDEUL, 5, 930, 5
EOSPOL, 5, 2.2e9
$
CHAPTER 40
$=============================================================
$
$ Allocation of material to geometric regions.
$ --------------------------------------------
TICEUL1 11 11
TICREG 1 11 CYLINDER1 3 1 3
TICREG 2 11 CYLINDER2 5 2 2
TICREG 3 11 SPHERE 4 4 5 1
$
CYLINDR 1 .13 .125 .2252 .17 .125 .2944 +
+ .035
CYLINDR 2 -.1381 .125 .26 -.2381 .125 .26 +
+ .035
SPHERE,4,,-.1381, .125, .26, 1000
$
$ Initial material data.
$ ----------------------
TICVAL 1 XVEL -75 ZVEL -129.9
TICVAL 2 XVEL 200
$
$ LAGRANGE
$
$ Property, material and yield model.
$ -----------------------------------
PSHELL1 2 2 Blt Gauss 3 .83333 Mid +
+ .0015
$
MATD024,2,4527,1.150e11,.314,1.38e8,,0.1
$
PSHELL,3,999,1.E-3
PSHELL,4,999,1.E-3
$
MATD009,999,1.E-20
$
$ Boundary constrain.
$ --------------------
CORD2C 1 0.0 0.0 0.0 0.0 0.25 0.0 +
+ 0.0 0.125 0.25
$
$ -------- Material Air id =4
MATDEUL 4 1.1848 4
$ |
$ -> density
$
$-----------------------------Domain 2------------------------------
$
TICEUL1,12,12
TICREG,11,12,SPHERE,7,4,5,1.0
SPHERE,7,,0.0,0.0,0.0,500.0
TICVAL,5,,SIE,2.1388E5,DENSITY,1.1848
$
$===Coupling Surface 2
$
COUPLE,2,2,OUTSIDE,,,,,,+
CHAPTER 40 655
+,,,,,,,,,+
+,,2
$
BSURF 2 7393 THRU 8448 13729 THRU 14048 14577+
+ THRU 15236
MESH,2,ADAPT,0.01,0.01,0.01,,,,+
+,-0.26,-0.015,-0.05,,,,,,+
+,,,,,,,EULER,6
$
$ coupling interaction
$
COUPINT,2,2,1
$
ENDDATA
Input File(s)
File Description
nug_40.dat MD Nastran input file for multiple material Euler element using FSI technique
chapter 41: Shaped Charge Penetrating Two Plates
Shaped Charge Penetrating

41 Two Plates

Summary 657

Introduction 658


FEM Solution 660

Results 712


Input File(s) 714
CHAPTER 41 657
Shaped Charge Penetrating Two Plates
Summary
Title Chapter 41: Shaped Charge Penetrating Two Plates
Features • Wall Boundary of Euler Mesh
• Transient Initial Condition of Euler Region
• Axis-symmetric Analysis
• Structural multi material with shear strength and void
Geometry
Copper Plate Voids
Explosive Steel Plates

Material properties • Explosive
Military Compound B (See EOSIG in MD Nastran QRG)
• Copper
Density = 8960 kg/m3
Shear Modulus = 0.477E11 Pa
Johnson-Cook Yield Model
Minimum Pressure of Spallation = -2.5E10 Pa
• Steel
Shear Modulus = 0.818E11 Pa
Equivalent Yield Stress = 1.4E9 Pa
Minimum Pressure of Spallation = -3.8E9 Pa
Analysis characteristics Transient explicit dynamic analysis (SOL 700)
Boundary conditions Wall Boundary on the part of Explosive Case
Element types Euler: 8-node solid element for explosive, void, steel, and copper
FE results 1. Snap Shots of Liner Collapse, Jet Formation and Plates Penetrated
2. Velocity field of explosive gases, liner, and jet at 20 s
CHAPTER 41
Introduction
Figure 41-1 Model
When a metal cone is explosively collapsed onto its axis, a high-velocity rod of molten metal, the jet, is ejected out of
the open end of the cone. The cone is called a liner and is typically made of copper. The jet has a mass approximately
20 percent of the cone mass, and elongates rapidly due to its high velocity gradient. This molten rod is followed by
the rest of the mass of the collapsed cone, the slug. Typical shaped charges have liner slope angles of less than 42
degrees ensuring the development of a jet; with jet velocities ranging from 3000 to 8000 m/s. A typical construction
of a shaped charge is shown in Figure 41-2.
Figure 41-2 Typical Construction of Shaped Charge

CHAPTER 41 659
An example simulation of shaped charge formation is carried out to demonstrate the ability of SOL 700 to perform
such a simulation. A simplified axisymmetric model of explosives and a copper liner is created in a finite volume Euler
mesh. Explosive are detonated starting from a point on the axis of symmetry at the end of the explosives. The
simulation is carried out for 60 s after detonation of the explosives. The jet is formed and penetrates two thick plates.
See Figure 41-3 for the model layout.
Figure 41-3 SOL 700 Model Setup
Typical shaped charges are axisymmetric. However, aiming at higher velocity, 3-D designs are targeted. 3-D
simulation of shaped charge formation would be necessary to avoid excessive experimental work. SOL 700 has full
abilities to perform such a 3-D simulation.
SOL 700 Model
The model is simplified as shown in Figure 41-3. The aluminum casting is replaced with a rigid body.
Detonation is assumed to start at a point on the axis at the rear end of the explosives. The liner shape is slightly
simplified as shown in the figure. The retaining ring is assumed rigid and is modeled as a wall boundary for the Euler
Mesh (BARRIER). SI units are used in this example.
CHAPTER 41
FEM Solution
A. Euler Mesh and Liner:
A triangular prismatic Finite Volume Euler mesh is used with head angle of 5 degrees as shown in Figure 41-4. A very
fine mesh is used to accurately simulate the behavior of the extremely thin liner. The liner is placed in this Euler mesh.
Symmetry conditions (closed boundary, default Euler boundary condition) are imposed on the two rectangular faces
of the prism to create an axisymmetric behavior.
Figure 41-4 Euler Mesh
The liner material pressure – density relationship is modeled with EOSPOL model. The liner is made of copper and
the constants are taken as follows:
a1 1.43E11 N/m2
a2 0.839E11 N/m2
a3 2.16E9 N/m2
b1 0.0
b2 0.0
b3 0.0
Material yield strength is modeled with a Johnson-Cook yield model. The constants are taken as follows:
A 1.2E8 N/m2
B 1.43E9 N/m2
C 0.0
n 0.5
CHAPTER 41 661
m 1.0
0 1.0
Tmelt 1356.0 K
Troom 293.0 K
Cv 399.0 J/kg
Other liner material properties of liner are as follows:
Density 8960 Kg/m3

Constant shear model 0.477E11 N/m2
Constant spallation model -2.5E10 N/m2
In the input file:
MATDEUL 701 8960. 711 712 713 714

EOSPOL, 711, 1.43+11, 0.839+11, 2.16+9
SHREL,712,0.477E11
$ Johnson-Cook
$ A B n C m EPS0 Cv
YLDJC,713, 1.2E8, 1.43E9, 0.5, 0.0, 1.0, 1.0, 399.0,+
$ TMELT TROOM
+, 1356.0, 293.0
$
PMINC,714,-2.5E10
It is very easy to define the shape and position of the liner by using the method of geometrical regions when creating
the initial conditions of the liner material.
CYLINDR, 1,, -0.5391, -0.56, 0., 2.0, 0.4147, 0.,+

+,0.2958
CYLINDR, 2,, -0.5391, -0.56, 0., 2.0, 0.4147, 0.,+
+,0.2939
CYLINDR, 3,, 0.2, 2.0406, 0., 0.2047, 2.0406, 0.,+
+,2.0019
TICVAL,2,,DENSITY,8960.
B. Casting and Retaining Ring:

The casting is assumed to be rigid. It is modeled by the default Eulerian boundary condition (closed boundary). The
retaining ring is also assumed to be rigid and is modeled by a barrier.
C. Plates:
Two thick plates are placed in this Euler mesh. Plate material is defined as steel:
MATDEUL 801 7830. 811 812 813 814

EOSPOL, 811, 1.64E+11
SHREL,812,0.818E11
YLDVM,813,1.4E9
CHAPTER 41
PMINC,814,-3.8E9
The shapes and positions of the plates are defined by using the method of geometrical regions.
CYLINDR, 4,, 0.22, 2.0406, 0., 0.223, 2.0406, 0.,+

+,2.05
CYLINDR, 5,, 0.27, 2.0406, 0., 0.273, 2.0406, 0.,+
+,2.05
D. Explosive:
The explosive is modeled by ignition and growth equation of state. The explosive is placed in this Euler mesh.
EOSIG,100,,,,,,,,+
+,,,,,,,,,+
+,,,,,99,,MCOMPB,SI
The explosive material is taken from the database that is build into SOL 700.
To initialize the whole Euler mesh, a TICEUL entry will be defined.
TICEUL1 1 1
TICREG 1 1 ELEM 1 100 1 1.
TICREG 2 1 CYLINDER1 701 2 2.
TICREG 3 1 CYLINDER2 3.
$
SET1 1 1 THRU 15342
TICVAL,1,,DENSITY,1630.,SIE,4.29E6
CHAPTER 41 663
Create a New Database

Enter the MD Explicit Workspace.
b. Click Save As
c. File name, enter CH41
d. Click Save
c d
CHAPTER 41
Change the Units
a. Tools: Options
c. Click Standard Units
d. Select the line with m, kg, s, ...
e. Click OK
f. Return to User Options screen and click OK
e
CHAPTER 41 665
Import the Model Geometry
a. File: Import
b. Select Nastran
c. Look in: CHAPTER41
d. Select sch_model.bdf
e. Click Open
b
c
d
e
CHAPTER 41
Create Explosive Material Compound B

Ignition and Growth Equation of State
a. Click: EOS
b. Select [07] EOS Ignition
c. For Name: enter EOSIG_100
d. For MID, enter 100
e. For DBEXP, select MCOMPB
f. For UNITCNV, select SI
g. For ITRMAX, enter 99
h. Click Create
i. EOSIG_100 is added
c e
d f
g
i
h
CHAPTER 41 667
Create Explosive Material Compound B (continued)

Shear Model Explosive
a. Click: Shear
b. Select Elastic Shear Model
c. For Name: enter SHREL_101
e. For G, enter 3.E9
f. Click Create
g. SHREL_101 is added
a
b
c
d e
g
CHAPTER 41

Yield Model Explosive
a. Click: Yield
b. Select Von Mises Yield
c. For Name: enter YLDVM_102
e. For YIELD, enter 2.E8
f. Click Create
g. YLDVM_102 is added
c
d e
f
CHAPTER 41 669

Eulerian Material Explosive
a. Click: Eulerian
b. Select Eulerian Material
c. For Name: enter MATDEUL_103
e. For RHO, enter 1630
f. Double click EID; select Select
g. For Entity Selection, select EOSIG_100; click OK
h. Double click SID; select Select
i. For Entity Selection, select SHREL_101; click OK
j. Double click YID; select Select
k. For Entity Selection, select YLDVM_102; click OK
l. Click Create
m. MATDEUL_103 is added
a
b
c
d e f h j m
g
i
k
CHAPTER 41
Create Material Copper Liner

Linear Polynomial Equation of State
a. Click: EOS
b. Select [01] EOS Linear Polynomial
c. For Name: enter EOSPOL_701
e. For A1, enter 1.43E11
f. For A2, enter 8.39E10
g. For A3, enter 2.16E9
h. Click Create
i. EOSPOL_701 is added
a
b
i
c
d
e f g
h
CHAPTER 41 671
Create Material Copper Liner (continued)

Shear Model Copper Liner
a. Click: Shear
e. For G, enter 4.77E10
f. Click Create
a
b
c
d e
f
g
CHAPTER 41

Yield Model Copper Liner
a. Click: Yield
b. Select Johnson-Cook Yield
c. For Name: enter YLDJC_703
e. For A, enter 1.2E8
f. For B, enter 1.43E9
g. For N, enter 0.5
h. For CP, enter 399
i. For TM, enter 1356
j. For TR, enter 293
k. Click Create
l. YLDJC_703 is added
a
b
c l
d e f g h
i j
k
CHAPTER 41 673

Spall Limit Copper Liner
a. Click: Spall
b. Select PMINC
c. For Name: enter PMINC_704
e. For Value, enter -2.5E10
f. Click Create
g. PMINC_704 is added
a
b
c
d e
f
CHAPTER 41

Eulerian Material Copper Liner
a. Click: Eulerian
g. For Entity Selection, select EOSPOL_701; click OK
h. Double click SID; select Select;
i. For Entity Selection, select SHREL_702 click OK
k. For Entity Selection, select YLJC_703; click OK
l. Double click PID; select Select
m. For Entity Selection, select PMINC_704; click OK
n. Click Create
o. PMINC_704 is added
a
b
c
d e f h j l
n o
g m
i k
CHAPTER 41 675
Create Material Steel Plates

Linear Polynomial Equation of State
a. Click: EOS
b. Select [01] EOS Linear Polynomial
c. For Name: enter EOSPOL_801
e. For A1, enter 1.64E11
f. Click Create
g. EOSPOL_801 is added
a
b
g
c
d e
f
CHAPTER 41
Create Material Steel Plates (continued)

Shear Model Steel Plates
a. Click: Shear
e. For G, enter 8.18E10
f. Click Create
a
b
c
d e
f
g
CHAPTER 41 677

Yield Model Steel Plates
a. Click: Yield
b. Select Von Mises Yield
c. For Name: enter YLDVM_803
e. For A, enter 1.4E9
f. Click Create
g. YLDJC_803 is added
c g
d e
f
CHAPTER 41

Spall Limit Steel Plates
a. Click: Spall
b. Select PMINC
c. For Name: enter PMINC_804
e. For Value, enter -3.8E9
f. Click Create
g. PMINC_804 is added
a
b
c
d e
f
g
CHAPTER 41 679

Eulerian Material Steel Plates
a. Click: Eulerian
g. For Entity Selection, select EOSPOL_801; click OK
h. Double click SID; select Select;
i. For Entity Selection, select SHREL_802 click OK
k. For Entity Selection, select YLJC_803; click OK
l. Double click PID; select Select
m. For Entity Selection, select PMINC_804; click OK
n. Click Create
o. PMINC_804 is added
a
b
c
d e f h j l
n
o
g m
i
k
CHAPTER 41
Create Cylinders
Cylinder 1 defining outer surface of the liner
a. Click: Cylinder
b. Select XYZ
c. For XYZ Input: enter -0.5391 -0.56 0 2 0.4147 0; click OK
d. For Radius, enter 0.2958
e. Click Modify
f. Cylinder_1 is added
a b
e
CHAPTER 41 681
Create Cylinders (continued)

Cylinder 2 defining inner surface of the liner
a. Click: Cylinder
b. Select XYZ
c. For XYZ Input: enter -0.5391 -0.56 0 2 0.4147 0; click OK
e. Click Modify
a b
e
CHAPTER 41

Cylinder 3 defining the rear end of the liner
a. Click: Cylinder
b. Select XYZ
c. For XYZ Input: enter 0.2 2.0406 0 0.2047 2.0406 0; click OK
e. Click Modify
a b
e
CHAPTER 41 683

a. Click: Cylinder
b. Select XYZ
e. Click Modify
a b
e
CHAPTER 41

a. Click: Cylinder
b. Select XYZ
e. Click Modify
a b
e
CHAPTER 41 685

Sphere 6 covering the entire model
a. Click: Sphere
b. Select XYZ
c. For XYZ Input: enter 0 0 0; click OK
d. For Radius, enter 1
e. Click Modify
f. Shpere_6 is added
b
a
e
CHAPTER 41
Create Initial Values

Initial values explosive
a. Click: TIC
b. Click TICVAL
c. For ID: enter 1
d. For Title, enter TICVAL_1
e. For Density, enter 1630
f. For SIE, enter 4.2E6
g. Click Modify
h. TICVAL_1 is added
a
b
c d
e f
g
h
CHAPTER 41 687
Create Initial Values (continued)

Initial values copper liner
a. Click: TIC
b. Click TICVAL
c. For ID: enter 2
f. Click Modify
g. TICVAL_2 is added
a
b
c d
e
f
g
CHAPTER 41
Create Initial Values (continued)

Initial values steel plates
a. Click: TIC
b. Click TICVAL
c. For ID: enter 3
f. Click Modify
g. TICVAL_3 is added
a
b
c d
e
f
g
CHAPTER 41 689
Create Initial Regions

Initial region explosive
a. Click: TIC
b. Click TICREG
c. For ID: enter 1
d. For Title, enter TICREGL_1
e. Double click VID; select Select
f. For Entity Selection, select Sphere_6; click OK
g. Double click MID; select Select
h. For Entity Selection, select MATDEUL_103 click OK
i. Double click TICID; select Select
j. For Entity Selection, select TICVAL_1; click OK
k. For Level, enter 1
l. Click Modify
m. TICREG_1 is added
c d
e g i k
l
h j
f m
CHAPTER 41
Create Initial Regions (continued)

Initial region copper liner
a. Click: TIC
b. Click TICREG
c. For ID: enter 2
f. For Entity Selection, select Cylinder_1; click OK
l. Click Modify
c d
e g i k
l
f h j
m
CHAPTER 41 691

Initial region of void
a. Click: TIC
b. Click TICREG
c. For ID: enter 3
g. For Level, enter 3
h. Click Modify
i. TICREG_3 is added
c d
e g
h
i
CHAPTER 41

Initial region copper liner
a. Click: TIC
b. Click TICREG
c. For ID: enter 4
l. Click Modify
c d
e g i k
l
h j
f
m
CHAPTER 41 693

Initial region steel plate 1
a. Click: TIC
b. Click TICREG
c. For ID: enter 5
l. Click Modify
c d
e g i k
l
f h j
m
CHAPTER 41

Initial region steel plate 2
a. Click: TIC
b. Click TICREG
c. For ID: enter 6
l. Click Modify
c d
e g i k
l
h j
f
m
CHAPTER 41 695
Create Initial Condition Euler
a. Click: TIC
b. Click TICEU1
c. For ID: enter 1
d. For Title, enter TICEUL_1
e. Click NREG; enter 6
f. Click Modify
g. Double click TSID1; select Select
h. For Entity Selection, select TICREG_1 click OK
i. Double click TSID2; select Select
j. For Entity Selection, select TICREG_2 click OK
k. Double click TSID3; select Select
l. For Entity Selection, select TICREG_3 click OK
m. Double click TSID4; select Select
n. For Entity Selection, select TICREG_4 click OK
o. Double click TSID5; select Select
p. For Entity Selection, select TICREG_5 click OK
q. Double click TSID6; select Select
r.;For Entity Selection, select TICREG_6 click OK
s. Click Modify
t. TICEUL_1 is added
a
b
c d
e h
f j l
g
i
k
m
o n p t
r
q
s
CHAPTER 41
Create Eulerian Element Property
a. Under Materials and Properties in Properties, click: 3D

b. Click PEULER1
c. For Name: enter PEULER_1
d. For Type, select MMSTREN
e. Double click SID1; select Select
f. For Entity Selection, select TICEUL1_1; click OK
g. Click Create
h. In the Model Browser tree, right click PEULER1
i. Select Properties
j. In the Modify PEULER_1 Property window, click Change Region
k. In the Pick Window, select All
l. Click Done
m. Click Modify
c
d f
e
g
m
h
k l
CHAPTER 41 697
Create Node Set Segments

Locate the rear end of the copper liner
a. Zoom around Cylinder_3 area in window

b. Tools: Identify
c. From Pick window Identify Entities, select Nodes
d. Select nodes next to Cylinder_3 (Node 23593); in Pick window Identify Entities, click Exit
e. Assemble: Contact Set
e. Click: Node Set Segment
f. Select five (5) nodes next to Cylinder_3
g. In the Node Set Segment window, for Name:, enter BCSEG_1
h. In the Node Set Segment window, for Node Set:, enter 10
i. Click OK
j. BCSEG_1_1 is added
f b
d
g
a c
h
i
CHAPTER 41
Create Barrier
a. LBC tab: Couple: Eulerian

b. Select Barrier
c. From Pick window CREATE BARRIER, select Nodes
d. Click Node 23593
e. Select Plane YZ; click OK
f. For ID: enter 1
g. For Name: enter Barrier_1
h. Double click BCID
i. Select BCSEG_1; click OK
j. Click DIR to unselect
k. Click Modify
l. Barrier_1 is added
a c f g
j
h
b
k
e
d
l
CHAPTER 41 699
Define Values for PARAMs

Define DYINISTEP parameters
a. Job Parameter: PARAM

b. For Name: enter PARAM_1
c. For SID: enter 1
d. For N: enter DYINISTEP
e. For V1: enter 1.E-11
f. Click Create
g. Click Exit
h. PARAM_1 is added
b c
d e
f g
h
CHAPTER 41
Define Values for PARAMs (continued)

Define Results Output Frequency

b. For Name: enter DYPARAM_1
c. For SID: enter 1
d. For F1: enter LSDYNA
e. For F2: enter BINARY
f. For F3: enter D3PLOT
g. For F4: enter 5.E-6
h. Click Create
i. DYPARAM_1 is added
b
c
d e f g
i
CHAPTER 41 701
Define Values for PARAMs (continued)

Define VELMAX parameter

b. For Name: DYPARAM_2
c. For SID: 2
d. For F1: enter VELMAX
e. For F2: enter 20.E3
f. Click Create
g. Click Exi
h. DYPARAM_2 is added
b
c
d e
f g
h
CHAPTER 41
Create a New Nastran Job
a. Model Browser: Right click over sch_model.bdf

c. For Solver Input File, choose Chapter41/SESSION/Chapter41.bdf
d. SXLaunch: For File name: enter Chapter41.bdf
e. Click Save
f. Click OK
a b
d e
f
CHAPTER 41 703
Define Load Cases and Export a Nastran Input File
a. Model Browser: Right click over Load Case Control

c. Select Subcase Nonlinear Static Parameters
d. For Ending Time, enter 60.E-6
e. For Number of Time Steps, enter 12
f. Click Apply
g. Model Browser: Right click over Displacement Output
h. Click Delete
i. Model Browser: Right click over Element Stress Output
j. Click Delete
k. Right click NewJob
l. Click Export
m. Click Run (optional)
c d
e
a b
g h j
i
l
m
CHAPTER 41
Run MD Nastran Solver
a. Double click MD Nastran icon

b. Select Chapter41.bdf
c. Click Open
d. Click Run
a
b
d
CHAPTER 41 705
Access the MD Nastran Results

To access the results, the ARC file is attached.
a. Under File, select Attach Results

b. File path, select CHAPTER41.DYTR_EULER_0.ARC
c. Click Open
d. Click Apply
b
c
e d
Note: If SimX can’t access the results, do the following:

File -> Save
File -> New
File –> Attach Results
Attach Options: BOTH
OK
CHAPTER 41
Create Fringe Plot
a. Results: Fringe
b. File path, select CHAPTER41.DYTR_EULER_0.ARC
c. For Result Cases, select Cycle 0, Time 0
d. For Result type, select DENSITY
e. Click Update
d
b
c
CHAPTER 41 707
Create Fringe Plot (continued)

Adjust Spectrum Colors
a. Results: Spectrum
b. Spectrum Manager: click Add
c. Spectrum: enter Spectrum_1
d. Click Update
e. Click Calculator
f. Click Colors
g. Click and drag colors from the table to the bar
h. Click Apply
i. Click OK
j. Check the colors
b
a
f
c d
i h
j
CHAPTER 41
a. State plot property editor: click Fringe

b. Spectrum Manager: click Add
c. Spectrum range, Spectrum: enter Spectrum_1
d. Click Update; observe graphic
e. Click Plot Data
f. For Result cases, select Cycle 2993, Time 1.0; observe graphic
g. Repeat e. and f. for Time 2, 3, 4, 5, and 6; observe graphics on following page
d a
c
c
b
f
e f
g
CHAPTER 41 709
Time = 0
Time = 1.E-5
Time = 2.E-5
Time = 3.E-5
Time = 4.E-5
Time = 5.E-5
Time = 6.E-5
CHAPTER 41
Animate Fringe Plot

Create a Fringe Plot with animation.
a. Results: Fringe
b. State plot property editor: click Fringe
c. For Result cases, select CHAPTER41.DYTR
d. Click Density
e. Select Animate
f. Click Update
f
c
e
d
CHAPTER 41 711
Animate Fringe Plot (continued)

Create mpeg file
a. State plot property editor: click Animation

Record Attributes, select Movie Filename
c. SimXpert Results Animation File: File name, enter Animation
d. Click Save
e. Click Record Animation button
f. Click Play Animation button
g. Click Stop Animation button
a
g e
f b
c d
CHAPTER 41
Results
Figure 41-5 shows the initial position of the copper liner and two thick plates at 0s, snap shots of
liner collapse, jet formation and plates penetrated at 10 s, 20 s, 30 s, 40 s, 50 s and 60 s.
Figure 41-5 Initial Position of the Copper Liner and Two Thick Plates, Snap Shots of Liner Collapse, Jet
Formation and Plates Penetrated (Courtesy – Postprocessing by CEI Ensight)
Figure 41-6 shows the velocity field of explosive gases, liner, and jet at 20 s. A jet velocity of about 6000 m/s is
achieved
Figure 41-6 Velocity Field of Explosive Gases, Liner, and Jet

CEND
TITLE = SHAPED CHARGES TEST
$ for QA purpose, run shorter time
$ENDTIME = 1.E-5
CHAPTER 41 713
IC = 1
TSTEPNL=1
$$
$
BEGIN BULK
TSTEPNL 1 10 1.E-06 1
PARAM*,DYINISTEP,1.E-11
PARAM*,DYMINSTEP,1.E-13
DYPARAM,VELMAX,20.0E+03
DYPARAM,LSDYNA,BINARY,D3PLOT,1.E-5
$
INCLUDE model.bdf
INCLUDE wall.dat
$ EXPLOSIVE
$
MATDEUL 100 1630. 100 101 102
$
EOSIG,100,,MCOMPB,SI,,,,,+
+,,,,,,,,,+
+,,,,,,,,,+
+,,,,,99
$
SHREL,101,3.E9
$
YLDVM,102,2.E8
$
$ COPPER
$
MATDEUL 701 8960. 711 712 713 714
EOSPOL, 711, 1.43+11, 0.839+11, 2.16+9
SHREL,712,0.477E11
$ Johnson-Cook
$ A B n C m EPS0 Cv
YLDJC,713, 1.2E8, 1.43E9, 0.5, 0.0, 1.0, 1.0, 399.0,+
$ TMELT TROOM
+, 1356.0, 293.0
$
PMINC,714,-2.5E10
$
$ STEEL
$
MATDEUL 801 7830. 811 812 813 814
EOSPOL, 811, 1.64E+11
SHREL,812,0.818E11
YLDVM,813,1.4E9
PMINC,814,-3.8E9
$
TICEUL1 1 1
TICREG 1 1 ELEM 1 100 1 1.
TICREG 3 1 CYLINDER2 3.
CHAPTER 41
$
PEULER1, 1 ,, MMSTREN, 1
SET1 1 1 THRU 15342
CYLINDR, 1,, -0.5391, -0.56, 0., 2.0, 0.4147, 0.,+
+,0.2958
CYLINDR, 2,, -0.5391, -0.56, 0., 2.0, 0.4147, 0.,+
+,0.2939
CYLINDR, 3,, 0.2, 2.0406, 0., 0.2047, 2.0406, 0.,+
+,2.0019
CYLINDR, 4,, 0.22, 2.0406, 0., 0.223, 2.0406, 0.,+
+,2.05
CYLINDR, 5,, 0.27, 2.0406, 0., 0.273, 2.0406, 0.,+
+,2.05
$
TICVAL,1,,DENSITY,1630.,SIE,4.29E6
$
BARRIER,1,2
$
ENDDATA
Input File(s)
File Description
nug_41.dat MD Nastran input file for wall boundary of Euler element
Chapter 42: Mine Blast Under a Vehicle
42 Mine Blast Under a Vehicle

Summary 716

Introduction 717


Results 722

Input File(s) 727

Video Examples 727
CHAPTER 42
Summary
Title Chapter 42: Mine Blast Under a Vehicle
Features • Using Dummy boundary to make closed volume
• Using Leakage to make free flow between two Euler meshes
• Explosive modeled by ideal gas
Geometry Outer Euler Zone
Inner Euler Zone
Vehicle
Ground
Explosive
Material properties • Vehicle Structure

Density = 7.85E-9 ton/mm3
Young’s Modulus = 2.1E5 ton/mm/s2
Poisson’s ratio = 0.3
Yield stress = 250. ton/mm/s2
• Euler (Air)
Density = 1.29E-12 ton/mm3; Gamma = 1.4
• Specific Internal Energy = 1.9385E8 ton-mm2/s2
• Euler (Explosive - equivalent to TNT of 7kg and radius of .25 meter)
Density = 107.E-12 ton/mm3; Specific Internal Energy = 3.9E12 ton/mm2/s2
• Ground – Rigid
Boundary conditions • Fixed boundary condition of ground
• In and out directional flow boundary of outer euler zone
Element types • 2-node bar element for stiffener of vehicle
• 4-node shell element for vehicle, dummy elements and ground
• 8-node hex element for euler which is automatically generated by MESH option
FE results 1. Acceleration plot at 0.0008 seconds
2. Stress Distribution plot at 0.0008 seconds
CHAPTER 42 717
Mine Blast Under a Vehicle
Introduction
This is a simulation of an explosion under a vehicle. The vehicle has triggered a mine that is exploding underneath the
bottom shield. In this example, the actual explosion of the mine is not modeled. Instead, the simulation is started
moments after the mine explodes. This is called the blast wave approach. At the location of the mine, a high density
and high specific energy is assumed in the shape of a small sphere. During the simulation, this region of high density,
energy, and high pressure, expands rapidly. The blast wave interacts with the bottom shield and causes an acceleration
of parts of the flexible body. The intent of this simulation is to find the location and the value of the maximum
acceleration.
SOL 700 Model

An outline of the basic numerical model is shown in Figure 42-1 below. It is composed of the following main
components:
a. Vehicle Structure
b. Euler Domain 1 - air outside vehicle and compressed air (explosive)
c. Euler Domain 2 - air inside vehicle
d. Ground
e. Fluid Structural Coupling
Figure 42-1 Outline of Basic Numerical Model

CHAPTER 42
A. The Vehicle:
Vehicle structure is modeled by QUAD, TRIA shell elements and some BAR elements.
Figure 42-2 Vehicle Structure
Material properties are taken as follows:
Density 7.85E-9 tonne/mm3

Modulus of elasticity 210000. tonne/mm/s2
Poison ratio 0.3
Yield stress 250. tonne/mm/s2
Assumed that there will be no failure of the structure. In a part of the structure, there is a hole through which air and
pressure waves can freely flow. This hole will be modeled with dummy shell elements.
B. Euler Domain 1:
The first Euler domain is the air on the outside of the vehicle. The properties of air at rest are:
Density 1.29E-12 tonne/mm3

Gamma 1.4
Specific internal energy 1.9385E8 tonne-mm2/s2
CHAPTER 42 719
In the input file:
MATDEUL,230,1.29e-12,203,,,,,,+
+,,1.01
TICVAL,5,,DENSITY,1.29E-12,SIE,1.938e11
At the location of the mine, a small region will be modeled with high density and specific internal energy equivalent
to TNT of 7kg when the sphere has a radius of .25 meter:
Density 107E-12 tonne/mm3

Specific Internal Energy 4.9E12 tonne-mm2/s2
The input file will show:
TICVAL,4,,DENSITY,107E-12,SIE,3.9e12
SPHERE,400,,1797.5,0.,-450.,250.
The Euler region will be modeled by using the MESH entry. The region will have to be large enough to contain the
entire vehicle, including when the vehicle is in motion:
MESH,1,BOX,,,,,,,+
+,-2623.,-1403.,-903.,6100.,2800.,2150.,,,+
+,30,10,10,,,,EULER,201
For the most accurate blastwave simulations, it is advised to use the Second-order Euler solver of SOL 700. This is
activated by specifying the second-order option on the Euler property entry and specifying the parameter to use the
second-order Range Kutta integration method:
PARAM,RKSCHEME,3
PEULER1,201,,2ndOrder,101
To initialize the whole first Euler mesh, a TICEUL entry will be defined. To initialize the Euler domain, other than
within the sphere of the explosion, a second large sphere is used. Because it has lower priority, the Euler elements
within the mine blast are will still initialized with high density and energy:
TICEUL1,101,11
TICREG,1,11,SPHERE,400,230,4,20.
TICREG,2,11,SPHERE,501,230,5,1.
SPHERE,400,,1797.5,0.,-450.,250.
SPHERE,501,,0.,0.,-5000.,10000.
The Euler domain has infinite boundaries. This can be achieved by defining a zero gradient flow boundary on the
outside of the Euler mesh. Use an empty FLOWDEF entry:
FLOWDEF,202,,HYDRO,,,,,,+
+,FLOW,BOTH
CHAPTER 42
C. Euler Domain 2:
The second Euler region represents the air inside the vehicle. Also for the second Euler region, a MESH entry is used.
The air is at rest again, so the same properties apply:
TICEUL1,102,12
TICREG,3,12,SPHERE,502,230,5,5.
SPHERE,502,,0.,0.,-5000.,10000.
Many of the previous cards will be used to initialize the density and energy (TICVAL) and material (DMAT/EOSGAM)
in this Euler region:
MATDEUL,230,1.29e-12,203,,,,,,+
+,,1.01
EOSGAM,203,1.4
D. The Ground:
The ground is modeled as rigid body using dummy QUAD elements. It is used to close the Euler boundary under the
vehicle so the blast wave will reflect on this boundary:
PSHELL,999,999,1.
MATRIG,999,,,,1.0E10,0.00,0.00,-800.,+
+,1.E10,0.0,0.0,1.E10,0.0,1.E10,,,+
+,,,,,,,,,+
+,,,,1,7,7
E. Fluid Structure Interaction:

In order to make fluid structure interaction possible, a closed volume needs to be defined. The car model itself is not
closed, so a dummy boundary will be defined to close the volume. This extra surface consists of three parts:
Part 1 resides on the back,

Part 2 is the top cover, and
Part 3 is the vent on the bottom of the vehicle.
For all these parts, dummy shell elements are defined and hole definitions will be defined.
Figure 42-3 Dummy Shell Elements Defined to Close the Volume

CHAPTER 42 721
The input for dummy shell elements
PSHELL,900,901,1.
PSHELL,910,901,1.
PSHELL,920,901,1.
MATD009,901,1.E-20
With this closed volume, the coupling surface can be defined. For each Euler domain, a separate surface is required.
However, in this model, the interaction surface consists of the same elements, except for the extra ground elements
(pid=999) for the outer Euler domain region 1. The surface definition will make use of the properties of the elements.
The outer surface:
BCPROP,97,60,61,62,110,135,150,900,+
+,910,920,999
The inner surface:
BCPROP,98,60,61,62,110,135,150,900,+
+,910,920
Now the coupling surfaces can be defined. For the outer region, all elements inside the volume are not active. The
covered option will, therefore, be set to INSIDE. Attached to this surface will be the first Euler MESH:
COUPLE,1,97,INSIDE,ON,ON,11,,,+
+,,,,,,,,,+
+,,1
The inner Euler domain is constrained by surface 2. For this volume, the outer Euler elements will be covered:
COUPLE,2,98,OUTSIDE,ON,ON,,,,+
+,,,,,,,,,+
+,,2
As discussed before, there are holes in the coupling surface. To this end, a flow definition is required for one of the
coupling surfaces. In this example, the flow cards are referenced from the first coupling surface. The input to define
flow between the regions is:
LEAKAGE,1,11,1,PORFCPL,84,CONSTANT,1.0
BCPROP,1,900
Also, for each of the other two flow surfaces, these set of cards are repeated
$
BCPROP,2,910
$
BCPROP,3,920
$
CHAPTER 42
Finally, the flow definition itself prescribes that the Euler region from coupling surface 1 is interacting with the Euler
region from coupling surface 2:
PORFCPL,84,LARGE,,BOTH,2
F. Miscellaneous:
a. Because this model uses the coupling surface interface, the time step safety factor for Eulerian elements has
to be .6. However, the Lagrangian elements (the quadratic and triangular elements) determine the time-step,
and it is beneficial to use a higher time step safety factor for the Lagrangian elements:
PARAM,STEPFCTL,0.9
b. To show results every .0002 seconds the following output request was added:
DYPARAM, LSDYNA, BINARY, D3PLOT,.0002
PARAM, CPLSARC,.0002
Results
The Figure 42-4 below shows the location, value, and time of the maximum acceleration. The stress distribution at this
time is also in Figure 42-5.
Figure 42-4 Acceleration Plot

CHAPTER 42 723
Figure 42-5 Stress Distribution Plot

CEND
TITLE= Job name: mine blast (mm/tonne/s/K)
IC=1
SPC=1
$
TSTEPNL=1
BEGIN BULK
$------- Parameter Section ------
$
DYPARAM,RKSCHEME,3
DYPARAM,FASTCOUP
DYPARAM,STEPFCTL,0.9
PARAM*,DYINISTEP,.5E-7
PARAM*,DYMINSTEP,1.E-13
$
$
DYPARAM,LSDYNA,BINARY,D3PLOT,.0002
PARAM,CPLSARC,.0002
$
MESH,1,BOX,,,,,,,+
+,-2623.,-1403.,-903.,6100.,2800.,2150.,,,+
+,30,10,10,,,,EULER,201
$
MESH,2,BOX,,,,,,,+
+,-2621.,-1201.,-251.,5900.,2400.,1250.,,,+
+,30,10,10,,,,EULER,202
$
$
TICEUL1,101,11
CHAPTER 42
$
TICREG,1,11,SPHERE,400,230,4,20.
TICREG,2,11,SPHERE,501,230,5,1.
$
SPHERE,400,,1797.5,0.,-450.,250.
SPHERE,501,,0.,0.,-5000.,10000.
$
$
TICEUL1,102,12
$
TICREG,3,12,SPHERE,502,230,5,5.
$
SPHERE,502,,0.,0.,-5000.,10000.
$
$
MATDEUL,230,1.29e-12,203,,,,,,+
+,,1.01
$
EOSGAM,203,1.4
$
+,FLOW,BOTH
$
COUPLE,1,97,INSIDE,ON,ON,11,,,+
+,,,,,,,,,+
+,,1
$
$ Define flow thru the holes
$
BCPROP,1,900
$
BCPROP,2,910
$
BCPROP,3,920
$
$
COUPLE,2,98,OUTSIDE,ON,ON,,,,+
+,,,,,,,,,+
+,,2
$
BCPROP,97,60,61,62,110,135,150,900,+
+,910,920,999
$
BCPROP,98,60,61,62,110,135,150,900,+
+,910,920
$
$ ========== PROPERTY SETS ==========
CHAPTER 42 725
$
$ * pbar.9988 *
$
PBAR 9988 222 3600.1000000.1000000.2000000.
$
$ * pbar.9989 *
$
PBAR 9989 222 100000. 3.E+8 3.E+8 6.E+8
$
$ * pbar.9990 *
$
PBAR 9990 222 3000. 200000.2500000.3000000.
$
$ * pbar.9993 *
$
PBAR,9993,111,459.96,25066.,55282.,16543.
$
$ * pbar.9996 *
$
PBAR,9996,111,895.52,309450.,55349.,48782.
$
$ * pbar.9999 *
$
PBAR,9999,111,736.,490275.,827555.,2095137.
$
$ * pshell.30 *
$
PSHELL 30 111 3
$
$ * pshell.40 *
$
PSHELL 40 111 4
$
$ * pshell.50 *
$
PSHELL 50 111 5
$
$ * pshell.60 *
$
PSHELL 60 111 6
PSHELL 61 111 6
PSHELL 62 111 6
$ * pshell.80 *
$
PSHELL 80 111 8
$
$ * pshell.110 *
$
PSHELL 110 111 11
$
$ * pshell.120 *
$
PSHELL 120 111 12
$
CHAPTER 42
$ * pshell.135 *
$
PSHELL 135 111 13.5
$
$ * pshell.150 *
$
PSHELL 150 111 15
PSHELL 151 111 15
$
$ * pshell.200 *
$
PSHELL 200 111 20
$
$ * pshell.450 *
$
PSHELL 450 111 45
$
$ dummy elements for coupling surface
$ hole
PSHELL,900,901,1.
$ top cover
PSHELL,910,901,1.
$ side cover
PSHELL,920,901,1.
$
MATD009,901,1.E-20
$
$ ground
PSHELL,999,999,1.
$
MATRIG,999,,,,1.0E10,0.00,0.00,-800.,+
+,1.E10,0.0,0.0,1.E10,0.0,1.E10,,,+
+,,,,,,,,,+
+,,,,1,7,7
$
$ * conm2 *
$
CONM2,5000,1145,,1.5
CONM2,5001,1146,,1.7
$
$ ========= MATERIAL DEFINITIONS ==========
$
MATD024,111,7.85e-09,210000.,.3,250E10
$
MAT1,222,210000.,,.3,7.85e-09
$
INCLUDE model.bdf
INCLUDE ground.dat
$
ENDDATA
CHAPTER 42 727
Input File(s)
File Description
nug_42.dat MD Nastran input file for leakage using dummy element
Video Examples
Import and Inspect Model

To see a video example of this step, click on the image or caption below to view a streaming video for this section; it
lasts approximately four minutes to import and inspect the model.
Figure 42-6 Video of Importing To and Inspecting the Model

CHAPTER 42
Create Properties
lasts approximately two minutes.
Figure 42-7 Video to Create Properties

CHAPTER 42 729
Create Eulerian Domains

lasts approximately five minutes.
w
Figure 42-8 Video to Create Eulerian Domains

CHAPTER 42
Create Eulerian Mesh

lasts approximately three minutes.
Figure 42-9 Video to Create Eulerian Mesh

CHAPTER 42 731
Create Coupling Surfaces

Figure 42-10 Video to Create Coupling Surfaces

CHAPTER 42
Create Leakage
Figure 42-11 Video to Create Leakage

CHAPTER 42 733
Define Job Parameters

Figure 42-12 Video to Define Job Parameters

CHAPTER 42
Attach and View Results

lasts approximately eight minutes.
Figure 42-13 Video to View Results

Chapter 43: Blastwave Hitting a Bunker
43 Blastwave Hitting a Bunker

Summary 736

Introduction 737


Results 739


Input File(s) 797
CHAPTER 43
Summary
Title Chapter 43: Blastwave Hitting a Bunker
Contact features • Fast Coupling Technique
• Multiple Eulerian Domains with failure
• Free flow between two euler zones on the side faces of bunker
• Explosive modeled by ideal gas
Geometry Euler Zone 2
Euler Zone 1
Bunker
Blast
Ground
Material properties • Bunker Structure

Density = .000734 lbf-s2/inch4
Young’s Modulus = 2.9E7 lbf/in2
Yield stress = 5.E4 lbf/in2
Plastic strain at failure = 0.21
• Euler (Air)
Density = 1.2E-7 lbf-s2/inch4
Gamma = 1.4
Specific Internal Energy = 3E+8 lbf-in
• Euler (Explosive - equivalent to TNT of 7kg and radius of .25 meter)
Specific Internal Energy = 3E+9 lbf-in
• Ground
Rigid
Boundary conditions • Fixed boundary condition of ground
• In and out directional flow boundary of outer euler zone
Element types • 4-node shell element for bunker and ground
• 8-node hex element for euler which is automatically generated by MESH option
FE results 1. Isosuface plot of Specific Internal Energy (SIE) at 0.01 seconds
2. Deformed Effective Stress plot at 0.01 seconds
CHAPTER 43 737
Blastwave Hitting a Bunker
Introduction
The purpose is to demonstrate application of multi-Euler domains to failing coupling surfaces. The problem simulates
a bunker, located on the ground that is open at the sides and is surrounded by air. Gas can flow freely through the sides
of the bunker. A blast wave is ignited close to the bunker and expands into the air. When by the impact of the blast
wave, the bunker surface fails gas will flow trough the bunker surface.
SOL 700 Modeling
The bunker and the ground consist of cquad4 shell elements. The elements of the bunker are Lagrangian deformable
shells and the ground is modeled as rigid, using a MATRIG. The explosive/air region is modeled by two Euler meshes.
The first domain models the inside of the bunker, and the second one models the outside of the bunker. For the
interaction between the bunker and an Euler domain, a unique coupling surface has to be used, therefore, two coupling
surfaces are needed.
The first coupling surface, for modeling the inside of the bunker, consists of the following facets:
• The 180 degrees cylindrical surface and the two open sides of the bunker. The two open sides are represented
by dummy shell elements. These are elements 1 to 2240.
• The top of the ground that lies within the bunker. This is a square and is formed by elements 2241 to 3280.
These facets make up a closed coupling surface, as shown in Figure 43-1.
This coupling surface contains gas inside, and therefore Euler elements outside the coupling surface should not be
processed and so the COVER is OUTSIDE.
CHAPTER 43
Figure 43-1 Coupling Surface 1
The second coupling surface consists of the following facets:
• The 180 degrees cylindrical surface and the two open sides of the bunker. These are elements 1 to 2240. The
top of the ground inside the bunker is not part of the second COUPLE.
• The top of the ground that is outside the bunker and 5 dummy surfaces of the ground that are used to close the
coupling surfaces. These are formed by the elements 3413 to 4012, 4095 to 4340, 4505 to 4709, 4894 to 7904.
These facets make up a closed coupling surface, as shown in Figure 43-2.
Figure 43-2 Coupling Surface 2
This coupling surface is used for simulating the gas outside the coupling surface. So Euler elements inside the coupling
surface should not be processed and the COVER has to be set to INSIDE. The second coupling surface uses the second
Euler mesh and serves as inner boundary surface for this Euler mesh. The outside boundary of this mesh is where the
Euler domains ends and boundary conditions for this boundaries are provided by a FLOWDEF. The FLOWDEF is
chosen as non-reflecting. Waves exit the Euler domain with only little reflection.
CHAPTER 43 739
To get an accurate expansion of the blast wave, the diffusion should be kept at a minimum, and therefore the Roe solver
with second-order is used. Interactive failure will be used for the bunker structure, while porosity will be used for the
open sides:
• The bunker elements can fail and gas flows through the failed elements from outside the bunker into the
bunker. All elements of the bunker are assigned to a BSURF, and occur in both coupling surfaces. They are
able to fail interactively, using the COUP1FL entry. These parts are formed by elements 1 to 1600. The nodes
of the failed elements are constrained in space by using PARAM, NZEROVEL, YES, to preserve the geometry
of the coupling surfaces from severe distortion.
• Since gas can flow through the two sides without any obstruction, these two areas are modeled with BSURF
entries, and are opened by using a PORFLCPL entry. These sides are modeled with dummy shell elements and
consist of elements 1601 to 2400.
The couple cards refer to mesh-number. The first mesh for the Euler elements inside the bunker is created and
initialized by:
MESH,2,BOX,,,,,,,+
+,-430.,0.,-1287.,837.,480.,1296.,,,+
+,24,16,30,,,,EULER,301
The value “2ndOrder” activates the Roe solver with second-order accuracy. The property id is the link between the
TICEUL1 entry 101 and the MESH entry. The second Euler mesh for the Euler elements outside the bunker is created
and initialized by:
MESH,1,BOX,,,,,,,+
+,-647.,0.,-1293.,1057.,447.,1293.,,,+
+,33,23,37,,,,EULER,201
Results
Figures 43-3 and 43-4 show a fringe plot and an isosurface. Figure 43-4 has been created by Ensight.
Figure 43-3 Deformed Effective Stress Plot of the Bunker

CHAPTER 43
Figure 43-4 Isosurfaces Created using SIE Variable for the Two Euler Domains

CEND
TITLE= Job name is: bunker
IC=1
SPC=1
TSTEPNL=1
$
BEGIN BULK
$
$INCLUDE mesh.dat
INCLUDE model.dat
$
TSTEPNL 1 20 0.0005 1
DYPARAM,FASTCOUP,,FAIL
PARAM*,DYINISTEP,1E-7
PARAM*,DYMINSTEP,1E-8
DYPARAM,LIMITER,ROE
DYPARAM,RKSCHEME,3
DYPARAM,LSDYNA,BINARY,D3PLOT,0.002
$
$ ========== PROPERTY SETS ==========
$
$ * steel prop *
$
PSHELL 1 1 .150
$
$ * dummy_shell *
$
PSHELL,2,2,1E-3
MATD009,2,1E-20
$
CHAPTER 43 741
$
PSHELL 3 4 .100
$
$ ========= MATERIAL DEFINITIONS ==========
$
$
$ -------- Material steel id =1
MATD024,1,.000734,2.9e+07,.3,50000,,.21
$
$ -------- Material AIR id =3
MATDEUL 3 1.2e-07 3
EOSGAM 3 1.4
$
$ -------- ground
MATRIG 4 .000734 2.9e+07 .3
$
$ ======== Load Cases ========================
$
$ ------- General Coupling: GENERAL -----
$
$
COUPLE 7 1 INSIDE ON ON 16 +
+ +
+ 1 1
$
BSURF 1 1 THRU 2240 3413 THRU 4012 4095+
+ THRU 4340 4505 THRU 4709 4894 THRU 7904
$
$
COUP1FL,1,1.2e-07,3e+08
$
COUPLE 8 11 OUTSIDE ON ON +
+ +
+ 2 2
$
BSURF 11 1 THRU 3280
$
$
COUP1FL,2,1.2e-07,3e+08
$
$
COUPINT,1,7,8
$
LEAKAGE,1,16,32,PORFCPL,81,,1.0
BSURF 32 1601 THRU 2240
$
$ ------- Rigid Body Constraints -----
$
SPCD2 1 RIGID MR4 1 0 1 0.
CHAPTER 43

TABLED1 1 +
+ 0. 1. 1. 1. ENDT
$
$-----Mesh.dat---------------
$
MESH,1,BOX,,,,,,,+
+,-647.,0.,-1293.,1057.,447.,1293.,,,+
+,33,23,37,,,,EULER,201
$
$ Inner Euler
$
MESH,2,BOX,,,,,,,+
+,-430.,0.,-1287.,837.,480.,1296.,,,+
+,24,16,30,,,,EULER,301
$
$
$
TICEUL1 101 101
$
SPHERE 8 -536.4 165 -453.6 85
SPHERE 5 -536.4 165 -453.6 10000
$
$
TICEUL1 111 111
$
SPHERE 9 -53.4 100 -673.6 10000
$
$
$ ------- TICVAL BC AIR-INI -----
TICVAL 4 DENSITY 1.2e-07 SIE 3e+08
$
$ ------- TICVAL BC EXP-INI -----
TICVAL 5 DENSITY3.84e-06 SIE 3e+09
$
$
+,FLOW,BOTH
$
ENDDATA
CHAPTER 43 743

This example shows how to use SimXpert for a blast wave hitting a bunker shell. The two open sides are each modeled
by a fully porous subsurface using PORFCPL The flow of gas through failed shell elements is taken into account by
activating interactive failure.
For simulations with coupling surfaces with failure, the Roe solver is used. The second-order Roe solver is used to
minimize the diffusion of the blast wave.
Two types of result files are required:
• ARC which includes the Euler element results
• d3plot which includes the Lagrangian element results
Run SimXpert with MD Explicit Workspace
a. For Default Workspace:, select MD Explicit
a
CHAPTER 43
Import the Model Data
a. File: select Import

b. Select Nastran
c. Select model.dat, click Open
d. The model is imported into the Model Browser
d
a
c
CHAPTER 43 745
Create Equation of State (Ideal Gas)
a. Materials and Properties tab: EOS

b. Select [12] EOS Ideal Gas
c. For Name enter EOSGAM_3
d. For PID enter 3
e. For GAMMA enter 1.4
f. Click Create
g. New EOS is added
d e
g
CHAPTER 43
Create Flow Boundary
a. LBCs tab: Flow

b. Select FLOWDEF
c. For ID: enter 202
d. For Title: enter FLOWDEF_202
e. Click FLOW; select BOTH
f. Click Modify
g. New FLOWFED is added
a
b
c d
g
CHAPTER 43 747
Create Transient Initial Condition for Euler (Air)
a. LBCs tab: TIC

b. Select TICVAL
c. For ID: enter 4
d. For Title: enter TICVAL_4
e. Click DENSITY; enter 1.2E-07
f. Click SIE; enter 3.0E+08
g. Click Modify
c d
e f
h
CHAPTER 43
Create Transient Initial Condition for Euler (TNT) (continued)
a. LBCs tab: TIC

b. Select TICVAL
c. For ID: enter 5
d. For Title: enter TICVAL_5
e. Click DENSITY; enter 3.84E-6
f. Click SIE; enter 3.0E+09
g. Click Modify
c d
e f
h
CHAPTER 43 749
Create Sphere Shape for TNT
a. LBCs tab: Sphere

c. For X,Y,Z Coordinate, enter -536.4, 165.0, -453.6; click OK
d. For ID, enter 8
e. For Title, enter Sphere_8
f. For RADIUS, enter 85.0
g. Click Modify
h. Sphere_8 is added
d e g
g
CHAPTER 43
Create Sphere Shape for Outside Air (continued)
a. LBCs tab: Sphere

d. For ID, enter 5
g. Click Modify
h. Shpere_5 is added
h
b
d e
f
h
g
CHAPTER 43 751
Create Sphere Shape for Inside Air (continued)
a. LBCs tab: Sphere

d. For ID, enter 9
g. Click Modify
h. Sphere_9 is added
d e
f
g h
CHAPTER 43
Create Euler Material
a. Materials and Properties tab: Eulerian

c. For Name, enter MATDEUL_3
d. For MID, enter 3
e. For RHO, enter 1.2e-7
f. Double click EID, select Select
g. For Entity Selection, select EOSGAM_3; click OK
h. Click Create
i. MATDEUL_3 is added
a
b
c
d e
f
h
g
i
CHAPTER 43 753
Create Transient Initial Value for TNT
a. LBCs tab: TIC

b. Select TICREG
c. For ID, enter 1
d. For Title, enter TICREG_1
e. Activate TYPE
f. Double click VID, select Select
g. For Entity Selection, select Sphere_8; click OK
h. Activate and double click MID, select Select
i. For Entity Selection, select MATDEUL_3; click OK
j. Activate and double click TICID, select Select
k. For Entity Selection, select TICVAL_5; click OK
l. For LEVEL, enter 2
m. Click Modify
n. TICREG_1 is added
c d n
e
l
f h j
i
g k
CHAPTER 43
Create Transient Initial Value for Outer Air (continued)
a. LBCs tab: TIC

b. Select TICREG
c. For ID, enter 2
e. Activate TYPE
m. Click Modify
c d
e n
l
f h j
g i k
CHAPTER 43 755
Create Transient Initial Value for Inner Air (continued)
a. LBCs tab: TIC

b. Select TICREG
c. For ID, enter 3
e. Activate TYPE
m. Click Modify
c d
e n
l
f h j
i k
g
CHAPTER 43
Create Transient Initial Value Conditions of Eulerian Zone
a. LBCs tab: TIC

b. Select TICEUL1
c. For ID, enter 101
d. For Title, enter TICEUL1_101
e.For NREG, enter 101
f. Click Modify
g. TICEUL1_101 is added
a
b
c d
g
CHAPTER 43 757
Create Transient Initial Conditions of Eulerian Zone (continued)

Modify the Transient Initial Condition
a. Double click TICEUL1_101

b. Double click TSID1, select Select
c. For Entity Selection, select TICREG_1; click OK
d. Double click TSID2, select Select
e. For Entity Selection, select TICREG_2; click OK
f. Click Modify
b
d
f
a
c
e
CHAPTER 43
a. LBCs tab: TIC

b. Select TICEUL1
c. For ID, enter 111
d. For Title, enter TICEUL1_111
f. Click Modify
f. TICEUL1_111 is added
a
b
c d
e
g
CHAPTER 43 759
a. Double click TICEUL1_111

b. Double click TSID1; select Select
c. For Entity Selection, select TICREG_3; click OK
d. Click Modify
d
a
c
CHAPTER 43
Create Eulerian Property
a. Materials and Properties tab: 3D

b. Select PEULER1
c. For Name, enter PEULER_201
d. For PID, select 201
e. For TYPE, select 2ndOrder
f. Double click SID, select Select
g. For Entity Selection, select TICEUL1_101; click OK
h. Click Create
i. PEULER1_201 is added
c
e f
d
i
g
CHAPTER 43 761
Create Eulerian Property (continued)
a. For Name, enter PEULER_301

b. For PID, select 301
c. For TYPE, select 2ndOrder
d. Double click SID, select Select
e. For Entity Selection, select TICEUL1_111; click OK
f. Click Create
g. PEULER1_301 is added
a
c d
b
d
g
e
CHAPTER 43
Create Mesh for Outer Euler
a. LBCs tab: Eulerian

b. Select Mesh
d. Deactivate DXVEL through ZREF
e. For XO, enter -647.0; for YO, enter 0.0; for ZO, enter -1293.0
f. For DX, enter 1057.0; for DY, enter 447.0; for DZ, enter 1293.0
g. For NX, enter 33; for NY, enter 23; for NZ, enter 37
h. For PROP, select EULER
i. Double click PID, select Select
j. For Entity Selection, select PEULER1_201; click OK
k. Click Modify
l. Mesh_1 is added
c d
e f
g h
i
k j
CHAPTER 43 763
Create Mesh for Inner Euler
a. LBCs tab: Eulerian

b. Select Mesh
d. Deactivate DXVEL through ZREF
e. For XO, enter -430.0; for YO, enter 0.0; for ZO, enter -1287.0
f. For DX, enter 837.0; for DY, enter 480.0; for DZ, enter 1296.0
g. For NX, enter 24; for NY, enter 26; for NZ, enter 30
h. For PROP, select EULER
i. Double click PID, select Select
j. For Entity Selection, select PEULER1_201; click OK
k. Click Modify
l. Mesh_2 is added
c d
e f
g h l
i
k j
CHAPTER 43
Create Coupling for Outer Coupling Surface Failure
a. LBCs tab: Couple

b. Select COUP1FL
c. For ID, enter 1
d. For Title, enter COUP1FL_1
e. For RHO, enter 1.2E-07
f. For SIE, enter 3.0E+08
g. Deactivate XVEL, YVEL, ZVEL, PRESSURE, and MATERIAL
h. Click Modify
i. COUP1FL_1 is added
c d
g
e f
h
CHAPTER 43 765
Create Coupling for Inner Coupling Surface Failure
a. LBCs tab: Couple

b. Select COUP1FL
c. For ID, enter 2
d. For Title, enter COUP1FL_2
e. For RHO, enter 1.2E-07
f. For SIE, enter 3.0E+08
g. Deactivate XVEL, YVEL, ZVEL, PRESSURE, and MATERIAL
h. Click Modify
i. COUP1FL_2 is added
c d
g
e f
h
CHAPTER 43
Create Group for Outer Coupling Surface
a. Right click on the Model Browser tree, select New

b. Select Group, select Create
c. For Pick entities: deactivate Pick nodes and Pick Part options
d. In Main window, select all elements
e. In Group window for Add/Remove Content, click Add to group
f. Under Member list, see that all elements are added
g. Click OK
c
d
e
g
CHAPTER 43 767
Create Group for Outer Coupling Surface (continued)
a. In the Model Browser tree, select PSHELL_1_model.dat and PSHELL_2_model.dat

b. Select Hide
c. From the Ribbon menu: select Advanced Pick Dialog
d. In Extended Pick Dialog, select Contiguous [Auto]
e. Select the inside part of the base plates
f. In Group window for Add/Remove Content, click Remove from Group
g. Under Member list, see that assigned elements are removed
h. Click OK
b e
Useful Tip!
If using Show Selection List option, the elements
selected are shown in Selected Items dialog
f g
h
CHAPTER 43
Create Group for Inner Coupling Surface
a. Right click on the Model Browser tree, select New

b. Select Group, select Create
c. From the Ribbon menu: select Advanced Pick Dialog
d. In Extended Pick Dialog, select Contiguous [Auto]
e. Select the inside part of the base plates
f. In Group window for Add/Remove Content, click Add to group
g. Under Member list, see that all elements are added
g
CHAPTER 43 769
Create Group for Inner Coupling Surface (continued)

b. Select Show Only
c. In the Main Window: select all the elements
d. In Group window for Add/Remove Content, click Add to group
e. Under Member list, see that all elements are added
f. Total in the Member list should now be 3280
g. Click OK
c
a
g
CHAPTER 43
Create Inner Coupling Surface
a. In the Model Browser tree, select GROUP_2

b. Select Show Only
c. LBCs tab: Couple
d. From the Pick Window: select Shells for BSURF
e. In the Main Window: select all the elements
f. Click Done
d e
f
CHAPTER 43 771
Create Inner Coupling Surface (continued)
a. For ID, enter 8

b. For Title, enter COUPLE_8
c. For COVER, select: OUTSIDE
d. Activate REVERSE and CHECK
e. Activate and double click MID, select Select
f. For Entity Selection, select Mesh_2; click OK
g. Activate and double click COUP1FL, select Select
h. For Entity Selection, select COUP1FL_2; click OK
i. Click Modify
a b
c d
e g
f h
i
CHAPTER 43
Create Porosity
a. LBCs tab: Accessory

b. Select PORFCPL
c. For ID, enter 81
d. For Title, enter PORFCPL_81
e. For SIZE, select LARGE
f. Activate FLOW, select BOTH
h. For Entity Selection, select COUPLE_8; click OK
i. Click Modify
c d
a e f g
i
CHAPTER 43 773
Create Leakage
a. In the Model Browser tree, select PSHELL_2_model.dat

b. Select Show Only
c. LBCs tab: Accessory
d. Select LEAKAGE
e. From the Pick Window: select Shells for BSURF
f. In the Main Window: select all the elements
g. Click Done
h. For ID, enter 1
i. For Title, enter LEAKAGE_1
j. For NPOR, enter 1
k. Click Modify
a
c
f
e
h i
j
k
CHAPTER 43
Modify Leakage
a. In the Model Browser tree, double click LEAKAGE_1

b. Double click SUBID1
c. For Entity Selection, select BSURF_4; click OK
d. For PORTYPE1, select PORFCPL
e. Double click PORTYPID1, select Select
f. For Entity Selection, select PORFCPL_81; click OK
g. Activate COEFF1, select CONSTANT
h. Activate COEFFV1, enter 1.0
i. Click Modify
a
b d e
f
c
g
h
i
CHAPTER 43 775
Create Outer Coupling Surface
a. In the Model Browser tree, select Group_1

b. Select Show Only
c. LBCs tab: COUPLE
d. From the Pick Window: select Shells for BSURF
e. In the Main Window: select all the elements
f. Click Done
e
d
CHAPTER 43
Create Outer Coupling Surface (continued)
a. For ID, enter 7

b. For Title, enter COUPLE_7
c. For COVER, select: INSIDE
d. Activate REVERSE and CHECK
e. Activate and double click PORID, select Select
f. For Entity Selection, select LEAKAGE_1; click OK
h. For Entity Selection, select COUP1FL_1; click OK
i. Click Modify
a b
c d
i
g
f h j
CHAPTER 43 777
Create Coupling Surface Interaction
a. LBCs tab: Couple

b. Select COUPINT
c. For ID, enter 1
d. For Title, enter COUPINTL_1
e. Double click CID1, select Select
f. For Entity Selection, select COUPLE_7; click OK
g. Double click CID2, select Select
h. For Entity Selection, select COUPLE_8; click OK
i. Click Modify
a c d
i
b
e g
f h
CHAPTER 43
Create Boundary Condition

b. Select Hide
c. LBCs tab: LBC
d. Select SPC BC and select Fully Fixed Constraint
e. From the Pick Window: select Nodes
f. In the Main Window: select all the nodes
g. Click Done
d
b
f
e
g
CHAPTER 43 779
Create Parameters
a. Job Parameters tab: PARAM

b. For Name, enter PARAM_1
c. For SID, enter 1
d. For N, enter DYINISTEP
e. For V1, enter 1.E-7
f. Click Create
g. For Name, enter PARAM_2
h. For SID, enter 2
i. For N, enter DYMINSTEP
j. For V1, enter 1.E-8
k. Click Create
b c g h
d e i j
f k
CHAPTER 43
Create Parameters (continued)
a. Job Parameters tab: DYPARAM

b. For Name, enter DYPARAM_1
c. For SID, enter 1
d. For F1, enter FASTCOUP
e. For F3, enter FAIL
f. Click Create
g. For Name, enter DYPARAM_2
h. For SID, enter 2
i. For F1, enter LIMITER
j. For F2, enter ROE
k. Click Create
l. For Name, enter DYPARAM_2
m. For SID, enter 2
n. For F1, enter RKSCHEME
o. For F2, enter 3
p. Click Create
b
c
d e
g
h
i j
l
m
n o
p
CHAPTER 43 781
Create Parameters (continued)
a. Job Parameters tab: DYPARAM_BINARY_option

b. For Name, enter DYPARAM_BINARY_option_3
c. For SID, enter 3
d. Activate DT_D3PL, enter 0.002
e. Click Create
b
c
e
CHAPTER 43
Create New SOL700 Job
a. In the Model Browser tree, right click model.dat

c. For Solver Input File, change the input file name and location
d. Click OK
a
b
d
CHAPTER 43 783
Create New SOL700 Job (continued)
a. In the Model Browser tree, right click Loadcase Control

c. Select Subcase Nonlinear Static Parameters
d. For Ending Time, enter 0.01
f. Click Apply
g. Click Close
a
b
c
d
e
g
CHAPTER 43
Execute the Job
a. In the Model Browser tree, right click NewJob

b. Click Run
b
CHAPTER 43 785
Attach the Analysis Results File

After a job is finished, there are two types of results: ARC and d3plot. Both files are attached to SimXpert. The d3plot
result file is attached first.
a. Under File, select Attach Results

b. File path, select the desired path
c. Open, select nug_43a.dytr.d3plot
d. Attach Options, select Both
e. Click Apply
f. View the Lagrangian results
b
d c
a e
f
CHAPTER 43
Attach the Analysis Results File (continued)

The ARC result file is attached second.
a. File path, select the desired path

b. Open, select NUG_43A.DYTR_EULER_FV1_0.ARC
d. Click Apply
e. View the Outer Euler results
a
c
b
e
CHAPTER 43 787
a. File path, select the desired path

b. Open, select NUG_43A.DYTR_EULER_FV2_0.ARC
d. Click OK
e. View the Inner Euler results
a
c
e
CHAPTER 43
Display the Deformation Results

Create a deformation plot of Lagrangian results.
a. In the Model Browser tree, select all the Euler elements

b. Select Hide
c. Check to see that all Euler elements are hidden
d. Results tab: Deformation
e. Result entities: Result cases: nug_43a.dytr.d3plot, select Time 0.0100956
f. Results entities: Result type, select Displacement Components
g. Click Target entities
h. In current window, change Target entities to Elements
i. In Main Window, select all Lagangian elements
j. Plot Data, click Deformation
d g
f
i
j
h
CHAPTER 43 789
Display the Deformation Results (continued)
a. Deformed display scaling: click True

b. Click Update
c. In Main Window, check the deformation plot
a b
c
CHAPTER 43
Display the Stress Results

Create a stress fringe plot of Lagrangian results.
a. Deformed display scaling: click True

b. Plot type, select Fringe
c. Result entities: Result cases: nug_43a.dytr.d3plot, select Time 0.0100956
d. Results entities: Result type, select Stress Components
e. Result entities: Deviation, select von Mises
e
d
c
b
CHAPTER 43 791
Display the Stress Results (continued)
a. In current window, change Target entities to Elements

b. n Main Window, select all Lagangian elements
c. Click Fringe tab
d. In current window, change Element edge display entities to Element edges
e. Click Update
f. In Main Window, check the stress fringe plot
a
b
c
d e
f
CHAPTER 43
Display the Euler Pressure Iso-surface Results

Create a pressure iso-surface plot of Eulerian results.
a. In the Model Browser tree, select only the outer Euler elements (FV1)
b.Select Show Only
c. Check to see that all outer Euler elements are shown
d. Plot type, select IsoSurface
e. Result entities: Result cases: NUG_43A.DYTR.EULER_FV1_0.ARC,
select Time 0.0101689
f. Results entities: Result type, select PRESSURE
g. Click Target entities
d e
CHAPTER 43 793
Display the Euler Pressure Iso-surface Results (continued)

b. n Main Window, select all outer Eulerian elements
c. Click IsoSurface tab
d.:First value, enter 19.5244
e. Click Update
f. In Main Window, check the iso-surface plot of the outer Euler zone
a
b
f
CHAPTER 43
a. In the Model Browser tree, select only the inner Euler elements (FV2)
b.Select Show Only
c. Check to see that all inner Euler elements are shown
d. Name, select Create Attribute
e. For Enter the plot attribute name, enter IsoSurf 02; click OK
f. Result entities: Result cases: NUG_43A.DYTR.EULER_FV2_0.ARC,
select Time 0.0101689
g. Results entities: Result type, select PRESSURE
h. Click Target entities
a
b
e
d
f
CHAPTER 43 795

b. n Main Window, select all inner Eulerian elements
c. Click IsoSurface tab
d. First value, enter 19.5244
e. Click Update
f. In Main Window, check the iso-surface plot of the inner Euler zone
c b
f
CHAPTER 43
a. In the Model Browser tree, select elements

b. Select Hide All
c. In Main Window, check the iso-surface plot of the Eulerian elements and the
stress/deformation plot of the Lagrangian elements
c
CHAPTER 43 797
Input File(s)
File Description
nug_43a.dat MD Nastran input file for l=blast on bunker using Fast Coupling technique
nug_43b.dat Geometry of Euler elements
nug_43c.dat Geometry of Lagrangian structure elements
Chapter 44: Concentric Spheres with Radiation
Concentric Spheres
44 with Radiation

Summary 799

Introduction 800


Material Modeling 807


Results 808

Modeling Tips 809


Video 854
CHAPTER 44 799
Concentric Spheres with Radiation
Summary
Title Chapter 44: Concentric Spheres with Radiation
Features Hemi-cube versus Gaussian Integration Methods
Geometry T∞ = 0 t = 0.05
i 2
ε = 0.7
2
R = 1.5 o
T=? ε = 1.0
2
o
ε = 0.9
1
t = 0.01
R=1 1
T = 1000
Units: inch, watt, K
Material properties k 1 = 4.0W   in – K  k 2 = 6.0W   in – K 

2 4
 = 3.66x10 – 11 W   in – K 
Analysis characteristics • Nonlinear steady state thermal analysis

Boundary conditions Inside sphere temperature fixed at 1000 K. The heat sink is ambient temperature at zero
K where the radiation to space boundary condition is applied on the outer sphere.
Stefan-Boltzmann constant is  (above).
Element type 4-node QUAD4
FE results Outer sphere temperature using different radiation schemes and compared to an
analytic solution
Temperature K (Grid 367)

Analytic 710.30
710.5
Gaussian integration 709.85
Hemi-cube 708.91
710.0
709.5
709.0
708.5
708.0
Analytic Gaussian integration Hemi-cube
CHAPTER 44
Introduction
This problem demonstrates the ability of the Nastran SOL 400 thermal nonlinear solution sequence to perform thermal
radiation view factor calculations using the Hemi-cube and Gaussian integration methods. The Gaussian adaptive
integration view factor calculation method has been with Nastran for many years. The view factor computed by the
Gaussian method is extremely accurate. However, as the problems get big, computation time is roughly proportional
to the number of surfaces squared. The introduction of Hemi-cube method in MD Nastran permits the solution of very
large scale view factor problems where previously the use of the Gaussian method was overly time intensive. As
compared to the adaptive Gaussian method, we have seen an improvement in CPU speed of 33 times in some
problems. The CPU time increases linearly with the number of radiation surfaces because in Hemi-cube, the
computation time is linearly proportional to the number of surfaces. In this problem, we have an analytical solution in
which we compare both Hemi-cube and the Adaptive Gaussian integration methods to see which method offers the
most accuracy.
Modeling Details
Figure 44-1 Concentric Spheres (top sector of outer sphere removed)
As shown in (Figure 44-1), the inner sphere with radius equal to 1 inch is subjected to a constant temperature of
1000°K (red). There is radiation exchange between the inner and the outer sphere (orange). The outer sphere radiates
to space at an ambient temperature of zero K with view factors equal to 1.0.
Reference Solution
For these two diffuse isothermal concentric spheres, the view factors need to be determined. Since all of the energy
leaving the inner sphere (1) will arrive at the outer sphere (2), F 1 – 2 = 1.0 . The reciprocity relation for view factors
CHAPTER 44 801
gives A 1 F 1 – 2 = A 2 F 2 – 1 , or F 2 – 1 =  R 1  R 2  2 . Since the inner sphere cannot see itself, F 1 – 1 = 0 . Finally since energy
must be conserved, the sum of all view factors of a closed cavity must be unity, which yields, F 2 – 2 = 1 –  R 1  R 2  2 .
Notice how the number of view factors grow as the square of the number of surfaces, i.e. two surfaces yield 4 view
factors. Given the geometry of the spheres as R 1 = 1 and R 2 = 1.5 , the four view factors become:
F1 – 1 = 0 F1 – 2 = 1
4 5 . Below is an equation for calculation of outer sphere temperature where the outer sphere is
F 2 – 1 = --- F 2 – 2 = ---
9 9
radiating to space at absolute zero and a view factor of 1. (Holman, Jack P. Holman Heat Transfer. McGraw-Hill,
2001).
 1 = 0.9 2 = 1 2 = 0.7
ou t inner
T 1 = 1000
2 2
A1 = 4    R1 A2 = 4    R2
A 1 = 12.566 A 2 = 28.274
1 A1  1 
C = ----- + ------  ---------------- – 1 C = 1.302
1 A2  2 
inner
4
A1  T1
D 2 = --------------------------------------------
-
A1 + C  2  A2
out
D 2 = 2.545  10 11 T2 = D2
0.25 T 2 = 710.299
This solution assumes perfect conduction (no resistance to heat flow) in the outer sphere.
While, in general, the view factors cannot be obtained from analytical solutions, in this simple problem, the view
factors can be found analytically and we can use these view factors in a simple three grid model to check our analytic
solution above. One grid represents the inner sphere, another represents the outer sphere, and the last grid represents
the ambient temperature of the outer sphere.
Nastran test file: user1_point.dat
$Model concentric sphere with two nodes
$ Length in Inches
$! NASTRAN Control Section
NASTRAN SYSTEM(316)=19
$! File Management Section
$! Executive Control Section
SOL 400
CEND
ECHO = NONE
$! Case Control Section
TEMPERATURE(INITIAL) = 21
TITLE=MSC.Nastran job created on 05-Dec-03 at 13:33:05
CHAPTER 44
SUBCASE 1
$! Subcase name : subcase_1
$LBCSET SUBCASE1 lbcset_1
SUBTITLE=Default
SPCFORCES(SORT1,PRINT,REAL)=ALL
OLOAD(SORT1,PRINT,REAL)=ALL
THERMAL(SORT1,PRINT)=ALL
FLUX(PRINT)=ALL
ANALYSIS = HSTAT
SPC = 23
NLSTEP = 1
BEGIN BULK
$! Bulk Data Pre Section
PARAM SNORM 20.
PARAM K6ROT 100.
PARAM WTMASS 1.
PARAM* SIGMA 3.6580E-11
PARAM POST 1
PARAM TABS 0.0
$! Bulk Data Model Section
RADM 11 0.0 0.9 RadMat_1
RADM 12 0.0 0.7 RadMat_1
RADM 13 0.0 1. RadMat_1
PHBDY 1 12.566 PHBDY_1_
PHBDY 2 28.274 PHBDY_2_
GRID 101 0.0 0.0 0.0
GRID 102 1. 0.0 0.0
$!
SPOINT 777
CHBDYP 1 1 point 10 101 +
+ 11 1. 0.0 0.0
CHBDYP 2 2 point 10 102 +
+ 12 -1. 0.0 0.0
CHBDYP 3 2 point 102 +
+ 13 -1. 0.0 0.0
SPC 23 101 1 1000.
SPC 23 777 1 0.0
RADBC 777 1. 3
RADCAV 1 +
+
VIEW 10 1
VIEW3D 10
RADSET 1
RADMTX 10 1 0.012.56637
RADMTX 10 215.70922
RADLST 1 1 1 2
TEMPD 21 900.
TEMP 21 777 0.0
TEMP 21 101 1000.
NLSTEP 1 1. +
+ GENERAL 25 +
+ FIXED 1 1 +
+ HEAT PW 0.001 1.E-7AUTO 5
CHAPTER 44 803
ENDDATA b1272084
Notice that the Stefan-Boltzmann constant (sigma) is 3.66e-11 W/in2/K4 and, the radiation matrix is define above by
A1 F1 – 1 = 0 A 1 F 1 – 2 =  12.566   1
the RADLST and RADMTX, RADMTX = = 0 12.56637
4 5
A2 F2 – 1 =  28.274   --- A 2 F 2 – 2 =  12.566   --- sym 15.70796
9 9
The radiation matrix must be symmetric to conserve energy (reciprocity relation A 1 F 1 – 2 = A 2 F 2 – 1 ), and the
symmetric terms are not entered. Running this three node problem yields the output below with the temperature of the
outer sphere of 710.31, agreeing to within 4-digits of our analytic solution of 710.3.
T E M P E R A T U R E V E C T O R
POINT ID. TYPE ID VALUE ID+1 VALUE ID+2 VALUE ID+3 VALUE ID+4 VALUE ID+5 VALUE
101 S 1.000000E+03 7.103098E+02
777 S 0.0
Solution Highlights
The following are highlights of the Nastran input file necessary to model this problem using 700 elements to represent
the inner and outer spheres with 1268 radiating surfaces:
SOL 400
CEND
ECHO = SORT
SUBCASE 1
$! Subcase name : NewLoadcase
$LBCSET SUBCASE1 DefaultLbcSet
FLUX(PRINT)=ALL
ANALYSIS = HSTAT
SPC = 35
NLSTEP = 1
BEGIN BULK
PARAM WTMASS 1.
PARAM GRDPNT 0
NLMOPTS HEMICUBE1
PARAM POST 1
PARAM OGEOM NO
PARAM MAXRATIO 1e+8
CHAPTER 44
The use of a steady-state thermal analysis is indicated by ANALY=HSTAT. The NLMOPTS parameters indicate that we
are using the Hemi-cube method as the view factor calculation method. If one desires to run the Gaussian integration
method, then you do not need the NLMOPTS bulk data entry.
The inner sphere is composed of CHBDYG elements (see command details below) numbered from 6987 through
7214, and the outer sphere is from 7215 to 7734. The set1 ID option is used on the RADCAV bulk data entry to sum
up all the view factors between the inner and outer spheres for comparisons against theory.
Radiation- View Factor Calculation (CHBDYG Element)

The CHBDYG element is used in Nastran thermal analysis for any surface heat transfer phenomenon such as radiation
or convection or imposing heat flux on these elements.
CHBDYG 6987 AREA4 2 3
3390 3389 3397 3398
CHBDYG 6988 AREA4 2 3
3404 3403 3389 3390
RADM 3 0.9 0.9 Radm_3

RADM 4 0.7 0.7 Radm_4
RADM 5 1. 1. Radm_5
RADSET 4
RADCAV 4 YES 4 0.1
VIEW3D 4 0 0 0 0.0 0.0 0.0
$!
VIEW 2 4 KSHD 1 1
CHAPTER 44 805
In this case, we have CHBDYG element 6987 with TYPE='AREA4' bounded by grid 3390, 3389, 3397, 3398. The
normal vector is defined by the grid connectivity and is directed from the inner sphere to the outer sphere (Figure 44-2
and Figure 44-3). The internal sphere has KSHD defined on the 4th field of the VIEW data entry, which means that this
group of elements can shade the view of other elements. The external sphere has KBSHD defined which means that
these elements can also be shaded by other elements. The reason that we have specified the shading flag is to speed
up the sorting for these potential blockers in the view factor calculations. In general when the surface is very complex,
the use of the flag called BOTH is recommended. The RADSET option tells us there is only 1 cavity in the model, and
the 2nd field on the VIEW points to the IVIEWF or IVIEWB on the CHBDYG field 5th or 6th, respectively. For a plate
element, there is top and the bottom surface for view factor calculations. For a solid element, only the front side
IVIEWF should be used. The inner sphere here is represented by number as 1 on the field 5 (IVIEWF) on the CHBDYG.
The 7th and 8th represent the ID for the RADM option where 7th field is the top surface RADM ID and the 8th field is
the bottom surface RADM ID. The RADM specified the emissivity used for the sphere and, in this case, the emissivity
for the inner sphere is equal to 0.7.
The RADCAV bulk data entry indicates that we will print the summary of view factor calculations. In this case, we
have a complete enclosure and, therefore, the view factor summation should equal 1.0. The surface numbers 703, 704
are the ID numbers for the CHBDYG that has the radiation exchange.
*** VIEW FACTOR MODULE *** OUTPUT DATA *** CAVITY ID = 4 ***
ELEMENT TO ELEMENT VIEW FACTORS

SURF-I SURF-J AREA-I AI*FIJ FIJ SCALE
6987 -SUM OF 5.19803E-02 9.99998E-01

6988 -SUM OF 6.14400E-02 9.99997E-01
6989 -SUM OF 4.30822E-02 9.99988E-01
6990 -SUM OF 4.36718E-02 1.00000E+00
6991 -SUM OF 5.08568E-02 1.00000E+00
The continuation field on the RADCAV is optional.
Radiation - RADBC (radiation to space)

On the outer sphere, we have a radiation to space using the view factor supplied on the 3rd field on the RADBC. (see
Example below) The 2nd field on the RADBC points to the ambient grid ID 100001 and, in this case, we have the grid
fixed at 0° K.
SPOINT 6497
SPC 5 6497 1 0.0
TEMP 33 6497 0.0
RADBC 6497 1. 0 -6467
CHBDYG 6467 AREA4 5
5987 5975 5976 5986
RADBC 6497 1. 0 -6468
CHBDYG 6468 AREA4 5
5989 5976 5975 5988
RADBC 6497 1. 0 -6469
CHBDYG 6469 AREA4 5
5997 5996 5975 5987
CHAPTER 44
Please note the negative EID represents that the radiation to space is effected from the back surface (opposite to the
direction of normal) of the element.
Also, we have the temperature boundary conditions applied to all grids on the inner sphere at 1000 K via the SPC
option.
SPC 1 1 1 1000.
RADBC Space Radiation Specification
Specifies an CHBDYi element face for application of radiation boundary conditions.
Format
1 2 3 4 5 6 7 8 9 10
RADBC NODAMB FAMB CNTRLND EID1 EID2 EID3 -etc.-
Example
1 2 3 4 5 6 7 8 9 10
RADBC 5 1.0 101 10
Field Contents Type Default

NODAMB Ambient point for radiation exchange. I>0
FAMB Radiation view factor between the face and the ambient point. R>0
CNTRLND Control point for radiation boundary condition. (Integer > 0; Default = 0) I>0 0
EIDi CHBDYi element identification number. ( Integer  0 or “THRU” or “BY”)
Remarks:
1. The basic exchange relationship is:
• if CNTRLND = 0, then q =   FAMB   e   T 4e – T 4amb 
• if CNTRLND > 0, then
4 4
q =   FAMB  u CNTRLND   e   T e – T amb 
CHAPTER 44 807
Figure 44-2 Normal Vectors Point Outward from the Inner Sphere
Figure 44-3 Normal Vectors Point Inward for the Outer Sphere
Material Modeling
Thermal conductivity value is supplied on the MAT4 bulk data entry.
MAT4 1 4. Iso_1
MAT4 2 6. Iso_2
Solution Procedure
The nonlinear procedure used is defined using the following NLPARM entry:
NLSTEP 1 1. +
+ FIXED 1 +
+ HEAT UPW 0.001 0.001 1.E-7PFNT
CHAPTER 44
In thermal analysis, the TEMPD bulk data entry specifies the initial temperature for the nonlinear radiation analysis.
In this case, an initial guessed temperature of 800° was used. A casual selection of initial guessed temperature is not
so important in a nonlinear conduction and convection thermal analysis. However, for nonlinear radiation analysis
where the thermal radiation transfer is given by Q = A  T 14 – T 24  , an initial guess is very helpful. The error (residual)
is proportional to the temperature to the 4th power. It is. therefore, recommended to specify a higher estimated
temperature in a radiation dominant problem.
The default method for the NLPARM is the AUTO method in SOL 400 analyses. The convergence criterion is based
on UPW. In this problem, you can achieve convergence by either the PFNT method (as above) or the AUTO method:
NLSTEP 1 1. +
+ FIXED 1 +
+ HEAT UPW 0.001 0.001 1.E-7AUTO
The U convergence criterion measures the error tolerance for the temperature. It has a recommended value of 1.0e-3
or smaller for thermal problem. The P and W convergence criteria measure the error tolerances for the load and work,
respectively.
The number of increments is specified on the 3rd field of the NLPARM data entry (NINC). This should be set to 1 for
steady-state thermal analyses since convergence can be achieved in one step only. This, typically, is not the case for
structural analyses, where NINC is set to 10 by default. Generally, the PFNT or FNT methods are used for highly
nonlinear mechanical analyses.
Results
Analytic 710.30
710.5
Hemi-cube 708.91
710.0
709.5
709.0
708.5
708.0
Both methods yield temperatures very close to the analytical solution.

CHAPTER 44 809
Figure 44-4 Hemi-cube Results
Modeling Tips
The current model uses 1268 surfaces to define the radiating surfaces of both spheres. The CPU run times for the
Gaussian and Hemi-cube methods are nearly the same, at 27 seconds.
Figure 44-5, however, shows the dramatic increase in run time for the Gaussian model and the clear benefits of the
Hemi-cube method as the number of surfaces increases.
At 20,000 surfaces, the Gaussian model takes 33 time longer to complete.
CPU Time (s)

12000
10000
Gaussian
8000 Hemi-cube
6000
4000
2000
0
0 5000 10000 15000 20000
Number of Surfaces
Figure 44-5 CPU Run Times
CHAPTER 44

The same physical model will now be built, run and postprocessed with SimXpert. The Gaussian integration scheme
will be used to compute the viewfactors. While the dimensions of length in the summary and nug*.dat files is inches,
the model built here with SimXpert will use the same geometry but with units of meters. The only other change will
be in the selection of the correct units of the Stefan-Boltzmann constant (p. 844).
Units
a. Tools: Options
b. Observe the User Options window
e. Length = m, Mass = kg, Time = s, Temperature = Kelvin, and Force = N
c e
a
CHAPTER 44 811
Create First Hemispherical Surface

b. Select Arc
c. Select 3 Points
d. For X,Y,Z, Coordinate, enter 0.0245, 0, 0; input, click OK
e. For X,Y,Z, Coordinate, enter 0, 0.0245, 0; input, click OK (not shown)
f. For X,Y,Z, Coordinate, enter -0.0245, 0, 0; click OK (not shown)
g. Click OK
h. Observe in the Model Browser tree: Part 1
l. Observe the curve arc
b
a c
h
i
CHAPTER 44
Create First Hemispherical Surface (continued)
a. Geometry tab: Surface/Revolve

b. Select Vector
d. Click OK
e. For Axis, select X; click OK
f. For Entities screen select the Curve arc
g. For Angel Of Spin (Degrees), enter 180; click OK
h. Observe the first hemispherical surface
a
b
f
g
j
h
-
CHAPTER 44 813
Create Part for Second Hemispherical Surface
a. Assemble tab: Parts/Create Part

b. Use defaults of form
c. Click OK
d. Observe Part_2 in the Model Browser Tree
d
CHAPTER 44
Create Second Hemispherical Surface

b. Select Arc
c. Select 3 Points
d. For X,Y,Z, Coordinate, enter 0.0381, 0, 0; input, click OK
e. For X,Y,Z, Coordinate, enter 0, 0.0381, 0; input, click OK (not shown)
f. For X,Y,Z, Coordinate, enter -0.0381, 0, 0; click OK (not shown)
g. Click OK
h. Observe the curve arc
b
c
h
-
CHAPTER 44 815
Create Second Hemispherical Surface (continued)
a. Geometry tab: Surface/Revolve

b. Select Vector
d. Click OK
e. For Axis, select X; click OK
f. For Entities screen select the Curve arc
g. For Angel Of Spin (Degrees), enter 180;
h. Click OK
i. Observe the second hemispherical surface
a
b
f
g
ik
CHAPTER 44
Create Third Hemispherical Surface
a. Tools: Transform/Reflect
b. Select X-Y Plane
c. Select Make Copy
d. Select Inner (smaller) hemispherical surface
e. Click Done; then click Exit
f. A third hemispherical surface is created that is the same color as the copied surface
g. Observe that there is another Part in the Model Browser tree
b
c
g
CHAPTER 44 817
Create Third Hemispherical Surface (continued)
a. In the Model Browser tree, right click on PART_1.COPY; select Change Color
b. Select a different color
c. Observe that the third hemispherical surface is now a different color
a c
CHAPTER 44
Create Fourth Hemispherical Surface
a. Tools: Transform/Reflect
b. Select X-Y Plane
c. Select Make Copy
d. Select outer (larger) hemispherical surface
e. Click Done; then click Exit
f. A fourth hemispherical surface is created that is the same color as the copied surface
g. Observe that there is another Part in the Model Browser tree
b
c
e g
a
f
CHAPTER 44 819
Create Fourth Hemispherical Surface (continued)
a. In the Model Browser tree, right click on PART_2.COPY; select Change Color
b. Select a different color
c. Observe that the fourth hemispherical surface is now a different color
a
CHAPTER 44
Create Material Properties
a. Materials and Properties tab: Material/Isotropic

b. For Name enter Inner_sphere
c. For Description enter a description
d. For Young’s Modulus enter 10e9 (needed for the software to run)
e. For Poisson’s Ratio enter 0.28 (needed for the software to run)
f. For Thermal Conductivity enter 157.48
g. Click OK
b
c
d
e
gf
h
CHAPTER 44 821
Create Material Properties (continued)
a. Materials and Properties tab: Material/Isotropic

b. For Name enter Outer_sphere
c. For Description enter a description
d. For Young’s Modulus enter 10e9 (needed for the software to run)
e. For Poisson’s Ratio enter 0.28 (needed for the software to run)
f. For Thermal Conductivity enter 236.22
g. Click OK
b
c
d
e
h
CHAPTER 44
Create Inner Sphere Element Property
a. Create the element property for the inner sphere

b. Right click on PART_2; select HIDE to hide the outer hemispherical surfaces
c. Repeat Step b. for PART_2.COPY
d. Create the element property for the inner sphere
c
CHAPTER 44 823
Create Inner Sphere Element Property (continued)
a. Materials and Properties tab: 2D Properties/Shell

b. For Name, enter Inner_sphere
c. For Entities screen, select the two inner hemispherical surfaces
d. For Material, select Inner_sphere from the Model Browser tree
e. For Part thickness, enter 2.54e-4
f. Click OK
c
d
e c
f
CHAPTER 44
Create Outer Sphere Element Property
a. Create the element property for the outer sphere

b. Right click on PART_1; select HIDE to hide the outer hemispherical surfaces
c. Repeat Step b. for PART_1.COPY
d. Right click on PART_2; select SHOW to show the outer hemispherical surfaces
e. Repeat Step d. for PART_2.COPY
f. Create the element property for the outer sphere
f
CHAPTER 44 825
Create Outer Sphere Element Property (continued)
a. Materials and Properties tab: 2D Properties/Shell

b. For Name, enter Outer_sphere
c. For Entities screen, select the two outer hemispherical surfaces
d. For Material, select Outer_sphere from the Model Browser tree
e. For Part thickness, enter 1.27e-3
f. Click OK
c
d
e
c
f
CHAPTER 44
Create Surface Mesh for Outer Sphere
a. Meshing tab: Automesh/Surface

b. For Surface to mesh screen, select both surfaces
c. For Element Size, enter 0.35
d. For Mesh type, select Quad Dominant
e. For Element property, select Outer_sphere from the Model Browser tree
f. Click OK
b b
f
CHAPTER 44 827
Create Surface Mesh for Outer Sphere (continued)
a. Display the geometric surfaces in wireframe

b. Display the elements as shaded
c. Observe resulting mesh for the outer sphere
d. Notice the elements at the geometric interface are congruent
e. Verify that the elements at the interface are connected
e
CHAPTER 44
Create Surface Mesh for Inner Sphere
a. Display only the inner sphere using the picks in the Model Browser tree and those of the Render toolbar
for Geometry and FE.
a
CHAPTER 44 829
Create Surface Mesh for Inner Sphere (continued)
a. Meshing tab: Automesh/Surface

b. For Surface to mesh screen, select both surfaces
c. For Element Size, enter 0.35
e. For Element property, select Inner_sphere from the Model Browser tree
f. Click OK
b b
f
CHAPTER 44
Create Surface Mesh for Inner Sphere (continued)
a. Display the geometric surfaces in wireframe

b. Display the elements as shaded
c. Observe resulting mesh for the inner sphere
d. The elements at the geometric interface are congruent
e. Verify that the elements ar the interface are connected
e
CHAPTER 44 831
Equivalence All Nodes
a. Right Click Part_1 Show All

b. Nodes/Elements Modify/Equivalence
c. Select All
d. Observe Highlighted Nodes
e. OK
f. Observe 52 merged unreferenced nodes deleted
a d
f
CHAPTER 44
Create Fixed Temperature LBC for Inner Sphere
a. LBCs tab: Heat Transfer/Temperature BC

b. For Name, enter Temperature_inner
c. For Entities screen, select the two inner hemispherical surfaces; best to have only the Pick Surfaces
icon active and pick near the center of an element away from the nodes.
d. For Temperature, enter 1000
e. Click OK
c c
d
e
CHAPTER 44 833
Create Fixed Temperature LBC for Inner Sphere (continued)
a. Observe the applied temperatures as values

b. Display temperature values; turn Detailed Rendering On/Off
c. Set Geometry and FE to Wireframe
d. Double click on Temperature_Inner under LBC in the Model Browser
e. Click on Visualization tab
f. Select Short under LBC Type and Value Labels
g. Select Associated Geometry under Display on Geometry / FEM
h. Click OK
h
CHAPTER 44
Create Fixed Temperature LBC for Inner Sphere (continued)
a. Observe the applied temperatures (red dots)

b. Select FE Shaded
a
CHAPTER 44 835
Create Radiation Enclosure LBC Between Spheres
a. Create two radiation enclosure faces (inner and outer spheres)

b. LBCs tab: Heat Transfer/Encl Rad Face
c. For Name, enter Encl Rad Face_Inner
d. For Entities screen, select both the inner hemispherical surfaces
e. Click on Advanced
f. For Shell surface option select, Front; direction of the element normals is found by
Quality tab: edit/fix Elements/Fix Elements/Normals
g. For Shell surface option, select Front
h. For Absorptivity, enter 0.9
i. For Emissivity, enter 0.9
j. Click OK
e
f
g
h
i
j
CHAPTER 44
Create Radiation Enclosure LBC Between Spheres (continued)

b. Display only the outer sphere surfaces
c. Using the Model Browser tree, hide the inner surfaces and show the outer surfaces
d. Observe the outer surfaces
d
CHAPTER 44 837

b. LBCs tab: Heat Transfer/Encl Rad Face
c. For Name, enter Encl Rad Face_outer
d. For Entities screen, select both the outer hemispherical surfaces
f. For Shell surface option select, Front; direction of the element normals is found by
Quality tab: edit/fix Elements/Fix Elements/Normals
g. For Shell surface option, select Back
h. For Absorptivity, enter 0.7
i. For Emissivity, enter 0.7
j. Click OK
d
e
g
h f
i
j
CHAPTER 44
a. Create a single radiation enclosure

b. LBCs tab: Heat Transfer/Radiation Enclosure
c. For Name, enter Rad Enclosure
d. For Shadowing Option, select NO
e. For Unused Enclosure Faces, select Encl Rad Face_outer
f. Click the > icon
g. For Unused Enclosure Faces, select Encl Rad Face_inner
h. Click the > icon
i. Click OK
g
f
e h
i
CHAPTER 44 839
Radiation Enclosure LBC Between Spheres (continued)
a. Create a single radiation enclosure; display created Radiation Enclosure LBS form
b. In the Model Browser tree under LBC, double click Radiation Enclosure
c. Observe the form for Rad Enclosure
b
CHAPTER 44
Create Radiation to Space From Outer Sphere
a. Create radiation to space (ambient)

b. LBCs tab: Heat Transfer/Rad to Space
c. For Name, enter Rad to Space
d. For Entities screen, select the two outer surfaces
e. For Ambient temperature, enter 0.0
f. For View Factor, enter 1.0
g. For Absorptivity, enter 1.0
h. For Emissivity, enter 1.0
i. For Shell surface option, enter Front
j. Click OK
d d
e
f
g
h
i
j
CHAPTER 44 841
a. Specify parameter values for SOL 400 analysis

b. Right click on FileSet
c. Select Create new Nastran job
d. For Job Name, enter a title
e. For Solution Type, select SOL 400
f. For Solver Input File, specify the fine name and its path
g. Unselect Create Default Layout
h. Click OK
b
c
h
CHAPTER 44

b. Right click on Load Cases
c. Select Create Loadcase
d. For Name (Title), enter NewLoadcase
e. For Analysis Type, select Nonlinear Steady Heat Trans
f. Click OK
f
CHAPTER 44 843

b. Right click on Load/Boundaries
c. Select Select Lbc Set
d. For Selected Lbc Set, select DefaultLbcSet in the Model Browser tree
e. Click OK
f. To see the contents of DefaultLbcSet, click on it in the Model Browser tree
d
CHAPTER 44

Remember that our length unit is meter, so the correct Stefan-Boltzmann constant to pick will have units of W/M2/K4.

c. For Default Init Temp, enter 750.0
d. For Absolute Temp Scale, select 0.0
e. For Stefan-Boltzmann, select 5.6696e-8 W/M2/K4 (Expert)
f. Click Apply
d
e
CHAPTER 44 845

Finally let’s pick the hemicube viewfactor algorithm
a. Right Click Solver Control

b. Select Direct Input (BULK)
c.Enter nlmopts,hemicube,1
d. Check box Export this Section
e. Click Apply and Close
c nlmopts,hemicube,1
a
d
e
CHAPTER 44

c. For Text Output, select Print
d. Click Apply
c
b
d
CHAPTER 44 847
a. Specify parameter values for Sol 400 analysis

b. Double click on Loadcase Control
c. Select Subcase Steady State Heat
d. Click Temp Error
e. For Temperature Tolerance, enter 0.01
f. Click Load Error
g. For Load Tolerance, enter 1e-5
h. Click Apply
i. Click Close
d
e
f
g
b
CHAPTER 44
a. Specify parameter values for Sol 400 analysis

b. Right click on Output Requests
c. Select Nodal Output Requests
d. Select Create Temperature Output
e. Click OK
b
e
CHAPTER 44 849
Perform SimXpert SOL 400 Thermal Analysis
a. Perform steady state heat transfer analysis Sol 400

b. Right click on rad_between_concentric_spheres
c. Select Run
d. After the analysis is complete, the shown files are created
c
CHAPTER 44
a. Analysis complete, attach the .xdb results file

b. File: Attach Results
c. Select Results
d. Click OK
d
CHAPTER 44 851
Display the Temperature Results
a. Create a fringe plot for the temperature results

b. Display just the two original surfaces (PART_1 and PART_2)
c. Results tab: Results/Fringe
d. For Result Cases, select Non-linear: 100. % of Load
e. For Result type, select Temperatures
f. Click Target entities
g. Screen select the elements for the two surfaces
f
e
g
CHAPTER 44
Display the Temperature Results (continued)

b. Click Label attributes
c. Set color to black
d. Set format to Fixed
e. Click Update
c
d
e
CHAPTER 44 853
Display the Temperature Results (continued)

b. Observe the fringe plot
b
709.3
1000
Input File(s)
File Description
nug_44a.dat MD Nastran input using Hemi-cube method
nug_44b.dat MD Nastran input using Gaussian integration method
MD Nastran input with simple three grid model with user-defined
nug_44c.dat
radiation matrix
Ch_44b.SimXpert SimXpert model file
Ch_44c.SimXpert SimXpert model file
CHAPTER 44
Video

Analytic 710.30
710.5
Hemi-cube 708.91
710.0
709.5
709.0
708.5
708.0

Chapter 45: Transient Thermal Analysis of Power Electronics
Transient Thermal Analysis of

45 Power Electronics

Summary 856

Introduction 857


Solution Highlights 857

Results 860

Modeling Tips 864


Input File(s) 919
 Video 919
CHAPTER 45
Summary
Title Chapter 45: Transient Thermal Analysis of Power Electronics
Features Transient thermal analysis using CHEXA elements
Geometry
Units: mm, g, sec, C
Copper
Aluminum
10 X 10 X 8
1.295 X 1.295 X 0.2
Y
2
Flux 1.4907 W/mm
Z X
(0 to 10 seconds)
Material properties k Cu = 0.386W   mm – K  k Al = 0.204W   mm – K 

Cp Cu = 0.383J   g – K  Cp Al = 0.896J   g – K 
Analysis characteristics Nonlinear transient thermal analysis

Boundary conditions All material is initially at 25oC then a heat flux is applied on top surface of the copper
chip for 10 seconds.
Element type 8-node CHEXA
FE results Temperature contours at t = 10 seconds.
CHAPTER 45 857
Transient Thermal Analysis of Power Electronics
Introduction
This problem demonstrates the transient thermal capability of SOL 400 in solving a short duration heating on a chip
through a copper tab attached to an aluminum backing.
Modeling Details
Units: mm, g, sec, C
Copper
Aluminum
10 X 10 X 8
1.295 X 1.295 X 0.2
Y
2
Flux 1.4907 W/mm
Z X
(0 to 10 seconds)
Figure 45-1 Chip Analysis (Nastran Test File: chip1.dat)
In many applications, the power dissipation inside integrated circuits is transient in nature. The device maybe turned
on for 10 seconds or less. The above model (Figure 45-1) consists of D2pak copper tab mounted on the aluminum heat
sink. Due to the symmetry, only a quarter of the model is meshed.
Solution Highlights
The following are highlights of the Nastran input file necessary to model this problem:
SOL 400
CEND
ECHO = SORT
IC = 13
SUBCASE 1
FLUX(PRINT)=ALL
ANALYSIS = HTRAN
SPC = 15
CHAPTER 45
DLOAD = 16
NLSTEP = 1
BEGIN BULK
PARAM POST 1
PARAM PRGPST NO
MAT4 1 0.386 0.383 0.00895 Cu
MAT4 2 0.204 0.896 0.00271 Al
PSOLID 1 1 PSOLID_1
PSOLID 2 2 PSOLID_2
$ CHBDYG Surface Elements

CHEXA 126 1 17 18 1 19 179 181+
+ 147 183
CHEXA 127 1 179 181 147 183 180 182+
+ 148 184
CHEXA 128 1 18 20 2 1 181 185+
+ 149 147
CHEXA 129 1 181 185 149 147 182 186+
+ 150 148
$ Loads for Load Case : tran
TABLED1 1 LINEAR LINEAR +
+ 0.0 1. 10. 1. 10.1 0.0 100. 0.0+
+ ENDT
$!
TLOAD1 1 2 1
QBDY3 2 1.5 0 2176
CHBDYG 2176 AREA4
148 150 158 156
$ Dynamic Load Table : flux_time
TABLED1 1
0. 1. 10. 1. 10.2 0. 20. 0.
100. 0. ENDT
$ Default Initial Temperature
TEMPD 13 25.
DLOAD 16 1. 1. 1
NLSTEP 1 12. +
+ GENERAL -10 0 5 +
+ FIXED 600 5 +
+ HEAT UPW 0.01 0.01 0.01ITER 2 +
+ 10 2 0.2
The transient thermal analysis is indicated by ANALY=HTRAN. The IC option in the case control section points to the
initial temperature of the model. In this case, The IC=1 points to the TEMPD in the bulk data section, and the initial
temperature is set at 25 oC. The DLOAD bulk data in the case control either points to the DLOAD in the bulk data with
same ID.
Furthermore, the DLOAD in the bulk data section can then point to the multiple load set ID that refers to either
TLOAD1, which called a time dependent table TABLED1 or TLOAD2 which has built in function such as unit step, sine,
or cosine functions.
CHAPTER 45 859

+ 0.0 1. 10. 1. 10.1 0.0 100. 0.0+
+ ENDT
TLOAD1 1 2 1
QBDY3 2 1.5 0 2176
CHBDYG 2176 AREA4
148 150 158 156
DLOAD 16 1. 1. 1
Field 3 on the TLOAD1 record has an integer value of 2 which points to a transient heat load of QBDY3 with this same
set ID. In the field 6 of the TLAOD1 is the ID of time-dependent table of this heat flux. We see that the heat load is 1.0
from time equals to 0 to 10 seconds and, at 10.2 seconds, we shut this heat load back to zero.
Solution Procedure
The nonlinear procedure used is defined through the NLSTEP entry:
NLSTEP 1 12. +
+ GENERAL -10 0 5 +
+ FIXED 600 5 +
+ HEAT UPW 0.01 0.01 0.01ITER 2 +
+ 10 2 0.2
We are running a total 600 time steps with equal steps of 0.02 seconds and output the temperature at every 5th step.
This means that the temperature will then be output at 0.1, 0.2, and 0.3 seconds, respectively. Also we can use the
Method called FIXED and the convergence is set on the error on temperature (U) with 0.01 as the error tolerance. Grid
point 195 is the fastest responding in the copper tab; it is also used in subsequent graphs to illustrate how fast the chip
heats up and cools down.
Figure 45-2 Early Temperature History of Grid Point 195

CHAPTER 45
Results
Figure 45-3 Temperature Contours at 5 Seconds
Figure 45-4 Temperature History Past 10 Seconds
Suppose that the user decided to add a fan to increase the cooling on top. To simulate this, we will apply convection
boundary condition on the top surface where the convection coefficient is a function of time and the ambient
temperature is also at 25oC. We can then compare this run against the previous run that has no convection. Convection
is applied as a heat transfer coefficient of H = 0.02W   mm 2 – C  . The temperature contours at 5 seconds are shown in
Figure 45-5.
CHAPTER 45 861
Figure 45-5 Temperature Contours at 5 Seconds
Another comparison between the two models is shown in Figure 45-6, where the influence of the cooling is very
obvious with the entire model returning to the initial conditions after about 20 seconds.
Figure 45-6 Temperature Histories With and Without Cooling
By applying the convection on the top surface, the temperature of the chip is now cooled from 40.3 to 33.2oC. In this
run we have a total of three time dependent boundary conditions. The DLOAD in the bulk data section (Nastran test
file Chip_spcd1.dat) points to multiple TLOAD1 options as shown in the table below.
Grid (enforced
Boundary temperature as a
Conditions TLOAD1 ID SPCD/DAREA function of time) TABLED1 (ID)
H(time) 2 5 2556 2
Heat flux(time) 1 3 1
Tambient(time) 6 8 2555 3
CHAPTER 45
The SPCD is used only on enforced temperature as a function of time.

TLOAD1 1 3 1
TLOAD1 2 5 1 3
TLOAD1 6 8 1 2

+ 0.0 1. 10. 1. 10.1 1. 100. 1.+
+ ENDT
+ -10. 0.02 0.0 0.02 5. 0.02 10. 0.02+
+ 20. 0.02 ENDT
+ 0.0 1. 100. 1. ENDT
$!
PCONV 4 3 0 0.0
MAT4 3 1.
SPOINT 2555
SPCD 5 2555 25.
SPC1 4 2555
TEMP 21 2555 25.
$!
SPOINT 2556
SPCD 8 2556 1.0
SPC1 7 2556
TEMP 21 2556 0.02
QBDY3 3 1.5 0 2176
CHBDYG 2176 AREA4
148 150 158 156
TEMPD 21 25.
SPCADD 23 4 7
DLOAD 24 1. 1. 1 1. 2 1. 6
NLSTEP 1 12. +
+ GENERAL -10 0 5 +
+ FIXED 600 5 +
+ HEAT UPW 0.01 0.01 0.01ITER 2 +
+ 10 2 0.2
SPOINT 2555 indicates the ambient temperature for the convection, while SPOINT 2556 represents the variation of
convection coefficient with time.
CHAPTER 45 863
CONV Heat Boundary Element Free Convection Entry
Specifies a free convection boundary condition for heat transfer analysis through connection to a surface element
(CHBDYi entry).
Format:
1 2 3 4 5 6 7 8 9 10
CONV EID PCONID FLMND CNTRLND TA1 TA2 TA3 TA4
TA5 TA6 TA7 TA8
Example:
1 2 3 4 5 6 7 8 9 10
CONV 2 101 3 201 301

EID CHBDYG, CHBDYE, or CHBDYP surface element I > 0
identification number.
PCONID Convection property identification number of a I>0
PCONV entry.
FLMND Point for film convection fluid property I>0 0
temperature.
CNTRLND Control point for free convection boundary I>0 0
condition.
TAi Ambient points used for convection. I > 0 for TA1 TA1 for TA2
I > 0 for TA2 through TA8 through TA8
$ Convection to Ambient of Load Set : htime

PCONV 4 3 0 0.0
MAT4 3 1.
SPOINT 2555
SPCD 5 2555 25.
SPC1 4 2555
TEMP 21 2555 25.
SPOINT 2556
SPCD 8 2556 1.0
SPC1 7 2556
TEMP 21 2556 0.02
CONV 2201 4 2556 2555

CHBDYG 2201 AREA4
17 18 37 73
CHAPTER 45
The SPOINT 2556 is on the field 5 (CNTRLND) on the CONV, and the SPOINT 2555 is on the field 6 (TA1). The
field 6 on the MAT4 option is the convection coefficient times the tabeld1 ID 2 where this a function of time. At time
equal to zero, the value is equal to 0.02, and time equal to 10 seconds, the value is 0.03.
For SPOINT 2556, we used SPCD and SPC1 to specify enforced temperature as a function of time. The value of 1.0
that specified on the field 5 on the SPCD bulk data entry actually is a scale multiplier to the TABLED1 ID 2 that it refers
to.
The ambient temperature is constant at 25oC, but we could make it time dependent as well. It is important that for any
enforced temperature as a function of time or any use of a control node in RADBC or CONV bulk data entries, that a
value of 1 is specified on field 5 on the TLOAD1 or TLOAD2 entry to indicate that this refers to the SPCD.
Modeling Tips
The transient thermal analysis involved a lot more data compared to a steady state thermal analysis since every time
step requires a temperature distribution. It is sensible to monitor those nodes that handle the time-dependent boundary
conditions. In this case, the convection coefficient as a function of time is applied to SPOINT 2556 which, when
plotted as a graph in SimX, should behave as described by the input. The other point of interest is where the heat load
is applied.
Adaptive time stepping facilitates capturing transient thermal behavior more precisely than uniform stepping, because
the length of each time step changes based upon changes in temperature. To invoke adaptive time stepping requires
the nonlinear procedure defined through the NLSTEP entry:
NLSTEP,6,12.0
,GENERAL,10,1,10
,ADAPT,0.001,1.0E-5,0.5
,HEAT,U,1.0E-6,1.0E-6,1.0E-6,AUTO
and a backward Euler thermal operator with the NDAMP parameter:
PARAM,NDAMP,0.5
This will run for a total time period of 12 seconds with an initial time step of 12/1000. The minimum time step is
12*1e-5; the convergence is set to U and is at 1e-6. The allowable range of the NDAMP parameter is -2.414 to 0.414,
and any NDAMP value that violates this range is reset to the closest allowable value. Here it triggers the backward
Euler operator. (NDAMP = 0 would be the Crank-Nicholson operator). The adaptive time stepping would avoid the
small oscillation seen in Figure 45-4 since the backward Euler operator is both stable and immune to oscillations. The
input files nug_45c.dat and nug_45d.dat use this operator.
CHAPTER 45 865
Run SimXpert with Structures Workspace

a. For the Default Workspace, select Structures
a
CHAPTER 45
a. Tools: Options
b. Observe the User Options Window
d. For Basic Units, specify the model units
e. Length = mm; Mass = g; Time = s; Temperature = celsius, Force = N
f. Click OK
a b
c e
CHAPTER 45 867
Create a Surface with a 45° Angle
a. Create two straight curves

b. Geometry tab: Curve/Curve
c. For X,Y,Z Coordinate, enter 1.295, 0, 0; click OK
d. For X, Y, X Coordinate enter 1.295, 1.295, 0; click OK
e. Click Apply
f. For X,Y,Z Coordinate, enter 10, 0, 0; click OK (not shown)
g. For X,Y,Z Coordinate, enter 10, 10, 0; click OK (not shown)
f. Click Apply
c d
f
CHAPTER 45
Create a Surface with a 45° Angle (continued)
a. Create two straight curves

b. Geometry tab: Surface/Filler
c. For Curves screen, select 2 curves
d. Click OK
c c
d
CHAPTER 45 869
Mesh the Surface
a. Create mesh seeds on the four curves of the surface

b. Meshing tab: Automesh/Seed
c. For Curves screen, select the shortest curve and the opposite curve
d. Select Number of Elements, enter 5; click OK
e. Do this for the lower-right curve, using One Way Bias
f. Select Number of Elements and L2/L1
g. For Number of Elements, enter 10
h. For L2/L1, enter 5; click OK
i. Do this for the last curve, using One Way Bias (not shown)
j. Select Number of Elements and L2/L1 (not shown)
k. For Number of Elements, enter 10
l. For L2/L1, enter 0.2; click OK (1/5) (not shown)
b c
e i
c
f
g f
h
CHAPTER 45
Mesh the Surface (continued)
a. Create mesh seeds on the four curves of the surface

b. Meshing tab: Automesh/Surface
c. For Surfaces to mesh screen, select the surface
e. For Mesh method, select Mapped
f. Click OK
d
e
f
CHAPTER 45 871
Reflect the Part
a. Reflect (mirror) the Part (surface and its mesh)

b. Tools: Transform/Reflect
c. To define a plane to reflect about, create a node at the origin (0,0,0) and one above it (0,0,10)
d. Nodes/Elements tab: Create/Node
e. For X,Y,Z Coordinate, enter 0,0,0; click OK
f. For X,Y,Z Coordinate, enter 0,0,10; click OK (not shown)
g. Click OK
g
CHAPTER 45
Reflect the Part (continued)

b. Tools: Transform/Reflect
c. For Plane, select Any Plane
d. Select Make Copy
e. Select Nodes
f. Select the node at the origin
g. Select the node at the tip of the surface (interior angle is 45°)
h. Select the node that is above the origin
b c
d
e h f
CHAPTER 45 873
Reflect the Part (continued)

b. From Reflect - Any Plane pick panel, select Parts
c. Screen select the Part
d. Click Done; then click Exit
b c
d
CHAPTER 45
Create a Square Surface to be Congruent at Lower-left
a. Create a square surface at the lower-left corner of the Part

b. Geometry tab: Curve/Curve
c. For Entities screen, select the node at the origin and the node to its right
d. Click OK
c c
d
CHAPTER 45 875
Create a Square Surface to be Congruent at Lower-left (continued)

b. Geometry tab: Surface/Filler
c. For Curves screen, select the curve just created and the curve just above it
d. Click OK
c c
d
CHAPTER 45
Mesh the Square Surface at Lower-left

b. Meshing tab: Automesh/Surface
c. For Surfaces to mesh screen, select the square surface just created
d. Click OK
c c
d
CHAPTER 45 877
Connect the Adjacent Elements (continued)
a. Connect the adjacent elements using equivalence

b. Nodes/Elements tab: Modify/Equivalence
c. Set geometry to wireframe (not shown)
d. Tools: Identify to display the node labels (not shown)
e. For Entities screen, select all the nodes
f. For Merging tolerance, enter 0.05
g. Click OK
e e
g
CHAPTER 45
Connect the Adjacent Elements (continued)
a. Connect the adjacent elements using equivalence

b. Click OK
c. View: Clear Labels (not shown)
d. Tools: Identify (not shown)
e. For Identify Entities pick panel, select Nodes (not shown)
f. Click All (not shown)
g. Click Exit (not shown)
h. Observe only one node label
i. View: Clear Labels (not shown)
b h
CHAPTER 45 879
Sweep 2-D Elements to Create 3-D Elements
a. Create 3-D elements by sweeping the 2-D elements

b. Meshing tab: FEM based/Normal
c. For Shell Elements screen, select all the elements
d. For Distances, enter -8
e. For Layers, enter 8
f. Click OK
c c
d
e
f
CHAPTER 45
Sweep 2-D Elements to Create 3-D Elements (continued)

b. Model Views: Isometric View
c. Observe the 3-D elements
b c
CHAPTER 45 881
Create 3-D Elements for Applying Heat Flux
a. Create 2-D elements at the location where they are needed

b. View > Entity Display Filter: Show/Hide 3D FE
c. Tools: Transform/Translate (not shown)
d. For Translate XYZ, enter 0, 0, 8
e. Select Make Copy
f. Select Elements
g. Model Views: Top
h. Screen select the 2-D elements for the square surface
i. Select Done
j. Model Views: Isometric View
d
j
g
f
h
b
i
CHAPTER 45
Create 3-D Elements for Applying Heat Flux (continued)

b. Observe the new 2-D mesh that is to be sued to create the 3-D elements for the application region for
the heat flux
c. Rotate model as needed
b
CHAPTER 45 883
a. Create 2-D elements at the location where they are needed

b. Meshing tab: FEM based/Normal
c. For the Shell Elements screen, select the 2-D elements that were just created
d. For Distances, enter -0.2
e. For Layers, enter 2
f. Click OK
g. Model Views: Isometric View (not shown)
h. Render:FE Shades with Edges (not shown)
c c
d
e
f
CHAPTER 45

b. Observe the 3-D meshes
b
CHAPTER 45 885
Delete All 2-D Elements
a. Eliminate all 2-D Elements for the model

b. Edit: Delete
c. From the Delete pick panel, select Elements
d. Select Advanced
e. From the Extended Pick Dialog, select CQUAD4
f. Select the entire model
g. Click Done
h. In the Delete window, click Yes
i. Click Exit
e
d
g i
h
CHAPTER 45
Connect All 3-D Elements
a. By using equivalence, all 3-D elements can be connected

b. Modes/Elements: Modify/Equivalence
c. For Entities screen, select the entire model
d. For Merging tolerance, enter 0.5
e. Click OK
f. Click OK
e f
CHAPTER 45 887
Material Properties
a. Design material properties for Copper and Aluminum

b. Materials and Properties tab: Material/Isotropic
c. For Name, enter Copper
d. For Young’s Modulus, enter 210
f. For Thermal Conductivity, enter 0.386
g. For Specific Heat, enter 0.383
h. For Thermal Density, enter 0.00895
i. Click OK
d
e
f
g
h
i
CHAPTER 45
Material Properties (continued)
a. Design material properties for Copper and Aluminum

b. Materials and Properties tab: Material/Isotropic
c. For Name, enter Aluminum
d. For Young’s Modulus, enter 210
f. For Thermal Conductivity, enter 0.204
g. For Specific Heat, enter 0.896
h. For Thermal Density, enter 0.00271
i. Click OK
d
e
f
g
h
i
CHAPTER 45 889
Element Properties
a. Define element properties for Copper and Aluminum parts of the model
b. Materials and Properties tab: 3D Properties/Solid
c. For Name, enter SOLID_Copper
d. For Entities screen, select the solid elements that are to represent the Copper
e. under Material on the Model Browser tree, select Copper
f. Click OK
d d
e
e
CHAPTER 45
Element Properties (continued)
a. Define element properties for Copper and Aluminum parts of the model
b. Materials and Properties tab: 3D Properties/Solid
c. For Name, enter SOLID_Aluminum
d. For Entities screen, select the solid elements that are to represent the Aluminum
e. Under Material on the Model Browser tree, select Aluminum
f. Click OK
d d
e
e
CHAPTER 45 891
Define Time Dependent Heat Flux on Copper Chip
a. To define the time dependent heat flux that is to be normal to the Copper chip, first define the time
dependent function for the heat flux
b. Fields/Tables tab: Tables/NastranBDF/Tabled1
c. For Name, enter TABLE_1
d. For X and Y values, enter the values shown below
e. Click OK
b c
e
CHAPTER 45
Define Time Dependent Heat Flux on Copper Chip (continued)
a. Define the time dependent heat flux that is to be normal to the Copper chip
b. LBCs tab: Heat Transfer/Normal Flux
c. For Name, enter Normal_Flux_Copper_Chip
d. For Entities screen, select the nodes at the top of the chip
e. For Heat Flux, enter 1.4907
f. Under Flux vs Time scaling function on the Model Browser tree, select TABLE_1
g. Click OK
d d
e
f
g
CHAPTER 45 893
Define Time Dependent Heat Flux on Copper Chip (continued)
a. Define the time dependent heat flux that is to be normal to the Copper chip
b. Observe the model with the applied heat flux
b
CHAPTER 45
Create a SimXpert Analysis File
a. Create a SimXpert analysis file for performing an MD Nastran analysis

b. Right click on FileSet, and select Create new Nastran job
c. For Job Name, enter a title
d. For Solution Type, select SOL400
e. For Solver Input File, select the path
g. Click OK
e
f
g
CHAPTER 45 895
Create a SimXpert Analysis File (continued)

b. Right click on Load Cases and select Create Loadcase
c. For Name (title), enter NewLoadcase
d. For Analysis Type, select Nonlinear Transient Heat Trans
e. Click OK
e
CHAPTER 45

b. Right click on Loads/Boundaries and select Select Lbc Set
c. For Selected Lbc Set, enter DefaultLbcSet; click OK
d. Under LBC Set in the Model Browser, double click on DefaultLbcSet to observe the lbcs
that are assigned
e. Click Cancel
c
CHAPTER 45 897

b. Under Simulations, transient analy power... in the Model Browser, double click on Solver Control
c. Select Solution 400 Nonlinear Parameters
d. For Default Init Temperature, enter 25; click Apply
e. Select Output File Properties
f. For Test Output, select Print
g. Click Apply
h. Click Close
f
e
b
2009 MSC.Software Corporation
g
h
CHAPTER 45

b. Under Simulations, transient_analy_power... NewLoadcase in the Model Browser, double click on
Loadcase Control
c. Select Subcase Transient Heat Transfer Parameters
d. For Initial Time Step, enter 0.02
f. Click on Temperature Error
g. For Temperature Tol., select 0.01
h. Click Apply (not shown)
i. Click Close (not shown)
b
d
c e
f
g
CHAPTER 45 899
a. Create a SimXpert analysis fole for performing an MD Nastran analysis

b. Under Simulations, transient_analy_power...,Load Cases, NewLoadcase in the Model Browser,
right click on Output Requests
d. Select Create Temperature Output Request
e. Click on Suppress Print
f. For Sorting., select By Frequency/Time
g. Click OK
e
f
g
CHAPTER 45
Run a SimXpert Analysis
a. Perform a SimXpert thermal analysis

b. Under Simulations in the Model Browser, right click on transient analy power elect
c. Select Run
c
CHAPTER 45 901
a. Attach the SimXpert result file

b. Click on Attach Results
c. For File path, select the results file transient_analy_power_elect.xdb
d. Click OK
d
CHAPTER 45
Display a Chart of Temperature Results
a. Display the thermal results for all the times

b. Results tab: Results/Chart
c. For Results Cases., select the results for all the times
d. For Results Type, select Temperatures
e. For Target Type, select Nodes
f. Pick Filters: Accumulate Mode
d e
f
CHAPTER 45 903
Display a Chart of Temperature Results (continued)

b. Select two nodes; e.g., Node 1522 and Node 67
c. For Independent axis., select Time
d. Click Add Curves
b
c
b
CHAPTER 45

b. Observe the temperature results
b
CHAPTER 45 905
Define Free Convection off Heat Storage Body
a. Define free convection off top of model

b. LBCs tab: Heat Transfer/Free Convection
c. For Name, enter Free Convection_Al_Body
d. For Ambient Temperature, enter 25
e. To make picking easier, hide the lbc Normal Flux_Copper_Chip (not shown)
f. For Entities screen, select the nodes at the top of the Aluminum body. Make sure to select
the node at the corner
g. DO NOT CLICK OK
.
c
d
f
f
f
CHAPTER 45
Define Free Convection off Heat Storage Body (continued)

b. Change the picking to Pick Filters: Accumulate Mode
c. Change to different view using Model Views: Front (not shown)
d. For Entities screen, select the remaining nodes at the top of the Aluminum body
f. For Convection coefficient, enter 0.02
g. Click OK
d d
e
g
CHAPTER 45 907
Define Free Convection off Heat Storage Body (continued)

b. Observe the model with its free convection markers
b
CHAPTER 45
Create a SimXpert Analysis File

b. Under FileSet in the Model Browser, right click on Create new Nastran job
c. For Job Name, enter a new title
d. For Solution Type, select SOL400
e. For Solver Input File, select the path
g. Click OK
e
f
g
CHAPTER 45 909

b. Right click on Load Cases, and select Create Loadcase
c. For Name (Title), enter NewLoadcase
d. For Analysis Type, select Nonlinear Transient Heat Trans
e. Click OK
e
CHAPTER 45

b. Right click on Loads/Boundaries, and select Select Lbc Set
c. For Selected Lbc Set, enter DefaultLbcSet
d. Double click on DefaultLbcSet to observe the lbcs that are assigned
e. Click Cancel
c f
d
CHAPTER 45 911

b. Double click on Solver Control
d. For Default Init Temperature, enter 25;click Apply
f. Select Output File Properties
g. For Text Output, select Print; click Apply
h. Click Close
b
g
f
h
CHAPTER 45

c. Select Subcase Transient Heat Transfer Parameters
d. For Initial Time Step, enter 0.02
f. Click on Temperature Error
g. For Temperature Tol., enter 0.0.1; click Apply
h. Click Close (not shown)
d
c e
f
g
b
CHAPTER 45 913

d. Select Create Temperature Output Request
e. Click on Suppress Print
f. For Sorting, select By Frequency/Time
g. Click OK
e
f
g
CHAPTER 45
Run a SimXpert Analysis
a. Perform a SimXpert thermal analysis

b. Right click on tran_analy_with_free_conv
c. Select Run
c
CHAPTER 45 915
a. Attach the SimXpert result file

b. Click on Attach Results
c. For File path, select results file tran_analy_with_free)conv.xdb
d. Click OK
d
CHAPTER 45

b. Results tab: Results/Chart
c. For Result Cases, Select the results for all the times
d. For Result Type, select Temperatures
e. For Target type, select Nodes
f. Pick Filters: Accumulate Mode
d e
f
CHAPTER 45 917

b. Select two nodes; e.g., Node 1522 and Node 67
c. For Independent axis, select Time
d. Click Add Curves
b
c
b
CHAPTER 45

b. Observe the temperature results
b
CHAPTER 45 919
Input File(s)
File Description
nug_45a.dat MD Nastran transient thermal input file - fixed step without cooling
nug_45b.dat MD Nastran transient thermal input file - fixed step with cooling
Ch_45a.SimXpert SimXpert data corresponding to nug_45a.bdf
nug_45c.dat MD Nastran test deck using adaptive approach for heating only
nug_45d.dat MD Nastran test deck using adaptive approach for heating with convection cooling
Video

Chapter 46: Thermal Stress Analysis of an Integrated Circuit Board
Thermal Stress Analysis of an

46 Integrated Circuit Board

Summary 921

Introduction 922



Results 925

Modeling Tips 926


Input File(s) 969
 Video 970
CHAPTER 46 921
Thermal Stress Analysis of an Integrated Circuit Board
Summary
Title Chapter 46: Thermal Stress Analysis of an Integrated Circuit Board
Features Chaining thermal and stress analysis in one execution
Geometry
Chip
Leads
Case
Paste
14 x 14 x 3.22
Units: mm, N, C
Material properties
Material k W   mm  C  E N   mm 2   (1/C)
Lead frame 0.147 6.9x104 1.0x10-6
Chip 0.168 5.52x104 1.0x10-5
Case 0.0714 4.5x104 1.0x10-6
Paste 0.02016 2.0x103 1.0x10-5
Analysis characteristics Nonlinear thermal analysis followed by a stress analysis

Thermal boundary conditions: The heat flux is applied on top surface of the chip with heat flux
equal to 0.025 W/(mm2 oC). Convection heat transfer with ambient (at 70 oC). Top surface of the
case - 4.05x10-5 W/(mm2 oC). Bottom Surface of the case - 2.026x10 -5 W/(mm2 oC) Sides
Boundary conditions
(adjacent to the lead frame where it is fixed) - 7.0x10-5. There is radiation loss on top of the outer
case to ambient at 40 oC with emissivity equal to 0.8 and view factor is 1.0. Structure boundary
conditions: Fix the end of the lead frame.
Element type 8-node CHEXA
FE results Thermal contours and resulting displacement contours
Thermal Contours Displacement Contours
CHAPTER 46
Introduction
This example demonstrates the chaining of thermal and structural analysis in SOL 400 whereby the first step is a
nonlinear steady state thermal analysis subject to heat flux on the chip, convection and radiation boundary conditions,
and the second step is a nonlinear static analysis using the temperatures from the first step. The thermal stress analysis
chaining has always been available in the linear heat transfer to linear static analysis using param, heatstat,yes in the
SOL 101 run. However, it was not possible previously in Nastran to run a nonlinear heat transfer followed by the static
analysis in a single execution because SOL 101 is a linear heat transfer solution. The only alternative is to run a
nonlinear thermal analysis using SOL 153 and used the resulting temperature punch file as the input thermal load for
your stress analysis. The user can output a punch file by specifying TEMP(PRINT,PUNCH)=all in the first run. This
will create a punch file that consists of temperature for every grids in the model. In the thermal stress run he can use
the TEMP(LOAD)=1 in the case control to use the temperature load in the static run. Chaining of thermal and structural
analyses facilitates design studies based on:
1. changing the materials properties
2. changing the thermal boundary conditions
3. changing structure constraints
whereby the temperatures as well as the corresponding displacements are visualized in a single run.
Modeling Details
Bonded joints are used in the design of a circuit board. A change in temperature due to the equipment operation can
introduce stresses in joined materials of dissimilar thermal expansion coefficient. In this case we have chip heating
due to the applied power, causing thermal gradients in the different materials which, together with the fixed
displacements cause high stresses near the end of the lead frame.
The chip dimension (Figure 46-1) is 3.80 mm by 3.80mm with thickness equal to 0.7 mm. It is mounted on top of
adhesive (paste). The outer case dimension is 14 mm by 14 mm by 3.22 mm.
Chip
Figure 46-1 Chip, Paste, and Lead Frame (Nastran Test File: hybrid_radbc_unit.dat)
CHAPTER 46 923
14 x 14 x 3.22
Figure 46-2 Outer Case
A heat flux is applied to the top surface of the chip with heat flux equal to 0.025 W/(mm2oC). The top surface, bottom
surface and the sides (adjacent to the lead frame where it is fixed) of the case are subjected to convection heat loss.
Heat is convected to the environment at 70oC. The respective heat transfer coefficient for the top, bottom and sides
are 4.05x10-5 W/(mm2oC), 2.026x10-5 W/(mm2oC) and 7.00x10-5 W/(mm2oC). Finally there is a radiation loss on top
of the outer case to ambient environment of 40oC with emissivity equal to 0.8 and view factor is 1.0.
The structural boundary conditions include fixing the end of the lead frame as shown in Figure 46-3.
Figure 46-3 Structural Boundary Conditions
The material properties are shown in Table 46-1.
Table 46-1 Material Properties

Material k W   mm – K  E N   mm 2   (1/C)
Chip 0.147 6.9x104 1.0x10-6
Lead Frame 0.168 5.52x104 1.0x10-5
Case 0.0714 4.5x104 1.0x10-6
Paste 0.02016 2.0x103 1.0x10-5
In running a thermal stress analysis, it is important to check you have specified a thermal coefficient of expansion on
the field 7 on the MAT1 bulk data entry. Otherwise, there will be no thermal expansion in your problem.
CHAPTER 46
It is important that you have a consistent set of units. In this case, the thermal conductivity has units of W/(mm2 K),
and therefore your Young's modulus should be in the unit of N/(mm2). This consistency also applies to the Stefan-
Boltzmann constant also used in the radiation boundary conditions with units of W/(mm2 K).
Solution Highlights
The following are highlights of the Nastran input file necessary to model this problem:
SOL 400
CEND
ECHO = SORT
SUBCASE 1
$LBCSET SUBCASE1
ANALYSIS = NLSTAT
STEP 1
$LBCSET STEP1.1 Thermal
$! Step name : Thermal
ANALYSIS = HSTAT
SPC = 36
LOAD = 37
NLSTEP = 2
TSTRU = 38
FLUX(PRINT)=ALL
STEP 2
$LBCSET STEP1.2 Structural
$! Step name : Structural
SPC = 11
ANALYSIS = NLSTAT
NLSTEP = 3
DISPLACEMENT(SORT1,PRINT,REAL)=ALL
STRESS(SORT1,PRINT,REAL,VONMISES,CORNER)=ALL
BEGIN BULK
PARAM SNORM 20.
PARAM K6ROT 100.
PARAM WTMASS 1.
PARAM LGDISP 1
PARAM TABS 273.15
PARAM POST 1
CHAPTER 46 925
There are two steps in this analysis. The first step is associated with the thermal boundary conditions as indicated with
ANALY=HSTAT. The second step is the thermal stress analysis and the structure boundary condition which the
ANALY=NLSTAT. The TEMP(load)=1 in the second step will allow the Step 2 to pick up the calculated temperature
from step 1 as the thermal load for the calculation of thermal stress. Please note that the param,lgdisp,1 is required
when chaining thermal and structural analyses. The TEMP(INITIAL)=9 points to the TEMPD,9,0.0 in the bulk data
section. This indicates the initial stress free temperature is at zero degrees. The thermal strain is then equal to the
product of the linear coefficient of thermal expansion times the change in temperature. In this example, the thermal
coefficient of expansion is constant, temperature dependency is also readily possible.
Following is the output from the thermal analysis and thermal stress analysis.
1 JUNE 11, 2010 MD NASTRAN 5/21/10 PAGE 896
0 SUBCASE 1 STEP 1
LOAD STEP = 1.00000E+00
T E M P E R A T U R E V E C T O R
POINT ID. TYPE ID VALUE ID+1 VALUE ID+2 VALUE ID+3 VALUE ID+4 VALUE ID+5 VALUE
6320 S 8.666747E+01 8.661747E+01 8.657528E+01 8.654037E+01 8.651233E+01 8.649082E+01
6327 S 8.697186E+01 8.687786E+01 8.679778E+01 8.672908E+01 8.667010E+01 8.661977E+01
6333 S 8.657732E+01 8.654223E+01 8.651408E+01 8.649251E+01 8.647716E+01
1 JUNE 11, 2010 MD NASTRAN 5/21/10 PAGE 9546
0 SUBCASE 1 STEP 2
LOAD STEP = 1.00000E+00
D I S P L A C E M E N T V E C T O R
POINT ID. TYPE T1 T2 T3 R1 R2 R3

99 G -7.002653E-04 -5.229975E-04 1.484855E-03 0.0 0.0 0.0
100 G -8.090116E-04 -5.227823E-04 1.456455E-03 0.0 0.0 0.0
101 G -8.938556E-04 -5.234344E-04 1.425087E-03 0.0 0.0 0.0
102 G -1.037468E-03 -5.227153E-04 1.400765E-03 0.0 0.0 0.0
103 G -1.272494E-03 -4.961967E-04 1.366653E-03 0.0 0.0 0.0
Results
Figure 46-4 Temperature Contours

CHAPTER 46
Figure 46-5 Resulting Displacements (Magnified Displacements for Deformed Plot)
Figure 46-6 von Mises Stress Contour at Five Seconds
Modeling Tips
Always check consistency of units; the basic units are mm, N, and oC(K).
$watt/mm.C
MAT4 1 .147 1. 1.
$ Material Record : mat1.2
MAT4 2 .168 1. 1.
MAT4 3 .0714 1. 1.
MAT4 4 .02016 1. 1.
$
CHAPTER 46 927
MAT1,1,6.9e4,,0.3,,1.0e-6
$ Material 2 : leadframe
MAT1,2,5.52e4,,0.3,,1.0e-5
$ Material 3 : new
MAT1,3,4.5e4,,0.3,,1.0e-6
$ Material 4 : paste
MAT1,4,2.0e3,,0.3,,1.0e-5

This example shows how to use SimXpert for a chained thermal/stress analysis. It will create thermal lbcs for normal
heat flux, normal convection, and radiation to space. It will also create the structural lbc for pinned ends to electrical
leads. The thermal/stress analysis simulation parameter values will be defined. The results can be viewed after the
thermal/stress analysis is performed.
Units
a. For default workspace, select Structures
a
CHAPTER 46
a. Tools: Options
b. Observe the User Options Window
e. Length = mm; Mass = g; Time = s; Temperature = celsius, Force = N
f. Click OK
a b
c e
CHAPTER 46 929
Import FE Model into Separate Parts
a. Import finite element model into separate parts

b. Tools: Options
c. General: input/Output/Nastran.Sturctures
d. Unselect Reduce Parts
e. Click OK
2009 MSC.Software Corporation WS9-8

CHAPTER 46
Import MD Nastran Nodes and Elements File
a. Import MD Nastran nodes and elements file

b. File: Import/Nastran
c. Select nug_46_bdf.bdf
d. Click OK
c
CHAPTER 46 931
MD Nastran Nodes and Elements Model
a. MD Nastran nodes and elements model

b. Model Views: Isometric View
c. Render FE Shaded with Edges
d. View Manipulation: Fill
b c
CHAPTER 46
Material Properties
a. Material properties of the imported model

b. Double click, one at a time, on each of the four material names
c. Observe the thermal-mechanical contents of the material forms
d. Click Cancel
b
CHAPTER 46 933
Material Properties (continued)
a. Material properties of the imported model

c. Click Thermal tab
d. Observe the thermal contents of the material forms
e. Click Cancel
b
d
WS9-12
CHAPTER 46
Element Properties
a. Element properties of the imported model

c. Observe the element property contents of the property forms
d. Click Cancel
b
CHAPTER 46 935
Apply Normal Heat Flux
a. Create applied heat flux. Apply it to the top of the chip

b. Display just the chip by hiding everything else. Right click SOLID_5_nug_46_bdf.bdf;
then select Show Only
c. Observe the chip element only
d. Use Model Views: Isometric or Left
e. LBCs tab: Heat Transfer/Normal Flux
f. For Name, enter Normal Flux_Top_Chip
g. For Entities screen, select the nodes at the top of the chip
h. For Heat Flux, enter 9.025
i. Click OK
f
.
b . g
h
g
CHAPTER 46
Normal Heat Flux Applied to Top of Chip
a. Create applied heat flux. Apply it to the top of the chip

b. Observe the heat flux markers
c. Show the entire model
d. Change the color of the markers to red using the Visualize tab for the LBC
c
b
CHAPTER 46 937
Free Convection Applied to Top of Case
a. Create applied free convection. Apply it to the top of the case

b. Model Views: Left
c. LBCs tab: Heat Transfer/Free Convection
d. For Name, enter Free Convection_Top_Case
e. For Ambient temperature, enter 70
f. For Entities screen, select all the nodes at the top of the case
g. Click Advanced
h. For Convection coefficient, enter 4e-5
i. Click OK
e
f
g
f
CHAPTER 46
Model with Heat Flux and Free Convection on Top
a. Observe the entire model with normal heat flux on the chip and free convection on the top
of the case
a
CHAPTER 46 939
Free Convection Applied to Sides of Case

b. Model Views: Top
c. Hide the lead frame
d. LBCs tab: Heat Transfer/Free Convection
e. For Name, enter Free Convection_Sides_Case
f. For Ambient temperature, enter 70
g. For Entities screen, select all the nodes at two sides of the case
h. Click Advanced
l. For Convection coefficient, enter 7e-5
j. Click OK
f
g
h
g
CHAPTER 46
Model with Heat Flux and Free Convection to Sides
a. Observe the entire model with normal heat flux on the chip and free convection on the top
and two sides of the case
a
CHAPTER 46 941
Free Convection Applied to Bottom of Case

c. LBCs tab: Heat Transfer/Free Convection
d. For Name, enter Free Convection_Bottom_Case
e. For Ambient temperature, enter 70
f. For Entities screen, select all the nodes at the bottom of the case
g. Click Advanced
h. For Convection coefficient, enter 2.02e-5
i. Click OK
e
f
g
f
CHAPTER 46
Model with Heat Flux and Free Convection on Case
a. Observe the entire model with normal heat flux on the chip and free convection on the top,
two sides, and bottom of the case
a
CHAPTER 46 943
Entire Model with Lead Frame
a. Observe the entire model with the lead frame

b. Show the lead frame
a
CHAPTER 46
Radiation to Space Applied to Top of Case
a. Create radiation to space. Apply it to the top of the case

c. LBCs tab: Heat Transfer/Rad to Space
d. For Name, enter Rad to Space_Top_Case
e. For Entities screen, select all the nodes at the top of the case
f. For Ambient temperature, enter 40
g. For Viewfactor, enter 1.0
h. Click Advanced
i. For Absorptivity, enter 1
j. For Emissivity, enter 1
k. For Shell surface option, select Front
l. Click OK
c
d
.
e
f
g
h
i
j
k
e
CHAPTER 46 945
Model with Radiation to Space
a. Observe the entire model with normal heat flux, free convection, and radiation to space
on the case
a
CHAPTER 46
Define Structural LBC
a. Create a structural lbc for the stress analysis

b. LBCs tab: LBC Set/LBC Set
c. For Name, enter Structural
d. Click OK
e. This LBD set will be populated subsequently
d
CHAPTER 46 947
Create Pinned Constraint at Toe of Lead Frame
a. Create a structural pinned lbc constraint at the toe of the lead frame
b. LBCs tab: Constraints/Pin
c. For Name, enter Pinned Constraint_Toe_Lead
d. Use Model Views: Left or Front
e. For Entities screen, select the toe lead frame nodes
f. Click OK
e e
CHAPTER 46
Model with Structural Pinned Constraint
a. Observe the model with structural pinned constraints
a
CHAPTER 46 949
a. Create a SimXpert analysis file for MD Nastran

b. Right click on nug_46_bdf.bdf
c. Select Create new Nastran job
d. For Job Name, enter ch46
e. For Solution TYpe, select SOL400
f. For Solver Input File, select the path
g. Unselect Create Default Layout
h. Click OK
c
d
g
h
CHAPTER 46

b. Right click on Load Cases
c. Select Create Loadcase
d. For Name (Title), enter NewLoadcase
e. For Analysis TYpe, select Nonlinear Steady Heat Trans
f. Click OK
f
CHAPTER 46 951

b. Right click on Load Steps
c. Select Create Loadstep
d. For Name (Title), enter Thermal
e. For Analysis TYpe, select Nonlinear Steady Heat Trans
f. Click OK
b
c
f
CHAPTER 46

b. Right click on Load Steps
c. Select Create Loadstep
d. For Name (Title), enter Structural
e. For Analysis TYpe, select Nonlinear Static
f. Click Use Temperature Set from Preceeding Heat Transfer Step
If Applicable
g. Click OK
f
g
CHAPTER 46 953

b. Right click on Load/Boundaries
c. Select Select Lbc Set
d. For Selected Lbc Set, select DefaultLbcSet
e. Click OK
e
CHAPTER 46

d. For Default Init Temperature, enter 0
e. For Large Displacement, select Large Disp and Follower Force
e
CHAPTER 46 955

b. For Absolute Temperature Scale, select 273.15 Degree Celsius
c. For Stefan Boltzmann Constant, select 5.6699E-14 WATTS/mm2/K4
d. Click Apply (not shown)
e. Click Close (not shown)
b
c
CHAPTER 46

c. Select Output File Properties
d. For Text Output, select Print
e. Click Apply
f. Click Cost
d
c
f
CHAPTER 46 957

c. Select Subcase Steady State Heat Transfer Parameters
d. Click Temperature Error
e. For Temperature Tolerance, enter 0.01
f. Click Load Error
g. For Load Tolerance, enter 1e05
h. Click Apply (not shown)
i. Click Close (not shown)
d
e
f
g
CHAPTER 46

d. Click Create Temperature Output Request
e. Click OK
e
CHAPTER 46 959

c. Select Elements Output Requests
d. Click Create Element Stress Output Request
e. Click OK
e
CHAPTER 46

b. Right click on ch46
c. Select Run
b c
CHAPTER 46 961
Attach SimXpert Results File
a. Attach a SimXpert MD Nastran results file

c. For File path, select ch46.xdb
d. Click OK
d
CHAPTER 46
Display Thermal Results
a. Display temperature results as a fringe plot

b. Results tab: Results/Fringe
c. For Result Cases, select SC1: Non.-linear: 100 % of Load
d. For Result type, select Temperatures
e. Click Update
c d
CHAPTER 46 963
Display Thermal Results (continued)
a. Observe the temperature results
a
CHAPTER 46
Display Structural Results using OP2 File
a. To display the structural results for the R3.2 release of SimXpert, use an .op2 file
c. Select Output File Properties
d. For Binary Output, select OP2
e. Click Apply
f. Click Cost
f
CHAPTER 46 965
Perform a SimXpert Analysis for OP2 Results File
a. Perform a SimXpert analysis using MD Nastran

b. Right click ch46
c. Select Run
c
CHAPTER 46
Detach .xdb Thermal Results File
a. Before attempting to attach the .op2 file, detach the .xdb file
b. File: Detach Results file
c. Select ch46.xdb
d. Select OK
e. Click Yes
b
CHAPTER 46 967
Attach SimXpert Results OP2 File
a. Attach a SimXpert MD Nastran results file

c. For File Path, select ch46.op2
d. Click OK
d
CHAPTER 46
Display Structural Results using OP2 File
a. Display von Mises results as a fringe plot

b. Results tab: Results/Fringe
c. For Result Cases, select SC1: Step 2: Non-linear: 100 % of Load
d. For Result type, select Stress Tensor
e. For Derivation, select von Mises
f. Click Update
f
d e
c
CHAPTER 46 969
Display Structural Results using OP2 File (continued)
a. Observe the von Mises stress results
Input File(s)
File Description
nug_46.dat MD Nastran chaining thermal and thermal stress test file.
Ch46.SimXpert SimXpert data corresponding to above
CHAPTER 46
Video
Thermal Contours Displacement Contours

Chapter 47: Dynamic Impact of a Rigid Sphere on a Woven Fabric
Dynamic Impact of a Rigid

47 Sphere on a Woven Fabric

Summary 972

Introduction 973



Results 980

Modeling Tips 982

Input File(s) 983

Video 983
CHAPTER 47
Summary
Title Chapter 47: Dynamic Impact of a Rigid Sphere on a Woven Fabric
Features Beam-to-beam contact, beam-to-rigid contact, dynamic contact, bilinear Coulomb
friction model, isotropic elastic material, nonlinear property extensions to beam
elements
Geometry R = 1 cm
Material properties E = 10GPa ,  = 1500kg  m

3
Analysis characteristics Nonlinear transient analysis with adaptive time stepping and geometric nonlinearity due
to large displacements and large rotations
Boundary conditions Fabric is clamped on all four sides; sliding, frictional contact between the beam elements
of the fabric and between the fabric and the sphere.
Applied loads The rigid sphere hits the fabric at the center with an initial velocity of 100m  s .
Element type 2-node thin elastic beam element with transverse shear effects
FE results 1. Deformed shape and contact status
2. History plot of z-displacements of the rigid sphere
3. Frictional contact forces
CHAPTER 47 973
Dynamic Impact of a Rigid Sphere on a Woven Fabric
Introduction
This example demonstrates the beam-to-beam contact capabilities of MD Nastran SOL 400. In contrast to the standard
grid-to-segment based contact, beam-to-beam contact is a true segment-to-segment contact, in which the beam
elements are able to touch each other at arbitrary locations mid-way between the grid points of the elements and can
slide along each other, with or without friction. The model consists of a woven fabric which is impacted by a rigid
sphere. The fabric is a plane weave and consists of 2  12 sinusoidally shaped yarns. It is clamped along the four sides
and the yarns are initially in contact at their intersections (see Figure 47-1). The total area of the fabric is 6  6 cm 2 . The
sphere, with a radius of 1cm and a mass density of 981.25 kg  m 3 , hits the fabric with an initial velocity of 100m  s at
the center.
R = 1 cm
Figure 47-1 Geometry of the Fabric with the Beam Elements Displayed with the True Cross Section
Modeling Details
A numerical solution has been obtained with MD Nastran’s SOL 400. The details of the finite element model, contact
simulation, material, load, boundary conditions, and solution procedure are discussed below.
The case control section of the input contains the following options for a nonlinear analysis:
BCONTACT = 0
SUBCASE 1
STEP 1
ANALYSIS=NLTRAN
TSTEPNL = 1
BCONTACT = 1
SPC = 1
IC = 2
The analysis is a nonlinear transient analysis and contains a single subcase with one step. The step has time stepping
procedure and convergence control settings defined via TSTEPNL, contact table and parameters via BCONTACT, fixed
displacements (or single point constraints) via SPC, initial velocity via IC, and the displacements results for
the .f06 (output) file.
CHAPTER 47
PARAM LGDISP 2
The large strain option is activated for the nonlinear property extensions PBEMN1 to the beam elements, via the option:
NLMOPTS LRGSTRN 1
This option selects (among other things) the updated Lagrange formulation of these elements, which is needed for a
proper treatment of the large rotations of the beams.
Element Modeling
The yarns are modelled by 1440 2-node CBEAM elements with an elliptical cross section. The orientation vector v
that is used to construct the local element y- and z-directions of the beams points in the basic Y-direction for the yarns
in the basic X-direction and it points in the basic X-direction for the yarns in the basic Y-direction. The element y-
directions of the beams are thus parallel to the basic XY-plane. The major axis of the elliptical cross section coincides
with the element y-direction and is also parallel to the basic XY-plane. The minor axis coincides with the element z-
direction (see Figure 47-1 and Figure 47-2).
z-elem
b
a
y-elem
Figure 47-2 Elliptical Cross-Section of the Yarns
The semi-major and semi-minor axes of the cross section are a = 1.25mm and b = 0.5mm , so that the area and the
moments of inertia of the cross section read:
–6 2
A = ab = 1.9635  10 m , (47-1)
 3 – 13 4
I 1 = --- a b = 7.6699  10 m , (47-2)
4
 3 – 13 4
I 2 = --- ab = 1.2272  10 m . (47-3)
4
The cross-section properties for the yarns are defined via the PBEAM option as follows:
PBEAM* 1 1 1.963495408E-06 7.669903939E-13
* 1.227184630E-13 0.000000E+00 4.448544285E-13
* 0.000000E+00 0.000000E+00
*
in which the torsional stiffness of the beam elements is taken as J =  I 1 + I 2   2 .

CHAPTER 47 975
The nonlinear extensions to the beam elements can be activated using the PBEMN1 property extension to the regular
PBEAM or PBEAML options in the manner shown below:
PBEMN1 1
LS
This PBEMN1 option selects a thin elastic beam element with transverse shear effects, which is similar to the standard
CBEAM element with only a PBEAM property, except that the former allows nonlinear material behavior, such as
plasticity effects, to be used for the beam elements. In this example, no nonlinear material effects are considered, but
the beam elements with and without the property extension will be compared in the elastic regime.
Modeling Contact
The standard contact algorithm of MD Nastran is based on a grid-to-segment approach. The grid points on the surface
of the touching (or slave) contact body can touch the segments on the surface of the touched (or master) contact body.
Here, the segments of a contact body are, for example, the faces of solid elements, the top and bottom surfaces of shell
elements, and the surface of a rigid contact body. The grid-to-segment algorithm works well for contact between solid,
shell and rigid contact bodies. It even works fine if the slave body consists of beam elements and the master is a solid,
shell or rigid contact body. In that case, the grid points of the beams can touch the segments on the surface of the solid,
shell or rigid body.
If both slave and master body consist of beam elements, then the grid-to-segment approach is not very convenient.
Beams generally touch each other somewhere in the middle of the element and not necessarily at the grid points. The
beam-to-beam contact algorithm of MD Nastran SOL 400 addresses this case. It is a true segment-to-segment contact
algorithm, in which the beam elements of the slave contact body can touch the beam elements of the master contact
body at arbitrary points mid-way between the grids of the elements. Moreover, beam elements which are in contact
can slide along each other with or without friction. The beam-to-beam contact algorithm is activated by the BEAMB
option to BCPARA. It supplements the standard grid-to-segment algorithm, that is, the grid points of a beam contact
body can touch the surface of solid, shell or rigid bodies through the grid-to-segment algorithm and, if beam-to-beam
contact is activated, then the beam elements can also touch beam elements of another (or the same) contact body.
The cross section of the beam elements is taken into account when two beam elements are coming in contact, but the
actual shape of cross-section, defined by PBEAM or PBEAML, for example, is ignored. Instead, a circular cross-section
is assumed for contact. The radius of the contact cross-section is called the “beam contact radius” and must be defined
via the BCBMRAD option. The beam contact radius is defined on a per element basis and may vary from element to
element. However, if a beam element is initially in contact with another beam element and during the analysis slides
off that element to a third beam element with a different contact radius, the sudden jump in the contact radius may lead
to convergence problems. Therefore, the contact surface of the beam elements of a contact body is smoothed by
averaging the beam contact radii of the elements at the common grid points. The resulting contact surface for a
sequence of beam elements is a piecewise conically shaped surface (see Figure 47-3). Note that the beam contact
radius is not used when the grid points of the beam element touch a solid, shell or rigid contact body.
CHAPTER 47
Tr
Be u e
am (s
Co m
oo
nta th
ct ed
Ra )C
diu on
s= ta
0.1 ct
Su
5m rfa
m ce
Be
am
Co
nta
ct
Ra
diu
s=
0.1
0m
m
Figure 47-3 Conically Shaped (Smoothed) Contact Surface Obtained by Averaging the Beam Contact
Radii at the Grids
The present example contains three contact bodies. The first two bodies consist of the beam elements representing the
yarns in the basic X-direction and the beam elements representing the yarns in the basic Y-direction, respectively (see
Figure 47-1). The third contact body is the rigid sphere. The beam-to-beam contact algorithm is used to model contact
between the yarns. The standard grid-to-segment based contact algorithm handles contact between the grid points of
the yarns and the rigid sphere. Friction is included in the analysis, in the form of the force based, bilinear Coulomb
friction model (type 6).
The BCPARA bulk data option defines the number of bodies in contact and contact parameters like the friction type
FTYPE and the beam-to-beam contact flag BEAMB.
BCPARA 0 NBODIES 3 BEAMB 1 FTYPE 6
The deformable contact bodies are defined by the bulk data entries BCBODY and BSURF. The BCBODY option defines
the contact body with its ID, dimension, type of body etc. and BSURF identifies the elements forming the deformable
body.
$ yarns parallel to basic X-direction
BSURF 1 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31
…
$ yarns parallel to basic Y-direction
BSURF 2 61 62 63 64 65 66 67
68 69 70 71 72 73 74 75
76 77 78 79 80 81 82 83
84 85 86 87 88 89 90 91
…
Note that the dimension of the two deformable contact bodies is set to 3D even though the bodies consist of 1D beam
elements. This is because the contact body lives in 3D-space, that is, all grid points have 3 displacement degrees of
freedom.
CHAPTER 47 977
The rigid sphere is defined as a load-controlled rigid contact body using a BCBODY bulk data option. The BCBODY
includes the NURBS surface definition of the sphere. The CONTROL field is set to the ID (1) of the control grid point
associated with the body. In contrast to a position or velocity controlled rigid body, the load-controlled body does not
have a prescribed motion. Instead, the displacement degrees of freedom of the control grid point are the displacements
of the rigid body and can be controlled by single point constraints or loads on the control grid point in the usual way.
In this example, the rigid body will be free to move in the basic Z-direction, while the motion in the other two
directions will be suppressed via single point constraints (see below).
The sphere is initially located in the positive Z-half space of the basic coordinate system, at some distance from the
fabric. During the initial contact search, the body will be moved towards the fabric, such that it just touches the fabric
at start of the first time step. This initial contact body approach is activated by the BCONTACT = 0 case control option.
During the approach, the rigid body is moved in the direction of the velocity defined by the APPROV section of the
BCBODY.
$ rigid sphere
BCBODY* 3 3D RIGID 0
* 0 0.00000000E+00 0 1
* 0 0.00000000E+00 0.00000000E+00 0.00000000E+00
* 1.00000000E+00
* RIGID 1 1sphere
*
* APPROV
* 0.00000000E+00 0.00000000E+00 -1.00000000E-02
* NURBS -5 9 3
* 3 24 48 0
$ control points
* 0.00000000E+00 -1.00000000E-02 1.20000000E-02
…
The rigid body represents a solid sphere with a mass density of 981.25 kg  m 3 , a radius of 1cm and a total mass of just
over four (4) grams. The mass of the sphere can conveniently be assigned to the load-controlled rigid body through a
concentrated mass element (CONM2) at the control grid point of the rigid contact body:
CONM2* 2000 1 4.1102503884E-3
define the touching conditions at the start of the analysis, during the initial contact search and the contact body
approach. The BCTABLE with ID 1 is the main BCTABLE used to define the touching conditions for later time steps
in the analysis, and it is flagged using BCONTACT = 1 in the case control section. The two BCTABLEs are identical
and specify that the yarns parallel to the basic X-direction (contact body 1) can touch the yarns parallel to the basic Y-
direction (contact body 2) and that the grid points of both beam contact bodies can touch the rigid sphere (contact body
3). The BCTABLEs also define the friction coefficient (0.1) for all possible contact combinations.
$ contact table for initial rigid body approach
BCTABLE 0 2
SLAVE 1 0.10 0
0 0 0
MASTERS 2 3
SLAVE 2 0.10 0
0 0 0
MASTERS 3
CHAPTER 47
$
$ main contact table
BCTABLE 1 2
SLAVE 1 0.10 0
0 0 0
MASTERS 2 3
SLAVE 2 0.10 0
0 0 0
MASTERS 3
The definition of the beam contact radii for the beam elements completes the contact set-up. The radii are defined via
the BCBMRAD option. This is a mandatory option if beam-to-beam contact is used. Since the beams generally will
touch each other in the direction of the minor axis of the elliptical cross-section of the beam elements (see
Figure 47-1), the beam contact radius is set equal to the semi-minor axis a for all beam elements in the model.
$ beam contact radius
BCBMRAD 5e-4 ALL
Material Modeling
The isotropic, Hookean elastic material properties of the deformable body are defined using the MAT1 option as
follows:
MAT1* 1 1.000000E+10 0.000000E+00
* 1.500000E+03 0.000000E+00
Young’s modulus is taken to be 10GPa and the mass density is set to 1500 kg  m 3 .

The fabric is clamped at all four sides:
SPC1 1 123456 2 3 4 5 124 184
185 186 187 188 189 485 486 487
488 489 490 491 492 493 494 790
791 792 793 794 795 855 856 857
858 859 860 1156 1157 1158 1159 1160
1161 1162 1163 1164 1165 1461 1462 1463
1464 1465
The rigid sphere is allowed to move only in the basic Z-direction and is given an initial velocity in that direction
towards the fabric. As explained in the preceding section, the motion of the sphere is controlled by the displacements
of the control grid point of the body, so the displacements of the control grid in the basic X- and Y-direction are
suppressed,
SPC1 1 12 1
and the grid is given an initial velocity of 100m  s in the negative basic Z-direction via the TIC option.
TIC 2 1 3 -100.
The latter is selected via the IC case control option in the step.
CHAPTER 47 979
Solution Procedure
The time-stepping procedure to be used is defined through the following TSTEPNL entry:
TSTEPNL 1 400 5e-7 PFNT UV
.100
0
In a dynamic contact analysis in MD Nastran SOL 400, the Generalized-Alpha operator with zero spectral radius is
automatically chosen by the program. The Generalized-Alpha operator uses two parameters NDAMP and NDAMPM in
its formulation. By varying the values of these parameters, the spectral radius can be varied from 0.0 to 1.0. For contact
problems, NDAMP is automatically taken as 0.0 and NDAMPM as 1.0, yielding a spectral radius of zero. This is well-
suited to damp out high frequencies that are normally excited during the impact process. Other features that are
automatically used by the dynamic contact algorithm to avoid high frequency content include the following: There is
no projection of the contacting segment onto the contacted segment. A contacting segment that falls within the distance
tolerance is simply constrained in its current position. Also, if there is penetration detected during the Newton-
Raphson iterations, the maximum penetration is used as a scale-back factor to reduce the time step and restart the
increment with the reduced time step.
The TSTEPNL entry controls the time stepping for the solution. Important parameters of the TSTEPNL entry are as
follows:
• ID (2nd field of entry 1) - The ID is used as a cross-reference in the case control section to identify the
TSTEPNL entry to be used for a particular step.
• NDT, DT, NO (3rd - 5th fields of entry 1) - These parameters control the total simulation time, the initial
analysis time step, the output frequency and the maximum possible time step. The product of NDT and DT
defines the total simulation time - in the current problem, the total simulation time comes out to be 2x10-4 s.
NO is left as blank in the current problem - the default value of NO is 1 - this implies that for this problem,
output is desired at every single step. In addition, the maximum time step cannot exceed NO times DT - which
means that for this problem, the maximum time step cannot exceed 5e-7s. In general, for impact problems,
given that the energy conversion (from kinetic energy to strain energy and vice-versa) occurs during very
small time intervals, it is important to keep tight control over the time-steps.
• METHOD, KSTEP (6th and 7th fields of entry 1) - In the present problem, METHOD is taken as PFNT. FNT or
PFNT is a recommended default for contact problems. PFNT denotes Pure Full Newton Technique wherein
the operator matrix is reformed at every iteration. KSTEP is left as blank in the present problem, which for the
PBEAM + PBEMN1 elements case will default to -1 and for the PBEAM case will default to 1. KSTEP = 1
indicates that the stiffness at the start of the next increment is taken to be the same as the stiffness at the last
iteration of the previous increment while KSTEP = -1 indicates that the stiffness is again updated at the start
of the next increment.
• CONV (9th field of entry 1) and EPSU (2nd field of entry 2) - In the present problem, this is taken as UV. U
indicates displacement control and V indicates the vector component method. The ratio of the maximum
iterative change in the displacement over the maximum incremental change in the displacement is calculated.
Convergence is established when this ratio is < EPSU (0.1 in the present problem). Note that, by default, for V
style checking, separate checks are made over translational degrees of freedom and over rotational degrees of
freedom. If the rotational check is deemed to be unnecessary, use can be made of the MDLPRM,MRCONV,N,
in which N is set to 2 or 3 to by-pass the rotation check.
CHAPTER 47
• MAXBIS (2nd field of entry 3) - controls the maximum number of bisections allowed for each time step. In
the present problem, this number is set to 0. It should be noted that the penetration check and possible time-
step cutback is independent of the value of MAXBIS or DTBIS (the smallest bisection time possible).
• ADJUST (3rd field of entry 3) - controls the time step skip factor for automatic time step adjustment. The
blank field allows ADJUST to default to 5 in the present problem. A non-zero ADJUST value allows the
following additional checks at the end of an increment:
• After the first 2 increments wherein the user-given time-step is used, the analysis is restarted with either the
same time step or possibly a smaller time-step. If the prescribed time step violates frequency-based time
step estimates, then the first 2 increments are repeated with the program-evaluated time step. This restart
allows good accuracy at the start of the analysis if a high initial time step has been prescribed.
• At a frequency of every ADJUST increments, the dominant frequency of the system is estimated and is used
to evaluate the optimal time step. The number of steps (MSTEP) to resolve this dominant period can be
defined by the user (4th field of entry 3). MSTEP defaults to 10 (for mildly non-linear) and 20 (for highly
non-linear). The time step for subsequent increments is reduced by a factor of ½ or ¼ if the optimal time
step is smaller than the current time step. Similarly, the time step for subsequent increments is increased by
a factor of 2 or 4 if the optimal time step is larger than the current time step.
• The final optimal time step for the next increment is based on two algorithms - the frequency algorithm
(which allows both increase and decrease in time steps and is only checked when ADJUST > 0) and the
output algorithm (which is independent of the ADJUST value). After the frequency algorithm comes up
with predicted time step, the time step may again be adjusted such that it satisfies the frequency requirement
and becomes an even sub-multiple (1, 1/2, ¼, etc.) of the required output time. Note that if the time step is
reduced arbitrarily due to a penetration cutback, then the time steps for the next few increments may be
changed unevenly before they become regularized.
Results
Figure 47-4 shows the final deformed shape of the fabric in two views. The contact status is displayed as well. The
latter is 1 at the grid points of beam elements in contact and 0 otherwise and indicates that the yarns are in contact at
the crossings. The displacement in the basic Z-direction of the rigid sphere is plotted as a function of time in
Figure 47-5 for different friction coefficients and for standard beam elements with only a PBEAM property as well as
for beam elements with a PBEMN1 nonlinear extension. The first conclusion that can be drawn from this figure is the
fact that, in the elastic regime, the standard beam element and the beam element with the nonlinear extension give
basically the same results. The difference, of course, is that the beam element with PBEMN1 extension can also be
used with material non-linearities, such as plasticity effects. The second thing that stands out is the effect of the
friction. Due to friction, the yarns more-or-less stick to each other, so there is less sliding and the fabric behaves stiffer
than without friction. This can also be seen from Figure 47-6, in which the final deformed shapes are drawn for the
frictionless case and the case with friction.
CHAPTER 47 981
Figure 47-4 Contact Status (red is touching) and Final Deformed Shape of the Fabric
Standard Beam and Beam

with nonlinear extension for
Friction Coefficient of 0.2

Friction Coefficient of 0.1

no Friction
Figure 47-5 Displacement of the Rigid Sphere in the Basic Z-direction

CHAPTER 47
(a) (b)
Figure 47-6 Deformed Shape Without Friction (a) and With Friction Coefficient of 0.2 (b)
Modeling Tips
The beam-to-beam contact algorithm is a symmetric algorithm, in the sense that the same contact condition is found,
whether beam element A is touching beam element B, or element B is touching element A. This means that the choice
of the slave and master contact bodies on the BCTABLE entry is less important for beam-to-beam contact than it is for
the standard grid-to-segment based contact. For the latter, the proper choice of slave and master may be critical in
certain cases, particularly if the mesh densities of the bodies differ significantly.
In this chapter, no nonlinear material effects such as plasticity, are considered. The standard CBEAM element with only
a PBEAM or PBEAML property supports only elastic material behavior, but if the nonlinear extension PBEMN1 is used
in combination with the PBEAML property, nonlinear material effects can be taken into account. The PBEAML can then
refer to, for example, a MAT1 material with an associated MATEP entry, to include plasticity effects. Note that the shape
of the cross-section must be known to the program to be able to do the cross-section integration, required for nonlinear
material behavior. Therefore, a beam element with a PBEAM property cannot support nonlinear material effects, not
even with a PBEMN1 extension.
In the present problem, the output frequency NO is defined as 1. This causes output at every step and also prevents the
time step from increasing beyond the initial value (5e-7 seconds). In many contact / impact problems, it is beneficial
to have a time step value that does not exceed the user-prescribed initial time step value - however one may not desire
a NO value of 1 always since that may cause very large output file sizes. For such cases, a larger value of NO (NO =
5, 10, etc.) can be prescribed and ADJUST can be set to 0. The ADJUST = 0 setting forces the program to by-pass
the frequency check thereby preventing any time step increase and the output algorithm ensures that the time step is
regularized as quickly as possible and that output is produced whenever the time reaches NO times DT.
CHAPTER 47 983
Input File(s)
File Description
nug_47a.dat MD Nastran input with standard beam element but without friction
nug_47ax.dat MD Nastran input with beam element with nonlinear extension PBEMN1 but without friction
nug_47b.dat MD Nastran input with standard beam element and friction
nug_47bx.dat MD Nastran input with beam element with nonlinear extension PBEMN1 and friction
Video
R = 1 cm

Chapter 48: Shape Memory Analysis of a Stent
Shape Memory Analysis of

48 a Stent

Summary 985

Introduction 986



Results 990

Modeling Tips 991

Input File(s) 992

Reference 992
CHAPTER 48 985
Shape Memory Analysis of a Stent
Summary
Title Chapter 48: Shape Memory Analysis of a Stent
Features Shape memory material model, both mechanical and thermo-mechanical.
Geometry
Material properties AS
E a = E m = 50000Mpa ,  a =  m = 0.33 ,  s = 1631.7Mpa ,
AS SA SA
f = 1931.4Mpa , C a = 8.66 ,  s = 1688.7Mpa ,  f = 1558.8Mpa ,
C m = 6.66
Analysis characteristics Quasi-static analysis using: fixed time stepping and material nonlinearity due to plastic
or thermoelastic behavior
Boundary conditions Tangential displacement is fixed
Applied loads Prescribed displacements at the end nodes of the stent
Element type 8-node solid elements
FE results History plots of stress versus strain (z-components) for a specific node for both the
mechanical and thermo-mechanical model
Stress Strain Relation for Thermo-Mechanical Model Stress Strain Relation for Mechanical and Thermo-Mechanical Model
800 800
T=-150 Vol_mart=100% Therm-Mech T=0

T=-150 Therm-Mech T=30
700 700
T=-70 Thermo-Mech T=50
T=0 Mech T=0
T=10 Mech T=30
600 T=30 600 Mech T=50
T=50
500 500
400
400
Stress ZZ
Stress ZZ
300
300
200
200
100
100
0
0
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018
-100
-100
-200
-200
Strain ZZ
Strain ZZ
CHAPTER 48
Introduction
This problem demonstrates the ability of MD Nastran SOL 400 to model shape memory materials. The most common
materials which have shape memory properties are alloys of nickel and titanium. The shape memory effect is due to a
phase change between martensite and austenite phases in the alloy. These phases have identical chemistry but different
crystalline structures; body-centered-tetragonal for martensite and face-centered-cubic for austenite. Transitioning
between these two phases requires only a small amount of activation energy giving the transformation. A cold
collapsed stent sheathed in a catheter can be deployed in a plaque lined blood vessel by the self-expansion caused by
the change in room to body temperature, with the stent expansion keeping the vessel open and blood flowing properly.
In other words, the stent’s “remembered” shape keeps the blood vessel open.The martensite phase forms when the
material is cooled down, or it can form when stress is applied to a hot material. In this phase extensive deformation
can occur as a thermoelastic martensitic shear mechanism. This deformation can be undone when the material is re-
heated, or at simple unloading of a hot material. When a hot (unstrained) specimen is cooled it is initially in the
austenite phase. Upon cooling between martensite start M s and martensite finish M f temperature the specimen will
change to the martensite phase. Conversely starting from a cold specimen which is in a martensic phase upon heating
between austenite start A s and austenite finish A f temperatures, the specimen will change to the austenite phase.
Different temperature ranges can be distinguished T  M s , M s  T  A f , A f  T  T c , where T c is defined as the
temperature above which the yield strength of the austenite phase is lower than the stress required to induce the
austenite-martensite transformation. Uniaxial tensile tests will show the following responses. For T  M s , the
specimen is completely in the martensite phase. The stress versus strain curves will display a smooth parabolic type
behavior, the deformation is caused by the movement of defects such as twin boundaries and the boundaries between
variants. Unloading occurs nearly elastically and the accumulated deformation caused by the reorientation of the
existing martensite and the transformation of any pre-existing austenite, remains after the specimen is completely
unloaded. Note that the deformation is entirely due to oriented martensite and this would be recoverable upon heating
to temperatures above the ( A s – A f ) range. This would show the shape memory effect. For A f  T  T c , the specimen
shows pseudo elastic behavior. In this range the specimen is in the austenite phase, and stress induced martensite is
formed, along with the associated deformation; upon unloading the martensite is unstable and reverts to austenite
thereby undoing the accumulated deformation. For T  T c when the stress is higher than the yield stress no phase
transition takes place, and the austenite phase will deform plastically which cannot be undone. Figure 48-1 shows
thermo-mechanical response of NiTi, the data is of Miyazaki et al. (1981). In this case, M s = 190K , M f = 128K ,
A s = 188K , and A f = 221K . Two different models are available to simulate the shape memory behavior: a
mechanical model, and a thermo-mechanical model. The thermo-mechanical model describes the complete behavior
as discussed before. The mechanical model only describes the super elastic behavior, and thus can only be used at
higher temperatures. In this example, a stent will be analyzed at different ambient temperatures. Simple loading and
unloading is applied. Stress-strain graphs will show the response at the different ambient temperatures.
CHAPTER 48 987
(a) 77K (b) 153K (c) 164K

300
200
100
0 0 0
400
(d) 224K (e) 232K (f) 241K
Tensile Stress (MPa)
300
200
100
0 0 0
(h) 273K (i) 276K
600 (g) 263K
400
200 Ms = 190K
AF = 221K
0 2 4 0 2 4 0 2 4
Strain (%)
Figure 48-1 Thermal history
Modeling Details
Figure 48-2 shows a representation of the stent which is modeled. At a prescribed ambient temperature the stent is
loaded and unloaded by prescribing the displacement in the z-direction. For modeling reasons isotropic material is
chosen at the end parts of the stent. In this way no local effects will occur where the displacements are prescribed.
Smaller steps are chosen during the unloading part. Small steps are also needed to capture the shape memory behavior.
Figure 48-2 Model of the Stent

CHAPTER 48
The case control section of the input file contains the following options for nonlinear analysis:
ENDC
STRESS(SORT1,plot,REAL,VONMISES,BILIN)=ALL
NLSTRESS(SORT1,plot,REAL,VONMISES,BILIN)=ALL
SUBCASE 1
STEP 1
TITLE=Loading.
ANALYSIS = NLSTATIC
NLPARM = 1
SPC = 2
LOAD = 3
STEP 2
TITLE=Unloading.
ANALYSIS = NLSTATIC
NLPARM = 2
SPC = 4
LOAD = 3
Two STEPS are defined to do the loading and the unloading. It is possible to obtain extra post quantities to examine
the behavior of the shape memory material. To do this, the NLOUT option should be used in combination with the
NLSTRESS option in the following way:
NLSTRESS(NLOUT=10)=ALL
BEGIN BULK
NLOUT 10 VOLFMART CPHSTRN
See the MD Nastran Quick Reference Guide for which output quantities can be selected. In this case the volume
fraction of martensite and the phase transformation strain tensor will be printed in the .f06 file and can be
postprocessed in SIMX..
Large displacement effects are included in the nonlinear analysis using the large strain option:
NLMOPTS LRGS 1
For the mechanical model the multiplicative decomposition formulation is used, this is set automatically for the
elements using this material behavior. It can be activated for the whole model using
NLMOPTS LRGS 2
Element Modeling
contains various options which are especially important to do nonlinear analysis, and are needed to be able to use shape
memory material. The nonlinear extensions to lower-order solid element, CHEXA can be activated by using the
PSLDN1 property option to the regular PSOLID property option in the manner shown below:
PSOLID 1 1 0
PSLDN1 1 1 1 +
+ C4 SOLI L +
CHAPTER 48 989
The PLSLDN1 option allows the element to be used with different kinds of inelastic material models, one being the
shape memory model. This element is also used in both large displacement and large strain analyses and has no
restrictions on the kinematics of deformation unlike the regular CHEXA elements with only PSOLID property entry.
Material Modeling
The material properties for the thermo-mechanical model is given using the MATSMA option. The mechanical model
uses a subset of these properties. The following material properties for the shape memory material are used:
E a = E m = 50000Mpa Young’s modulus
 a =  m = 0.33 Poisson’s ratio

AS
s = 1631.7Mpa Starting tensile stress in austenite-to-martensite transformation
AS
f = 1931.4Mpa Finishing tensile stress in austenite-to-martensite transformation
C a = 8.66 Slope of the stress dependence of austenite

SA
s = 1688.7Mpa Starting tensile stress in martensite-to-austenite transformation
SA
f = 1558.8Mpa Finishing tensile stress in martensite-to-austenite transformation
C m = 6.66 Slope of the stress dependence of martensite
This data corresponds to temperature ranges where the martensite  austenite phase transformations take place at
o o o o o
M s = – 45 C , M f = – 90 C , and A s = 5 C , A f = 20 C , where T 0 = 200 C . The initial volume fraction of
o
martensite is taken M f ra c = 0 for all cases except for the case where T i n it = – 150 C , then the volume fraction of
martensite is M f ra c = 1 .
The corner parts of the stent are modeled using isotropic material properties using the MAT1 option.
MATSMA 1 2 200. 0.008573
50000. 0.33 1.E-05 1.E+20 1631.7 1931.4 8.66
50000. 0.33 1.E-05 1.E+20 1688.7 1558.8 6.66
0. 0. 100. 1.E+20
300. -4. 2. 0. 2.75 0. 3. 1.
MAT1 2 50000. .33 1.

CHAPTER 48

The loading is prescribed by a displacement of 0.008m in the z-direction. For unloading, the displacement goes back
to zero. To improve stability, the nodes are only allowed to move in the radial and axial direction. To obtain this, a
cylindrical coordinate system is applied to each node using the CORD2R option, and the tangential movement is fixed.
The ambient temperature is prescribed on all nodes using the TEMP option, and is activated in the case control file
using TEMPERATURE(INITIAL)=1.
Solution Procedure
NLPARM 1 30 PFNT PV ALL
NLPARM 2 60 PFNT PV ALL
30 Increments are used for the loading and 60 increments for the unloading. Two STEPS are defined to do the loading
and unloading. The analysis is performed at different ambient temperatures to study the material behavior,
respectively.
Results
Analyses are performed for the thermo-mechanical and mechanical models at different temperatures. Figure 48-3
shows the stress-strain relationship for one node (node number 1292) at different ambient temperatures for the thermo-
mechanical model. The z-component of the stress and strain of this node is collected during the loading and unloading
o
and plotted in the figure. At T = – 150 C an analysis is performed with a martensite volume fraction of 0% and an
analysis with a volume fraction of 100%. Note that for 0% martensite no plastic behavior occurs. If no martensite is
present no plastic behavior can occur, and due to the low temperature no martensite can form due to stress. Physically
this would however be an unstable situation, and the martensite volume fraction should be set. This is different for
o
T = – 75 C where martensite will form if none is present, and the material will show plastic behavior. Also note that
o
since these are temperatures below A f = 20 C the plastic deformation cannot be undone. This only happens for the
o o o
case where T = 30 C , and T = 50 C . The simulation for T = 10 C stops prematurely, because it cannot find
convergence. The material behavior can be sensitive during unloading, in this case reducing the timestep further did
not help. What would help to get convergence in this case is to refine the mesh.
Figure 48-4 compares the results of the mechanical model with the thermo-mechanical model. The mechanical model
is designed to simulate the super-elastic behavior, so it should be used for higher temperatures. The results show a
similar response.
CHAPTER 48 991
Modeling Tips
The behavior of the shape memory material can be quite sensitive to the loading. Therefore, the user must use
sufficiently small timesteps, and the mesh should be fine enough. It is best to use the PFNT option of NLPARM for
stability.
Stress Strain Relation for Thermo-Mechanical Model
800
T=-150 Vol_mart=100%
T=-150
700
T=-70
T=0
T=10
600 T=30
T=50
500
400
Stress ZZ
300
200
100
0
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018
-100
-200
Strain ZZ
Figure 48-3 Results for the Thermo-Mechanical Model (Node Number 1292)
Stress Strain Relation for Mechanical and Thermo-Mechanical Model
800
Therm-Mech T=0
Therm-Mech T=30
700
Thermo-Mech T=50
Mech T=0
Mech T=30
600 Mech T=50
500
400
Stress ZZ
300
200
100
0
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018
-100
-200
Strain ZZ
Figure 48-4 Comparison of the Mechanical and Thermo-mechanical Model (Node Number 1292)
CHAPTER 48
Input File(s)
File Description
o
nug_48a.dat Mechanical model with ambient temperature of T = 0 C
o
nug_48b.dat Mechanical model with ambient temperature of T = 30 C
o
nug_48c.dat Mechanical model with ambient temperature of T = 50 C
o
nug_48d.dat Thermo-mechanical model with ambient temperature of T = – 150 C
o
nug_48e.dat Thermo-mechanical model with ambient temperature of T = – 70 C
o
nug_48f.dat Thermo-mechanical model with ambient temperature of T = – 0 C
o
nug_48g.dat Thermo-mechanical model with ambient temperature of T = 10 C
o
nug_48h.dat Thermo-mechanical model with ambient temperature of T = 30 C
o
nug_48i.dat Thermo-mechanical model with ambient temperature of T = 50 C
Reference
Miyazaki, S., Otsuka, K., Suzuki, S. 1981. Transformation pseudoelasticity and deformation behavior in a Ti-
50.6at%Ni alloy. Scripta Metallurgica, 15 (3); 287-292.
Chapter 49: Shell Edge Contact
49 Shell Edge Contact

Summary 994

Introduction 995



Results 1001

Modeling Tips 1003


Input File(s) 1035

Video 1036
CHAPTER 49
Summary
Title Chapter 49: Shell Edge Contact
Features Case 1: In-plane glued edge deformable-deformable contact
Case 2: General shell edge deformable-deformable contact
Geometry Units: m, N, s Units: in, lbf, s
y'
z' x'
y' x'
shell edge contact
z' 10.0 m 5 x 2 x 0.05
z'
y shell edge contact y'
45o x'
z x
10.0 m
Case 1: Modal Analysis of a Thick Rombic Plate Case 2: Diagonal Crushing of Square Tube
Material properties Case 1: E = 200GPa ,  = 0.3 ,  = 8000  kg  m3 

Case 2: E = 2.1x10 11 psi ,  = 0.3
Analysis characteristics Case 1: Modal analysis using in plane glued edge contact
Case 2: Quasi-static analysis using general shell edge contact
Boundary conditions • Case 1:
Upper and lower half of plate are connected using glued edge contact
Fixed conditions at all four edges
In-plane displacements restrained at all nodes except those nodes at the edges of the
glued contact line
• Case 2:
Edge-to-edge contact between two square tubes
Clamped condition at bottom edge of lower tube
Applied loads Case 2: Move top edge of top tube down two inches.
Element type 4-node shell elements
FE results Displacement Contours
Case 1: Mode 1 134.18 Hz
Seam
CHAPTER 49 995
Shell Edge Contact
Introduction
The 3-D contact capability introduced in MD Nastran R2 supported a general node to surface contact in all
translational degrees of freedom. The feature of shell edge to shell edge contact was added in the R3 release of MD
Nastran. The following two cases are considered to demonstrate two different types of shell edge contact.
Case 1: Modal analysis of thick rhombic plate. This is a NAFEMS test case involving evaluation of
natural frequencies of a fully clamped rhombic plate. The plate is divided into two equal
parts in the vertical direction. These two parts are meshed with different mesh densities and
then connected with in-plane glued edge contact.
Case 2: Diagonal crushing of two square tubes. This model demonstrate the capability of general
shell edge contact by crushing the lower square tube with the upper square tube as a result
of the edge contact between the two tubes.
Modeling Details
MD Nastran's solution sequences 103 and 400 are used to demonstrate the shell edge contact capability with the two
test cases. The details of the finite element model, contact simulation, material, load, boundary conditions, and solution
procedure for these two models are discussed below.
Case 1: Two equal parts of rhombic plate are meshed with different mesh densities of 16 x 32 and 20 x 40 CQUAD4
elements. These two parts do not share any node at their common edge as they are connected using in-plane glued edge
contact. The FE model used for the modal analysis (SOL 103) shown in Figure 49-1 and the case control section part
of the input is given below:
SUBCASE 1
METHOD = 1
BCONTACT = 1
SET 10 = 1,2,3,4,5,6
SET 20 = 137,182,213,280,327,593,600,639,703,744
SPC = 2
OMODE = 10
DISP(PLOT,PUNCH)=20
The modal analysis method to be used for extracting the eigenvalues is referenced by the METHOD option, and the
associated contact table to be used is referenced by the BCONTACT option. The SPC option refers to the set of
boundary conditions to be applied and the OMODE option identifies the list of modes to be extracted.
CHAPTER 49
Case 1 Case 2
bsurf-1 bsurf-1
bsurf-2 bsurf-2
Y
Z X
Y X
Z
Figure 49-1 FE Models used for Cases 1 and 2 of Shell Edge Contact
Case 2: The rectangular sides of each square tube are meshed using 5x10 CQUAD4 elements. The FE details for the
SOL 400 analysis of Case 2 are given in Figure 49-1. The case control section part of the input for this model is given
below:
SUBCASE 1
STEP 1
ANALYSIS = NLSTATIC
NLPARM = 1
BCONTACT = 1
SPC = 2
LOAD = 1
BOUTPUT(SORT1,REAL)=ALL
This section defines convergence controls via NLPARM, contact table and parameters via BCONTACT, applied
displacements and loads via SPC and LOAD, and the displacements, stress, and contact results for the output file.
Material Modeling
The isotropic, Hookean elastic material properties of the deformable body for Case 1 are defined in the SI
(international) system using the following MAT1 option:
MAT1 1 2.+11 .3 8000.
The MAT1 entry for Case 2 is given in the same system below:
MAT1 1 2.1+11 .3 1.
CHAPTER 49 997
Shell Edge Contact
Element Modeling
contains various options with special relevance to nonlinear analysis. For the SOL 400 analysis of Case 2, the
nonlinear extensions to the lower-order shell element, CQUAD4, are activated by using the PSHLN1 property option
in conjunction with the regular PSHELL property option in the manner shown below:
PSHELL 1 1 .05 1 1
PSHLN1 1 1
C4 DCT L
For the modal analysis of Case 1, regular CQUAD4 elements are defined using the following PSHELL option.
PSHELL 1 1 1. 1 1
Modeling Contact
The BCPARA option used for the Case 2 model is given below. It defines the number of bodies in contact, together
with the maximum number of contact entities (e.g. patches), nodes on the periphery of the contact surfaces and bias
factor. The general shell edge contact option is enabled by activating the beam to beam contact flag BEAMB.
BIAS .95 BEAMB 1
The definition of the contact bodies consists of the BCBODY Bulk Data Entry which defines the deformable body
including the body ID, dimensionality, type of body, type of contact constraints and friction, etc. while the BSURF
identifies the elements forming a part of the deformable body. The following BCBODY entries are used for cases 1 and
2. Figure 49-2 identifies the contact bodies used in both these models.
BSURF 1 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
…
Figure 49-2 Contact Status Plot for Modal Analysis (Case 1)

CHAPTER 49
To identify the interaction between the contact bodies, the BCTABLE Bulk Data Option is used. BCTABLE with ID 0
is used to define the touching conditions at the start of the analysis. This is a mandatory entry required in SOL 400 for
contact analysis and it is flagged in the case control section through the optional BCONTACT = 0 option. The
BCTABLE with ID 1 is used to define the touching conditions for later increments in the analysis, and it is flagged using
BCONTACT = 1 in the Case Control Section.
A contact option, COPT, in BCTABLE allows more advanced control on how the contact bodies should interact with
each other. COPT is defined using the formula COPT= =A+10*B+1000*C, where the terms A, B, and C are defined as
follows:
A: the outside of the solid elements in the body
= 1: the outside will be in the contact description (DEFAULT)
B (flexible bodies): the outside of the shell elements in the body
= 1: both top and bottom faces will be in the contact description, thickness offset will be included
(DEFAULT)
= 2: only bottom faces will be in the contact description, thickness offset will be included
= 3: only bottom faces will be in the contact description, shell thickness will be ignored
= 4: only top faces will be in the contact description, thickness offset will be included
= 5: only top faces will be in the contact description, shell thickness will be ignored
= 6: both top and bottom faces will be in the contact description, shell thickness will be ignored
Note if B = 6 for both bodies in a contact combination, then nodes that separate from a body, cannot come in contact
again in the current step or in subsequent steps unless a different flag is chosen for one of the bodies.
B (rigid bodies): the rigid surface
= 1: the rigid surface should be in the contact description (DEFAULT)
C (flexible bodies): the edges of the body
= 1: only the beam/bar edges are included in the contact description (DEFAULT)
= 10: only the free and hard shell edges are included in the contact description
= 11: both the beam/bar edges and the free and hard shell edges are included in the contact description
Note that C has no effect if beam-to-beam contact is not switched on (i.e., BEAMB is left as 0 on BCPARA).
The following BCTABLE entries are used for the SOL 103 analysis of Case 1:
BCTABLE 1 1
SLAVE 2 0. 0. 0. 0. 3
0 0 0
FBSH 1.+20 0. 0. 60 60
CHAPTER 49 999
Shell Edge Contact
It is important to note that the in-plane edge glued contact is activated by assigning value 60 for COPTS1 and COPTM1
in the 4th line of the BCTABLE option. The value 60 (B = 6) signifies that the edges are checked for contact without
taking the shell thickness into account. Glued contact is defined by using a value of 3 for IGLUE in the 2nd line of the
BCTABLE option. The value of IGLUE=3 allows moments to be transmitted across the contacting interface. JGLUE=0
in the 3rd field of the 3rd line ensures that glued nodes do not separate during the modal analysis. The contact status
plot for Case 1 is presented in Figure 49-2.
For the SOL 400 analysis of Case 2, the regular shell edge contact option is activated by assigning value of 10010
(B=1 and C=10) for COPTS1 and COPTM1 in the following BCTABLE entries:
BCTABLE 0 1
SLAVE 2 0. 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0. 10010 10010
MASTERS 1
BCTABLE 1 1
SLAVE 2 0. 0. 0. 0. 0
0 0 0
FBSH 1.+20 0. 0. 10010 10010
MASTERS 1
B = 1 in the definition of the COPT flags indicates that the thickness and both faces are considered for contact and
C = 10 indicates that the shell edges are included in the contact description.

For the SOL 103 analysis (Case 1), the boundary conditions are applied through the following SPC cards. No
additional loads are applied for this analysis.
SPCADD 2 1 3
SPC1 1 126 1 THRU 23
SPC1 1 126 25 THRU 44
…
SPC1 3 123456 1 THRU 23
SPC1 3 123456 44 65 86 107 128 149
For the SOL 400 analysis (Case 2), the loading and boundary conditions are applied with the following SPCD and
SPC cards.
SPCADD 2 1 3
FORCE 1 1 0. .57735 .57735 .57735
SPCD 1 1 3 2. 2 3 2.
SPCD 1 3 3 2. 4 3 2.
…
SPC1 1 123456 36
SPC1 1 123456 391 THRU 400
SPC1 3 123456 1 THRU 20
The loading and boundary conditions applied for Cases 1 and 2 are presented in Figure 49-3. For Case 1, the
displacements u x = u y =  z = 0 for all nodes and u z =  x =  y = 0 along all edges as shown in Figure 49-3
CHAPTER 49
except that the in-plane translation boundary condition for are not applied at the interface of the contact bodies so that
they do not conflict with the in-plane glued edge contact constraints.
Case 1
Case 2
Figure 49-3 Loading and Boundary Conditions for Cases 1 and 2
Solution Procedure
The modal analysis SOL 103 procedure for Case 1 is defined with the following EIGRL entry:
EIGRL 1 100. 500. 6 0 MASS
The six frequencies in the range 100 to 600 are requested through the above option.
The SOL 4 00 nonlinear procedure for Case 2 is defined through the following NLPARM entry:
NLPARM 1 10 PFNT 1 PV NO
0.1 0 0
0
The number of increments is provided in the 3rd field of the 1st line of NLPARM option. PFNT represents Pure Full
Newton Raphson technique wherein the stiffness is reformed at every iteration. The value of KSTEP=1 along with
PFNT option indicates that the stiffness matrix will not be updated between the convergence of a load increment and
the start of the next load increment. PV indicates that the maximum vector component of the residuals will be checked
for convergence. NO indicates that intermediate output will not be produced after every increment. The second line of
NLPARM indicates that a tolerance of 0.1 will be used for convergence checking. The nonlinear procedure also
deactivates Quasi-Newton, line search and cutbacks by assigning the value of 0 for MAXQN, MAXLS, and MAXBIS.
CHAPTER 49 1001
Shell Edge Contact
Results
Frequencies of 6 modes extracted from the modal analysis are indicated in the Table 49-1. It clearly shows that the
in-plane glued edge contact can be successfully used to assemble parts with different mesh densities, since the
predictions are within a 2% error. The mode shapes of the six modes for rhombic plate are presented in Figure 49-4.
Table 49-1 Comparison of Frequencies with NAFEMS Results

SOL 103 NAFEMS
Frequency Frequency
Mode Number Hz Hz %Error
1 134.18 133.95 0.17
2 204.37 201.41 1.47
3 270.59 265.81 1.80
4 284.56 282.74 0.64
5 341.13 334.45 2.0
6 385.79 NA -
Mode 1: 134.18 Hz Mode 2: 204.37 Hz
Mode 3: 270.59 Hz Mode 4: 284.56 Hz
Mode 5: 341.13 Hz Mode 6: 385.79 Hz
Figure 49-4 Mode Shapes of Thick Rhombic Plate

CHAPTER 49
Figures 49-5 and 49-6 demonstrate that the shell edge contact is properly detected as the top tube crushes the
lower tube.
Contact Status
50 % Load 100 % Load
Figure 49-5 Contact Status Plots for Square Tubes with Shell Edge Contact
Z-Displacement
Figure 49-6 Original and Deformed Shapes of Square Tubes with Shell Edge Contact
CHAPTER 49 1003
Shell Edge Contact
Modeling Tips
The most important aspect in the shell edge contact analysis is the COPT options introduced in BCTABLE. This gives
more flexibility for users to define the interaction between different contact bodies (solid or shell or beam elements).
Readers can observe the changes in results for the two cases presented in this chapter by removing the COPT options
in BCTABLE.
It is also possible to define the COPT options in the BCPARA and BCBODY options. The options ITOPBM, ITOPSH, and
ITOPSL in the BCPARA option and COPTB in the BCBODY option can be used to define the same COPT option in cases
where BCTABLE is not used in the model with BCONTACT=ALLBODY option. This is recommended as an exercise
for the readers.
It is important to remember that the general shell edge contact capability is activated by setting the beam to beam
contact flag option BEAMB to 1 in BCPARA entry.
CHAPTER 49

This example will take you through Case 2 of the Shell Edge Contact Cases. The required input file can be downloaded
by clicking the nug_49b.dat link in the Input File(s) section of this document.
a. Tools: Options
c. For Basic Units, specify the model units
Length = mm; Mass = kg; Time = s; Temperature = kelvin, Force = N
d. Click OK
b
c
a
d
CHAPTER 49 1005
Shell Edge Contact
Import FE Mesh
a. File
b. Select Import
c. Select Nastran
d. Select nug49_mesh.bdf
e. Click Open
e
CHAPTER 49
Set Model View
a. View
b. Select Model Views
c. Select Front
d. Select Fill
a
d
c
CHAPTER 49 1007
Shell Edge Contact
Define Material

b. Material, select Isotropic
c. Young’s Modulus: enter 2.1e11
d. Poisson’s Ratio: enter 0.3
e. Click OK
a
b
e
CHAPTER 49

b. 2D Properties, select Shell
c. Entities: select PSHELL_nug49_mesh.bdf
d. Material: select Iso_1
e. Part thickness: enter 0.05
f. Click Advanced
a
b
c
d
e
f
c
d
CHAPTER 49 1009
Shell Edge Contact
Define Property Data (continued)
a. Click Non Linear

b. Membrane material, select Iso_1
c. Bending material: select Iso_1
d. Analysis type: select IS
e. Corner elements keyword: select C4
f. Element structural behaviour: select DCT
g. Integration scheme: select L
h. Click OK
b c
a
b
c
d
e
f
g
h
CHAPTER 49
Define Contact Body for Lower Part
a. LBCs tab
b. Contact, select Deformable Body
c. Name: enter body_lower
d. Type: select Deformable Surface
e. Pick Entities: select 200 Elements
f. FEM filters: select Pick Elements
g. Select elements from lower part of shell
h. Click OK
a
b
c
d
e
f
h
CHAPTER 49 1011
Shell Edge Contact
Define Contact Body for Upper Part
a. LBCs tab
b. Contact, select Deformable Body
c. Name: enter body_upper
d. Type: select Deformable Surface
e. Pick Entities: select 200 Elements
f. FEM filters: select Pick Elements
g. Select elements from upper part of shell
h. Click OK
a
b
c
d
e
h
CHAPTER 49
a. LBCs tab
b. Contact, select Table
c. Click Deactivate All
d. Touching Condition for body 1: set to 2
e. Distance Tolerance: enter 0
f. Individual Contact Detection: select Double Sided
g. Individual Slave Option Flag: select 100010
h. Individual Master Option Flag: select 10010
i. Click OK
c
d
g
h
i
CHAPTER 49 1013
Shell Edge Contact
a. LBCs tab
b. Constraints, select Fixed
c. Name: enter fix-z
d. Entities: select nodes at the top edge of body_upper
e. Click OK
a
b
e
CHAPTER 49
Define Boundary Conditions (continued)
a. LBCs tab
b. Constraints, select General
c. Name: enter disp-z
d. Entities: select nodes at the top edge of body_upper
e. Tz: select 2.0
f. Click OK
d
CHAPTER 49 1015
Shell Edge Contact
Analysis Setup
a. Model Browser: right click FileSet (nug49_mesh)

c. Name: enter ch49b
d. Solution Type: select SOL400
e. Solver Input File: select ch49b.bdf
f. Uncheck Create Default Layout
g. Click OK
a
b
d
e
f
g
CHAPTER 49
a. Model Browser: nug49_mesh.bdf, ch49b, right click Load Case

c. Click OK
a
b
c
CHAPTER 49 1017
Shell Edge Contact
a. Model Browser: nug49_mesh.bdf, ch49b, right click Loads/Boundaries

c. Selected BCT Table, select BCTABLE_1
d. Click OK
e. Model Browser: nug49_mesh.bdf, ch49b, right click Load Case
e. Select Create Loadcase
g. Name (Title): enter subcase-1
h. Click OK
e
f
h
CHAPTER 49
a. Model Browser: Load Cases, subcase-1, double click Load Case Control
c. Stiffness Update Method: select PFNT
d. Uncheck Use Default Tolerance Setting
e. Check Load Error, for Load Tolerance: enter 0.01
e. Check Vector Component Method
g. Intermediate Output Control: select Yes
h. Click Apply
i. Click Close
b
c
e
e
h
i
CHAPTER 49 1019
Shell Edge Contact
a. Model Browser: double click Load Case Control

c. Number of Steps: enter 10
d. Click Apply
e. Click Close
b
c
d
e
CHAPTER 49
a. Model Browser, subcase-1, right click Load/Boundaries

c. From Model Browser with control key and mouse, select fix-z and disp-z
d. Click OK
b
c
d
CHAPTER 49 1021
Shell Edge Contact
a. Model Browser, subcase-1, right click Load/Boundaries

b. Select Contact Table
c. Selected BCT Table, select BCTABLE_1
d. Click OK
c
CHAPTER 49
a. Model Browser, subcase-1, right click Output Request

Click OK
e
CHAPTER 49 1023
Shell Edge Contact

Click OK
a
b e
CHAPTER 49

e. Click OK
e
CHAPTER 49 1025
Shell Edge Contact
a. Model Browser, ch49b, double click Solver Control

b. Contact Control Parameters, select Contact Detection Parameters
c. Distance Tolerance, enter 0
d. Bias on Distance Tolerance: enter 0.9
e. Click Activate 3D Beam-Beam Contact
f. Click Apply
g. Click Close
c
d
e
b
f
g
CHAPTER 49
a. Model Browser, ch49b, double click Solver Control

b.Select Output File Properties
c. Nastran DB Options, select Master/DBALL
d. Binary Output: select OP2
e. Click Apply
Click Close (not shown)
b c
e
CHAPTER 49 1027
Shell Edge Contact
Analysis
a. File, click Save

b.Model Browser, right click ch49b
c. Select Run
d. Click Save (after completion of job)
e. File, click New
a
b
e
d
CHAPTER 49
Postprocessing
a. File, click Attach Results

b.File path: select MASTER
c. Attach Options: select Both
d. Click OK
b
c
d
CHAPTER 49 1029
Shell Edge Contact
a. Results tab
b.Results: select Deformation
c. Deformed display scaling: select True
d. Click Plot Data tab
e. Plot attribute, Plot type, Deformation
f. Result Cases, select last increment
g. Result Type, select Displacements, Translational
h. Click Update
a
b
h
e g
f
CHAPTER 49
a. State plot property editor

b.Check Animate
c. Result Cases, select SC1_Step1
d. Result Type, select Displacements, Translational
e. Click Update
e
d
b c
CHAPTER 49 1031
Shell Edge Contact
a. Click Pause icon
a
CHAPTER 49
a. Results tab
b.Results: select Fringe
c. Check Animate
d. Result Cases, select SC1_Step1
e. Result Type, select contactforce,Normal
f. Click Fringe tab
g. Element edge display, Display, select Element edges
h. Click Label attributes tab
i. Select appropriate color for labels
j. Click Update
c e
d
i
j
CHAPTER 49 1033
Shell Edge Contact
CHAPTER 49
a. Click Pause icon

b.Click Plot Data tab
c. Result Type, select Nonlinear Stresses
d. Derivation, select X Component
e. Click Update
e
c
d
CHAPTER 49 1035
Shell Edge Contact
Input File(s)
File Description
nug_49a.dat MD Nastran input for modal analysis of rhombic plate (Case 1)
nug_49b.dat MD Nastran input for diagonal crushing of square tubes (Case 2)
CHAPTER 49
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately nine minutes
Contact Status

Chapter 50: Large Rotation Analysis of a Riveted Lap Joint
Large Rotation Analysis of a

50 Riveted Lap Joint

Summary 1038

Introduction 1039



Results 1046

Modeling Tips 1049

Input File(s) 1049

Video 1049
CHAPTER 50
Summary
Title Chapter 50: Large Rotation Analysis of a Riveted Lap Joint

Features • Use an empirical formula to characterize the rivet stiffness
• Compare point-to-point and patch-to-patch connection types
• Compare CFAST and CWELD patch-to-patch connection types
• Demonstrate large rotation capability of the connector elements
• Hookean, isotropic material
Geometry Units: mm plate length = 160
rivet diameter = 4 plate overlap = 60
rivet pitch = 20 plate thickness = 1.2
1 2 3
Material properties E = 60GPa ,  = 0.3

Analysis characteristics Quasi static analysis using geometric nonlinearity due to large displacements and large
rotations
Boundary conditions • Left end of the lower plate clamped
• Symmetry conditions on the strip edges
Applied loads • Apply a total tensile load of 2400 N to the right end of the upper plate, which is normal
to this edge and parallel to the plate.
• Prior to this loading make a rigid body rotation of 45° about the global y-axis
Element types CQUAD4, CWELD, CFAST, or CBUSH
FE results • Equivalent stress in lap joint model with patch-to-patch CWELD/PWELD
• Load transfer through the rivets

• Deformed shape of the lap joint
CHAPTER 50 1039
Large Rotation Analysis of a Riveted Lap Joint
Introduction
This example demonstrates the modeling and analysis of a lap joint. Two plates are joined using a riveted connection.
Three methods of modeling the rivets are considered, resulting in three different analysis models. In the first two, the
rivets are modeled with bushing elements since their flexibility is given by an empirical expression. They are
connected to the plates using a point-to-point or a patch-to-patch connection. The third method models the rivets with
beam elements and connects them to the plates using patch-to-patch connections.
The first method uses a point-to-point connection and requires the bushing elements to be defined explicitly as
CBUSH elements, together with its grids. The grids of the bushing elements need to coincide with grids of the plate
elements, so this imposes a limitation on how the plates can be meshed, since plate grids must be present at locations
where a connection is desired. Furthermore this method leads to a strongly localized load transfer, especially when the
plate mesh is relatively fine.
The second method uses a patch-to-patch connection, which is modeled using CFAST. This method generates the
bushing elements internally and does not require their grids to be coincident with plate grids. In addition to the bushing
element, a set of constraints is generated internally to connect the bushing grids to the plate elements on each side of
the connection. This eliminates the need of nearly congruent meshes on both sides with grids at the location of the
connection.
The third method uses a patch-to-patch connection, which is modeled using CWELD. This method internally generates
beam elements instead of bushing elements, but the way of connecting the beam grids to the plates is the same as for
CFAST. In this case, the stiffness of the rivets is given by the standard beam stiffness formulations for a beam with
circular cross-section having linear elastic material behavior.
The lap joint has three rows of rivets in the loading direction. For this analysis only, a strip (one rivet pitch of 20 mm
wide) of the lap joint is modeled with proper symmetry boundary conditions along the edges of the strip that are
parallel to the xz-plane.
The shear flexibility (see Vlieger, H., Broek, D., “Residual Strength of Cracked Stiffened Panels, Built-up Sheet
Structure”, Fracture Mechanics of Aircraft Structure, AGARD-AG-176, NATO, London, 1974) is calculated as
follows:
E rv d Er v d 
C s = ----------- 5 + 0.8  -------------
1 mm
- + ---------------
- = 4.3x10 – 5 ---------
E rv d E t E  N
pl pl pu t pu
the axial rivet stiffness is calculated using a simple formula:

EA N
K a = --------------------------------- = 314160 ---------
 L = 2.4mm  mm
These values are entered as the translational stiffness values of the bushing elements. Their rotational stiffness values
are assumed to be zero, but a small torsional stiffness is added to avoid singularities. Beam elements have bending and
torsional stiffness given through their formulation, so there is no risk of singularities
CHAPTER 50
Modeling Details
A numerical solution has been obtained with MD Nastran's solution sequence 400 performing a nonlinear static
analysis. The details of the finite element model, the material, load, and boundary conditions and the solution
procedure are discussed below.
The case control section of the input contains the following options for a nonlinear analysis:
TITLE = MD Nastran job with connectors
SUBTITLE = lap joint with 3 rivets modeled by CWELD
LABEL = riveted lap joint
SET 1 = 337,338,339
SET 2 = 354,365,376,387,398,409,420
SET 3 = 1,12,23,34,45,56,67
SPCFORCES(SORT1,REAL)=3
OLOAD(SORT1,REAL)=2
FORCE(SORT1,REAL,VONMISES,BILIN)=1
SUBCASE 1
TITLE=SC1
$ Tensile load in (1,0,0) direction
STEP 1
ANALYSIS = NLSTATIC
NLPARM = 2
SPC = 2
LOAD = 2
SUBCASE 2
TITLE=SC2
$ Rigid body rotation over -45 degrees about y-axis
STEP 1
ANALYSIS = NLSTATIC
NLPARM = 1
SPC = 2
LOAD = 50
$ Tensile load in (1,0,1) direction
STEP 2
ANALYSIS = NLSTATIC
NLPARM = 2
SPC = 2
LOAD = 20
The analysis contains two subcases essentially analyzing the same type of loading but in different spatial positions.
The first subcase performs one step by applying the tensile load in x-direction. The second subcase performs two steps:
the first step rigidly rotates the lap joint through 45° about the model y-axis and the second step applies the tensile load
in this rotated position. It is clear that the CBUSH or CBEAM forces in the connector elements as well as the stress state
in the plates at the end of each subcase must be the same, thus illustrating the large displacement capability of these
connections. Each step defines a nonlinear static analysis via ANALYSIS, has a definition of convergence control via
NLPARM, fixed displacements (or single point constraints) via SPC, forced displacements (in this case a rotation) and
applied loads via LOAD. The displacement and stress results and other output requests for the .f06 (output) file apply
to both subcases. Some output requests are limited to sets via the use of SET.
CHAPTER 50 1041
The mesh of the lap joint is shown in Figure 50-1 where each plate is meshed by 28 x 6 CQUAD4 elements with 18x6
elements in the overlap region. Figure 50-1 also displays a zoomed in view of one of the rivets in a patch-to-patch
connection and a top view of the overlap region displaying the locations of the auxiliary grids in the connection.
Figure 50-1 Finite Element Mesh of the Lap Joint and Locations of the Rivets
PARAM LGDISP 1
This parameter is needed to account for all geometrically nonlinear effects and is essential even if no large rigid body
rotation is applied prior to loading of the joint.
Plate Element Modeling

The standard options to define the element connectivity, the grid locations and the element properties are used in the
bulk data section of the input:
$ Elements and Element Properties for region : lower_plate
PSHELL 1 1 1.2 1 1
$ Elements in: "lower_plate"
CQUAD4 1 1 1 2 13 12
CQUAD4 2 1 2 3 14 13
...
$ Elements and Element Properties for region : upper_plate
PSHELL 2 1 1.2 1 1
$ Elements in: "upper_plate"
CQUAD4 169 2 211 212 231 230
CQUAD4 170 2 212 213 232 231
CHAPTER 50
...
$ Nodes of the Entire Model
GRID 1 0. 0. 0.
GRID 2 10. 0. 0.
...
Modeling the Connections

The input for the three different methods of the connection is summarized below:
Connection method 1: Explicitly define the CBUSH elements and their properties to make point-to-point connections
between the plates.
$ Connector elements and properties, point-to-point
PBUSH 3 K 3.1416E52.3226E42.3226E4 100.0
CBUSH 337 3 138 271 1.0 0.0 0.0
CBUSH 338 3 144 277 1.0 0.0 0.0
CBUSH 339 3 150 283 1.0 0.0 0.0
Each CBUSH element has two grids entered in fields 4 and 5 and references its properties through the property ID in
field 3. In this application, the local x-direction of the CBUSH element is from the first grid to the second. Fields 6,7,
and 8 define an orientation vector lying in the x-y plane (similar to the CBEAM element). The properties are entered
through PBUSH and only stiffness values are entered in this model. The K in field 3 indicates that the next values are
stiffness values. The first three are the translational stiffness values: first the axial stiffness followed by two shear
stiffness values. The next three are the rotational stiffness values of which only the first (.e., the torsion value) has been
entered so the bending values are zero.
Connection method 2: Define patch-to-patch connections between the plates using bushing elements generated
through CFAST and their properties through PFAST.
$ Connector elements and properties, patch-to-patch
PFAST 3 4. -1 3.1416E52.3226E42.3226E4 100.0
CFAST 337 3 PROP 1 2 421
CFAST 338 3 PROP 1 2 422
CFAST 339 3 PROP 1 2 423
Each CFAST fastener element internally generates a CBUSH element and a number of RBE3 elements to connect the
CBUSH grids through a number of auxiliary grids to the plates. The approximate location of each fastener is entered
as the GS grid in field 7 of the CFAST input. The two plates on each side of the connection are identified through their
property IDs in fields 5 and 6 and the connection method PROP is specified in field 4. Each CFAST references its
properties through a PFAST property ID entered in field 3. The properties of the fastener are defined in the PFAST
input. The fastener diameter is entered in field 3 and is used to compute the locations of the auxiliary grids. Fields 4
and 5 make specifications about the element coordinate system of the internally generated CBUSH element. The
default is a local system with its first direction from the first grid to the second of the CBUSH element. Field 6, 7, and
8 specify the translational stiffness values, where the first is the axial stiffness (in the element local x-direction) and
the next two are the shear stiffness values. The next three fields specify the rotational stiffness values of which only
the first (i.e., the torsion value) has been entered, so the bending values are zero. The GS grids are used to determine
the end node locations of the CBUSH elements. The surface on each side of a connection is identified by a PSHELL
property ID. The nearest projection point of the GS grid on the shell elements sharing this property ID defines a grid
point of the internally generated CBUSH element. Four auxiliary grids are positioned around each projection point
CHAPTER 50 1043
forming a square auxiliary patch. The connection is established by connecting the CBUSH grids to the auxiliary
patches with RBE3 elements and connecting the auxiliary grids to the plate structure with RBE3 elements. Thus each
fastener involves one CBUSH and ten RBE3 elements which are being generated internally. Any unspecified CBUSH
grids and the auxiliary grids are also generated internally.
Connection method 3: Define patch-to-patch connections between the plates using beam elements generated through
CWELD and their properties through PWELD.
$ Connector elements and properties, patch-to-patch

PWELD 3 2 4.
CWELD 337 3 421 PARTPAT
1 2
1 2
1 2
Each CWELD weld element internally generates a CBEAM element and a number of RBE3 elements to connect the
CBEAM grids through a number of auxiliary grids to the plates. The approximate location of each weld is entered as
the GS grid in field 4 of the CWELD input. The two plates on each side of the connection are identified through their
property IDs in fields 12 and 13 (i.e. fields 2 and 3 of the second input line) and the connection method PARTPAT is
specified in field 5. Each CWELD references its properties through a PWELD property ID entered in field 3. The
properties of the weld are defined in the PWELD input. The weld diameter is entered in field 4 and is used to compute
the locations of the auxiliary grids and the cross-section properties of the beam. The weld material data are referenced
through a material ID in field 3. The GS grids are used to determine the end node locations of the CBEAM elements.
The surface on each side of a connection is identified by a PSHELL property ID. The nearest projection point of the
GS grid on the shell elements sharing this property ID defines a grid point of the internally generated CBEAM element.
Four auxiliary grids are positioned around each projection point forming a square auxiliary patch. The connection is
established by connecting the CBEAM grids to the auxiliary patches with RBE3 elements and connecting the auxiliary
grids to the plate structure with RBE3 elements. Thus each weld involves one CBEAM and ten RBE3 elements which
are being generated internally. Any unspecified CBEAM grids and the auxiliary grids are also generated internally.
The internally generated grids get IDs with high offsets w.r.t. the grids entered in the input. In a similar way, internally
generated RBE3s get IDs with high offsets with regard to the elements entered in the input. The internally generated
CBUSH or CBEAM elements retain the element ID of the CFAST or CWELD from which they originate.
Material Modeling
The isotropic, Hookean elastic material properties of the plates and rivets are defined using the following MAT1
options:
$ Material Record : plate_material
MAT1 1 60000. .3
$ Material Record : rivet_material
MAT1 2 60000. .3
The Young's modulus is taken to be 60000 MPa with a Poisson's ratio of 0.3.
CHAPTER 50

The clamped condition for the left side of the lower plate constrains all six degrees of freedom of the grids on this side:
$ Displacement Constraints of Load Set : clamped edges
SPC1 1 123456 1 12 23 34 45 56
67
The symmetry condition for both edges of the strip (lower and upper plate) constrains the y-displacement and the x-
and z-rotations of all grids on these edges:
$ Displacement Constraints of Load Set : symmetry edges
SPC1 3 246 1 THRU 11
SPC1 3 246 67 THRU 77
SPC1 3 246 79 THRU 96
SPC1 3 246 193 THRU 229
SPC1 3 246 325 THRU 343
SPC1 3 246 345 THRU 354
SPC1 3 246 411 THRU 420
The two conditions are combined in SPCADD, so they can be activated simultaneously in the two subcases:
$ Displacement constraints for both subcases
SPCADD 2 1 3
The loading in subcase 1 at the right side of the upper plate is applied as concentrated forces in (1,0,0) direction to the
grids on this side. The corner grids only carry half the force, so the loading represents a uniformly distributed load over
the edge on this side. The FORCE definitions are combined in one LOAD definition with SID 2:
$ Nodal Forces of Load Set : tensile_load in Subcase 1, Step 1
FORCE 3 365 0 400. 1. 0. 0.
FORCE 3 376 0 400. 1. 0. 0.
FORCE 3 387 0 400. 1. 0. 0.
FORCE 3 398 0 400. 1. 0. 0.
FORCE 3 409 0 400. 1. 0. 0.
$ Nodal Forces of Load Set : tensile_load_corner in Subcase 1, Step 1
FORCE 1 354 0 200. 1. 0. 0.
FORCE 1 420 0 200. 1. 0. 0.
$ Loads for Subcase 1:
LOAD 2 1. 1. 1 1. 3
The loading in step 1 of subcase 2 consists of a forced rigid body rotation of 45° about the y-axis of the model. In step
2, this rotated position must be retained but must be combined with the external forces at the right end of the upper
plate. Hence the repetition of the forced rotation with two different SIDs (50 in step 1, and 20 in step 2):
$ Rigid rotation about y-axis in Subcase 2, Step 1
SPCD,50, 1,5,-0.7854
SPCD,50,12,5,-0.7854
SPCD,50,23,5,-0.7854
SPCD,50,34,5,-0.7854
SPCD,50,45,5,-0.7854
SPCD,50,56,5,-0.7854
SPCD,50,67,5,-0.7854
$ Rigid rotation about y-axis in Subcase 2, Step 2
CHAPTER 50 1045
SPCD,20, 1,5,-0.7854
SPCD,20,12,5,-0.7854
SPCD,20,23,5,-0.7854
SPCD,20,34,5,-0.7854
SPCD,20,45,5,-0.7854
SPCD,20,56,5,-0.7854
SPCD,20,67,5,-0.7854
The loading in step 2 of subcase 2 at the right side of the upper plate is applied as concentrated forces in (1,0,1)
direction to the grids on this side. The corner grids only carry half the force, so the loading represents a uniformly
distributed load over the edge on this side. The FORCE definitions are combined in one LOAD definition with SID 20:
$ Nodal Forces of Load Set : tensile_load in Subcase 2, Step 2
FORCE,30,365,0,400.,0.707107,0.0,0.707107
FORCE,30,376,0,400.,0.707107,0.0,0.707107
FORCE,30,387,0,400.,0.707107,0.0,0.707107
FORCE,30,398,0,400.,0.707107,0.0,0.707107
FORCE,30,409,0,400.,0.707107,0.0,0.707107
$ Nodal Forces of Load Set : tensile_load_corner in Subcase 2, Step 2
FORCE,10,354,0,200.,0.707107,0.0,0.707107
FORCE,10,420,0,200.,0.707107,0.0,0.707107
$ Loads for Subcase 2, Step 2:
LOAD 20 1. 1. 10 1. 30
Solution Procedure
NLPARM 1 45 PFNT 25 U NO
,1.0E-4,1.0E-4
NLPARM 2 10 PFNT 25 UP NO
,1.0E-4,1.0E-4
PFNT represents the “Pure” Full Newton Raphson technique where the stiffness is updated every iteration. KSTEP (the
field following PFNT) is left blank and in conjunction with PFNT, it indicates that stiffness needs to be updated between
the end of a load increment and the start of the next load increment. 25 is the maximum number of allowed recycles
for every increment. U indicates that convergence testing will be done based on the displacement error. UP indicates
that convergence testing will be done based on the displacement error and the load equilibrium error. NO indicates that
result output will be produced at the end of every step. The second line of NLPARM indicates that tolerances of 0.0001
will be used for convergence checking.
The number of increments is provided in the 3rd field of the NLPARM option and since no adaptive load stepping has
been activated all increments will be of equal size. The NLPARM with ID = 1 is used to control the rigid body rotation
of 45° in step 1 of subcase 2. Thus, each increment makes a rotation of 1°. Since the motion is a rigid body motion,
the lap joint remains stress free and there are no loads acting on the joint. Therefore, only displacement convergence
testing is done during this phase, no load convergence testing. The NLPARM with ID = 2 is used to control the loading
of the lap joint in step 1 of subcase 1 and step 2 of subcase 2. Thus, the total load is applied in ten equal load increments.
During this phase, the lap joint no longer remains stress free and both displacement and load convergence testing
are activated.
CHAPTER 50
Results
Figure 50-2, Figure 50-3, and Figure 50-4 show the equivalent stress distribution for the three connection methods.
Only the overlap region is shown here because the stresses near the rivets are of primary interest. It can be observed
that the maximum equivalent stress in the point-to-point connection displayed in Figure 50-2 is higher than the
maximum equivalent stress in the patch-to-patch connection shown in Figure 50-3. This is as expected since the patch-
to-patch connection provides a less localized load transfer in the connection. A difference can also be observed
between the CFAST and CWELD connections. With the CFAST connection, there is direct control over the stiffness
values in the different deformation modes of the element (axial, shear, bending and torsion deformations); whereas
with the CWELD, these stiffness values are determined by the underlying beam formulations. There is clearly an
advantage for the CFAST when the stiffness values are known from empirical expressions based on a detailed
investigation of the connections in question. The stress state shown is at the end of step 1 in subcase 1. It can easily be
verified that the stress state at the end of step 2 in subcase 2 is the same, illustrating the proper handling of the large
rotation.
Figure 50-2 Equivalent Stress in Lap Joint Model with Point-to-point CBUSH/PBUSH
CHAPTER 50 1047
Figure 50-3 Equivalent Stress in Lap Joint Model with Patch-to-patch CFAST/PFAST
Figure 50-4 Equivalent Stress in Lap Joint Model with Patch-to-patch CWELD/PWELD
CHAPTER 50
Figure 50-5 Deformed Configuration of the Overlap Region in the Patch-to-patch Connection with
CFAST/PFAST
Table 50-1 lists the shear force in the three rivets for the three connection methods. These results are taken from the
output at the end of step 1 of subcase 1. It can easily be verified that these results at the end of step 2 in subcase 2 are
the same.
Table 50-1 Rivet Shear Forces

FRivet-1 (N) FRivet-2 (N) FRivet-3 (N)
point-to-point:
825 748 825
CBUSH/PBUSH
patch-to-patch:
843 713 843
CFAST/PFAST
patch-to-patch:
919 561 919
CWELD/PWELD
Figure 50-5 shows the deformed configuration of the overlap region in the patch-to-patch connection with CFAST at
the end of step 1 in subcase 1. Clearly an effect of geometrical nonlinearity can be observed as the joint shows the
tendency to align the lower and upper plates in the direction of the external load. The plot shows the deformations in
true scale. It can easily be verified that the other two models display a similar behavior.
CHAPTER 50 1049
Modeling Tips
For geometrically complicated structures, modeling riveted joints (or similar types of spot connections) with point-to-
point connections using CBUSH elements (or other line type elements like CBEAM) can be a labor intensive task since
it requires meshes with hard points at the rivet locations. Making such congruent or near congruent meshes may prove
to be very difficult. Moreover this type of connection creates stress singularities at the point of connection, because of
the highly localized load transfer. CFAST and CWELD connections can eliminate these drawbacks, since more grids
near the point of connection are involved in the load transfer. The patch-to-patch type connection methods involving
auxiliary patches are preferred when the area of the connector element is large with respect to the size of the element
faces to which the connection is made. In general this improves the accuracy of the load transfer between the connected
surfaces.
CFAST has more flexibility to define the mechanical properties, because the stiffness values for the different
deformation modes of the element (i.e. axial, shear, bending, and torsion deformation) can be specified independently.
With CWELD, the stiffness values follow from the underlying beam formulations.
Input File(s)
File Description
nug_50a.dat Input for the point-to-point connection with CBUSH/PBUSH
nug_50b.dat Input for the point-to-point connection with CFAST/PFAST
nug_50c.dat Input for the patch-to-patch connection with CWELD/PWELD
Video
Units: mm plate length = 160

rivet diameter = 4 plate overlap = 60
rivet pitch = 20 plate thickness = 1.2
1 2 3

Chapter 51: Creep of a Tube
51 Creep of a Tube

Summary 1051

Introduction 1052



Results 1055

Modeling Tips 1057

Input File(s) 1057
CHAPTER 51 1051
Creep of a Tube
Summary
Title Chapter 51: Creep of a Tube
Features Real time creep analysis based on adaptive time stepping
• Assumed strain formulation to ease bending locking
Geometry
x-symmetry
0.26 in
y-symmetry
pressure
X
1.9175 in
Z Y
Material properties · 4.51

E = 21.46Mpsi ,  = 0.3 , Norton Creep  c = 4x10 – 24 
Analysis characteristics Quasi static analysis using adaptive time stepping for real time creep with geometric and
material nonlinearity due to large strain and creep
Boundary conditions Only half of the tube is modeled due to symmetry. The symmetric conditions are applied
to suppress rigid body motions
Applied loads • A pressure of 66 psi is applied to the inner surface of the tube in the first load step
within the second. This is to apply pressure load at the beginning of analysis.
• At the second load step, the pressure load remains unchanged for 1000 hours during the
creep step.
Element types CQUAD4 with assumed strain formulation
FE results Creep strain contours on deformed shape
CHAPTER 51
Introduction
This problem demonstrates the ability of the Nastran SOL 400 nonlinear solution sequence to perform a creep analysis
using adaptive time stepping. A stainless steel oval is pressurized at a uniformly high temperature and over time
allowed creep. The details of the finite element model, material and creep properties, load, boundary conditions,
solution procedure, and adaptive creep stepping are discussed below.
Modeling Details
Element Modeling
The FE-mesh of the tube is shown in Figure 51-1. The model consists of 200 4-node plane strain elements and 255
nodes. Only half of the tube is modeled due to symmetry. The symmetric conditions are applied to suppress rigid body
motions.
Y Z
Figure 51-1 The Finite Element Mesh of (half of) the Tube
contains various options which are especially important for nonlinear analysis. The nonlinear extensions to lower-
order plane strain element CQUAD4 can be activated by using the PSHLN2 property option in addition to the regular
PLPLANE property option:
PLPLANE 1 1
PSHLN2 1 1 1 1.0 +
+ C4 PLSTRN L
The PSHLN2 option allows the element to be used in both large displacement and large strain analysis and has no
restrictions on the kinematics of deformation unlike the regular CQUAD4 elements with only the PLPLANE property
entry. These standard elements are more suitable for large rotations but small strain analysis due to their linear
formulation in the co-rotational system. While the difference may be small or even negligible in a truly linear analysis,
nonphysical behavior may be seen in the results from analyses in which the linear assumptions are exceeded and these
options are not used.
Material Modeling
The isotropic, Hookean elastic material along with the creep properties are defined using the following MAT1 and
MATVP options:
MAT1 1 2.14+7 .3
MATVP 1 4.e-24 4.51,
CHAPTER 51 1053
Creep of a Tube
The Young's modulus is taken to be 21.4 Mpsi with a Poisson's ratio of 0.3. The Norton creep model is defined by
· 4.51
 c = 4x10 – 24  .
The standard options to define the element connectivity, the grid locations, and the element properties are used in the
bulk data section of the input:
$ Elements and Element Properties for region : lower_plate
PSHELL 1 1 1.2 1 1
$ Elements in: "lower_plate"
CQUAD4 1 1 1 2 13 12
CQUAD4 2 1 2 3 14 13
...
$ Elements and Element Properties for region : upper_plate
PSHELL 2 1 1.2 1 1
$ Elements in: "upper_plate"
CQUAD4 169 2 211 212 231 230
CQUAD4 170 2 212 213 232 231
...
$ Nodes of the Entire Model
GRID 1 0. 0. 0.
GRID 2 10. 0. 0.
...

The symmetric conditions are defined to suppress the rigid motion motions:
SPCADD 2 1 3
SPC1 1 1 81 91 101 111 121 206
216 226 236 246
SPC1 3 2 16 32 48 64 80
A pressure of 66 psi, acting on the inner surface of the tube, is converted to a set of equivalent nodal forces:
LOAD 3 1. 1. 2
FORCE 2 1 1.573 1. 0. 0.
FORCE 2 2 1.573 1. 0. 0.
...
Solution Procedure
Control Parameters
Creep and large strain effects are included in the nonlinear analysis using the option:
NLMOPTS,CREEP,
,LRGSTRN,1,
,ASSM,ASSUMED
CHAPTER 51
The CREEP field activates the creep analysis. The LRGSTRN field indicates the use of large displacement, large rotation
kinematics and large strains of the element.
Because it is an analysis with isotropic, elastic Hookean material, and the large strain option is on, the assumed strain
formulation is toggled on with the NLMOPTS input. The assumed strain formulation provides better bending behavior
for the continuum elements.
Solution Parameters
SUBCASE 1
STEP 1
ANALYSIS = NLSTATIC
NLSTEP = 1
SPC = 2
LOAD = 3
NLSTRESS(SORT1,REAL,NLOUT=101)=ALL
STEP 2
ANALYSIS = NLSTATIC
NLPSTEP = 2
SPC = 2
LOAD = 3
NLSTRESS(SORT1,REAL,NLOUT=101)=ALL
$
BEGIN BULK
NLOUT 101 CCASTRSS CCRPSTRN EQCRSTRN
$
The analysis contains a single subcase with two steps. The internal pressure of the tube is applied in the first load step
in one increment. The real time in the first load step is second implying (nearly) no creep in the step. In the second
load step, the pressure remains unchanged for seconds to allow the material to creep. Each step has a convergence
control via NLSTEP, single point constraints via SPC, load via FORCE, and the displacements and stress results for
the .f06 (output) file. The NLOUT entry specifies the quantities of output sought via Cauchy stress, creep strain, and
equivalent creep strain.
The nonlinear procedure used is defined through the following NLSTEP entry. In the first load step:
NLSTEP 1 1.00E-09
GENERAL 40 0 10 0
FIXED 1 1
MECH PV 0.00 .100E-010.00 PFNT 0 3
$
The total time of this step is 1.0E-09 with fixed stepping of one increment. The PV method is used for convergence
control with the tolerance as 0.01 and with stiffness update method as PFNT signifying full Newton Raphson procedure
with stiffness being updated during every iteration.
CHAPTER 51 1055
Creep of a Tube
In the second load step, the load stepping is controlled by the following NLSTEP entry:
NLSTEP 2 3.47e6
GENERAL 40 0 10 1
ADAPT 5.0E-06 1.0E-12 .500 6 1.50 -1 999999
0 .200E-03 1 1 1 .100 10.0
MECH PV 0.00 .100 0.00 PFNT -1 3
$
TABSCTL 1
ENCSI 5.00E-011.00E+30
The NLSTEP entry for the second load step has the total time as 3.47e6. Adaptive time stepping is employed in this
step with user-driven criteria using the option CRITID=1 (5th field in second line of the ADAPT entry).
The TABSCTL entry specifies the user criteria for load step control which is referred to by the NLSTEP entry for the
second load step. The data ‘ENCSI’ specifies the type of user criterion to use followed by the first and second target
values (5.00e-1 and 1.00e+30).
Results
Figure 51-2 shows the original and deformed tube at the end of simulation. The x-displacements of node 80, node with
largest displacement, after the two load steps are 5.486e-3 and 2.083e-1 in, respectively (Figure 51-3). About 98%
deformation comes from the material creep.
Figure 51-2 Original and the Deformed Tube

CHAPTER 51
Figure 51-3 X Displacement History for Node 80
A curve of the equivalent von Mises stress with respect to the creep strain at node 80 is given in Figure 51-4. The
significant stress relaxation over time due to creep effects can be observed.
Figure 51-4 Curve of Equivalent Stress via Creep Strain at Node 80

CHAPTER 51 1057
Creep of a Tube
Modeling Tips
There are three critical inputs for a creep analysis.
• Activate creep analysis using NLMOPTS,CREEP,
• Input creep material properties using MATVP (and MATEP for implicit creep).
• Define real time adaptive stepping for creep using NLSTEP.
Input File(s)
File Description
nug_51.dat MD Nastran input
Chapter 52: Hydro-Forming of A Square Pan
Hydro-forming of a
52 Square Pan

Summary 1059

Introduction 1060



Results 1064

Modeling Tips 1065

Input File(s) 1066

Video 1066
CHAPTER 52 1059
Hydro-forming of a Square Pan
Summary
Title Chapter 52: Hydro-forming of a Square Pan
Features Large Deformation Hydro-Forming of Panels under Pressure loading
Geometry
Body 1: hex8 172.346 x 172.346 x 2.54
Body 2: quad4
254 x 254 x 2.54
X Y Units: m, N, s
Material properties E = 69GPa ,  = 0.3 , No hardening Y = 240MPa

Analysis characteristics Quasi-static contact analysis using adaptive time stepping with artificial damping,
geometric, and material nonlinearity due to large strain.
Boundary conditions Only one quarter of the plates are modeled due to symmetry. Symmetric conditions are
applied along with other suitable boundary conditions to suppress rigid body motions.
Applied loads Pressure applied on the upper surfaces of the solid and shell elements, respectively.
Element types CHEXA and CQUAD4 with assumed strain formulation
FE results Displacement contours on formed shape
CHAPTER 52
Introduction
This example demonstrates the ability of the MD Nastran SOL 400 nonlinear solution sequence to hydro-form a square
pan using pressure loads. Such problems exhibit geometrical instability because of the formation of wrinkles during
the forming process, posing substantial challenges for the analysis. These challenges require a robust algorithm to steer
through convergence process during the forming. Artificial damping, demonstrated herein, shows its capability to deal
with such wrinkling instabilities.
Modeling Details
A numerical solution has been obtained with MD Nastran's SOL 400 for a 3-D representation of the structure with
deformable-to-deformable contact between the two panels. The details of finite element model, contact simulation,
material, load, boundary conditions, and solution procedure are discussed below.
SOL 400
CEND
SUBCASE 1
STEP 1
ANALYSIS = NLSTATIC
NLSTEP = 1
BCONTACT = 1
SPC = 2
LOAD = 2
DISPLACEMENT(SORT1,PLOT,REAL)=ALL
NLSTRESS(SORT1,PLOT,REAL)=ALL
BOUTPUT(SORT1,PLOT,REAL)=ALL
The input data shown above defines the analysis type and loading sequences. ANALYSIS = NLSTATIC means that the
type of this SOL 400 analysis step is nonlinear quasi-static. One load step defined in the subcase. This step comprises
the pressure load application onto the surfaces of the solid and shell elements. The control parameters for the load
stepping and iterative procedures are defined by the bulk data option NLSTEP. The contact table and contact
parameters are given via BCONTACT. The displacement or rotational constraints are applied via SPC1. The pressure
loads are applied via two PLOAD4 entries, one for the shell surface (body2) and the other for the upper surface of the
solid body (body1).
The large strain and geometrical nonlinear characteristics are activated by the NLMOPTS/LRGS and LGDISP options,
respectively:
NLMOPTS LRGS 1
PARAM LGDISP 1
where the NLMOPTS entry field LRGS =1 triggers the large strain formulation and provides better behavior when
plasticity is present. LGDISP =1 indicates the use of large displacement, large rotation kinematics for the element.
The boundary conditions and pressure loads applied onto the two panels are shown in Figure 52-1. Due to symmetry,
only one quarter of the structure is shown.
CHAPTER 52 1061
X Y
Figure 52-1 Distributed Loads Applied on the Panel Surfaces
Element Modeling
contains various options which are especially important for nonlinear analysis. The nonlinear extensions to the lower-
order solid element, CHEXA can be activated by using the PSLDN1 property option in addition to the regular PSOLID
property option:
PSOLID 1 1 0
PSLDN1 1 1
C8 SOLID LRIH
The PLSLDN1 option allows the element to be used in both large displacement and large strain analysis and has no
restrictions on the kinematics of deformation unlike the regular CHEXA elements with only the PSOLID property
entry. The 8-node hexahedral element with the reduced integration scheme is very suitable for problem with severe
bending deformation.
The other panel is modeled with shell elements, and activated via two bulk data cards: PSHELL and PSHLN1. PSHELL
is the entry to define the regular shell element in Nastran. PSHLN1 is an extra entry for user to select the advanced
shell element which is more suitable for large strain and rotations:
PSHELL 2 1 2.54 1 1
PSHLN1 2
where 2.54 mm is the thickness of the shell elements.
Modeling Contact
In this example, contact occurs between the solid and shell panels between which glued contact is defined. Therefore
no friction is considered.
CHAPTER 52
define the touching conditions at the start of the analysis. This is a mandatory option required in SOL 400 for contact
analysis and it is flagged in the case control section through the optional BCONTACT = 0 entry. The BCTABLE with
ID 1 is used to define touching conditions for later increments in the analysis, and is flagged using BCONTACT = 1
in the case control section. Also, the SLAVE-MASTER combination specifies that the corresponding body is a slave
or master body. This, in literature, is variously referred to as either contacting body nodes or tied nodes (imagining the
situation of multi-point constraints). The nodes belonging to body 1 are said to belong to the master body, similarly
referred to as the contacted body nodes or the retained nodes.
BCTABLE 0 1
SLAVE 2 0. 0. 0. 0. 3
1 0 0
FBSH 1.+20 .9 0.
MASTERS 1
BCTABLE 1 1
SLAVE 2 0. 0. 0. 0. 3
1 0 0
FBSH 1.+20 .9 0.
MASTERS 1
The BCBODY entry defines the deformable body including the body ID, dimensionality, type of body, type of contact
constraints and friction, while the BSURF entry identifies the elements forming each part of the deformable bodies:
$ Contact Body: DeformBody_SHELL
BSURF 2 1 THRU 525
$ Contact Body: DeformBody_SOLID

BSURF 3 526 THRU 925
Material Modeling
The isotropic, Hookean elastic material properties of the deformable body are defined using the following MAT1
option as follows:
MAT1 1 69000. .3
The Young's modulus is taken to be 69 GPa with a Poisson's ratio of 0.3. Perfect plasticity is assumed with yield a
stress of 240 MPa.

Symmetry conditions are applied to the nodes along the X-axis and Y-axis. To remove rigid body motion, the boundary
nodes of the shell panel are constrained in the Z-axis.
$SXNAME LOADCOL 3 SPC1 "CONSTRAIN-UZ"
SPC1 3 3 1 THRU 26
SPC1 3 3 27 53 79 105 131 157+
CHAPTER 52 1063
+ 183 209 235 261 287 313 339 365+
$SXNAME LOADCOL 4 SPC1 "SYMM-SHELL-UX"

SPC1 4 156 26 52 78 104 130 156+
+ 182 208 234 260 286 312 338 364+
$SXNAME LOADCOL 5 SPC1 "SYMM-SHELL-UY"

SPC1 5 246 561 THRU 576
$SXNAME LOADCOL 6 SPC1 "SYMM-SOLID-UX"

SPC1 6 1 1455 THRU 1458
$SXNAME LOADCOL 7 SPC1 "SYMM-SOLID-UY"

SPC1 7 2 1377 1378 1381 1382 1385 1386+
+ 1389 1390 1393 1394 1397 1398 1401 1402+
SPCADD 12 3 4 5 6 7
The loading involves the application of pressure on the upper surfaces of the two bodies:
$SXNAME LOADCOL 1 PLOAD4 "PRESSURE-SHELL"
PLOAD4 1 1 -0.4
PLOAD4 1 2 -0.4
PLOAD4 1 3 -0.4
$SXNAME LOADCOL 2 PLOAD4 "PRESSURE-SOLID"

PLOAD4 2 526 0.4 578 586
PLOAD4 2 527 0.4 580 588
PLOAD4 2 528 0.4 584 592
LOAD 13 1. 1. 1 1. 2
Load ID 1 represents the distributed load applied to the solid panel. Load ID 3 is the pressure applied on the shell panel.
As shown above, the pressure applied is 0.4 MPa.
Solution Procedure
Adaptive time-stepping defined through the NLSTEP card is used in the example. Two flavors of adaptive stepping
are demonstrated: (a) a scheme using artificial damping in nug_52a and (b) a scheme without damping in nug_52b.
The step sequence control card (NLSTEP) in nug_52a is shown below:
NLSTEP 1 1. +
+ GENERAL 25 10 +
+ ADAPT 1.00E-2 1.E-5 0.50 1.2 -1 999999 +
+ 4 0.0002 +
+ MECH UPV 0.1 0.1 PFNT -1
Salient parameters defined through the above cards are as follows:
Total Time (2nd field on 1st card): 1.0
Max. Number of recycles (1st field on GENERAL card): 25
CHAPTER 52
Initial time step (1st field of 1st line of ADAPT card): 0.01
Desired Number of Recycles (4th field of 1st line of ADAPT card): blank - defaults to 4
Scale Factor (5th field of 1st line of ADAPT card): 1.2
Output Control (6th field of 1st line of ADAPT card): -1 (only last increment is output)
Damping flag (1st field of 2nd line of ADAPT card): 4
Convergence control flag (1st field of MECH card): UPV (vector components of displacements and residuals)
Convergence tolerances (2nd and 3rd fields of MECH card): 0.1
The parameters in nug_52b are identical with the exception of the damping flag - it is set to 0.
The damping algorithm in nug_52a only uses the initial time step information of the ADAPT card. It does not use the
desired number of recycles or the scale factor. The time stepping algorithm (increase of 1.5 or cutback of 0.5) is based
on a comparison of the incremental strain energy and the estimated damping energy.
The recycle based algorithm in nug_52b is based on a comparison of the actual number of recycles taken for
convergence to the desired number of recycles. The time step is allowed to increase if the number of actual Newton-
Raphson recycles < the desired number.
Results
Figure 52-2 shows the sequence of analysis with a close-up view of the square pan when damping is used for the
analysis. It can be seen that a wrinkle develops with the increase of applied pressure. For comparison purposes, another
job which does not use damping is also shown in Figure 52-3. It can be seen that the wrinkles develop more slowly
with loading. Without damping applied, the wrinkling occurs a little earlier and the analysis is extremely unstable. That
is why significantly more iterations are needed at the wrinkling stage. In some cases, this may cause an unsuccessful
analysis if the control parameters are not properly set.
CHAPTER 52 1065
Figure 52-2 Displacement Contours at Various Stages of Square Pan Forming - with Damping
Figure 52-3 Displacement Contours at Various Stages of Square Pan Forming - without Damping
Modeling Tips
Artificial damping typically acts as an extra strategy for analyses involving wrinkling and snap-through (softening of
materials) for both uniform and adaptive stepping strategies. Furthermore, for the recycle based approach, proper setup
of the adaptive time stepping control parameters can help when conducting nonlinear analysis. In general, the most
significant parameters that influence the number of increments / number of iterations are the initial time step and the
desired number of recycles. Some broad guidelines are as follows: For linear problems, the initial time step ratio can
be set as 1.0 and the desired number of recycles can be set as 4. For mildly nonlinear problems, the initial time step
CHAPTER 52
ratio can be set as 0.1 and the desired number of recycles can be set between 6 - 8. For highly nonlinear problems, the
initial time step ratio can be set as 0.01 and the desired number of recycles can be set between 8 - 10.
Contact analyses, especially with friction, often demonstrate strong nonlinearities due to the frequent touching of a
node or the sliding of a node from its contacting surface. Adding artificial damping will also help improve the stability
and the efficiency of such contact analyses. It is to be noted that in a glued contact between solid and shell elements,
the contact body comprising of the shell elements are to be modeled as the slave.
The default values for the adaptive time stepping scheme in Sol 400 represent a serious attempt to ensure successful
analysis completion in the general case. However, each problem will be helped by an intelligent choice of control
parameters. Generally, to start with a small time step is always better than a large initial time step, even though the cut
back will reduce the time step, it will cost more time completing the analysis. Also, it is recommended adjusting the
desired number of iterations accordingly if the convergence criteria change. For example, a tight convergence
tolerance requires more iterations than a loose tolerance. In the case of contact, a higher number of desired iterations
can speed up the analysis without scarifying accuracy.
For comparison purposes, both input decks are included with this demonstration.
Input File(s)
File Description
nug_52a.dat MD Nastran input for adaptive time stepping with artificial damping
nug_52b.dat MD Nastran input for adaptive time stepping without artificial damping
Video

Chapter 53: Chained Analysis: Fan Blade Out with Rotor Dynamics
Chained Analysis: Fan Blade

53 Out with Rotor Dynamics

Summary 1068

Introduction 1069


Results 1081

Input File(s) 1086

Video 1087
CHAPTER 53
Summary
Title Chapter 53: Chained Analysis - Fan Blade Out to Rotor Dynamics
Features • Chained implicit -> explicit -> implicit analyses
• Generation of FBO contact forces for loading on blade tips and case
• Transferring the unbalanced geometry of explicit FBO to implicit RD analysis
• Fusing the bearing using a force failure criterion
Geometry Implicit Prestess Explicit FBO Implicit RD
Fixed
Mount
Bearings
Material properties • Blade & Rotor (Titanium): Elastic- Plastic Material

 = 4.466 g/cm3,  = 0.35, Yield Stress = 1009 MPa
Tangent modulus = 731 MPa, Young’s modulus = 117 GPa
Plastic strain failure limit 0.2
• Case (various materials): Elastic-Plastic Material
Analysis characteristics Nonlinear implicit static, Transient explicit dynamic, and nonlinear implicit transient
analyses
Boundary conditions • Prestress Implicit: Fixed at the bearing locations
• FBO Explicit & RD Implicit: Fixed boundary at the mount
Applied loads Prestress Fan at 4500 rpm, Release blade, Rotor dynamics unbalance
Element types 1-node concentrated mass, 2-node beam, 4-node shell, and 8-node solid elements
FE results Unbalanced loading due to blade out
0.0008
0.0006
0.0004
0.0002
Z-location
0
-0.0008 -0.0006 -0.0004 -0.0002 0 0.0002 0.0004 0.0006 0.0008
-0.0002
-0.0004
-0.0006
-0.0008
Y-location
CHAPTER 53 1069
Chained Analysis: Fan Blade Out with Rotor Dynamics
Introduction
This example presents a multi-disciplinary, integrated implicit-explicit-implicit analysis process tailored for more
accurate and efficient simulations of aero engine fan blade-out events using MD Nastran. A Fan Blade Out (FBO)
event can be extremely nonlinear because of the heavy wide chord fan blades incorporated in the new generation of
high by-pass ratio jet engines. These new wide chord blades are used to meet airframe manufacturers’ demand for
higher thrust engines with improved performance and optimum weight. Airframe and engine manufacturers use
computerized analysis procedures to support the design of both the propulsion system and adjacent wing structures.
However, manufacturers, typically, do not share finite element models and, traditionally, construct a new model to suit
their analysis objective. For example, typical FBO models are very detailed and can exceed two or three million
elements whereby a rotor dynamics models is much coarser and can be under 50,000 elements. So the challenge
becomes how to transfer the FBO loads computed by the SOL 700 explicit solver (based on a very fine meshed model)
to a coarse model for rotor dynamics simulation in the SOL 400, all within one common modeling environment.
This example demonstrates the automated, multi-disciplinary simulation capability in MD Nastran to streamline the
FBO event simulation facilitated by SOL 700 and SOL 400 which normally consists of the following separate steps:
1. Pre-stress fan blade using conditions at the maximum rotating speed and including static loads such as gravity
with an implicit solution (SOL 700 implicit solver or SOL 400).
2. An explicit solution for few cycles with release of a fan blade to simulate: damage to the trailing fan blade(s);
fan rubs with the engine case; breakage or damage to the inlet or engine containment case; twisting and bending
of the FAN shaft and/or other rotating shafts.
3. An implicit solution to continue the analysis more rapidly and reach the steady state “windmilling” speed. This
is done by including realistic input forcing functions and damage incurred during the explicit solution.
Techniques to reduce the loads for application to a coarser model are introduced to preserve the solution
integrity.
4. This integrated MD Nastran SOL 700 explicit and SOL 400 implicit solution with the Nastran rotor dynamics
capability is used to predict the engine unbalance and to extract the whirling diagrams and critical tolerances
(Figure 53-1). This allows the engine manufacturers to share results of the explicit phase with other
manufacturers of modern airframe/propulsion system components seamlessly and without compromising
design secrets, thus achieving higher accuracy and improved productivity with fewer bottlenecks.
CHAPTER 53
Prestress – Implicit simulation

Choice of MD Nastran SOL 106/400 or 700 (Implicit)
Initial Condition for

explicit run
FBO/FOD – Explicit simulation

MD Nastran SOL 700 (bird strike)
Simulate damage and extract

mass, inertia and center of gravity
for rotordynamics unbalance
MD Nastran SOL400 RD (Unbalance loading) 0.0008
0.0006
0.0004
0.0002
Z-location
0
-0.0008 -0.0006 -0.0004 -0.0002 0 0.0002 0.0004 0.0006 0.0008
-0.0002
-0.0004
Extract final displacement after stabilization -0.0006
-0.0008
Y-location
Figure 53-1 Chained FBO-RD Analysis
The MD Nastran MASTER database is tailored to include only the FBO loads and other relevant information required
for rotor dynamic simulation without compromising the confidentiality of model geometry and modeling details. The
MASTER database can be shared between MD Nastran users from different companies and organizations for follow-
up analysis. For example, after the FBO analysis simulated by SOL 700, the MASTER database can be sent to airframe
manufacturers to use the loads in their rotor dynamics analysis facilitated by SOL 400. The following steps are
completely automated in SOL 400 rotor dynamics simulation:
1. Read the MASTER database generated by SOL 700 to use the FBO loads as a pre-condition to RD analysis.
2. Map the loads onto the coarse finite element model in RD simulation. An advanced search technology is
implemented in SOL 400 to identify the closest element to a given load. The load is then distributed over the
corner nodes of the element.
3. Synchronization of the explicit and implicit timesteps, The explicit timestep is much smaller than the implicit
timestep, so the timesteps need to be “synched up” when the analysis is switched from FBO analysis to RD
simulation. The synchronization is based on Fast Fourier Transformation (see Timestep Control on SOL 400
for details)
CHAPTER 53 1071
It is believed that this process can result in much higher levels of accuracy and dramatically reduce the cost of analysis
and design of the propulsion system and wing. The example problem that is used in this example is a representative
finite element model of an engine mounted on a wing.
SOL 700 Entries Included

SOL 700
TSTEPNL
DYPARAM,LSDYNA,DATABASE,SSSTATM
DBEXSSS
DYPARAM,LSDYNA,DATABASE,NCFORC
CSPOT
BLDOUT
SOL400
ANALYSIS=NLTRAN
ROTORG
RSPINT
CONM2
UNBALNC
CBUSH
PBUSH
PBUSHT
Loadings Types
The dynamic loads on the engine after the FBO can be classified under two categories:
a. Large amplitude transient impact loads generated inside the engine due to the released blade hitting the
containment and contact with the trailing blade(s).
b. The so-called “Seizure Torque” being applied on the fan rotor due to unbalance caused by the missing
blade. The seizure torque is a result of contact between the tip of the blades and the fan case (rubbing). If
the torque is large enough it could stall the engine causing a “seizure” (see below for more details).
The transient impact loadings are calculated and stored by SOL 700. Only three types of loadings are taken into
account.
1. Impact loads between the broken blade and the case
2. Rubbing loads on fan case
3. Rubbing loads on blade tips
Additionally, this release (MDR3) is limited to the analysis of only one released blade and assumes that there are no
other failed trailing blades. In other words, only the released blade is considered for unbalance. The other types of
loads and unbalances, such as impact loads between the broken blade and remaining blades unbalance generated by
breaking some of the remaining blades due to the impact between the broken and remaining blades and so on, will be
considered in future releases of MD Nastran.
The impact forces contain both a normal component (to the fan case) and tangential components which change with
time as the blade hits various parts of the containment ring. The released blade, pre-determined in the analysis and in
testing, is the only blade which is actually released at the hub and impacts the fan case. In many cases, the trailing
blade will impact the root of the released blade, causing the trailing blade to fail and break at a different location. As
CHAPTER 53
a result, one or more trailing blades will behave like shrapnel and will contribute significantly to the impact loads.
These forces and their contact locations are stored in SOL 700 “binout” as well as the MD Nastran database MASTER
file in the Nastran basic coordinate system. The entry BLDOUT in MD Nastran defines blade out force output
information and mapping criteria for a combined SOL 700 – SOL 400 Blade-out analysis (used both in the SOL 700
and subsequent SOL 400 analyses).
During the fan blade out event, as the unbalance forces  M u r 2  on the rotor make it to go off-center and the running
tip-clearance between the rotating blades and the stator structure is eliminated, the tips of the blades will rub against
the enclosure. The rubbing loads are distinguished between those that are applied on the fan case and those that are
located on the blade tips. There are equal and opposite sets of forces on the containment ring and on the blade tips.
The primary difference is that the rubbing loads on the containment ring can be stationary whereas the rubbing loads
on the blade tips are varying as the blades rotate and at any given instant, different blades on the rotor continue to
contact the stator structure in the same location. The rub loads  F rub  have radial and tangential components, with
radial component  F r  acting along the span of the blade and tangential component  F t  opposite to the direction of
motion of the rotor. Using the relationships for tip Coulomb damping with the coefficient of friction  , the magnitude
of the tangential component is computed as: F t = F r . Since the torque on the rotor produced by the frictional force
 Ft  always opposes the motion, its tendency would invariably be to slow-down the spin of the rotor-shaft. These
loads, if severe enough, may even stop it, a phenomenon called “seizure torque”. Thus, rubbing forces have normal
and tangential components  F r  and  F t  , respectively at the points of contact. Similar to impact forces, SOL 700
will compute the contact location and magnitude of the rubbing loads and store them into “binout” as well as the
“MASTER” file. The loads that have zero magnitude are filtered out and are not written to the database to save time
and disk space.
The unbalance force  M u r 2  , which results from the mass  M u  of the missing blade material, occurs whether the
remaining unbroken blades contact the containment ring or not. This force is output by SOL 700 in the Nastran basic
coordinate system and saved in the SOL 700 “binout” file. In addition, the mass of the broken blade will be saved for
use in the subsequent creation of UNBALNC entries for the SOL 400 rotor dynamics analysis.
Time Step Control in SOL 400

The contact forces computed by SOL 700 are stored and transferred to SOL 400. These forcing functions have very
small time intervals and they may unnecessarily increase the analysis time. In order to increase the timestep and
synchronize the explicit and implicit timesteps, a technique based on Fast Fourier Transformation (FFT) and Inverse
Fast Fourier Transformation (IFFT) is used to eliminate the high frequencies of the data.
First, the time histories from SOL 700 are changed by FFT from time domain to frequency domain. Next, the
frequency domain histories are processed by a low pass filter in which the low pass frequency can be selected by the
user. Finally, the histories are changed by Inverse FFT from frequency domain back to time domain.
CHAPTER 53 1073
Load Mapping Scheme
Distinguishing Rubbing & Impact

using different contac t definitions
Results are stored in binary

output file (binout) and MASTER
Requirement in SOL 700
Generate Rubbing force & impact

force entries in the different files
Pass to SOL 400 via “MASTER”

Read loads in SOL 400 by
DBLOCATE = *MASTER
Modeling Details
A simplified generic engine model was provided by Boeing for the purpose of this study (Figure 53-2). The engine
model was modified and enhanced by MSC to include realistic fan blades, rotor, three bearings (Figures 53-3 and
53-4)and other components. Typically, full FBO models can easily have millions of elements and degrees of freedom
to represent a realistic jet engine. However, for the purpose of this study, even though the FBO model was constructed
with a much finer mesh density than the rotor dynamics model, it is not as elaborate as the full engine models that are
used by manufacturers in their explicit simulation. The FBO model has 8864 nodes and 8256 shell elements and is
deemed to be sufficiently detailed to capture the physics of the problem and compute the impact and rubbing loads.
The fan blades were constructed by shell elements with various thicknesses across their width and length. The rotor
was made of a hollow rod with varied cross sections across its length and a rotational velocity of 4500 rpm. The
material for both rotor and fan blades is titanium grade with the following properties:
= 4.466 g/cm3 Poisson’s ratio = 0.35

y = 1009 MPa Tangent modulus = 731 MPa
Young’s modulus = 117 GPa Plastic strain failure limit 0.2
CHAPTER 53
Figure 53-2 Rotor Dynamics Model
fixed in y and z translational directions
fixed in x, y and z translational directions

fixed in x rotational direction
Figure 53-3 Implicit Prestress Blade and Rotor Model and Location of Bearings on the Rotor
CHAPTER 53 1075
Figure 53-4 Explicit FBO Engine Model and Location of Bearings on the Rotor
The bearings were modeled by constructing two concentric rings with pre-determined stiffness properties that can
contact each other. The flange on the bearings prevents the axial movement of the rotor during the fan blade out. The
bearing models and their properties are important design considerations to simulate the “fusing” during the FBO and
rotor dynamics analysis. Fusing is an event where a bearing or other support structure fails as a result of high loads
beyond the design strength of the fusing structure, and its stiffness is reduced to zero.
Input
The simulation consists of three runs. The first run is a prestress analysis that computes the deformations and stresses
due to rotational velocities. This computation is essentially linear static and an implicit solver is selected for the
purpose of computational efficiency. Boundary and initial conditions of the prestress run differ from the FBO run. In
the prestress run the three bearing points are fixed and a force in the circumferential direction is applied to the rotor
and fan blades.
Implicit Prestress Run
Since the entries and details of the prestress input file are quite similar to that of “Bird Strike on rotating fan blades
with prestress” example, explanation of the prestress input will be skipped.
Explicit FBO Run
Since the explicit FBO input is also similar to of the explicit input of “Bird Strike on rotating fan blades with prestress”
example, only additional or different entries will be explained.
SOL 700,NLTRAN STOP=1 PATH=3 BLADEOUT
BLADEOUT option activates the chaining simulation. All FBO forces assigned in BLDOUT entry will be stored in
“MASTER” file after the simulation.

CHAPTER 53
TSTEPNL entry describes the number of Time Steps (300) and Time Increment (1.e-4 seconds) of the simulation. End
time is the product of the two entries (30 ms).
DBEXSSS 111 21 2 3 4 5 6 7 +
+ 8 9 10 11 12 13 14 15 +
+ 16 17 18 19 20 101
DYPARAM LSDYNA DATABASESSSTATM .00008
DBEXSSS entry requests the statistics of subsystems. The subsystems are defined by BCPROP entries.
DYPARAM, LSDYNA,DATABASE,SSSTATM parameter requests to store the mass, mass center and mass inertia tensor
of the subsystems which are assigned by DBEXSSS entry. All information will be stored to jid.dytr.ssstat ascii file at
every 0.000008 seconds and will be used for unbalance input in the rotor dynamic simulation.
$
$ ALL BLADES
$
BCPROP,101,1011106,1011107,1011108,1011109,1011110,1011111,1011112,+
BCPROP 101 includes the properties of all blades and BCPROP 21 includes only the broken blade properties. These
two subsystem information will be used in UNBALANC and CONM2 entries of SOL 400 rotor dynamics simulation.
$
$ CONTACT ID SLAVE BODY MASTER BODY DESCRIPTION
$ 01 1 22 remaining all blades to direct contact case (recording)
$ 02 21 22 broken blade to direct contact case (recording)
$ 03 21 1 broken blade to remaining all blades
$ 04 1 remaining all blades (self contact)
$ 05 21 23 broken blade to non-direct contact case
$ 06 22 direct contact case (self contact)
$ 07 1001 1004 bearing point 1 : fuse at 6.0E-3 seconds
$ 08 1002 1005 bearing point 2
$ 09 1003 1006 bearing point 3
$
BCTABLE 1 9
SLAVE 1 0. 0. 0.1 0. 0
0 0 0
0.1 SS1WAY
+
+
+ 1 1
In the example, 9 contacts are defined. In order to reduce the size of binout file which includes the contact forces, only
the fan case is considered to capture the FBO loads. Only the contact forces between the remaining blades and the fan
case (contact 01) and the broken blade and the fan case (contact 02) are stored in the binout file. To store contact forces
in binout files, two options in BCTABLE and one parameter are required. SPR and MPR options can store the contact
forces on SLAVE and MASTER parts respectively. DYPARAM*,LSDYNA,DATABASE,NCFORC parameter controls
the timestep of contact forces output which are defined in BCTABLE.
CHAPTER 53 1077
To define the release mechanism, breakable joints (CSPOT) are used (53-5). These are elements that have coincident
nodes on the hub and the blade roots but are distinct.
Add breakable joints between

the hub and the released blade
Figure 53-5 Adding Breakable Joints
The breakable joints between the hub and the release blade are added using CSPOT. The joints will be released at
0.00001 seconds after the start of FBO simulation.
CSPOT 1111 101 10 1111

0.00001
..
CSPOT 1126 116 10 1126
CSPOT entry defines the complex or combined welds. This is used to connect two nodes which are defined by
BCGRID entry and are released (broken) at 0.00001 seconds.
BLDOUT 1 0 1.0E-6 0.0

0.09204 2.90E+1 0.244 12 0 0. 1. 0.
2 4 1 3 1 2 2 2
1 99 3 3 99 99 99 99
CHAPTER 53
BLDOUT entry defines the contact force output information and mapping criteria for a sequential SOL 700 FBO and
SOL 400 RD analyses. Using this entry, the all forces can be categorized and stored to MASTER file in the SOL 700
run. All slaves and masters in the BCTABLE must be assigned to BLDOUT entry using six different types of flags in
ISLVi’s and IMASTi’s. In the example, nine ISLVi’s and nine IMASTi’s are required because there are nine contact
definitions in BCTABLE. See MD Nastran Quick Reference Guide for other fields.
SPCD2 1 GRID 123 5 80 -1.

$
BCGRID 123 20003787THRU 2000386220003867THRU
2000394220003947+
+ THRU 20004022
The spin down event after the blade out can be defined by using a time-dependent pre-determined rotational speed of
the turbine using SPCD2, BCGRID, and TABLED1 entries.
Rotor Dynamics Run (SOL 400)

The FBO loads computed in SOL 700 are read by SOL 400 by assigning the _FBO.MASTER file to DBSET in the File
Management Section (FMS) of SOL 400 run.
nastran buffsize=65536
nastran dbcfact=4
nastran system(151)=1
init scratch logi=(scratch(9999000))
assign dbloc1='impact_FBO.MASTER'
dblocate datablk=(GEOM3K) logical=dbloc1 ,
where(projno>0 and version=* and wildcard)
SOL 400
SOL 400 executive control entry activates nonlinear static and transient analysis.
Case control commands are defined in the following box.
analysis=nltran
rigid=linear
RGYRO= 100
DISPLACEMENT(print,plot,SORT1,REAL)=ALL
STRESS(plot,SORT1,REAL)=ALL
STRAIN(plot,SORT1,REAL)=ALL
ANALYSIS=NLTRAN actives “nonlinear transient analysis”.

CHAPTER 53 1079
Bulk data starts with BEGIN BULK.
BEGIN BULK
..
$MATD024 403153 4.14E-4 1.60E+7 0.35000 2.5E5 1.38E5 0.25000
$
MAT1 101 1.60E+7 0.35000 4.14E-4
MATEP 101 SLOPE 2.5E5
1.38E5
In order to use equivalent material properties in SOL 400, all MATD024 materials models used in SOL 700 are
translated to MAT1 and MATEP with slope option.
TSTEPNL 100 4000 1.0E-4 2

1.0E-2 1.0E-2
0
TSTEPNL entry of SOL 400 controls the convergence criteria and data for nonlinear transient analysis.
ROTORG 10 10 THRU 21
$
RSPINT 10 11 10 RPM 1000
$
TABLED1 1000 +
+ 0.0 4500.0 0.012 4255.0 0.016 4096.6 0.028 3834.2 +
+ 0.042 3689.1 0.055 3605.1 0.25 2915.7 0.5 2250.0 +
+ 100. 2250.0 ENDT
ROTORG entry defines the rotor which consists of GRID IDs from 10 to 21. RSPINT entry indicates the rotational
direction which is assigned to the rotational axis from GRID 11 to GRID 10. The rotational speed is defined in
TABLED1, 10 for describing the speed down at various time steps. Note that the magnitude of the rotational velocities
defined in SOL 400 differ from SOL 700. This is because the unit of rotational velocity used in SOL 400 is RPM and
is different to that used by SOL 700 (radian/seconds)
$ impact_FBO.dytr.ssstat
subsystem: 1
total mass of subsystem = 0.91899477E-01

x-coordinate of mass center = 0.16037865E+03
y-coordinate of mass center =-0.28772884E+02
z-coordinate of mass center = 0.10338639E+03
....
subsystem: 21
total mass of subsystem = 0.59591613E+01

x-coordinate of mass center = 0.16148860E+03
y-coordinate of mass center = 0.41383951E-05
z-coordinate of mass center = 0.10000020E+03
inertia tensor in global coordinates

CHAPTER 53
row1= 0.2385E+04 -0.5329E-03 -0.2139E+01

row2= -0.5329E-03 0.1748E+04 -0.1921E-02
row3= -0.2139E+01 -0.1921E-02 0.1748E+04
-> translate
UNBALNC,100,0.0919,12,0.,1.,0.,,+
+,29.00,180.0,1.10995
$
$ blade + hub
$
CONM2, 2001,12, ,5.959,,,,,+
+, 0.2385E+04,0,0.1748E+04,0,0,0.1748E+04
$
GRID 12 161.488 0. 100.
The mass, mass center and mass inertia tensors computed in SOL 700 are stored in the impact_FBO.dytr.ssstat
file. These values are then used in SOL 400 to define mass unbalance by UNBALNC and CONM2 entries. As shown in
the box above, the order of the subsystem id numbers in ssstat file is determined by the order of DBEXSSS as
defined in SOL 700. For example, subsystem 1 represents the released blade while subsystem 21 represents all
blades and hub information. The unbalance mass in the UNBALNC entry is the same value of total mass as defined in
subsystem 1. ROFFSET and ZOFFSET of UNBALNC entry are calculated by the difference of the mass locations
between subsystem 1 and 21. In the example, the x-direction in SOL 700 FBO simulation is coincident with the z-
direction of the rotor in SOL 400 RD simulation. In addition, the mass inertia tensor of subsystem 21 is recorded to
Iij fields of CONM2 entry. GRID 12 which describes the mass location of hub and blades is also set to the same center
location of subsystem 21.
In the gyroscopic nonlinear transient analysis, only the additional unbalance mass is considered as opposed to FBO
simulation, where the unbalance mass results from losing mass due to blade out. Therefore, the additional mass must
be added to the opposite side of the location where blade-out occurred. To add the mass to the opposite side of the
blade out, the unbalance is assigned at the location which is measured 180 degrees in the positive direction of the local
unbalance coordinate system.
BLDOUT,1, 1, 1.0E-6, 0.0, 0, 0, 1.0E-3, 1

+,0.0919,2.9000E+1, 1.10995, 12, 0, 0.,1.,0.
BLDOUT entry is also used in SOL400. BLDOUT entry in SOL 400 can control and apply the FBO forces to the
nonlinear transient analysis using different time steps.
CBUSH 101 101 1002 1012 0

PBUSH 101 K 1.0E7 1.0E7
Bearings in SOL 400 are modeled using CBUSH elements. PBUSHT controls the failure criteria. The CBUSH element
is defined to fail at 1.65E5 lbf in radial (y-z) direction.
CHAPTER 53 1081
Results
The stress and deformation results between SOL 400 and SOL 700 are within 2% of each other, which is quite
acceptable (see Table 53-1). However, for this particular analysis, which took a few minutes to complete, SOL 400
ran the same model three times faster than the SOL 700 implicit solver.
Results of Prestress Implicit Simulation

SOL 400 SOL 700
Figure 53-6 Displacement Contours on Fan Blades and Rotor – SOL 400 vs. SOL 700
CHAPTER 53
SOL 400 SOL 700
Figure 53-7 Stress Contours on Fan Blades and Rotor – SOL 400 vs. SOL 700
Table 53-1 Comparison of SOL 400 vs. SOL 700 Pre-stress Results
Difference
SOL400 SOL 700 (refer to SOL 400 results)
Analysis Time 135 seconds 398 seconds 300%
Maximum Resultant Displacement 24.66 mm 24.13 mm 2.2%

(0.971 inch) (0.950 inch)
Maximum Equivalent Stress 710.2 MPa 696.4 MPa 2.0%
(103 ksi) (101 ksi)
The results and typical loads from the FBO analysis are demonstrated in Figures 53-8 to 53-12. The total simulation
time was 30 ms which is about three complete revolutions of the rotor. As explained in Loading Types section of
Introduction, only one blade was released and no trailing blades were broken. The simulation showed that even though
there is an impact between the trailing and the released blade (see Figures 53-8 and 53-9), no other blades are actually
broken. The plastic strains and stresses at t = 3 ms on the fan case are also shown in Figure 53-10.
CHAPTER 53 1083
Results of Fan Blade Out (FBO) Explicit Simulation

0.0015 seconds 0.0037 seconds
0.0037 seconds at a different angle
Figure 53-8 Effective Stress Contour
Figure 53-9 Snapshot of Contact Between Released Blade and Containment

CHAPTER 53
Plastic Strain Effective Stresses

Figure 53-10 Fan Case t = 3ms
The upper plot in Figure 53-11 shows the impact load and rubbing forces (magnitudes) on the fan case while the lower
plot shows the rubbing forces on the blade tip at a typical location. It is noteworthy to mention that total resultant
tangential rub loads on the case and blade tips should be equal and in opposite directions. However, as shown in
Figure 53-12, these loads are extracted at different locations and are meant as representative loads only. All load
components and their locations (in x, y and z coordinates) are recorded in the database for subsequent search and
mapping to the new rotor dynamics model, with its coarser mesh.
106 Force Magnitude (N) Node 31795 (case)
Impact (Max = 423,418 N) Rubbing Loads

105
Radial (Max = 78,842 N)
Tangential (Max = 15,767 N)
104
31795
103
31795
102
1405440
101 1405440
1
0 5 10 15 20 25 30
Time (ms)
10-1
106 Force Magnitude (N) Node 1405440 (blade)
105
Rubbing Loads
104 Radial (Max = 75,578 N)
Tangential (Max = 12,024 N)
103
102
101
1
0 5 10 15 20 25 30
Ti ( )
Figure 53-11 Loads
CHAPTER 53 1085
Figure 53-12 Node 31795 and 1405440 Locations on Case and Blade Tip
Results of Rotor Dynamics Implicit Simulation

In this analysis, the orbit diagrams between SOL 400 and SOL 700 (see Figure 53-13) demonstrate that the whirling
characteristics are similar and deformation magnitudes of the whirl are very close in the z-direction but differ in the
y-direction. The difference could be due to two contributing factors. The first is that the contact forces between the
trailing and released blades were not taken into consideration in the rotor dynamics simulation, but only the impact
and rubbing loads. The contact forces between the blades will have some contribution to the magnitude of the whirling
deformation in the y-direction. The second reason is because the sectional properties of the rotor at the center where
hub is located are approximated in the stick model for the rotor dynamics simulation. Figure 53-13 shows the orbit
diagram of the tip node of the rotor due to mass unbalance and predicts the maximum “whirl” deformations in each
direction.
3.0 Z-Displacement (inch)
2.5
2.0
Sol 700
1.5
1.0
Sol 400
0.5
0.0
-1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5
-0.5
Y-Displacement (inch)
-1.0
-1.5
-2.0
-2.5
Figure 53-13 Comparison of Orbit at the Tip of Rotor

CHAPTER 53
In the implicit rotor dynamic analysis, the failure load for bearing 1 is set to 734 kN (1.6E5 lbf). A radial dependence
is specified for the fuse option. Figure 53-14 shows the time history for the force in this bearing. The bearing is found
to fuse in less than a revolution after the FBO event. The time-to-fuse is then used to modify the explicit FBO analysis.
In the FBO analysis, fusing is modeled by deactivating contact between the two rings of the bearing at the analysis
time recorded in the implicit rotor dynamic analysis.
150000
Force-Y
Force-Z
100000 Force-magn
50000
0
0 0.002 0.004 0.006 0.008 0.01
-50000
-100000
-150000
Figure 53-14 Loadings on the First Bearing and Fusing After 0.004 Seconds
Input File(s)
File Description
nug_53a.dat MD Nastran Input file for prestress implicit analysis.
nug_53b.dat MD Nastran input file for fan blade out explicit analysis.
nug_53d.dat MD Nastran input file for rotor dynamics implicit analysis.
The end time and the time history output interval in the fan blade out simulation were modified in the input deck,
nug_53b.dat, to speed up the calculation. To get the same results as this document, please use the original end time
and time history interval which is suppressed in the input deck.
$ original
$TSTEPNL 1 300 .1e-3 1 ADAPT 2 10
$DYPARAM*,LSDYNA,DATABASE,NCFORC,.1e-5,3
$ modified
DYPARAM*,LSDYNA,DATABASE,NCFORC,.1e-4,3
CHAPTER 53 1087
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately seven minutes
0.0008
0.0006
0.0004
0.0002
Z-location
0
-0.0008 -0.0006 -0.0004 -0.0002 0 0.0002 0.0004 0.0006 0.0008
-0.0002
-0.0004
-0.0006
-0.0008
Y-location

Chapter 54: Ball Penetration using SPH Method
Ball Penetration using

54 SPH Method

Summary 1089

Introduction 1090


Results 1094

Input File(s) 1096
CHAPTER 54 1089
Ball Penetration using SPH Method
Summary
Title Chapter 54: Ball Penetration using SPH Method
Feature Single Particle Hydrodynamics (SPH) Capability
Geometry
V = 6.18 km/s Ball (SPH)
Plate (SPH)
Plate (Lagrangian)
Material properties Ball (SPH): Plate SPH and Lagrangian

Analysis characteristics Transient explicit dynamic analysis (SOL700)
Boundary conditions Explicit: Fixed boundary condition of plate edges
Applied loads Initial speed of the ball (0.618 cm/s in y-direction)
Element types 4-node shell elements
FE results Deformation plots at various times
t = 0.00 seconds t = 1.98 seconds

CHAPTER 54
Introduction
This is an example of a ball penetrating through a plate using SPH method. The initial velocity of the ball is 6.18 km/s
(0.618 cm/µs) in vertical direction. In the simulation, the center part of the plate and the ball projectile are modeled by
SPH elements.

SOL 700
TSTEPNL
DYPARAM,LSDYNA,BINARY,D3PLOT
CSPH
PSPH
EOSGRUN
SPHDEF
TIC
MATD010
PSOLIDD
MATD003
V = 6.18 km/s Ball (SPH)
Plate (SPH)
Plate (Lagrangian)
Figure 54-1 Red ball approaching green plate
SPH (Smoothed Particle Hydrodynamics) is a meshless Lagrangian numerical technique used to model the fluid
equation of motion. Although it was developed to simulate complicate astrophysical problems originally, SHP has
proved to be useful in certain class of problems where large mesh distortions occur such as high velocity impact, crash
simulation and compressible fluid dynamics.
CHAPTER 54 1091
Modeling Details
The circular section located at the center of plate was modeled using SPH elements and the remainder of the plate was
modeled using structural material property (MATD003). The ball is modeled with SPH elements and impacts the center
of the plate at 6.18 km/s. The model has a total of 19479 grid points, 300 solid elements and 18759 SPH particle
elements. The remaining structural elements were modeled using Hexahedrals. The simulation time was 20.0 seconds.
Input file
SOL 700 is an executive control entry and activates an explicit nonlinear transient analysis.
The case control section is below:
DLOAD = 1
IC = 1
SPC = 1
BCONTACT = 1
TSTEPNL = 1
The bulk entry section starts:
BEGIN BULK
$
TSTEPNL*1 6000 3.3333334E-03 *
*
$
$ DATABASE_BINARY
TSTEPNL is a SOL 700 bulk data entry which describes the number of Time Steps (6000) and Time Increment (3.33
ms) of the simulation. The end time is the product of these two entries. Notice here the Time Increment is only used
for the first step. The actual number of Time Increments and the exact value of the Time Steps are determined by SOL
700 during the analysis. The time step is a function of the smallest element dimension during the simulation.
The LSDYNA,BINARY,D3PLOT option of DYPARAM entry controls the output time steps of d3plot binary file. The
result plots at every 0.5 seconds are stored in d3plot binary file.
$
$ Number of SPH = 18759
CSPH* 10000001 11 8.2517613E-04 *

*
CHAPTER 54
The CSPH entry defines a SPH particle. The SPH element number (10000001) must correspond to the grid number
which describes the SPH element location. The lumped mass (8.25E-4) is applied on the SPH element.
$
$ Part = material type #10
$
PSPH* 10 2 2 *
* *
* 1.200000 0.2000000 4.000000 0.0 *
* 0.0 0.0
The PSPH entry defines the property of SPH particle. Both of the material property and equation of state are set to 2.
The smoothing length of the particles is set to 1.2. The scale factors for the minimum and maximum smoothing length
are set to 0.2 and 4.0, respectively.
$
$ Number of EOS = 2
$
EOSGRUN*2 0.5328000 1.339000 0.0 *
* 0.0 2.000000 0.4800000 0.0 *
* 0.0 *
*
The EOSGRUN entry defines a Gruneisen Equation of State.

The Gruneisen equation defines the pressure for compression as:
0
 0 C 2  1 +  1 – ----  – ---  2
a
 2 2 
p = ------------------------------------------------------------------------------------------------------ +   0 + a E
 2 3 2
1 –  S 1 – 1  – S 2 ------------- – S 3 --------------------2-
+1  + 1
And for tension as:
p =  0 C 2  +   0 + a E
All fields are set for the coefficients of two equations above. Please see MD Nastran Quick Reference Guide for details.
SPHDEF* 1 0 0.0 *
* 0 0 0.0 0.0 *
* *
*
CHAPTER 54 1093
The SPHDEF entry defines and controls the physics of SPH particles. All values of this example are assigned using
default values. See MD Nastran Quick Reference Guide for details.
$
MATD003*1 2.785000 0.7000000 0.2690000 *
* 2.9000000E-03 7.0000000E-02 1.000000 *
* 0.0 0.0 0.0 0 *
*
The MATD003 entry defines an isotropic and kinematic hardening plastic material including rate effects. This material
is used to model the boundary structural plate in the example. The density is 2.785 kg/cm3 and Young’s modulus is
0.7 GPa. The Poisson’s ratio, the yield stress and the tangential modulus are set to 0.269, 0.0029 GPa and 0.07 GPa,
respectively. The hardening parameter is set to 1, which describes the isotropic hardening only.
$
$ *INITIAL_VELOCITY_NODE
$
TIC* 1 10000001 1 *
* 0.0
…
$
$ *INITIAL_VELOCITY_NODE
$
TIC* 1 100001 1 *
* 0.0
TIC* 1 100001 2 *
* 0.6180000
…
MATD024 is a SOL 700 bulk data entry. It is used to model an elasto-plastic material with an arbitrary stress versus
strain curve and arbitrary strain rate dependency. Failure can also be defined based on the plastic strain or a minimum
time step size.
The TIC entry defines a nodal initial condition. In the example, all SPH grids have initial velocity conditions. Grid
point 10000001 is located at the center of the plate and has zero velocity to all directions. Other nodes on the center
of the plate have zero velocities similar to grid point 10000001. Grid point 100001 is located at the ball which has a
velocity of 0.618 cm/s in y direction. All nodes on the ball have the same velocity as grid point 100001.
$
MATD010 2 2.785 0.269 2.9E-03 0.0 -2.0E-2 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
CHAPTER 54
The MATD010 entry defines an elastic-plastic hydrodynamic material. This material is used to model SPH elements.
The density, shear modulus, yield stress and cutoff pressure are set to 2.785 kg/cm3, 0.269 GPa, 0.0029 GPa and -0.02
GPa, respectively.
$
$ Part = material type # 3
$
PSOLIDD*1 1 0 *
*
The PSOLIDD entry defines a solid element property using the element formulation and equation of state. In the
example, this entry can be changed to PSOLID because only the material property is assigned.
Bulk data entries that define grid points and solid type elements:
$
$ Number of Nodes = 19479
$
GRID 1 -0.3E+1 0.404 -0.30E+1
..
GRID 101791 0.667E-1-0.467 0.467
$
$ Number of Solid elements = 300
$2345678$2345678$2345678$2345678$2345678$2345678$2345678$2345678$2345678
CHEXA 1 1 13 14 20 19 1 2
8 7
..
CHEXA 300 1 714 715 720 719 704 705
710 709
Results
The deformation snapshots are shown at the various times in Figure 54-2. After impact, the projectile particles
penetrated the center of plate. In the simulation, the material properties of the projectile ball and the target plate are
the same. Due to the impact, the failure area of plate is larger than the diameter of projectile. Then the internal energy
of the plate is larger than that of the projectile.
CHAPTER 54 1095

Figure 54-2 Ball Penetration at Various Increments
CHAPTER 54
The nearly brittle impact event exchanges kinetic energy between the ball and plate while keeping the total energy
nearly constant as shown in Figure 54-3. The SPH methods introduces some artificial viscosity to smooth the shock
over several particles, and the total energy experiences about a 7% loss over the duration of the event.
0.30 Energy (J)
0.25 Total 7% loss
0.20
Ball
0.15
0.10 Plate
0.05
0.00
0 5 10 15 20
Time (s)
Figure 54-3 Energy Conservation
Input File(s)
File Description
nug_54.dat MD Nastran input file of explicit Ball penetration using SPH method
Chapter 55: Square Cup Deep Drawing using Forming Limit Diagram
Square Cup Deep Drawing

55 using Forming Limit Diagram
PART 1. Explicit Forming

 Summary
1098

Introduction 1099


Results 1104
PART 2. Implicit Spring Back

 Introduction
1108

 Results 1110

Input File(s) 1112

Reference 1112
CHAPTER 55
Summary
Title Chapter 55: Square Cup Deep Drawing using Forming Limit Diagram
Features • Failure criterion based on the Forming Limit Diagram
• Springback: Explicit -> Implicit switching
Geometry
Punch
Clamp
Sheet
Die
Material properties • Sheet Metal (aluminum sheet): Anisotropic Materials under Plane Stress Conditions
Exx = 71.0 GPa,  = 0.33
Stress constant = 0.0 MPa, Hardening modulus = 576.79 MPa
Strain offset = 0.01658, Exponent for power-law hardening = 0.3593
Lankford parameters: R0 = 0.71, R45 = 0.58, R90 = 0.70
• Punch, Die, and Clamp: Rigid
Analysis characteristics Transient explicit dynamic analysis (SOL 700 explicit single precision)
Nonlinear implicit static analysis (SOL 700 implicit double precision)
Boundary conditions • Explicit: Fixed boundary condition of Die and Clamp
• Implicit Springback: Fixed at the center point of the plate
Element types 4-node shell elements
FE results Stress Contour Plot, Forming Limit Diagram and more
Explicit Forming Implicit Spring Back
80.00%
Element will fail
at next step FLD at Mid. Surface
FLD with Safety margin
60.00%
Major True Strain (%)
40.00%
20.00%
0.00%
-30.00% -20.00% -10.00% 0.00% 10.00% 20.00%
-20.00%
Minor True Strain (%)
CHAPTER 55 1099
Square Cup Deep Drawing using Forming Limit Diagram
PART 1. Explicit Forming

Introduction
This is a sheet metal forming example of a plate with anisotropic behavior that is drawn through a square hole by
means of a punch. This particular example has experimental results from a verification problem of the 1993
NUMISHEET Conference held in Japan. The results are obtained at single punch depth (20 mm punch travel) for an
aluminum alloy plate. The material is seen to be anisotropic in its planar directions; i.e., the material behavior is
different for all directions in the plane of the sheet metal as well as in the out of plane direction. The data obtained
from the NUMISHEET Conference is as follows:
Aluminum Alloy
Thickness = 0.81 mm
Young’s modulus = 71 GPa
Yield stress = 135.3 MPa
Stress = 576.79 * (0.01658 + p)0.3593 MPa
Lankford parameters: R0 = 0.71, R45 = 0.58, R90 = 0.70
Friction coefficient = 0.162
The size of the plate modeled was 0.15 x 0.15 (in meters). No strain-rate dependency effects were included in the
material data, so the metal sheet was analyzed without these effects. The dimensions of the plate, die, punch, and clamp
are all given in Figure 55-1.

SOL 700
TSTEPNL
DYPARAM,LSDYNA,BINARY,D3PLOT
CSPH
PSPH
EOSGRUN
SPHDEF
TIC
MATD010
PSOLIDD
MATD003
CHAPTER 55
Figure 55-1 Dimensions of Plate, Die, Punch, and Clamp (in Millimeters)
CHAPTER 55 1101
Modeling Details
Punch
Clamp
Sheet
Die
X Y
Figure 55-2 SOL 700 Model (Exploded View)
The SOL 700 model is shown in Figure 55-2. The main parts in the finite element model are:
• sheet metal
• punch
• die
• clamp
Sheet Metal
The SOL 700 material model for sheet metals is a highly sophisticated model and includes full anisotropic behavior,
strain-rate effects, and customized output options that are dependent on material choice. Since not all of the materials
can be derived from the simplified set given by the NUMISHEET organization, most participants in the conference
used an isotropic material model. In reality, the process is definitely anisotropic and effects due to these differences
can be seen in the transverse direction. For materials displaying in-plane anisotropic behavior, the effect would be even
more noticeable. The parameters on the MAT190 (refer to the MD Nastran Quick Reference Guide) specify planar
anisotropic behavior and are as follows (for the aluminum sheet):
• MATD190 elastic material properties.
• Isotropic behavior was assumed in the elastic range:
Exx = 71.0 GPa
= 0.33
CHAPTER 55
• Planar anisotropic yielding and isotropic hardening were assumed in the plastic range:
A = Stress constant = 0.0 MPa
B = Hardening modulus = 576.79 MPa
C = Strain offset = 0.01658
n = Exponent for power-law hardening = 0.3593
• Lankford parameters:
R0 = 0.71
R45 = 0.58
R90 = 0.70
Punch, Die, and Clamp

These three components provide the constraints and driving displacement for the analysis and are modeled as rigid
bodies. Contact is then specified with the metal sheet using the friction coefficient values provided. The three contact
types are specified as following:
• Contact between the punch and the sheet
• Contact between the die and sheet
• Contact between the clamp and sheet
Finally, the punch is given a scaled downward velocity providing the driving displacement for the analysis.
Input File
SOL 700 is an executive control entry and activates an explicit nonlinear transient analysis.
Case control section is below:
DLOAD = 1
IC = 1
SPC = 1
BCONTACT = 1
TSTEPNL = 1
The bulk entry section starts:
BEGIN BULK
$
TSTEPNL 1 20 2.0E-3
$
DYPARAM LSDYNA BINARY D3PLOT 0.002
CHAPTER 55 1103
TSTEPNL is a SOL 700 bulk data entry which describes the number of Time Steps (20) and Time Increment (2.00 ms)
of the simulation. The end time is the product of the two entries. Notice here the Time Increment is only used for the
first step. The actual number of Time Increments and the exact value of the Time Steps are determined by SOL 700
during the analysis. The time step is a function of the smallest element dimension during the simulation.
LSDYNA,BINARY,D3PLOT option of DYPARAM entry controls the output time steps of d3plot binary file. The result
plots at every 0.002 seconds are stored in d3plot binary file.
Bulk data entries that define properties for shell elements
PSHELL1 1 1 BLT Gauss +

+ .81
MATD020 2 1.0 210.E9 0.3

1 4 7
The MATD020 entry defines the rigid material property. In the example, the clamp, die, and punch are modeled by the
rigid materials.
MATD190 1 2.7E-4 7.1E7 0.33 2.0 576.79E3.3593 0 +

+ 6.0 .71 .58 .70 .01658 +
+ 2.0 77 +
+ 1.0 0.0 0.0 +
+ 0.0 1.0 0.0
TABLED1,77,,,,,,,,+
+,-100.0,196.67,0.0,30.,30.,45.,40.,47.,+
+,50.,45.,ENDT
The MATD190 entry defines an anisotropic material developed by Barlat and Lian (1989) for modeling sheets under
plane stress conditions and with Forming Limit Diagram failure criteria. This material allows the use of the Lankford
parameters for the definition of the anisotropy.
In the model, Gosh’s hardening rule is used:
n
Y  p  = k  0 + p  – p
The forming limit diagram is defined in by TABLED1 as shown above.

All fields are set for the coefficients of equations. See MD Nastran Quick Reference Guide for details.
SPCD2,1,RIGID,MR2,3,0,100,1.0,,+
+
TABLED1,100,,,,,,,,+
+,0.0,-1000.,0.02,-1000.,ENDT
CHAPTER 55
The SPCD2 entry defines imposed nodal motion on a node, a set of nodes or nodes of a rigid body. The rigid punch is
moving downward at 1000 m/s from 0 to 0.02 seconds.
FORCE 9999 MR3 -19.6E6 1.
The FORCE entry defines a force on the grid point as well as rigids. Since the forces on the rigid body are not yet
supported by the Nastran input processor, TODYNA and ENDDYNA entries are used in conjunction with the FORCE
entry to by-pass the IFP (Input File Processor) and directly access SOL 700.
BCTABLE 1 3
SLAVE 1 0. 0. 0.162 0. 0
0 0 0
0.162 SS1WAY
+
+
The BCBODY entry defines a flexible or rigid contact body in 2-D or 3-D. Although SOL 700 only supports flexible
contact in BCTABLE, the rigid contact can be applied using the rigid material of contact bodies. In this example, all
contact body pairs are given 0.162 static and kinetic friction coefficients. The surface-to-surface, one way contact
method is used for all contact definitions.
BCBODY 1 DEFORM 1
..
$
BSURF 1 1 THRU 1600
..
The BCBODY entry defines a flexible or rigid contact body in 2-D and 3-D.
The BSURF entry defines a contact surface or body by element IDs. All elements with the specified IDs define a
contact body.
$
GRID 1 -75. 75. 0.0
..
GRID 4528 -8.33333-37.0067-75.405
$
CQUAD4 1 1 1 2 43 42
..
CQUAD4 4468 63 4527 4273 4274 4528
Results
To verify the result of MD Nastran, the major and minor principal strains at 0.015seconds are compared with those of
Numisheet and Dytran results in Figure 55-3 and Figure 55-4. Left plots of each figure were represented by
CHAPTER 55 1105
Makinouchi et al. (1993). The data in the plots were obtained from several companies which did the same test. MD
Nastran gave a solution well within the spread of experimental values.
Major Principal Strain
2.50E-01
2.00E-01
1.50E-01
Strain
1.00E-01
5.00E-02
0.00E+00
0 20 40 60 80 100 120
Distance from Center Along Line OB
Figure 55-3 Comparison of Major Principal Strain Along Line OB

(Numisheet and Dytran Results vs. MD Nastran SOL 700)
Minor Principal Strain
0.00E+00
0 20 40 60 80 100 120
-5.00E-02
-1.00E-01
Strain
-1.50E-01
-2.00E-01
-2.50E-01
Distance from Center Along Line OB
Figure 55-4 Comparison of Minor Principal Strain Along Line OB

(Numisheet and Dytran Results vs. MD Nastran SOL 700)
CHAPTER 55
80.00%
Element will fail FLD at Mid. Surface

at next step FLD with Safety margin
60.00%
Major True Strain (%)
40.00%
20.00%
0.00%
-30.00% -20.00% -10.00% 0.00% 10.00% 20.00%
-20.00%
Minor True Strain (%)
Figure 55-5 Forming Limit Diagram Along Line OB at 0.019 Seconds

CHAPTER 55 1107

Figure 55-6 Maximum Principal Strain Contour Plots at Mid Surface at Various Times
Note that the FLD diagram correctly predicts the failure of elements at t = 0.019 as shown in the stress fringe plots.
CHAPTER 55
PART 2. Implicit Spring Back

Introduction
Springback refers to an event in which there is elastic strain recovery after the punch is removed. This deformation
can alter the final desired shape significantly. In an explicit dynamic analysis, it can take some time before the
workpiece comes to a rest, so the springback simulation is performed using the implicit solver to speed up this part of
the analysis. Using explicit-implicit switching available in SOL 700, the residual deformations after sheet metal
forming are computed and used as a pre-condition for springback analysis. Because, in this example, there was a
failure at around 0.019 seconds in the sheet metal as shown in Part 1, the explicit simulation was terminated at 0.018
seconds. The initial condition, including the final stresses and deformation and the element connectivity of the explicit
run are transferred to the implicit run. The analysis scheme is described below.
SOL 700 Explicit

(Use SEQROUT Entry)
Generate jid.dytr.nastin
SOL 700 Implicit

(Include jid.dytr.nastin)
(Use SPRBCK Entry)
Figure 55-7 Analysis Scheme

SOL 700
MATD036
SEQROUT
SPRBCK
Modeling Details
The model of explicit run is the same as Part 1. In the implicit run, only the sheet metal is used.
Input File
Explicit Input File
BEGIN BULK
$
TSTEPNL 1 10 1.8E-3
CHAPTER 55 1109
As mentioned above, the end time of simulation is assigned to 0.018 seconds.
SEQROUT 10
BCPROP 10 1
The SEQROUT entry generates the jid.dytr.nastin file at the end of simulation. The nastin file includes the
final deformations and stresses of the assigned part. The nastin file can be used for a subsequent explicit or implicit
SOL 700 run. In the example, only the result for Part 10 which includes the sheet metal is written out to the nastin
file.
Implicit Input File
BEGIN BULK
$
TSTEPNL 1 10 1.8E-3
As mentioned above, the end time of simulation is assigned to 0.018 seconds.

Because all information of nodes and element connectivity is in jid.dytr.nastin file, Grid and CQUAD entries are
removed in the implicit input. Only one point boundary condition at the center and SPRBCK entry are added in the
input file.
Since MATD190 is not available in the implicit analysis, MATD036 is used instead of MATD190. MATD036 and
MATD190 are identical material models except that FLD is supported only in MATD190.
MATD036 1 2.7E-4 7.1E7 0.33 2.0 576.79E3.3593 0 +

+ 6.0 .71 .58 .70 .01658 +
+ 2.0 +
+ 1.0 0.0 0.0 +
+ 0.0 1.0 0.0
MATD036 is only different in the failure criteria using FLD. Others are the same as MATD190 in the explicit
simulations of Part 1 and 2.
SPRBCK 1 0.005 +
+ 200 0.0 1.00E-3 +
+ 2 1 100 1.0E-2 0.10 +
+ 1 1
SPRBCK activates the implicit spring back analysis. Nonlinear with BFGS updates solver type is used in the example.
See MD Nastran Quick Reference Guide for other fields.
SPC1 1 123456 841
Only one point at the center of the sheet metal is fixed to prevent singular condition in the implicit simulation.
CHAPTER 55
Results
The springback simulation from explicit to implicit runs works fine. The results of explicit and implicit analyses are
shown in Figures 55-8 to 55-10. Figure 55-8 shows the displacement contours at the start of analysis and at the end of
analysis. Note that the initial deformation of the plate grids in the implicit analysis is set to zero because the final
deformation of explicit analysis is applied to the initial location of grid points in the springback implicit analysis. In
Figure 55-9 the initial stress condition of springback implicit analysis is perfectly coincident with the final stage of
explicit analysis. The initial stress of implicit analysis causes the additional deformation in the springback implicit
analysis.
:
Explicit Simulation
t = 0.000 seconds t = 0.018 seconds (end of explicit run)
Because the final results are applied as

the initial condition for implicit
simulation, the initial deformation of
implicit simulation is set to 0.
Implicit Simulation
Initial condition of implicit run Final result of implicit run

Figure 55-8 Vertical (Z-direction) Displacement Contour Plot
CHAPTER 55 1111
Explicit Simulation
t = 0.000 seconds t = 0.018 seconds (end of explicit run)
Because the final results are applied as the

initial condition of implicit simulation, the
initial stress of implicit simulation is the same
as the final stress of the explicit simulation.
Implicit Simulation
Initial condition of implicit run Final residual stress of implicit run

Figure 55-9 von Mises Stress Contour Plot
The location of each grid point along the diagonal line of the plate at the end of the explicit and the springback analysis
is plotted in Figure 55-10; the maximum difference between these curves is around 0.756 mm. The centers of the
implicit and explicit sheet are positioned to have the same position as a reference, hence the largest differences tend
to appear at the ends of the sheet.
CHAPTER 55
at the end of explicit run 5

at the end of implicit run
Deformation to vertical direction

-100 -80 -60 -40 -20 0 20 40 60 80 100
-5
-10
-15
-20
Distance from center
Figure 55-10 Comparison of Vertical Displacements (z-direction) After Explicit and Springback
Simulations Along Diagonal Line of Plate
Input File(s)
File Description
nug_55a.dat MD Nastran input file of explicit square cup deep drawing analysis using
Forming Limit Diagram.
nug_55b.dat MD Nastran explicit input file for springback analysis.
nug_55c.dat MD Nastran implicit input file for springback analysis
nug_55d.dat MD Nastran stress and deformation information of explicit analysis for input
to implicit analysis
Reference
Makinouchi, A., Nakamachi, E., Onate, E., and Wagoner, R. H., “Numerical Simulation of 3-D Sheet Metal Forming
Processes, Verification of Simulation with Experiment,” NUMISHEET 1993 2nd International Conference.
Chapter 56: Hydroplaning Simulation
56 Hydroplaning Simulation

Summary 1114

Introduction 1115



Results 1116

Postprocessing with SimXpert 1119

Input File(s) 1129

Video 1130
CHAPTER 56
Summary
Title Chapter 56: Hydroplaning Simulation
Features • Single Material Hydrodynamic Euler
• General Lagrangian-Eulerian Coupling
• Implicit/Explicit chaining analysis
• Contact with friction
• Body force on Euler elements
Geometry
Road
Water
Tire and Wheel
Material properties • Rubber (Mooney-Rivlin Rubber Material)

Density = 1.13e-6 kg/mm3 = 1,130 kg/m3
Poisson’s Ratio = 0.49
• Euler Zone (Water)
Density = 1.0e-6 kg/mm3 = 1,000 kg/m3
Bulk Modulus = 0.216 kg-mm/ms2/mm2 = 216 MPa
• Road (Rigid)
• Wheel (Rigid)
Analysis characteristics Transient explicit dynamic analysis (SOL700) - Fluid Structure Interaction (FSI)
Boundary conditions • Inflow on the front boundary of Euler mesh
• Outer flow in the boundary of side and read Euler zone
Applied Loads • Body forces on water (only explicit)
X-direction: 0.5 mm/ms2
• Applying acceleration on road (only explicit)
X-direction: 0.5 mm/ms2
• Gravity loading (implicit and explicit)
• Concentration loading on wheel for vehicle weight (implicit and explicit)
4 kg-mm/ms2 = 4,000 N
Element type • 4-node shell element
• 8-node hex element
FE results • Stress Contour of the tire
• Deformation of the tire
• Iso-surface of water flow
CHAPTER 56 1115
Hydroplaning Simulation
Introduction
Hydroplaning or aquaplaning by a road vehicle occurs when a layer of water builds between the rubber tires of the
vehicle and the road surface. This leads to the loss of traction and prevents the vehicle from responding to control
inputs such as steering, braking, or accelerating. It becomes, in effect, an unpowered and unsteered sled.
Requested Solution
Effective stress and deformation of a tire and flow of water (footprint) are calculated depending on the simulation time.
The contact force between the tire and road and the flow direction of water may be required to study the tire separation
from the road although they are not included in the example.
Modeling Details
MD Nastran SOL700 supports the chaining analysis using implicit and explicit switching. In this example, the initial
loads are applied implicitly first and the results of the implicit run are used as the initial condition in the explicit
analysis.
Implicit Analysis
To reach the static equilibrium of the tire, virtual springs with small stiffnesses are added in y-direction at the center
of wheel. The gravity and the vehicle weight are applied to the center of the wheel. The contact between the tire and
the road is also applied. Figure 56-1 shows the assigned boundary conditions and the location of applied loadings.
Vehicle weight is applied at the center of wheel
Fixed node Fixed node
Y-direction
Only Y translational degrees

of freedom are free at each
wheel center
Tire
Road (fixed)
Figure 56-1 Loading and Boundary Conditions - Implicit Prestress Analysis
CHAPTER 56
Explicit Analysis
Similar to the prestress example in Chapter 9, the nastin file is used for applying the initial stress and deformation.
While, in reality, the wheel and tire rotate and move forward at the vehicle’s velocity on the wet road, in this example,
we run the wet surface under the free tire and wheel causing them to rotate due to frictional forces (see Figure 56-2).
This technique significantly reduces the simulation time. To rotate the tire under these conditions, high static and
dynamic frictional coefficients (1.2) are applied between the road and the tire. A high acceleration is defined for the
wet road to reduce the total analysis time. In addition, a lower value for the bulk modulus of water, generally 2.2 GPa,
is defined to increase the time step size.
Wheel and Tire

move translationally
Road and water move and

flow and translationally
Real Behavior Simulation

Figure 56-2 Schematic Comparison of the Real Tire Behavior and the Simulation
Results
Implicit Analysis
Start of Implicit Simulation End of Implicit Simulation (After Gravity is Applied)

CHAPTER 56 1117
Explicit Analysis
Effective stress contour
Since water hits and pushes up the tire, the effective stresses are reduced at the end of simulation. However the contact
area under the tire experiences relatively higher stress levels.
Time: 0 ms Time: 80 ms
Deformation
The tire deformations correlate well with the stress results showing deformations at bottom contact areas where water
hits the tire.
Time: 0 ms Time: 80 ms
CHAPTER 56
Iso-surface of water flow (FMAT Material fraction) = 0.5)
Time: 0ms Time: 20ms
Time: 40ms Time: 60ms
Time: 80ms
CHAPTER 56 1119
Postprocessing with SimXpert

After the job is finished, there are two types of results: ARC and d3plot files. Both files are attached to SimXpert and
are shown on the following pages.
a. For Default Workspace select MD Explicit
a
CHAPTER 56

b. For File Path, select the results file (attaching the d3plot file first)
c. Select the d3plot file.
d. Attach Options: click Both
e. Click Apply
f. Observe that the Lagrangian results are attached
a
b
c
d
f
CHAPTER 56 1121
a. For File Path, select the results file (to attach the ARC file)
b. Select the DYTR_EULER_0.ARC file
c.Attach Options: click Both
d. Click OK
e. Observe that the Outer Euler results are attached
a
c b
e
CHAPTER 56
Display the Deformation Results

The object of this step is to create a deformation plot of the Lagrangian results.
a. Model Browser: Delete S-7:demo_model as it is the dummy elements for the coupling between
Lagrangian and Euler elements and does not include any results.
b. Model Browser: Hide all EULER elements
c.Observe that all the Euler elements are hidden
d. Results tab: Deformation
e. For Result Cases, select all the Times in the dytr.d3plot tree
f. For Results type, select Displacement Component
g. Target entities, change to Elements
h. From Main Window, select all Lagangian elements
i. Plot Data, click Deformation
j
d
g
f h
i
CHAPTER 56 1123
Display the Deformation Results (continued)
a. Deformed display scaling, click True

b. Click Update
c.Check the deformation plot
a b
c
CHAPTER 56
Display the Stress Results

The object of this step is to create a stress fringe plot of the Lagrangian results.
a. Model Browser: Show only Part H-1 and S-2 as Part3 and 4 are rigid and have not stress results.
b. Change Plot type to Fringe
c.Check the Result Cases to see that all the Times in the dytr.d3plot tree are selected
d. For Result type, select Stress Components
e. For Derivation, select von Mises
f. For Results entities, select Target entities
f
e
d
c
CHAPTER 56 1125
Display the Stress Results (continued)
a. Target entities, change to Elements

b. Select all the Lagangian Elements in the Main Window
c. Plot Data: Select Fringe
d. Element edge display: Display, select Element edges
e. Click Update
f. Check the stress fringe plot in the Main Window
f
d e
CHAPTER 56
Display the Euler Pressure Iso-surface Results

This step creates a pressure iso-surface plot of the Eulerian results.
a. Target entities, change to Elements

b. Model Browser: Show Only the EULER elements
c. Check the Main Window to see that the Eulerian elements are shown
d. Plot type: Click IsoSurface
e. Select the all the Time in the DYTR_EULER.ARC tree
f. Result type, select FMAT
g. Click Update
h. Check the iso-surface plot in the Main Window
h
g
f
e
CHAPTER 56 1127
a. FE Display: FE Shaded
b. Change the Transparency
a
CHAPTER 56
Make Animation
a. Click: Animation
b. Click Forward
a
b
T= 0 ms T= 20 ms
CHAPTER 56 1129
Animation (continued)
T= 40 ms T= 60 ms
T= 80 ms
Input File(s)
File Description
Hydro_planning_explicit.dat MD Nastran explicit input
Hydro_planning_explicit.pre_dytr.nastin MD Nastran initial stress and configuration
information of explicit analysis for input to implicit
analysis which is included in
Hydro_planning_explicit.dat
Hydro_planning_implicit.bdf MD Nastran implicit model input which is included in
Hydro_planning_explicit.dat
Hydro_planning_implicit.dat MD Nastran implicit input
CHAPTER 56
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately five minutes and
explains how the post processing steps are performed.
Road
Water
Tire and Wheel

Chapter 57: Heating and Convection on a Plate for Heat Exchanger
Heating and Convection on a

57 Plate

Summary 1132

Introduction 1133



Results 1141

Modeling Tips 1142

Input File(s) 1142

Video 1142
CHAPTER 57
Summary
Title Chapter 57: Heating and convection on a plate
Features MD Nastran SOL 400: RCNS, RCNT, HSTAT, HTRAN
Geometry and Boundary Heat Flux: 500 W/m2 Convection to T = 25oC
Conditions
1 m x 1 m x 0.001 m
Aluminum: Thermal conductivity (K)= 167 W/m/°C, Specific heat (Cp) = 880 W/Kg/°C,
Material properties
Density(ρ) = 2700 Kg/m³
Analysis characteristics MD Nastran SOL 400: RCNS, RCNT, HSTAT, HTRAN
Element type CQUAD4 for surface
Numerical results Temperature results:
CHAPTER 57 1133
Heating and Convection on a Plate
Introduction
This problem demonstrates the applications of MD Nastran SOL 400 Thermal Solver (RCNS, RCNT, HSTAT, and
HTRAN).
Modeling Details
This problem introduces the basic steps to use MD Nastran SOL 400 Thermal Solver (RCNS, RCNT, HSTAT, and
HTRAN) by a simple rectangular surface model. In this problem, you will see how to change the cards to run different
solvers. This model has only one Quad element. A constant heat flux load is imposed onto the surface while cooling
the surface with uniform convection to a constant ambient temperature. Then you will analyze the model by running
different solvers for both steady and transient analysis. You will see how easy to switch between RC Network Solver
and FEM solver.
Surface Dimension = 1.0 m x 1.0 m x 0.001 m
Normal Heat Flux = 500 W/m²
Ambient Temperature = 25ºC
The material is Aluminum 6061 T6
Thermal Conductivity = 167 W/m.K
Specific Heat = 880 W/Kg
Density = 2700 Kg/m³
Top Surface Convection Coefficient = 6.5
Heat Flux: 500 W/m2 Convection to T = 25oC
1 m x 1 m x 0.001 m
Figure 57-1 Heating and Convection on a Plate

CHAPTER 57
Solution Highlights
The BDF files are pretty much similar, except some cards change in the Case Control Section and Bulk Data Post
Section. The main part of the BDF file is exactly the same.
MD Nastran SOL 400 RC Network Solver: RCNS (Steady State)

$# Case Control Section
TEMPERATURE (INITIAL)= 21
SUBCASE 1
$ Subcase name : NewLoadcase_RCNS
$LBCSET SUBCASE1 DefaultLBCSet
TITLE=NewLoadcase_RCNS
ANALYSIS = RCNS
NLSTEP = 1
SPC = 23
LOAD = 24
……
$# Bulk Data Post Section
TEMPD 21 0.0
SPCADD 23 2
DLOAD 24 1. 1. 1
NLSTEP 1
+ RCHEAT SNSOR 0.001 0.001 0.0 0.0 9.81
+ 5000
……
MD Nastran SOL 400 FEM Solver: HSTAT (Steady State)

TEMPERATURE (INITIAL)= 21
SUBCASE 1
$ Subcase name : NewLoadcase_RCNS
TITLE=NewLoadcase
ANALYSIS = HSTAT
SPC = 23
LOAD = 24
NLSTEP = 1
……
TEMPD 21 0.0
SPCADD 23 2
LOAD 24 1. 1. 1
NLSTEP 1
CHAPTER 57 1135
As you can see, if you have a BDF file for RCNS, or HSTAT, it is very easy to manually modify the files to run with
another solver. The NLSTEP entry for RC Network Solver has more control parameters, but actually most of them are
default parameters. The minimum requirement is as follows:
TEMPD 21 0.0
SPCADD 23 2
LOAD 24 1. 1. 1
NLSTEP 1
+ RCHEAT
MD NASTRAN SOL 400 RC Network Solver: RCNT (Transient)

IC = 21
SUBCASE 1
$ Subcase name : NewLoadcase_RCNT
TITLE=NewLoadcase_RCNT
ANALYSIS = RCNT
NLSTEP = 1
SPC = 23
DLOAD = 24
……
TEMPD 21 0.0
SPCADD 23 2
DLOAD 24 1. 1. 1
NLSTEP 1 2400.
+ RCHEAT FWDBKL 0.001 0.001 0.0 0.0 9.81 1.
+ 5000 100 0.0
MD NASTRAN SOL 400 FEM Solver: HTRAN (Transient)

IC = 21
SUBCASE 1
$ Subcase name : NewLoadcase_NTTR
TITLE=NewLoadcase_NTTR
ANALYSIS = HTRAN
SPC = 23
DLOAD = 24
NLSTEP = 1
……
TEMPD 21 0.0
SPCADD 23 4
DLOAD 24 1. 1. 1 1. 2
NLSTEP 1 2400.
+ ADAPT 100
CHAPTER 57
It is also easy to manually modify the files to switch to another solver. The NLSTEP entry for RC Network Solver has
more control parameters, but again most of them are default parameters. The minimum requirement is as follows:
TEMPD 21 0.0
SPCADD 23 2
DLOAD 24 1. 1. 1
NLSTEP 1 2400.
+ RCHEAT FWDBKL
+ 100.
CHAPTER 57 1137
NLSTEP Control Parameters for Mechanical, Thermal, and Coupled Analysis

(MD Nastran SOL 400 only)
NLSTEP specifies the convergence criteria, step size control between coupled loops and step/iteration control for each
physics loop in MD Nastran SOL 400. Additional fields were included in this pre-existing entry to provide control for
Resistance-Capacitor method of Heat Transfer Analysis.
Format
1 2 3 4 5 6 7 8 9 10
NLSTEP ID TOTTIME +
“GENERAL” MAXITER MINITER MAXBIS CREEP +
+ “FIXED” NINC NO +
+ “ADAPT” DTINITF DTMINF DTMAXF NDESIR SFACT INTOUT NSMAX +
+ ... +
“RCHEAT” SOLVER DRLXCA ARLXCA BALENG DAMPC GRVCON CSGFAC +
+ NRLOOP OUTINV DTIMEI
Example: Steady State

1 2 3 4 5 6 7 8 9 10
NLSTEP 1 +
+ RCHEAT SNSOR 0.001 0.001 0.001 0.0 0.0 9.81 +
+ 5000
Example: Transient
1 2 3 4 5 6 7 8 9 10
NLSTEP 1 1000 +
+ RCHEAT SNDUFR 0.001 0.001 0.0 0.0 9.81 1.0 +
+ 5000 100.0 10.0

ID Identification number. I0
TOTIM Total time for the load case R 1.0
“GENERAL” Keyword for parameters used for overall analysis.
... ...
“COUP” Keyword for parameters used for coupled analysis.
“RCHEAT” Keyword to indicate that RC Heat Transfer Analysis is
to be performed. See Remark 10.
SOLVER The Relaxation scheme to be used. C SNSOR - See Remark 12.
DRLXCA Diffusion node convergence criterion. R0 1.0e-3 - See Remark 11.
CHAPTER 57

ARLXCA Arithmetic node convergence criterion. R  0.0 1.e-3 - See Remark 11.
BALENG Allowable system energy imbalance. R  0.0 1.0e-3° - See Remark 11.
DAMPC Damping constant. R  0.0 0.0 nondimensional
GRVCON Gravitation constant. R  0.0 9.81 length/time2.
CSGFAC Time step control factor. R  0.0 1.0 non dimensional. See
Remark 13.
NRLOOP Number of relaxation loops allowed. I0 5000 loop
OUTINV Output interval. R  0.0 60.0 time. See Remark 13.
DTIMEI Time step. R  0.0 0.0 time. See Remark 13.
Remarks
1. Only one of FIXED, ADAPT, or ARCLN load time stepping scheme can be used on a specific NLSTEP entry.
FIXED or ADAPT may be used for a single physics STEP or for a coupled physics STEP/SUBSTEP. ARCLN is
only valid for a single physics STEP. If no FIXED, ADAPT, or ARCLN appear on a NLSTEP entry, then the default
is FIXED, with 50 increments.
2. The desired number of recycles is only used in static mechanical and heat transfer, not in dynamic mechanical.
In a coupled analysis, the time step change is calculated separately for heat and mechanica,l and the smallest
of the two is used.
3. When the time step is increased due to desired number of recycles, the previous time step is multiplied with
SFACT. When the time step is decreased, the factor is calculated internally based upon the minimum time step.
4. User criteria can be given in the TABSCTL entry via CRITTID. These criteria include rotation, displacements,
stresses, strains, creep strains. The time step is decreased if the current value of the value is larger than the user
specified limit. If LIMTAR is equal to 1 (“target”), it also increases the time step for the next increment if the
current value is smaller than the target value given.
5. If MAXITER is given a negative value and the MAXITER number of iterations are obtained, convergence is
assumed and the analysis will continue with the next increment.
6. The “ARCLN” entry is applicable to “MECH” analysis only and is ignored for creep analysis. The available
constraint types are as follows.
TYPE = “CRIS”:
i O T i O 2
 U n – U n   U n – U n  + w 2   i –  O 2 = l n
TYPE = “RIKS”:
i i–1 T i O
 Un – Un   U n – U n  + w 2  i = 0
TYPE = “MRIKS”:
i i–1 T i–1 O
 Un – Un   Un – U n  + w 2  i   i – 1 –  O  = 0
where:
CHAPTER 57 1139
w = user specified scaling factor (SCALEA)

 = load factor
l = the arc-length
The constraint equation has a disparity in the dimension by mixing the displacements with the load factor. The
scaling factor is introduced as user input so that the user can make constraint equation unit-dependent by a
proper scaling of the load factor ( w ). As the value of is increased, the constraint equation is gradually
dominated by the load term. In the limiting case of infinite, the arc-length method is degenerated to the
conventional Newton’s method.
7. The MINALR and MAXALR fields are used to limit the adjustment of the arc-length from one increment to the
next by:
MINALR  l new  l old  MAXALR
The arc-length adjustment is based on the convergence rate (i.e., number of iterations required for convergence)
and the change in stiffness. For constant arc-length during analysis, use:
MINALR = MAXALR = 1 MIMAR = MAZALR = 1
8. The arc-length l for the variable arc-length strategy is adjusted based on the number of iterations that were
required for convergence in the previous increment ( I max ) and the number of iterations desired for convergence
in the current increment (NDESIRA) as follows:
l new = l old  NDESIRA  I max 1  2
9. If a negative value is given to MAXCLP, the coupled analysis will proceed to the next increment even if the
coupled loop has not converged when the maximum number of coupled loops, |MAXCLP|, has been reached.
10. This entry is used for a nonfinite element, Resistance-Capacitor network method of analysis for heat transfer.
11. Convergence is determined by the combination of DRLXCA, ARLXCA, and BALENG. DRLXCA and ARLXCA
determine if relaxation is met on a node by node basis, rather than a residual vector length.
12. If, in Case Control, the ANALYSIS=RCNS, then valid values are:
SNSOR (Default) Successive over-relaxation method

SSQMR Steady state Quasi Minimal Residual method
SSSPM Steady state sparse matrix solver method
STDSTL An iterative solver aimed at the fourth root of a quartic for the network equations
(good for strong radiation dependence)
If, in Case Control, the ANALYSIS=RCNT, then valid values are:
SNDUFR (Recommended) An unconditionally stable, explicit method based on a modified Dufort-Frankel

scheme
SNFRDL Fast, accurate explicit forward differencing transient method
FWDBKL Implicit forward/backward differencing Crank Nicolson method
CHAPTER 57
SNADE Alternating direction explicit method

ATSDUF SNDUFR with automatic time step based on ERRMIN/ERRMAX
ATSFBK FWDBKL with automatic time step based on ERRMIN/ERRMAX
SNTSM Weighted implicit forward/backward differencing method
SNTSM3 Weighted implicit forward/backward differencing method
TRSPM Transient sparse matrix solver method
ATSSPM TRSPM with automatic time step based on ERRMIN/ERRMAX
TRQMR Transient Quasi Minimal Residual
ATSQMR TRQMR with automatic time step based on ERRMIN/ERRMAX
If SOLVER is left blank or set to SNSOR and ANALYSIS=RCNT, then internally the RC code will select SNDUFR.
13. About the time step:
a. The default computed time step (DTIMEU) = CSGMIN* CSGFAC. CSGMIN is based on the conductance in
the model and can be checked in the .sot file. If CSGFAC is not specified, it is internally set to 1.0.
b. In a normal sized model, CSGMIN is usually small enough for the time step which will assure a convergent
transient run.
c. CSGFAC is used to adjust the time step. It is recommended to determine the best CSGFAC to the model while
maintaining acceptable temperature errors.
d. If OUTPUT < CSGFAC*CSGMIN or OUTPUT < DTIMEI, then OUTPUT becomes the time step. All the
OUTPUT points are automatically required to be calculated.
e. DTIMEI is the forced time step which will ignore any other factors. Sometimes it may lead to inaccurate
answer if it is too large. DTIMEI does not affect the automatic time step solvers.
f. If the model size is very small, CSGMIN may be too big for the time step. A small CSGFAC or DTIMEI should
be used to adjust the time step.
g. CSGFAC*CSGMIN or DTIMEI should be small enough to “catch” any details in time fields, temperature
fields, or orbital flux arrays.
CHAPTER 57 1141
Results
Figure 57-2 Temperature Contour of Plate (Steady State)
Figure 57-3 Temperature Curves of Plate (Transient State)

CHAPTER 57
RCNS and HSTAT have the same steady state result. RCNT and HTRAN have the same transient temperature curves. These
curves are drawn in SimXpert/Result/Chart. The curves from RCNT/FWDBKL and HTRAN fit perfectly. The total time
(end tine) is 2400 seconds. The output interval is 100 seconds.
Modeling Tips
SimXpert uses ATSDUF as the default solver, and Sinda for Patran uses SNDUFR as the default solver. RC Network
Solver has other solvers available. For this specific model which has only one element and the thickness is very thin,
therefore CSGMIN is very small (CSGMIN is the minimum value of CSG for each node in the model. CSG = C   Gi ,
where C is the capacitance, and Gi is the conductors for this node), a very small time step will be required. We need
to set up some control parameters for ATSDUF or SNDUFR to make sure they have small enough time step to start
the transient analysis. For more information, please reference the MSC Sinda User's Guide or Sinda for Patran User's
Guide. The solver FWDBKL is an implicit solver which does not have this problem. FWKBKL is one of the implicit
transient solvers of RC Network Solver.
Input File(s)
Files Description
QT34_conv_rcns.dat MD Nastran SOL400/RC Network Solver thermal input file
QT34_conv_ntss.dat MD Nastran SOL400/FEM Solver thermal input file
QT34_conv_rcnt.dat MD Nastran SOL400/RC Network Solver thermal input file
QT34_conv_nttr.dat MD Nastran SOL400/FEM Solver thermal input file
Video
Heat Flux: 500 W/m2 Convection to T = 25oC
1 m x 1 m x 0.001 m

Chapter 58: Coupled Advection for Heat Exchanger
Coupled Advection for

58 Heat Exchanger

Summary 1144

Introduction 1145



Modeling Tips 1152

Input File(s) 1152

Video 1153
CHAPTER 58
Summary
Title Coupled Advection for Heat Exchanger
Features • 1-D fluid flow using PCONV1 entry
• Coupled advection using PRJCON and SET3 cards
Geometry
Length: 10 in.
Air Channel: 5(1x0.5)
Material properties • Aluminum: Thermal conductivity (K)= 4 W/in°C

• Air: Thermal conductivity (K)= 6.66e-4 W/in°C, Specific heat (Cp) = 456.2 j/lb°C,
Thermal density (ρ) = 5.01e-5 lb/in³, µ= 1.03e-6 lb/in.s, β= 3.43e-3/°C
• Inner wall thickness = 0.1 in, outside wall thickness = 0.05 in.
• Airflow: mass flow rate= 8.33e-3 lb/s
Analysis characteristics Solution 400 / RC Network solver. Steady state thermal analysis.
Boundary conditions Inlet temp of air flow= 20°C
Applied loads • Top surface heat flux = 20 W/in²
• Five coupled advection loads, convection coefficient = 0.3
Element type • CQUAD4 for surface, CHBDYP/FTUBE for air flow
Numerical results
Temperature Results
CHAPTER 58 1145
Coupled Advection for Heat Exchanger
Introduction
This problem demonstrates the coupled advection capability of SOL 400 RC Network Solver.
Modeling Details
This problem shows the application of coupled advection load. You will see how the air flow associates with the heat
exchanger surfaces. The heat exchanger is being modeled in SimXpert. A normal flux 20 W/in² is applied on the top
surface. Five curves are used to represent the air flow through the five channels. SimXpert supports the use of either
fluid nodes or curves for the fluid flow. When curves are used, SimXpert automatically converts them into fluid nodes
internally. For SOL400 RC Network Solver (RCNS or RCNT), the mass flow rate is a part of the 1-D fluid flow
property; therefore, the mass flow rate of the flow conductors does not change if they are attached to multiple surfaces
with multiple coupled advection loads. Please note: this is different with SOL400 FEM solver (HSTAT or HTRAN).
For SOL400 FEM solver, mass flow rate is a part of load. If the air flow is used by different coupled advection loads,
each load has its own mass flow rate. The total mass flow rate is the sum of all the coupled advection loads.
The mesh on the surfaces does not need to match that of the curves. This is because the thermal contact used to attach
the airfow to the surface allows for dissimilar meshes. However, using the same mesh size for the air flow and the
surface (Figure 58-1) to produce a one-to-one correspondence is preferred.
q = 20 W/in2
w
lo
rF
Ai
Structure: Aluminum Plate:

Inner Wall Thickness = 0.1 in K = 4.0W/inoC
Outside Wall Thickness = 0.05 in
Air Flow: Air:

Tin = 20oC K = 6.66e-4 W/inoC
mdot = 8.33e-3 lbm/s Cp = 456.2 J/lbmoC
h = 0.3 W/in2oC ρ = 5.01e-5 lbm/in
μ = 1.03e-6 lbm/in/s
o
β = 3.43e-3/ C
Figure 58-1 Heat Exchanger Model (Nastran Test File: QT26_exchang_all.dat)
CHAPTER 58
Solution Highlights
As a part of MD Nastran SOL 400, the RC Network Solver is indicated by ANALYSIS = RCNS for steady state
thermal analysis, and ANALYSIS = RCNT for transient analysis. SimXpert always creates a SPCADD or a LOAD in
the Bulk Data Post Section for RCNS or RCNT, even if there is only one SPC or one LOAD in the Bulk Data Model
Section. This is not the case for HSTAT or HTRAN models created by SimXpert.
The following are the highlights of the Nastran input file necessary to model this problem:
PCONV1 entry is used by RC Network Solver for Fluid property. Mass Flow Rate is defined as a property parameter
in PCONV1 entry for the fluid stream (a curve or a series of 1-D bar elements); therefore, the fluid stream’s mass flow
rate is a constant, even if it maybe referenced by multiple coupled advection loads. Please note: this is different with
Nastran/Thermal where mass flow rate is a part of coupled advection load. For Nastran/Thermal, the total mass flow
rate is the sum of the mass flow rates if a fluid stream is referenced by multiple coupled advection loads.
CHAPTER 58 1147
The PRJCON entry is used to link the two SET3 cards with a constant h value. The inlet temperature is defined as a
SPC for each node. The fluid flow is defined as a group of CHBDYP/FTUBE elements. The first SET3 entry contains
the CHBDYE surface element IDs where the coupled advection load applies. The second SET3 entry contains the
nodes along the fluid flow stream. The multiple CHBDYP elements are not allowed between the same two fluid nodes.
This is difficult with Nastran/Thermal.
The translator of RC Network Solver hooks the fluid stream nodes with the surface nodes during runtime based on the
nearest neighbor method.
CHAPTER 58
PCONV1 Thermal Convection Calculation Properties
Defines the properties required to calculate convective heat transfer. It can exist in a simple mode with convection
coefficient defined in the MID or in advanced mode where the H value is calculated using the geometric parameters and
referenced material.
Format
1 2 3 4 5 6 7 8 9 10
PCONV1 PID Corr ID MID Mdot Velocity Length or Flow Cross +
Diameter Section
Length Flow Cross Mdot f Velocity f Length or Flow Cross +
function Section Diameter f Section f
type type
+ C1 C2 C3 C4 C5 C6 C7 C8 +
+ C9 C10 C11 C12 C13 C14 C15 C16 +
+ C17 C18 C19 C20 C21 C22 C23 C24
Example
1 2 3 4 5 6 7 8 9 10
PCONV1 2 701 2 1.0
Format and Example

PID Property identification number, referenced by CHBDYP I  0
and/or CONV.
Corr ID ID of convection type in correlation library. I0 0
MID Material identification number for convection I0 0
calculation.
Mdot Mass flow rate. R 0.0
Mdot f Mass flow rate TABLEDj table ID. I0 0
Velocity Fluid velocity. R0 0.0
Velocity f Fluid velocity TABLEDj table ID. I0 0
Length or Diameter Geometry, based on Corr ID. R  0.0 0.0
Length or Diameter f type Geometry function type: I0 2
1= time
2= temperature
Length or Diameter f Geometric function TABLEMj or TABLEDj table ID I0 0
Flow Cross Section Flow Cross Section. R  0.0 0.0
CHAPTER 58 1149

Flow Cross Section f type Flow Cross Section function type I0 2
1= time
2= temperature
Flow Cross Section f Flow Cross Section function TABLEMj or TABLEDj table I  0 0
ID.
C1 thru C24 Geometric properties based on chosen convection R 0.0
correlation
Remarks
1. This entry is for RC Network solver only.
2. The PCONV1 entry contains the properties for a CONV and CHDBYP, and can be used for connecting with a
PRJCON. PID must be unique to both the PCONVID in PCONV and the PID in PHBDY. This will be the ID
referenced by CONV, PRJCON, and CHBDYP.
3. MATID must reference a MAT4 fluid material.
4. For Corr. ID and C1 thru C24, please reference MSC SINDA User’s Guide and Library Reference or the
P/Thermal User’s Guide.
CHAPTER 58
PRJCON Thermal RC Element Contact
Specifies a thermal connection between two regions of elements. The connection is automatically determined
geometrically as a projection of the slave region on to the master, and the strength of the connection is calculated based
on the properties given.
HEAT1
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT1 SET3 SET3 Slave h
Master
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT1 1 2 1.2
HEAT2
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT2 SET3 SET3 Slave PID
Master
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT2 1 2 1001
HEAT3
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT3 SET3 SET3 Slave F Emis Emis Slave
Master Master
CHAPTER 58 1151
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT3 1 2 1. 0.85 0.5
HEAT4
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT4 SET3 SET3 Slave F RADC id RADC id
Master Master Slave
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT4 1 2 1. 1001 1002

BID BCBODY identification number. I0 Required
HEATx Indicates the start of HEAT elements. C
SET3 Master ID of the master element collection for connection. I0 Required
SET3 Slave ID of the slave element collection for connection. I0 Required
h Convection correlation. R  0.0 Required
for HEAT1
PID PID of the property to be used for h value. I0 Required
for HEAT2
F View factor between parts. 0.0  R Required
 1.0 for HEAT3
& HEAT4
Emis Master Emissivity of master collection. R  0.0 Required
for HEAT3
Emis Slave Emissivity of master collection. R  0.0 Required
for HEAT4
RADC id Master RADMID of the material to be used for master emissivity I0 Required
value.
RADC id Slave RADMID of the material to be used for slave emissivity I0 Required
value.
CHAPTER 58
Remarks:
1. This HEATx and the later parameters are for RC Network solver only.
2. For HEAT2, PID must refer to a PCONV1 type, and not a PCONV or PCONVM.
3. RC Network Solver uses a projection method to determine the connection (not the “nearest neighbor method”).
In most of the cases, the projection method is more accurate than the nearest neighbor method.
Results
Figure 58-2 Temperature Contour of Heat Exchanger
SimXpert cannot display the temperature contour on the fluid stream but does on solid surface such as plate or solid
element faces. The air flows are heated by the wall, so the temperature at outlet points is higher than that at inlet points.
This also causes the temperature gradient on the heat exchanger surfaces. The heat conducts from the top surface to
the bottom surface through the six side walls; this causes the waves of the temperature contour.
Modeling Tips
The 1-D Fluid Flow properties are defined in Material and Property/1D Properties / Correlation. If you want to use
constant convection coefficient in the coupled advection loads, please select the 1D Fluid Flow option. If you want to
use convection correlation to calculate the convection coefficient, please pick the Convection Correlation option.
Please note coupled advection can be applied to the top or bottom of a surface and will produce the same results.
Input File(s)
File Description
QT26_exchang_all.dat MD Nastran SOL400/RC Network Solver thermal input file
CHAPTER 58 1153
Video
Length: 10 in.
Air Channel: 5(1x0.5)

CHAPTER 59
Chapter 59: Shallow Cylindrical Shell Snap-through
Shallow Cylindrical Shell

59 Snap-through

Summary 1155

Introduction 1156



Results and Discussion 1159

Input File(s) 1162

Video 1162
 References 1162
CHAPTER 59 1155
Shallow Cylindrical Shell Snap-through
Summary
Title Chapter 59: Shallow Cylindrical Shell Snap-Through
Features Snap-through of a shallow cylindrical shell structure
Geometry
Material properties E = 3.10275 kN/mm2;  = 0.3

Analysis characteristics Nonlinear static analysis using (i) arc-length method (ii) adaptive load stepping method
with damping
Boundary conditions The straight edges of the shell are hinged and the curved edges are free
Applied loads A point load applied at the center of the shell
Element type Four node thin and thick shell elements
FE results Load-deflection response
CHAPTER 59
Introduction
The purpose of this document is to demonstrate the arc-length solution capability of Nastran to solve snap-through
problems using the ARCLN option in NLSTEP entry. The example considered is a shallow cylindrical shell structure
which exhibits snap-through and snap-back behaviors under the action of a point load. This problem is widely used
by many researchers to investigate and validate various nonlinear arc-length procedures. The challenge with load
control nonlinear solution methods is that they fail to converge at limit points where the tangent stiffness matrix is
singular. Hence, these methods are not suitable for applications where the response of a structure beyond the limit point
is of interest. Although displacement control methods can capture the snap-through behavior of such problems, they
fail at the point where snap-back begins. The arc-length method which is a path following technique allows the
analysis to pass the limit points without any difficulty.
The model is analyzed in MD Nastran using the SOL 400 solution sequence. Crisfield’s arc-length scheme is
utilized for the nonlinear solution procedure. Nastran analysis results are compared with that of published solutions
(Crisfield, 1981).
Modeling Details
The geometry of the model, shown in Figure 59-1, is a cylindrical shell with radius R = 2540 mm, length 2L = 508
mm, and thickness h = 6.35 mm. The straight edges of the structure are pin supported and the curved edges are free.
The cylindrical segment subtends an angle 2 = 0.2 radians with the axis of the cylinder. A point load P is applied at
the midpoint of the shell structure.
Since the structure exhibits bi-planar symmetry, only a quadrant of the geometry is considered for the finite element
analysis. A 6 x 6 shell element mesh is used to discretize the model. The case control options used for the solution
sequence SOL 400 are
SUBCASE 1
SET 100 = 6,36
STEP 1
ANALYSIS = NLSTATIC
NLSTEP = 1
SPC = 2
LOAD = 2
DISPLACEMENT(SORT1,REAL,PUNCH)=100
OLOAD(PLOT,PUNCH)= 100
SPC and LOAD cards are used to identify the set numbers for displacement boundary conditions and applied loads,
respectively. DISPLACEMENT and OLOAD cards represent the analysis output for displacements and loads.
CHAPTER 59 1157
Figure 59-1 Geometric Model of the Cylindrical Shell Structure
Element Modeling
Four node quadrilateral shell elements (CQUADR) are used to model the structure. Properties of the elements, such as
shell thickness, are defined through the PSHELL entry. Additional nonlinear properties for the shell elements
corresponding to PSHELL are specified using the PSHLN1 option. Keyword C4 indicates that the next two entries in
that input line apply to elements with four corner nodes. DCTN implies a doubly-curved thin shell element type, and
LDK is the integration code. For thick shell elements, DCT and L options are used for the structural property and
integration code, respectively.
PSHELL 1 1 6.35 1 1
PSHLN1 1
C4 DCTN LDK
Material Modeling
Linear isotropic material properties are defined using MAT1 entry. Elastic modulus and Poisson’s ratio are the material
constant input for this analysis.
MAT1 1 3105. .3 1.

Figure 59-2 shows the loading and boundary conditions applied on the finite element model of the shell structure.
Since a quarter model is utilized, symmetry boundary conditions are applied along the edges  z = 0 and z = 0 .
Translational displacements in the x- and y-directions are constrained on the nodes along the edge  z = –  , which is
pin supported. A concentrated load of magnitude -250 N (total load on the full model = -1000N) is applied in the y-
direction on the node located at the midpoint of the structure  x = 0, z = 0  .
CHAPTER 59
Figure 59-2 Loading and Boundary Conditions on the Finite Element Model
SPCADD and LOAD cards define the single point constraint and load sets, respectively. Displacement constraints and
concentrated nodal forces are specified using SPC1 and FORCE cards, respectively.
SPCADD 2 1 3 4
LOAD 2 1. 1.
$ Displacement Constraints of Load Set : pinned
SPC1 1 12 1 7 8 9 10 11
$ Displacement Constraints of Load Set : symmetry_z
SPC1 3 345 1 2 3 4 5 6
$ Displacement Constraints of Load Set : symmetry_x
SPC1 4 156 6 32 33 34 35 36
$ Nodal Forces of Load Set : point_load
FORCE 1 6 0 250. 0. -1. 0.
Solution Procedure
The problem is analyzed in MD Nastran using the SOL 400 routine which is an implicit nonlinear solution procedure.
In the PARAM entry LGDISP = 1 enables the nonlinear large displacement capability with updated element
coordinates and follower forces effect. Control parameters for the nonlinear solution scheme are described through the
NLSTEP entry. The entries in GENERAL option are common to all types of analysis. The first three entries denote
maximum, minimum number of iterations allowed for each increment and maximum number of bisections in the
current increment.
PARAM LGDISP 1
NLSTEP 1 1.00
GENERAL 25 1 10
ARCLN CRIS 0.05 0.01 1.0001 5 1000
MECH PUV 0.001 0.001 0.00 PFNT 3
ARCLN keyword activates the arc-length load stepping strategy for the analysis. The type of arc-length scheme, CRIS
which represents Crisfield’s technique, is specified in the first field. The second field indicates the initial time step
expressed as a fraction of the total analysis load step time. Minimum and maximum allowable ratios of arc-lengths
CHAPTER 59 1159
between successive increments are specified in the next two fields. The sixth entry indicates the desired number of
iterations for convergence and the last field implies the maximum number of increments in the current load case.
The parameters for a mechanical analysis are described through MECH keyword. The first field flags to select the
convergence criteria. The next two fields indicate the tolerance error for displacement and load. The method for
updating the stiffness matrix is specified in the fifth field. The flag used in the last entry chooses the type of variables
to be considered for error check.
In this analysis, an initial load increment of 0.01, which is 1% of the total load applied, is used. A convergence check
on relative displacement and residual forces is selected and the corresponding tolerance values are 0.001 and 0.001.
Nodal rotations and moments are not included in the convergence check. Pure full Newton-Raphson method is
employed for updating the stiffness matrix which recalculates the tangent stiffness matrix for every iteration.
This problem can be solved alternately by adopting the automatic adaptive load stepping scheme with damping option.
This procedure is initiated with the ADAPT keyword which replaces the ARCLN option in the NLSTEP entry. Initial time
step, minimum and maximum time steps and the desired number of iterations are sequentially specified for the ADAPT
option. In the next line of input, the flag to activate damping (IDAMP) and the damping ratio (DAMP) are specified.
ADAPT 0.01 1E-5 0.5 5
4 2E-4
IDAMP = 4 employs the time step control method using damping. A damping ratio of 2x10-4 is used in this problem.
Results and Discussion

Force-deflection response of the structure modeled with thin shell elements is presented in Figure 59-3. The solid blue
line represents the behavior of the node at which the load is applied, and the red line indicates the response of the
midpoint of the free edge. From the response of the midpoint node, it is observed that the structure follows a stable
nonlinear path in the beginning phase of the analysis. As the applied load reaches a value of 596 N, the stiffness matrix
approaches singularity indicating an unstable equilibrium. At this limit point, the structure begins to snap-through and
the load-deflection curve exhibits a downward trend. It is to be noted that the displacement of the node under
observation is still in the downward direction. As the midpoint reaches a position corresponding to a displacement of
about 16.7 mm, it begins to move upwards indicating a snap-back phenomenon. The snap-back behavior lasts till the
displacement of the point attains 14.6 mm at which the motion of the midpoint reverses direction again. Snap-through
response continues until the load reaches -366 N after which the load-deflection curve follows a stable equilibrium
path.
Figure 59-4 shows a comparison of the solutions obtained with SOL 400 using thin and thick shell elements to the
results of Crisfield (1981). The Nastran results are in reasonable agreement with Crisfield’s solution which is
represented by dot markers in Figure 59-4. The variation in results is due to the difference in the finite element
approximation used by Crisfield (1981) and Nastran. Crisfield (1981) employed rectangular elements with quadratic
variation for in-plane displacements and a restricted quartic non-conforming shape functions for the out-of-plane
displacements. This example demonstrates that the arc-length scheme of MD Nastran captures the snap-through
behavior of shell structures with good accuracy.
Figure 59-5 presents the response of the shallow shell structure solved utilizing the adaptive time stepping procedure
with damping. The figure shows a comparison of load-deflection curves for thick and thin shell models and also
CHAPTER 59
between the adaptive and arc-length solution schemes. In the first phase of the curve when the structure is in stable
equilibrium, the two approaches yield matching results which indicates that the adaptive times stepping method
introduces negligible damping into the system. But, in the vicinity of the limit point, where the structure approaches
an unstable configuration, equilibrium is attained numerically by adding artificial damping. Beyond this point, while
the true equilibrium path follows a downward trend in the snap through and snap-back regimes, the adaptive time
stepping procedure follows a horizontal path as a solution is attempted at a constant load value of 608N (thin shell
model). The strain energy that needs to be relieved by the structure to remain in equilibrium is dissipated by damping.
The constant load response continues until the structure reaches the next undamped stable configuration corresponding
to this load value, after which the path followed by the curve is similar to the arc-length method. It is to be noted that
unlike the arc-length method this approach is not capable of predicting the stable configurations at load levels below
the current load step. But, the damping option is very useful when analyzing complicated structures posing
convergence problems due to local instabilities. In such cases, it must be ensured that energy dissipated by damping
does not exceed a small proportion of internal energy (e.g., 2%) so that the error introduced in the load-deflection
response is within an acceptable limit.
Figure 59-3 Load-Deflection Response of the Shallow Shell Structure

CHAPTER 59 1161
Figure 59-4 Comparison of Snap-through Load-deflection Responses
Figure 59-5 Response of the Structure with Automatic Adaptive Load Stepping Scheme and Damping
CHAPTER 59
Input File(s)
Files Description
nug_59a.dat Snap-through analysis using arc-length method
The model is analyzed using the adaptive load stepping method with
nug_59b.dat
artificial damping
Video
References
Crisfield, M. A., A fast incremental/iterative solution procedure that handles “snap-through”, Computers & Structures,
1981, 13, 55-62
Chapter 60: Deformable Baffle in a Duct using OpenFSI
Deformable Baffle in a Duct

60 using OpenFSI

Summary 1164

Introduction 1165

Results 1165

Input File(s) 1166

Video 1166
CHAPTER 60
Summary
Title Chapter 60: Deformable Baffle in a Duct using OpenFSI
OpenFSI Features Transient FSI simulation using one of the available OpenFSI CFD partner services
Geometry
Flow
Plate (1x 0.1 x 0.02 m)
Click on image above to play animation

Material Properties E = 2.3e+9 Pa,  = 0.33,  = 1000 Kg/m3
Analysis Type Nonlinear Transient
Boundary Condition Plate fix at bottom of channel, variable pressure due to fluid loads
Element Type 3D Brick
FE Results
www.acusim.com/papers/OpenFSI_overview.pdf
References
MD Nastran 2010 Release Guide
CHAPTER 60 1165
Deformable Baffle in a Duct using OpenFSI
Introduction
This example illustrates setting up a transient FSI simulation using one of the available OpenFSI CFD partner services
(OpenFSI-AcuSolve service from Acusim here). MD Nastran calculates the baffle deformation and nodal velocities
while the CFD code calculates the flow induced loads on the baffle wetted surfaces. The initial condition is a
converged CFD solution on the undeformed baffle. The SOL 400 nonlinear transient solution references the connected
OpenFSI service.
Figure 60-1 CFD Geometry of Flexible Baffle in Narrow Duct
Results
The flow excites the first natural frequency of the cantilever plate which is 5.28 Hz or a time period of 0.19 seconds
that is seen in the tip displacement history in Figure 60-2. Since the plate is elastic with no damping, the damping of
the tip oscillation is caused by viscous losses in the fluid flow.
Figure 60-2 Baffle Tip Displacement History

CHAPTER 60
Input File(s)
Files Description
plate_baffle_str.dat MD Nastran input file of flexible baffle
plate_fsi_baffle.xdb xdb produced from the OpenFSI baffle run using Acusolve (20Mb)
openfsi_baffle_cfd_ex AcuSolve input files (attached zip file 15Mb). AcuSolve installation
ample.ZIP required.
Use the plate_fsi_baffle.xdb results if you don't have access to AcuSolve or would like to skip the MD
Nastran OpenFSI run.
Video

Chapter 61: Steady State Heat Transfer due to Natural Convection between Two Noncontacting Bodies located in
Nearby Vicinity
Steady State Heat Transfer

due to Natural Convection
61 between Two Noncontacting
Bodies located in Nearby
Vicinity

Summary 1168

Introduction 1169

 FEM Solutions 1170

Results 1173

Input File(s) 1176
 Video 1176
CHAPTER 61
Summary
Title Chapter 61: Steady State Heat Transfer due to Natural Convection between Two
Noncontacting Bodies located in Nearby Vicinity
Contact Features • 3-D Shell – Solid Contact
• The two bodies are located at some distance from each other and do not come in contact
Geometry 3-D Shell elements (units: m)
Quarter Cylinder:
Diameter 10m
Length 10m 5m
Shell thickness 0.1m 10m
2m
3-D Solid elements (units: m) 3m

2m
Solid Cuboid:
Length 5m 5m
Breadth 3m
Thickness 2m 3m
Radius = 5m
Material Properties Quarter Cylinder:

Thermal Conductivity: 20 W/m-oC
Solid – Cuboid:
Thermal Conductivity: 10 W/m-oC
Analysis Type Steady State Heat Transfer – Natural Convection
Isotropic materials (with temperature independent properties)
Boundary • Heat Flux
Condition • Thermal Contact
• Natural Convection with Ambient Temperature
Element Type 3-D Shell
CQUAD4
Solid
CHEXA
Contact Data • The two bodies are separated by a minimum distance of 1.4m and maximum distance of 5m.
• Near contact option is enabled using a distance of 5m in BCTABLE entry.
FE Results • Temperature Plot
• Heat Flux Plot
CHAPTER 61 1169
Steady State Heat Transfer due to Natural Convection between Two Noncontacting Bodies
Introduction
A cuboid (5X3X2m) and a quarter cylinder (with a 10m diameter and 10m height) are placed as shown in Figures 61-1
and 61-2. Quarter cylinder (often referred as the shell in this document) is 0.1m thick. One face of the cuboid,
measuring 5X2m and away from quarter cylinder, is subjected to a heat flux of 100 W/m2. All the remaining faces of
the quarter cylinder and cuboid are exposed to atmosphere. The simulation demonstrates various capabilities available
in the MD Nastran SOL 400. This exercise demonstrates heat transfer simulation between two noncontacting
deformable bodies due to natural convection. Automated contact algorithms have been utilized to simulate the heat
transfer between the two.
Figure 61-1 FE Model of Two Bodies Participating in Heat Transfer

CHAPTER 61
5m
10m
2m
3m
2m
5m
3m
Radius = 5m
Figure 61-2 Schematic for the Two Bodies Participating in Heat Transfer
Requested Solution
Steady state temperature and heat flux plots are of interest to us. The availability of the nonlinear property extension
entry for shell and solid elements, allows the user to override standard Nastran heat elements. One can run this
simulation using standard Nastran elements. For this, the ANAL entry is set to IH which refers to the implicit heat
analyses elements. The solution presented includes:
• Temperature plots
• Heat Flux Plots
FEM Solutions
The contact, material/geometry, convergence, and other parameters used for the natural convection between the two
noncontacting deformable bodies are as follows:
Contact Parameters
The two noncontacting deformable bodies participating in the heat transfer are shown in Figure 61-2. The first body
in red, a deformable solid cube, receives heat directly from a heat source on one of its surface, measuring 5m X 2m
and away from the shell. The second body in green, a quarter cylinder, is the only other body participating in the
simulation. Due to conduction, remaining surfaces of the solid gets heated. The heat is then transfer from solid to shell
CHAPTER 61 1171
through thermal contact with h equals to 10 W/m2°C. The heat sink is on the outer side of the shell. The heat from this
surface is convected to ambient air at 25oC with h equals to 0.1 W/m2-oC.
$ Contact Body: deform_solid
BSURF 2 461 462 463 464 465 466 467+

+ 468 469 470 471 472 473 474 475+
+ 652 653 654 655 656 657 658 659+
+ 660
$ Contact Body: Deform_chexa
BSURF 3 101 102 103 104 105 106 107+

+ 108 109 110 111 112 113 114 115+
+ 452 453 454 455 456 457 458 459+
+ 460
BCBODY with user ID 1 is defined as a three dimensional deformable body associated with BSURF ID 2. BCBODY
with ID 2 represents three dimensional deformable quarter cylinder and is associated with BSURF ID 3.
$ Contact Table: BCTABLE_1
BCTABLE 1 1 +
$ Pair: Deform_chexa / deform_solid
+ SLAVE 2 +
+ 5. +
+ FBSH +
+ HHHB 10. +
+ MASTERS 1
BCTABLE with ID 1 is used in conjunction with the BCONTACT with ID 1 case control option to define the behavior
of two bodies during thermal interaction. A set of contact parameter is defined in the table above. The heat transfer
coefficient is defined as 10 W/m2. The distance below which near thermal contact behavior occurs is set to 5m. This
distance is referred by DQNEAR on BCTABLE.
For the purpose of simulation, two isotropic materials with constant thermal conductivity represented by the MAT4
entry are defined. Thermal conductivity for solid is set to 10 W/m-oC (represented by MAT4 ID 1) and 20 W/m-oC for
shell.
MAT4 1 10.
MAT4 2 20.
The quarter cylinder is 0.1m thick and is represented by PSHELL. Cuboids measuring 5m in length, 3m in breadth,
and 2m in height is represented by PSOLID. Additional nonlinear properties for PSHELL and PSOLID are specified by
PSHLN1 and PSLDN1, respectively. IH, which refers to ANAL value on PSHLN1 and PSLDN1 cards, specifies implicit
heat transfer elements.
CHAPTER 61
PSHELL 2 2 0.1
PSHLN1 2 2 IH
PSOLID 1 1
PSLDN1 1 1 IH +
Solid is meshed using CHEXA elements and CQUAD4 elements are used to mesh Shell.
CQUAD4 461 2 1 2 688 687
CQUAD4 660 2 874 875 126 125
…
CHEXA 101 1 127 128 135 134 204 205+
+ 212 211
CHEXA 460 1 580 581 588 587 657 658+
+ 665 664
…
NLSTEP with ID 1 specifies the convergence criteria, step size control between coupled loops, and step/iteration
control.
NLSTEP 1 1. +
+ FIXED 2 2 +
+ HEAT PW AUTO
In our case, most of the values have been set to default. Total time for the load case is set to 1. Since our problem
involves single physics, ‘Fixed’ load time stepping scheme is sufficient. Although the default number of increments
is 50 but in a steady state heat transfer simulation we are only interested in the last step, thus an increment of 2 is
sufficient.
HEAT specifies the parameters for heat transfer analysis. PW refers to convergence criteria and is used as default for
non contact problems. The P in PW refers to error tolerance in heat flux criteria and the W refers to error tolerance
work criteria. 0.01 is set as the error tolerance for both heat flux and work. Stiffness updates are enabled through
AUTO option.

Case control entries to conduct this analysis are mentioned below:
SUBCASE 1
$ Subcase name : subcase_1
$LBCSET SUBCASE1 lbcset_1
TITLE=subcase_1
SUBTITLE=subcase_1
LABEL=subcase_1
FLUX(SORT1,PRINT)=ALL
BCONTACT = 1
CHAPTER 61 1173
ANALYSIS = HSTAT
SPC = 3323
LOAD = 3324
NLSTEP = 1
SUBCASE 1 indicates the case being considered. BCONTACT = 1 is used to indicate the contact parameters for
SUBCASE 1. NLSTEP = 1 is used to flag the nonlinear procedure for SUBCASE 1. Temperature and heat flux are the
two standard output that have been requested. TEMPERATURE (INITIAL) specified initial temperature.
Results
Figure 61-3 shows the temperature plot. The highest temperature is recorded on a vertex which is farthest from the
shell and the minimum temperature is recorded on a node lying on the shell and is at a farthest distance from the solid.
The temperature is unlikely to change even if we change the DQNEAR value to 3m, as the contact set will remain
unchanged. Any further reduction will lead to increase in maximum temperature and decrease in minimum
temperature. Since the minimum distance between the two bodies is approximately 1.4, hence the solution won’t
converge if the DQNEAR values are set below the minimum distance. Figure 61-4 shows the heat flux plot. Table 61-1
confirms these findings.
Figure 61-3 Temperature Plot

CHAPTER 61
Figure 61-4 Heat Flux Plot
Table 61-1 Variation of Minimum and Maximum Values of Temperature and Heat Flux with
DQNEAR Values
Maximum Minimum Maximum Heat Minimum Heat
DQNEAR Temperature Temperature Flux Magnitude Flux Magnitude
S. No. Value (m) Value (oC) Value (oC) (W/m2) (W/m2)
1 5 209.1 106.0 495.3 10.7
2 4 209.1 106.0 495.3 10.7
3 3 209.1 106.0 495.3 10.7
4 2 255.9 96.90 682.4 14.9
5 1 N/A N/A N/A N/A
The users are encouraged to try out the simulation with different values of DQNEAR.
In addition, these entire scenarios can be simulated in a single run by using multiple subcases concept in SOL 400. By
definition, each subcase is completely independent of other subcase. Thus, we can have multiple BCTABLE in a single
run, and each subcase will then point to the specific BCTABLE.
SOL 400
CEND
ECHO = NONE
SUBCASE 1
$ Subcase name : NewLoadcase
CHAPTER 61 1175
$LBCSET SUBCASE1
TITLE=NewLoadcase
BCONTACT = 1
ANALYSIS = HSTAT
SPC = 3323
LOAD = 3324
NLSTEP=1
SUBCASE 4
$ Subcase name : NewLoadcase
$LBCSET SUBCASE1
TITLE=NewLoadcase
BCONTACT = 4
ANALYSIS = HSTAT
SPC = 3323
LOAD = 3324
NLSTEP = 2
BEGIN BULK
NLSTEP,1,1.0
,FIXED,2,2
,HEAT,PW,1.0E-2,1.0E-2,1.0E-2,AUTO
NLSTEP,2,1.0
,FIXED,2,2
,HEAT,PW,1.0E-2,1.0E-2,1.0E-2,AUTO
BCTABLE 1 1 +
+ SLAVE 2 +
+ 5. +
+ FBSH +
+ HHHB 10. +
+ MASTERS 1
BCTABLE 4 1 +
+ SLAVE 2 +
+ 2.0 +
+ FBSH +
+ HHHB 10. +
+ MASTERS 1
F06 Output
A number of case control options such as TEMPERATRE (INITIAL), BCONTACT, NLSTEP, etc have been used. (See
nug_61.bdf).
Temperature and heat flux values are requested for all computed load increment. This output is set by default (=0) in
the NLSTEP entry. If a positive integer is used to refer to INTOUT on the NLSTEP entry, it will allow output at equally
spaced intervals. In such cases, even the time steps will be temporarily adjusted to reach these points in time.
THERMAL(SORT1,PRINT)=ALL and FLUX(SORT1,PRINT)=ALL produces temperature and heat flux output for all
the nodes.
CHAPTER 61
Input File(s)
Files Description
nug_61.bdf MD Nastran input for simulating heat transfer between two non contacting
bodies through Natural Convection.
Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately four minutes

Chapter 62: Girkmann Problem using Axisymmetric Shell Elements
Girkmann Problem using

62 Axisymmetric Shell Elements

Summary 1178

Introduction 1179

Problem Statement 1179


Results and Discussions 1182

Conclusion 1184

Input File(s) 1184

Video 1185
 References 1185
CHAPTER 62
Summary
Title Chapter 62: Girkmann Problem using Axisymmetric Shell Elements
Contact Features • Use of axisymmetric shell elements
• Use of MPCs
Geometry
Material Properties E = 20.59 GPa ,  = 0 ,  = 3335.71 kg\m 3

for sperical shell subjected to gravity loading.
Same material properties except density is used for the stiffening ring not subjected to
gravity loading.
Analysis Type • Use of axisymmetric shell element (CAXISYM)
• Use of MPCs
Boundary Condition Boundary conditions of axisymmetry, Uy = 0 at the free end of the sperical shell.
Applied loads • Gravity loading for the axisymmetric shell
• Uniform normal pressure of 27.306 KPa is applied at the base AB of the stiffening ring
Element Type • 2-node axisymmetric shell element CAXISYM
• 4-node axisymmetric solid quad element CQUADX
FE Results 1. Interface shear force per unit circumference length between spherical shell and solid
stiffener.
2. Interface bending moment per unit circumference length.
3. Meridional angle at which maximum bending moment occurs and the value of maximum
bending moment per unit circumference length.
CHAPTER 62 1179
Girkmann Problem using Axisymmetric Shell Elements
Introduction
This example showcases the capability of CAXISYM elements. The problem demonstrated here was first discussed
by PitkÄaranta et al. (References). The FEA solution of the Girkmann problem was obtained and compared with the
solutions obtained by classical methods.
Problem Statement
A spherical shell of thickness h = 0.06m , crown radius Rc = 15.00m is connected to a stiffening ring at the meridional
angle  = 2  9  40  . The dimensions of the ring are: a = 0.60m and b = 0.50m . The radius of the midsurface of the
sperical shell is Rm = Rc  sin  .
The notation is shown in Figure 62-1. The z axis is the axis of rotational symmetry.
Figure 62-1 Girkmann Problem
Consider gravity loading only. The equivalent (homogenized) unit weight of the material comprised of the shell and
the cladding is 32.69 KN\m3 . Assume that uniform normal pressure PAB is acting at the base AB of the stiffening ring.
The resultant of PAB equals the weight of the structure. Assume that the stiffening ring is weightless. The goals of the
computations are as follows:
• To find the shear force at the interface between spherical shell and stiffening ring.
• To find the maximum bending moment.
• To find the meridional angle at which the maximum bending moment occurs.
Modeling Details
The spherical shell was modeled with axisymmetric shell element and stiffening ring with axisymmetric solid
elements as shown in Figure 62-2.
CHAPTER 62
Figure 62-2 FEA Model
Element Modeling
The spherical shell was modeled with 2-node axisymmetric shell elements CAXISYM. The properties for CAXISYM
were entered as given below:
PAXISYM 2 1 0.06 prop_axi
The CAXISYM elements were defined as given below:
CAXISYM 769 2 830 831
CAXISYM 770 2 831 832
CAXISYM 771 2 832 833
CAXISYM 772 2 833 834
CAXISYM 773 2 834 835
The solid stiffener was modeled with axisymmetric solid element CQUADX. First, the properties PLPLANE for the
CQUADX were defined:
PLPLANE 1 2 prop_axi
PSHLN2 1 2 +
+ C4 AXSOLID L prop_axi
The CQUADX elements were defined as given below,
CQUADX 1 1 1 10 11 2
CQUADX 2 1 2 11 12 3
CQUADX 3 1 3 12 13 4
…
Material Properties
The material properties were modeled by using MAT1 entry as given below:
MAT1 12.059+10 0.0 3335.71 0.0 mat_axi_
MAT1 22.059+10 0.0 mat_axi_
As Nastran applies gravity over the entire model by default, two material cards were defined. The material without
density was used for solid stiffener modeled with CQUADX so that the gravity load does not get applied on it.
CHAPTER 62 1181
Transformations and MPCs

To ensure the compatibility of rotational degrees of freedom between axisymmetric solid and shell elements, MPCs
were used. For the convenience of defining MPCs, transformations using local coordinate systems were defined for
the node at the junction between axisymmetric shell and axisymmetric solid elements,
Figure 62-3 Local Coordinate System
CORD2R 1 0 15. 17.8763 0.0 15. 17.8763 15.+

+ 15.0193017.89930 0.0
Then MPCs were defined between the node at the junction and the other nodes at the interface as given below:
MPC 1 187 2 1. 1185 2 -1. +
+ 1185 6 0.03
MPC 3 186 2 1. 1185 2 -1. +
+ 1185 6 0.02625
MPC 17 91 2 1. 1185 2 -1. +
+ 1185 6 -0.03
…
Loads and Boundary Conditions

For CAXISYM and CQUADX elements, the axis conventions for axisymmetry are: Y-axis is the axis of symmetry
and X-axis defines the radial direction. The symmetry boundary conditions of the axisymmetric problem was defined
constraining the axial degree of freedom  Uy = 0  of the node which lies on the axis of symmetry.
SPC 1 830 2 0.0
Gravity load was applied on the axisymmetric shell elements as given below:
GRAV 3 1. 0.0 -9.81 0.0
Pressure loading was applied at the bottom face of the solid stiffener. Pressure value was multiplied by 2 as per the
Nastran convention for the application of the pressure edge load on the axisymmetric problem.
PLOADX1 4 353 171425. 386 387 0.0
PLOADX1 4 354 171425. 387 388 0.0
CHAPTER 62
Analysis Parameters
Subcase corresponding to the loadcase that contains above loads and the boundary conditions were defined and
analysis was carried out by SOL 400 by using following parameters:
$# NASTRAN Control Section
$# File Management Section
NASTRAN SYSTEM (316)=19
ASSIGN OUTPUT2 = 'girk_fo_s400.op2', UNIT = 12, FORM = FORMATTED
$# Executive Control Section
SOL 400
CEND
ECHO = NONE
SUBCASE 1
STEP 1
$ Subcase name: DefaultLoadCase
TITLE=DefaultLoadCase
SET 10 = 769 THRU 1123
SET 20 = 830 THRU 1185
MPC = 33
SPC = 1
LOAD = 6
DISPLACEMENT (SORT1, PLOT, PRINT, REAL) =ALL
NLSTRESS (SORT1, PLOT, PRINT, REAL, VONMISES, CENTRE) =ALL
GPFORCE (PLOT, PRINT) =20
ANALYSIS = LNSTAT
Results and Discussions
Figure 62-4 Results
The f06 file generated out of the analysis was studied carefully and the STRESS-XY for the axisymmetric shell
element CAXISYM 1123 were noted as
CHAPTER 62 1183
Shear Stress-(sig-xy) for element CAXISYM 1123 is -1.577151E+04
Interface shear force/circumference length = sig-xy * shell thickness

Interface shear force/ circumference length = -1.577151E+04 * 0.06
= 946.3 KN/m
The grid point force balance for the interface element CAXISYM 1123 is as given below,:
So the bending moment/circumference at the interface i:

= 3475.662*2*π*r
= 3475.662*2*3.14159*15
= 36.878 N.m/m
In order to calculate the maximum bending moment and its location, we need to find the maximum bending stress and
its location. Now in order to calculate the bending stress one must know the stress distribution for the shell element.
The f06 file reports the stresses for upper layer and lower layer (i.e., LAYER I and LAYER 2) for the CAXISYM
elements. For example, the bending stress for the CAXISYM element 1123 is calculated as given below:
The bending stress can also be calculated as
Bending stress = [Total stress (LAYER 1) – Total stress (LAYER 5)]/2

= [(-4.711647E+05) – (-3.562409E+05)]/2
= -57461.9 N/m2
CHAPTER 62
The bending stress values for all CAXISYM elements are calculated like this and the node where the max. bending
stress occurs was noted. At that particular node, the bending moment would be maximum. Figure 62-5 shows the
variation of bending moment/thickness (N.m/m) with meridional angle.
Figure 62-5 Bending Moment vs. Meridional Angle
The maximum bending moment of 255.126 N.m/m occurs at the meridional angle of 38.15° as shown in Figure 62-5.
Conclusion
The following table shows the comparison of the results obtained from FEA modeling with that of theoretical one,
Results MD Nastran Theory % Error

Moment (Nm/m) 36.878 36.81 0.18%
Q1 (N/m) -946.291 -943.6 0.29%
Max. Moment (Nm/m) 255.126 253.97 0.46%
Angle (degrees) 38.150 38.08 0.18%
Input File(s)
Files Description
nug_62.bdf MD Nastran input for Girkmann problem using axisymmetric shell and solid elements.
CHAPTER 62 1185
Video
References
PitkÄaranta, J., Babuska, I. and Szabo, B. The Problem of Verification with Reference to the Girkmann Problem.
IACM Expressions. 24, January 2009, 14-15.
Chapter 63: Beam Reinforced Shell Structure using Offsets
Beam Reinforced Shell

63 Structure using Offsets

Summary 1187

Introduction 1188



Results 1192

Modeling Tips 1197

Input File(s) 1197
CHAPTER 63 1187
Beam Reinforced Shell Structure using Offsets
Summary
Title Chapter 63: Beam Reinforced Shell Structure using Offsets
Features • Case 1 – Reinforced shell structure with beam shell offsets
• Case 2 – Reinforced shell structure with RBE2 elements
Geometry
• Plate Structure:
• Plate1: Length 4000mm x Breadth 4000mm x Thick 70 mm
• Plate2: Length 2000mm x Breadth 4000mm x Thick 35 mm
• Beam1: Length 4000mm x Diameter 100mm x Thick 25 mm
• Beam2: Length 4000mm x Diameter 125mm x Thick 40 mm
Material properties Elastic-perfectly plastic material for beams and shells
E = 2.1e4 N/mm2,  = 0.3 , with yield stress σ y = 40 N/mm2 (for both case-1 and case-2)
Analysis characteristics Case-1: Nonlinear analysis of pressure loaded reinforced structure of shell with beams
using in-built shell offset and beam offset
Case-2: Nonlinear analysis of pressure loaded reinforced structure of shell with beams
using RBE2 constraints
Boundary conditions For case-1 and Case-2, fixed conditions on one side
Applied loads For case-1 and Case-2, pressure on the top surface of the shell
Element type • 4 node thick shell element
• 2 node beam
FE results • Deformed shape
• Stress plot
CHAPTER 63
Introduction
This release of MD Nastran incorporates enhanced capabilities of beams and shells with offsets. The offset option had
been included in earlier versions of MD Nastran, which allows elements being offset from the external grid points to
element connection points, with some limitations. This version eliminates the limitations of some characteristics not
being accounted for in case of offset, viz. differential stiffness (for buckling analysis); effects of thermal, pressure and
gravity loads; mass matrix computation; etc. The aim of this chapter is to demonstrate the various features available
in MD Nastran regarding in-built beam/shell offsets, which can be employed to analyze beam/shell structures.
The problem presented here is a stiffened plate with reinforcements, fixed at one end and subjected to uniform pressure
load. In analyzing such cases, it is common to model the beams and shells at a geometric location that is different from
the actual physical location. Such cases are common when shells or beams of varying thicknesses are adjacent to each
other and the top/bottom shell surfaces or beam flanges are to be aligned with each other. In such cases, it is convenient
to model all the shell nodes at the mid-surface of one of the shells or the beam nodes at the neutral axis of one of the
beams. The alignment of the top shell surfaces or beam flanges is then achieved by providing a suitable shell or beam
offset to the elements. Another common instance is when beams are used as stiffeners for shells. It is most convenient
to model the beam elements at the mid-surface of the shell and sharing the shell nodal connectivity. The fact that the
beam is actually offset by sum of half the plate thickness and half the height of the beam section is achieved by
providing a suitable beam offset.
This demonstration problem is analyzed using two methods - one using the offset option and the other using the
conventional RBE2 approach.
Case-1: The first method is to use the in-built beam/shell offset capability.
Case-2: The second method is to place the beams and shells at the actual offset position and then tie the nodes of
these elements back to the original position through manually defined RBE2 links. While this method is
quite accurate, it is quite cumbersome for large models. Furthermore, if the offset elements have to contact
other bodies, it is not possible since all degrees of freedom of the offset element nodes are already tied
through the RBE2 links.
The RBE2 approach is only used to compare the accuracy of the solution obtained using in-built beam/shell offsets
and the emphasis in this chapter is placed on describing the setup and solution using the actual in-built beam/shell
offset capabilities of MD Nastran.
Modeling Details
An overhanging flat plate structure that is reinforced by beams is subjected to a top face load. The plate structure has
a variable thickness along the length and the top surfaces of the thick and thin sections are aligned at the same level.
The top portion of the reinforcement beam cross-sections are welded to the bottom surface of the thicker plate. In the
geometric model (corresponding to Case-1), all the elements are modeled at the mid-surface of the thicker plate.
Suitable beam/shell offsets need to be provided to account for the difference between the geometric model and the
physical model.
The finite element mesh of the beam-plate structure is shown in Figure 63-1 and Figure 63-2. The geometric model
where the beams are at the shell mid-surface and in-built beam/shell offsets are used is shown in Figure 63-1. The
CHAPTER 63 1189
physical model with the beams and shells at their actual offset locations is displayed in Figures 63-1 and 63-2. This
model can be used with RBE2 links set up between the offset beams and the shell.
Figure 63-1 Reinforced Shell Structure with Beams Modeled at the Midsection of Structure
Figure 63-2 Reinforced Shell Structure with RBE2 Elements with Beams Modeled at Original Location
The plate is of length 6000 mm and width 4000 mm. The plate has a variable thickness along the length (70 mm over
the first 4000 mm and 35 mm over the remaining 2000 mm). The top surfaces of the thick and thin shells are aligned
at the same level. One reinforcement beam with a cross-sectional radius (mean) of 100 mm and thickness of 25 mm
is placed across the plate at the point where the plate thickness transition occurs. Two other reinforcement beams, each
with a cross-sectional radius of 125 mm and thickness of 40 mm, are placed along the length on either side of the plate.
The top portion of the beam cross-sections are welded to the bottom surface of the plate.
Element Modeling
Case-1: The plate of both the cross sections are modeled with lower order shell element (CQUAD4) and for the beam
reinforcements, lower-order beam elements (CBEAM) are used. The offset values are specified in the corresponding
field of the CQUAD4 entry. The non-linear extensions are activated by using the PSHLN1 property option in
conjunction with the regular PSHELL property option in the manner shown below:
CHAPTER 63
.
.
CQUAD4 101 2 113 124 125 114 17.5
CQUAD4 102 2 114 125 126 115 17.5
CQUAD4 103 2 115 126 127 116 17.5
.
.
CBEAM 151 3 113 114 1. 0. 0. BBB
0. 0. -135. 0. 0. -135.
CBEAM 152 3 114 115 1. 0. 0. BBB
0. 0. -135. 0. 0. -135.
.
.
PSHELL 1 1 70. 1 1
PSHLN1 1
.
.
.
PBEAML 3 1 TUBE
112.5 87.5
PBEMN1 3 1 N
+ C2 BEAM LCC
.
.
Similarly, for the two beam cases, PBEAML property is used with the nonlinear extension for the beam PBEMN1 being
activated.
Case-2: Except for the offsets values being zero, all the properties are identical to that of Case-1.
.
CQUAD4 131 2 157 168 169 158
CQUAD4 132 2 158 169 170 159
CQUAD4 133 2 159 170 171 160
.
.
CBEAM 101 4 122 124 0. 1. 0.
CBEAM 103 4 124 126 0. 1. 0.
.
.
PSHELL 1 1 70. 1 1
PSHLN1 1
.
.
PBEAML 3 1 TUBE
112.5 87.5
PBEMN1 3 1 N
+ C2 BEAM LCC
.
.
CHAPTER 63 1191
Material Modeling
All the elements of the structure are modeled with isotropic, elastic perfectly-plastic material using the MAT1 and
MATEP options. The yield stress is taken as 40 N/mm2.
MAT1 1 21000. .3 1.

For both the cases – Case-1 and Case-2 – the loading and boundary conditions are identical. One side of the plate
structure as shown in Figure 63-3 is constrained for displacement and rotations degrees of freedom using SPC1. A
uniform pressure load is applied on the top surface in the downward direction using the LOAD entry.
SPCADD 2 1
LOAD 2 1. 1. 1
$ Displacement Constraints of Load Set : apply1
SPC1 1 123456 1
SPC1 1 123456 4 THRU 13
$ Pressure Loads of Load Set : apply2
PLOAD4 1 1 -.0075 THRU 150
Figure 63-3 Loading and Boundary Conditions for Cases-1 and -2
Solution Procedure
The offset formulation is invoked with MDLPRM, OFFDEF, and LROFF in the bulk data section. This ensures that the
shell normal directions are used to define the offset direction at each shell grid point and that the effects of offset like
differential stiffness, loadings aspects of offset are taken into account.
MDLPRM OFFDEF LROFF
CHAPTER 63
The SOL400 nonlinear procedure is employed for both the cases, the parameters of which are defined through the
following NLSTEP entry:
NLSTEP 1 1.00
GENERAL 25 1 10
ADAPT 0.01 0.01 0.05 20 1.2 0
0
0
MECH UPV 0.010 0.010 0.01 PFNT 1
The NLSTEP keyword is followed by the identification number entry and by the total time of the analysis which is 1.0
in this case.
The second line gives the general stepping parameters associated with the analysis. The maximum number of iteration
(=25), maximum number of iteration needed for each increment (=1) and the maximum number of bisections allowed
in current step (=10).
The keyword ADAPT defines the adaptive time (load) stepping procedure which is followed by the parameters viz.
initial time step, minimum time-step as a fraction of total time, maximum time step, number of desired iterations per
increment, factor for increasing the time step, output flag, etc.
The keyword MECH stands for a mechanical analysis appended with the parameters such as flags for convergence
criteria selection followed by the error tolerance for displacement, load, and work, respectively. UP stands for
convergence criteria checking with respect to displacement, load and work. The PFNT character parameter stands for
“Pure Full Newton Raphson” which is the method for controlling stiffness updates.
Results
The displacement at center of the free end of the shell is compared for Case-1 and Case-2 in the Table 63-1.
Table 63-1 Comparison of Displacement at Center Node of Free End

Quantity Case-1 Case-2 % Difference
Displacement 446.6432 447.3165 0.0015
The plot of displacement field is shown in Figures 63-4 and 63-5.

CHAPTER 63 1193
Figure 63-4 Deformation Plot for Case-1
Figure 63-5 Deformation Plot for Case-2
The displacement at the center of the free end is shown against time for both the cases in Figures 63-6 and 63-7.
CHAPTER 63
Figure 63-6 Displacement at Center of Free End Against Time for Case-1
Figure 63-7 Displacement at Center of Free End Against Time for Case-2
CHAPTER 63 1195
The displacement at the nodes of free end is shown against y co-ordinate for both the cases in Figures 63-8 and 63-9.
The non-linear stress plots of both the cases are shown in Figures 63-10 and 63-11.
Figure 63-8 Displacement at Free End Against y Coordinate for Case-1
Figure 63-9 Displacement at Free End Against y Coordinate for Case-2

CHAPTER 63
Figure 63-10 Stress Plot for Case-1
Figure 63-11 Stress Plot for Case-2

CHAPTER 63 1197
Modeling Tips
The key aspect in this analysis is the offsets of beams and shells which can be invoked using the appropriate offset
parameters in the CBEAM and CQUAD4 bulk data entries.
It is to be noted that MD Nastran follows numerous element defaults options (please refer to NLMOPTS, SPROPMAP
entries in MD Nastran Quick Reference Guide). In particular to this analysis, if PSHLN1 option or PBEMN1 options
are not specified in the input, MD Nastran assumes these options as the MATEP option is specified in the material
properties for these elements.
Input File(s)
Files Description
nug_63a.dat MD Nastran input for “Reinforced shell structure with beam shell offset” (Case-1)
nug_63b.dat MD Nastran input for “Reinforced shell structure with RBE2 elements” (Case-2)
Chapter 64: Stent Analysis with Growing Rigid Body
Stent Analysis with Growing

64 Rigid Body

Summary 1199

Introduction 1200



Results 1204

Modeling Tips 1206

List of Input File(s) 1206

Video 1207
CHAPTER 64 1199
Stent Analysis with Growing Rigid Body
Summary
Title Chapter 64: Stent Analysis with Growing Rigid Body
Features • Case 1 – Expansion of stent simulating the deployment step
• Case 2 – Recoil of deployed stent simulating spring back
Geometry
• Stent dimensions:
• Internal radius: 0.92 mm; Thickness of wire: 0.08 mm; Length: 6.96 mm
• Rigid cylinder dimensions:
• Radius: 0.92 mm; Length: 7.00 mm
Material properties • Elastic-plastic material (Stainless steel SS316)
• E = 2.9E+07 N/mm2,  = 0.28 , with yield stress y = 2.05 N/mm2, Plasticity modulus
(slope) 3.2E+05 N/mm2.
Analysis characteristics Step-1: Stent expanded through rigid cylinder with 3 times growth factor.
Step-2: Stent analyzed for spring back by shrinking of rigid cylinder
Boundary conditions For step-1 and step-2, the stent is arrested for rigid body motion
Applied loads For step-1 and step-2, expansion is through radial growth of rigid cylinder
Element type • 8 node solid brick element
• Springs for arresting rigid body motion
FE results • Deformed shape
• Stress plot
• Spring-back deformed shape and residual stresses
CHAPTER 64
Introduction
A key feature of the table-driven growth/shrink of rigid bodies functionality is that the rigid body could be made to
change its shape in addition to translation and rotation (transformation). The evolution of growth/shrink can be
controlled by table driven input with time as independent variable which makes this functionality indispensable for
certain kind of analyses. This feature is illustrated with a typical balloon-expanded stent analysis as an example.
A stent is a small hollow metallic wire mesh which is placed in choked coronary arteries to help keep them distended
to ensure sufficient flow of blood. A stent, the key element of such a treatment – called angioplasty – is inserted and
placed into the artery in crimped state by means of a catheter and are deployed by means of balloon. The deployment
is done by expanding the balloon such that the stent undergoes plastic deformation to dilate the clogged artery and
holds it from constricting.
This problem illustrates the deployment and recoil (spring back) steps of the stent analysis. The deformation of balloon
is ignored and is replaced by a rigid growing/shrinking cylinder. In the deployment step, the cylinder is expanded such
that the radius grows three times its original size. And in the recoil step, the cylinder is shrunk to 1.5 times of its
original size.
Modeling Details
A simple stent of internal radius of 0.92 mm with wire thickness 0.08 mm and length 6.96 mm is modeled and meshed
with 8 node brick elements. The mesh contains 1014 brick elements, 4 spring elements and 4913 nodes. A rigid
cylindrical surface of 1.0 mm internal radius and 7.0 mm long is modeled which simulates the balloon.
The finite element mesh of the beam-plate structure with the rigid cylinder is shown in Figure 64-1.
Figure 64-1 Stent with Internal Expanding Rigid Cylinder

CHAPTER 64 1201
Element Modeling
The stent is modeled with lower-order solid brick elements (CHEXA). The non-linear extension is activated by using
the PSLDN1 property option in conjunction with the regular PSOLID property option in the manner shown below.
.
.
.
$!
CHEXA 1303 1 1 14 15 2 2807 2820+
+ 2821 2808
CHEXA 1304 1 2 15 16 3 2808 2821+
+ 2822 2809
CHEXA 1305 1 3 16 17 4 2809 2822+
+ 2823 2810
CHEXA 1306 1 4 17 18 5 2810 2823+
+ 2824 2811
.
.
.
.
PSOLID 1 1 PSOLID_1
PSLDN1 1 1 1 PSOLID_1
.
.
.
For the spring elements, which are used for arresting the rigid body motion, CELAS2 input is used as shown below.
.
.
.
$!
CELAS2 2605 1. 5405 1 3196 1 0.0 0.0BC_sprin
CELAS2 2606 1. 5405 1 2832 1 0.0 0.0BC_sprin
CELAS2 2607 1. 5405 1 2978 1 0.0 0.0BC_sprin
CELAS2 2608 1. 5405 1 3122 1 0.0 0.0BC_sprin
$!
.
.
.
Material Modeling
The stent which is generally made of Stainless steel (SS316) is modeled with isotropic, elastic-plastic material using
the MAT1 and MATEP options. The elasticity modulus is taken as 2.9E+07 N/mm2 with the Poisson’s ratio as 0.28.
The yield stress is taken as 205 N/mm2 with the plastic modulus as 3.2E+05 N/mm2.
.
.
.
MAT1 1 2.9E+7 0.28 SS316
CHAPTER 64
MATEP 1 Slope 205. Vmises Isotrop Addmean 320000. SS316

.
.
.

The stent is constrained to prevent rigid body motion through spring elements as shown in Figure 64-2.
Figure 64-2 Loading and Boundary Conditions of Stent
The central node is fixed which is connected to specific peripheral nodes through spring elements. And two sets of
selected peripheral nodes at one end of the model are arrested for movement in different directions such that the rigid
body rotations about all the three axes are arrested as shown.
.
.
SPC1 1 123456 5405
SPC1 2 12 2832 3196
SPC1 3 1 2978 3122
.
.
The stent is modeled as a deformable contact body and the rigid cylinder is modeled as a rigid contact body using
respective BCBODY entries. The rigid body growth factor is specified in a table for the y and z components such that
the radius of the cylinder enlarges and then shrinks with time.
.
.
+ 0.0 1. 1. 2. ENDT
TABL3D0 1 1 1 0
+ 0.0 1. 1. 3. 2. 2.
CHAPTER 64 1203
.
.
BCBODY 1 3D DEFORM 2 0.0 0
BCBODY 101 3D RIGID 1 -1+
+ +
+ GROW 1 1 +
+ RIGID 1 Rigid_1 +
NURBS -7 2 4 2 50 50 6
-1.2 0.0 -0.92 -1.2 -1.84 -0.92
-1.2 -1.84 0.92 -1.2 0.0 0.92
.
.
The TABLED1 entry is used for defining the table of growth factor with respect to time. As can be seen, the growth
factor is set as 1.0 at time=0.0 units; 3.0 at time=1.0 units and 2.0 at time=2.0 units. The total time of analysis is 2.0
units.
.
.
.
BCTABLE 1 1 +
$ Pair: STENT / RIGID_CYL
+ SLAVE 1 +
+ MASTERS 101
$! SX Names for Materials
.
.
The BCTABLE entry is used to define the contact pair properties.
Solution Procedure
The SOL400 nonlinear procedure is employed, the parameters of which are defined through the following
NLSTEP entry:
.
.
.
NLSTEP 1 2. +
+ GENERAL 200 -10 +
+ FIXED 200 10 +
+ MECH UPWV 0.01 0.1 0.1PFNT
.
.
.
in this case.
CHAPTER 64
The second line gives the general stepping parameters associated with the analysis. The keyword FIXED defines the
fixed time stepping procedure which is followed by the parameters viz. total number of steps followed by the intervals
in which output is sought.
criteria selection followed by the error tolerance for displacement, load and work respectively. UPWV stands for
convergence criteria checking with respect to displacement, load and work. The PFNT character parameter stands for
“Pure Full Newton Raphson” which is the method for controlling stiffness updates. The selection of optimum
convergence criteria is critical in an analysis as contact-intensive as this analysis. Though the minimum model
dimension is 0.08 mm, a liberal displacement criterion of 0.01 is chosen for faster convergence, but ensuring accuracy
by a relatively strict load and work criteria of 0.1 and 0.1, respectively.
The parameter LGDISP is set to 1, enabling the treatment of differential stiffness accounting large displacement effects.
The strain formulation flag GNLSTN is set to 1 signifying Green strain. And the nonlinear material option of LRGSTRN
is set to 1 signifying the usage of “Hypo-elasticity and additive plasticity with mean normal return” large strain
formulation.
.
.
.
PARAM LGDISP 1
MDLPRM GNLSTN 1
NLMOPTS LRGSTRN 1
.
.
Results
The nonlinear equivalent stress is plotted over the displaced stent at the end of expansion in Figures 64-3 and 64-4.
The undeformed stent is shown for comparison in Figure 64-3.
CHAPTER 64 1205
Figure 64-3 Nonlinear Equivalent Stress Plot on Deformed Mesh at End of Expansion (time = 1.0) with
respect to the Undeformed Mesh – Front View
Figure 64-4 Nonlinear Equivalent Stress Plot on Deformed Mesh at the End of Expansion (time = 1.0) –
Isometric View
CHAPTER 64
The nonlinear equivalent stress is plotted over the displaced stent at the end of recoil in Figure 64-5. It can be noticed
that the residual stresses are predominant near the joints.
Figure 64-5 Nonlinear Equivalent Stress (Residual Stress) Plot on Deformed Mesh at the End of Recoil
(time = 2.0) – Isometric View
Modeling Tips
It is to be noted that the stent nodes enters and leaves contact often during this contact intensive analysis. The
specification of the distance tolerance and the bias factor can largely influence the duration of analysis. Moreover,
during the shrink operation it can be noticed that the stent is relatively free to move and is restrained only by the soft
springs provided for arresting rigid body motion. This does not affect the real scenario where is stent normally clings
on to the blood vessel.
List of Input File(s)

Files Description
nug_64.dat MD Nastran input for “Stent Analysis with Growing Rigid Body”
CHAPTER 64 1207
Video

Chapter 65: Convection Correlations for PCB
Convection Correlations for

65 Printed Circuit Board (PCB)

Summary 1209

Introduction 1210



Results 1218

Modeling Tips 1219

Input File(s) 1219

Video 1219
CHAPTER 65 1209
Convection Correlations for Printed Circuit Board (PCB)
Summary
Title Chapter 65: Convection Correlations for PCB
Features • Natural convection correlation 701 by using PCONV1 entry
• Forced convection correlation 507 by using PCONV1 entry
• Contact loads by using PRJCON and SET3 cards
Geometry
The dimension of PCB is 9 x 6 x 0.0093 inches (copper thickness)

Material properties PCB: Copper K = 9.9 W/in C°; Copper Thickness = 0.0093 in
Chips: K = 2.24 W/in°C
Air: K = 6.66e-4 W/in°C; Cp = 456.2 J/lbm°C; ρ = 5.01e-5 lbm/in³;
μ = 1.03e-6 lbm/in s, β = 3.43e-3/°C
Analysis characteristics Solution 400/RC Network solver. Steady state thermal analysis.
Boundary conditions • Wall temperature = 25°C
• For Natural convection model: Tair = 20°C
• For Forced convection: Inlet Air Temperature = 20°C
Applied loads • Total surface heat = 5W, Total Heat on chips: 7.5W, 5W, 5W
• Contact load between PCB and chips with coefficient =12 W/in² °C
• Convection with correlation 701 for natural convection model
• Coupled advection with correlation 507 for forced convection model
Mass flow rate = 3.2E-3 lbm/s
Hydraulic Diameter = 0.2 in
Flow Cross Section = 0.6 in²
Interval between chips and next PCB = 0.1 in
Element type • CQUAD4 for PCB
• CTETRA for chips
• CHBDYP/FTUBE for air flow (for natural convection model)
FE results Temperature result:
CHAPTER 65
Introduction
This problem demonstrates the convection correlation feature of SOL 400 RC Network Solver.
Modeling Details
The dimension of PCB is 9 x 6 x 0.0093 inches (copper thickness). The two edges are fixed to the slots and have a
constant boundary temperature of 25°C. The total circuit power on the PCB is 5W, and the total power of the three
chips is 7.5W, 5W, and 5W, respectively. The PCB mesh and chip mesh do not match each other. RC Network Solver
has a special contact algorithm to deal with that.
The convection correlation 701 is used to simulate the natural convection of PCB and chips. The air temperature is
20°C. The convection correlation 507 is used to simulate the forced convection. The forced convection is applied to
both sides of the PCB and outer side of the chips. The inlet air temperature is 20°C.
o
Constant Boundary Temperature = 25 C
Contact Coefficient = 1.2 W/in2 oC
5W
Figure 65-1 PCB and Chips Model
0.1 in
Inlet T = 20oC
o
20 C
o
20 C
Figure 65-2 Natural and Forced Convection Models
Solution Highlights
Convection correlations are used to calculate the convection coefficients in different situations. MD Nastran RC
Network Solver supports 44 convection correlations. Each convection correlation consists of three tabs: Correlation
View, Variables, and Additional Coefficient. Correlation View form includes the description, formula, illustration, and
CHAPTER 65 1211
some geometry related parameters. These parameters are also displayed in the Variable form, along with the fluid
material parameters. Additional Coefficient is reserved for future use for some P/Thermal correlations.
Figure 65-3 Natural Convection Correlation 701 Forms
The natural convection model defines the convection correlation 701 by using PCONV1 entry, which is referenced by
CONV entry. The following are the highlights of the Nastran input file necessary to model the natural convection
problem with convection correlations:
......
……
CHAPTER 65
Figure 65-4 Forced Convection Correlation 507 Forms
The forced convection model uses the coupled advection load to link the fluid stream and surfaces. Instead of a
constant convection coefficient, a convection correlation is used to calculate the convection coefficient at run time.
PCONV1 entry defines the forced convection correlation 507. This entry is referenced by the CHBDYP and PRJCON
cards. The following are the highlights of the Nastran input file necessary to model the forced convection problem
with convection correlations:
......
......
......
......
CHAPTER 65 1213
PRJCON entry is used to link the two SET3 cards. A convection correlation PID (PCONV1 ID) is referenced if the
HEAT2 option is used. The inlet temperature is defined as a SPC for each inlet node of the fluid stream.
CHAPTER 65
PCONV1 Thermal Convection Calculation Properties
Defines the properties required to calculate convective heat transfer. It can exist in a simple mode with convection
coefficient defined in the MID or in advanced mode where the H value is calculated using the geometric parameters and
referenced material.
Format
1 2 3 4 5 6 7 8 9 10
PCONV1 PID Corr ID MID Mdot Velocity Length or Flow Cross +
Diameter Section
+ Length Flow Cross Mdot f Velocity f Length or Flow Cross +
function Section Diameter f Section f
type type
+ C1 C2 C3 C4 C5 C6 C7 C8 +
+ C9 C10 C11 C12 C13 C14 C15 C16 +
+ C17 C18 C19 C20 C21 C22 C23 C24
Example
1 2 3 4 5 6 7 8 9 10
PCONV1 2 701 2 1.0

PID Property identification number, referenced by CHBDYP I  0
and/or CONV.
Corr ID ID of convection type in correlation library. I0 0
MID Material identification number for convection I0 0
calculation.
Mdot Mass flow rate. R 0.0
Mdot f Mass flow rate TABLEDj table ID. I0 0
Velocity Fluid velocity. R0 0.0
Velocity f Fluid velocity TABLEDj table ID. I0 0
Length or Diameter Geometry, based on Corr ID. R  0.0 0.0
Length or Diameter f type Geometry function type: I0 2
1= time
2= temperature
Length or Diameter f Geometric function TABLEMj or TABLEDj table ID I0 0
Flow Cross Section Flow Cross Section. R  0.0 0.0
CHAPTER 65 1215

Flow Cross Section f type Flow Cross Section function type I0 2
1= time
2= temperature
Flow Cross Section f Flow Cross Section function TABLEMj or TABLEDj table I  0 0
ID.
C1 thru C24 Geometric properties based on chosen convection R 0.0
correlation
Remarks
2. The PCONV1 entry contains the properties for a CONV and CHDBYP, and can be used for connecting with a
PRJCON. PID must be unique to both the PCONVID in PCONV and the PID in PHBDY. This will be the ID
referenced by CONV, PRJCON, and CHBDYP.
3. MATID must reference a MAT4 fluid material.
4. For Corr. ID and C1 thru C24, please reference MSC SINDA User’s Guide and Library Reference or
P/Thermal User’s Guide.
CHAPTER 65
HEAT1
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT1 SET3 SET3 Slave h
Master
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT1 1 2 1.2
HEAT2
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT2 SET3 SET3 Slave PID
Master
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT2 1 2 1001
HEAT3
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT3 SET3 SET3 Slave F Emis Emis Slave
Master Master
CHAPTER 65 1217
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT3 1 2 1. 0.85 0.5
HEAT4
Format
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
HEAT4 SET3 SET3 Slave F RADC id RADC id
Master Master Slave
Example
1 2 3 4 5 6 7 8 9 10
PRJCON 1
HEAT4 1 2 1. 1001 1002

for HEAT1
for HEAT2
F View factor between parts. 0.0  R Required
 1.0 for HEAT3
& HEAT4
for HEAT3
for HEAT4
value.
value.
CHAPTER 65
Remarks
1. This HEATx and the later parameters are for RC Network solver only.
Results
Figure 65-5 Temperature Contour of PCB with Natural Convection
Figure 65-6 Temperature Contour of PCB with Forced Convection

CHAPTER 65 1219
For now, SimXpert can not display the temperature contour on the fluid stream. Apparently, the cooling effect of the
forced convection is much better than the natural convection.
Modeling Tips
In SimXpert Structural workspace, when you pick the back face of the solid chips for the contact loads, you may need
to hide the PCB surface first, so that the back face of the solid chips can be picked correctly.
The convection correlations are defined in Material and Property/1D Properties / Correlation. If you want to use
constant convection coefficient in the coupled advection loads, please select the 1D Fluid Flow option. If you want to
use convection correlation to calculate the convection coefficient, please pick the Convection Correlation option.
Input File(s)
Files Description
QT22_pcb_natural.dat MD Nastran SOL400/RC Network Solver thermal input file
QT25_pcb_forced.dat MD Nastran SOL400/RC Network Solver thermal input file
Video

Chapter 66: Satellite in Orbit
66 Satellite in Orbit

Summary 1221

Introduction 1222



Results 1231

Modeling Tips 1232

Input File(s) 1233
CHAPTER 66 1221
Satellite in Orbit
Summary
Title Chapter 66: Satellite in Orbit
Features: Enclosure Radiation, Orbital Heating and Radiation Exchange Factors, Multiple Orbits
and Pointing, MLI and Coating, Satellite with moving parts (articulating solar panels)
Geometry & Boundary Space ambient temperature = -273.15 °C (default value)
Conditions
ALU606: K = 167 W/m/°C, Cp = 940 J/Kg/°C, ρ = 2700 Kg/m³

Material properties
Honeycomb: K = 11.5 W/m/°C, Cp = 945 J/Kg/°C, ρ = 50 Kg/m³, Several coatings
Analysis characteristics Solution 400 / RC Network solver. Steady and transient thermal analysis.
Applied Loads Enclosure Radiation Face, Radiation Enclosure
Element type CQUAD4, CTRIA3
FE results
CHAPTER 66
Introduction
This problem demonstrates the orbital space application of SOL 400 RC Network Solver and Thermica v3.
Modeling Details
2m 1m
0.5 m
1m Y
Y
gaps: 0.1 m PANELS
Material : HONEYCOMB
Sun face : SOLARCELL
Anti -Sun face : BLACKPAINT
YOKE
Cylinders: Material : ALU6061
diam = 0.02 m 1m Coating : MLI
1.75 m
1m
1m 2m BODY FACES
Material : ALU6061
ANTENNA Inner coating : BLACKPAINT
Parabola: Material : HONEYCOMB Outer coating : MLI
diam=1.5 m System Emitting face : WHITEPAINT
height = 0.25 m reference frame Rear side: MLI
origin
1.25 m
2m
2.5 m
Figure 66-1 Satellite Geometry and Materials

CHAPTER 66 1223
Satellite in Orbit
Case 1: Single Round Orbit, Single Pointing, and Solar Panels

Articulation
Orbital Description: Pointing Description:
Reference line: Sun -Z toward Earth
Altitude: 1000 km +X along velocity vector
Inclination: 60° Moving Parts:
Solar time of ascending node: 16:00 Solar panels pointing to the Sun
Epoch: Spring 2000 1 axis of rotation
Figure 66-2 Satellite Orbit and Pointing for Case1

CHAPTER 66
Case 2: Multiple Orbital Arcs with Multiple Pointing, Solar Panels

Articulation
Orbital Arc #1: Sun Pointing
Reference line: Sun -Z toward Sun
Altitude: 1000 km +Y toward North Pole
Inclination: 60 deg Moving Parts:
Solar time of ascending node: 16h Solar panels pointing to the
Epoch: Spring 2000 Sun
Duration: 170 deg
Orbital Arc #2: Sun to Earth

Reference line: Sun -Z toward Sun
Altitude: 1000 km +Y toward North Pole
Inclination: 60 deg dYaw/dt = 0.25 deg/s
Solar time of ascending node: 16h dPitch/dt = 0.30 deg/s
True anomaly: 170 deg dRoll/dt = 0.26 deg/s
True anomaly step: 1 deg Moving Parts:
Duration: 10 deg Solar panels pointing to the Sun
1 axis of rotation
Orbital Arc #3: Earth Pointing
Reference line: Sun -Z toward Earth
Apogee: 3000 km +X along Velocity vector
Perigee: 1000 km Moving Parts:
Inclination: 60 deg Solar panels pointing to the Sun
Solar time of ascending node: 16h 1 axis of rotation
Argument of perigee: 180 deg
True anomaly: 0 deg
Duration: 180 deg
Figure 66-3 Satellite Orbit and Pointing for Case1

CHAPTER 66 1225
Satellite in Orbit
Solution Highlights
RC Network Solver uses VIEWEX entry to simulate the enclosure radiation loads. RADC entry is used to represent the
MLI or Coating materials.
RADSET 6
RADCAV 6 448 YES 0 FD
SPOINT 696
TEMP 37 696 -273.15
SPC 6 696 1 -273.15
RADM 7 1.
PHBDY 5 1.
CHBDYP 448 5 POINT 696
7 1. 0.0 0.0
VIEWEX 6 F AREA T T
THERMIC 1380. 0.3 -19. F F 5000 5000
99. 3600. 1.E-8
A black, unit area point element CHBDYP is used to define the radiation ambient temperature for a radiation
enclosure. This point element is referenced by RADCAV entry to link to the enclosure. The point is defined as a
SPOINT and SPC is used to define its temperature value. VIEWEX entry links with a radiation enclosure by the
ICAVITY ID, and define the external radiation solvers and some related control parameters. The orbital and pointing
parameters are not defined inside the bdf file. They are defined in the GUI of the external radiation solvers (such as
Thermica v3). The following shows the RADC cards which are used to define the coating and MLI materials for
radiation loads.
RADC 6 0.82 0.74 +
+ COAT Solar_ce
RADC 5 0.78 0.52 +
+ MLI 0.02
CHAPTER 66
VIEWEX Advanced RC Radiation Solver Parameters
Defines the radiation solver and correlating solver parameters for radiation calculations in RC heat transfer.
Note: You must have a copy of the external radiation code to use it.
Format NEVADA
1 2 3 4 5 6 7 8 9 10
VIEWEX ICAVITY Run RADK Disto Orbital Re-use +
Interactively Method existing
results
“NEVADA” RENO Reflection Restart RENO Ray VEGAS Ray Energy Confidence GRID +
count count Cutoff closure
+ GRID iterations Time Scale RADK cutoff
Format TSS
1 2 3 4 5 6 7 8 9 10
results
+ “TSS” +
Format THERMICA
1 2 3 4 5 6 7 8 9 10
results
+ “THERMIC” Solar FLux Planet Planet Restart Suppress VF Radiation Orbital +
Albedo BlackBody Articulation ray count flux ray
count
+ Confidence Time Scale RADK cutoff
Format TRASYS
1 2 3 4 5 6 7 8 9 10
results
+ “TRASYS” Axi Radial mesh Axi Axial Axi Angular Time RADK cutoff +
mesh mesh scale
Format SRR
1 2 3 4 5 6 7 8 9 10
results
+ “SRR” Gebhart Solver Convergence Max Iter Fij Fij Filter Fij Fij +
Tol smoothing cutoff Smoothing Smooth
method Tol Iter
+ Bij smoothing method Bij Filter cutoff Bij Smoothing Bij Max Iter
Tol
CHAPTER 66 1227
Satellite in Orbit
Format SRQ
1 2 3 4 5 6 7 8 9 10
results
+ “SRQ” Flux Solver Convergence Max Iter Fij Fij Filter Fij Fij +
Tol smoothing cutoff Smoothing Smooth
method Tol Iter

ICAVITY Cavity identification number. I0 Required
Run Interactively Run the radiation code interactively. C, FULL
“FULL”,
“T”, or “F”
Do not currently have batch mode for Thermica or
TSS.
Do not have interactive mode for TRASYS.
RADK Distro Method How to redistribute RADK onto elements. C, FULL
“FULL”,
“AREA”,
or
“DIRECT”
Orbital Use orbital analysis for radiation. Not supported in C, “T”, or “F”
SindaRad. “F”
Re-use existing Re-use previous radiation results. C, “T”, or “F”
results “F”
“NEVADA” Identification that NEVADA will be used. C
RENO Reflection Use reflection method of ray tracing for RADK. C, “T”, or “F”
“F”
Restart Use Restart option. C, “T”, or “F”
“F”
Reno Ray count Number of rays cast for Reno module I>0 5000
Vegas Ray count Number of rays cast for Vegas module I>0 5000
Energy Cutoff Energy cutoff level. I -3
Confidence Confidence Level percentage R > 0.0 99.0
GRID closure GRID closure tolerance. R > 0.0 0.001
GRID iterations Maximum GRID iterations I>0 300
Time Scale Orbital time scale factor, number of time units in an R > 0.0 1.0
hour (e.g., If using seconds, value would be 3600.0.).
RADK cutoff RADK filter smallest element. R > 0.0 1.0e-8
CHAPTER 66

“TSS” Identification that TSS will be used. C
“THERMICA” Identification that THERMICA will be used. C
Solar Flux Quantity of solar flux. R > 0.0 1380.0
W/m2
Planet Albedo Planetary Albedo. R -19,
assumes
Earth
orbit
Planet BlackBody Planet Blackbody. R -10.0,
assumes
Earth
orbit
Suppress VF Suppress view factor articulation. C, “T”, or “F”
Articulation “F”
Radiation ray count Number of rays cast for radiation calculation. I>0 5000
Orbital flux ray count Number or rays cast for radiation calculation. I>0 5000
“TRASYS” Identification that TRASYS will be used. C
Axi Radial mesh Axisymmetric element mesh in radial direction. I>0 1
Axi Axial mesh Axisymmetric element mesh in axial direction. I>0 1
AXI Angular mesh Axisymmetric element mesh in angular direction. I>0 5
“SRR” Identification that the SindaRad. RADK method will C
be used
Gebhart Solver Which RADK solver to use. “GS” or “FGS”
“FGS”
Convergence Tol Tolerance for convergence of RADK calculation. R > 0.0 1.0e-5
Max Iter Maximum allowable iterations to converge. I>0 50
Fij smoothing method How to filter view factors. C, “CROP” “CROP”
or “HIGH”
Fij Filter cutoff Parameter for filter. R > 0.0 1.0e-8
Fij Smoothing Tol Tolerance for smoothing. R 1.0e-4
Fij Smoothing Iter Maximum allowable iterations to smoothing. I>0 50
Bij smoothing method How to filter conductors C, “CROP” “CROP”
or “HIGH”
Bij Filter cutoff Parameter for filter. R > 0.0 1.0e-8
Bij Smoothing Tol Tolerance for smoothing. R 1.0e-4
CHAPTER 66 1229
Satellite in Orbit

Bij Max Iter Maximum allowable iterations to smoothing. I>0 50
“SRQ” Identification that the SindaRad QRad method will be C
used.
Flux Solver Which QRad solver to use. C, “GS” or “GS”
“CG”
Convergence Tol Tolerance for convergence of QRad calculation. R > 0.0 1.0e-5
Remarks
1. This entry is for RC Network solver only. EX means external radiation solvers.
2. Each entry type is designed for one specific radiation solver, except the very last two types, which are for
SINDARad’s two options:
NEVADA
TSS
THERMICA
TRASYS
SINDARad RADK method
SINDARad Q method
3. About more details about the parameters in the entry, please reference SINDA for Patran User’s Guide and
SINDARad User’s Guide.
CHAPTER 66
RADC Thermal Radiative Coating Properties
Defines the radiative properties of advanced materials such as coatings and multilayer insulation, commonly used in
the aerospace market.
Format COAT
1 2 3 4 5 6 7 8 9 10
RADC RADMID Emis Absorptivity IR Spec UV Spec +
+ “COAT” IR IR Transluc UV Transpa UV IR Refrac UV Refrac
Transpa Transluc Ind Ind
Format MLI
1 2 3 4 5 6 7 8 9 10
RADC RADMID Emis Absorptivity IR Spec UV Spec +
+ “MLI” Estar

RADMID Radiation material identification number. I0 Required
“COAT” Identification that a coating type material has been started. C 0
Emis Emissivity. R  0.0 1.0
Absorptivity Absorptivity. R  0.0 1.0
IR Spec IR Specularity. 0.0 < R  1.0 0.0
UV Spec UV Specularity. 0.0 < R  1.0 0.0
IR Transpa IR Transparency. 0.0 < R  1.0 0.0
IR Transluc IR Translucency. 0.0 < R  1.0 0.0
UV Transpa UV Transparency. 0.0 < R  1.0 0.0
UV Transluc UV Translucency 0.0 < R  1.0 0.0
IR Refrac Ind IR Refraction Index. R  1.0 1.0
UV Refrac Ind UV Refraction Index. R  1.0 1.0
MLI Identification that an MLI type material has been started. C
Estar MLI E-star parameter. R 0.0
Remarks
2. Estar is defined as the effective emissivity from the wall to MLI outer surface. The general value is around 0.01
to 0.03, the typical value is 0.02.
3. Emis is usually for the IR waveband, and Absorptivity is for the UV waveband.
CHAPTER 66 1231
Satellite in Orbit
Results
Figure 66-4 Temperature Contour of Satellite for Case 1 (Steady State)
Figure 66-5 Temperature Contour of Satellite for Case 2 (Steady State)

CHAPTER 66
Case1 (orbital period = 6307.1 sec.) Case2 (orbital period = 6595.5 sec.)
Figure 66-6 Temperature vs. Time on Solar Panels (Transient)
The steady state results are used as the initial conditions. They are actually the average temperatures over the whole
orbital period. The orbits in both cases have eclipses with the Earth shadow; therefore the steady state temperatures
are lower than the temperatures in the Sun shine period. That is why the curves have a sudden jump up at the beginning.
The lower temperature at the middle curves shows the eclipse effects on the solar panels. The green curves show the
shading effect caused by the satellite body and antenna. In case 2, during the first orbital arc period, the satellite body
and antenna point vertically to the Sun, along with the solar panels, so no shading effect at all, and the temperatures
are certainly much higher. During the third orbital arc period, the satellite body and antenna point to the Earth, while
the solar panels point to the Sun, the shading effect occurs at certain orbital locations. The temperatures are relatively
lower because the satellite orbit is much higher. The top points (inflexion) of the curves shows the locations where the
solar panels point to the Sun best, while the satellite body and antenna point to the Earth.
Modeling Tips
The parabolic primitive surface is not available in SimXpert V2010 for now, so we use a sphere surface instead. MD
Nastran can support the parabolic surface. If you want to use the parabolic surface, you will need to do some extra
work to manually modify the BDF file. The yokes which support the solar panels are deliberately ignored to simplify
the thermal models.
For transient analysis cases, the time scale factor in the radiation enclosure form is very important. If you use second
as the time unit for orbital period in Thermica, the time scale factor should be 3600.0.
CHAPTER 66 1233
Satellite in Orbit
Input File(s)
Files Description
QT13_satellite.dat MD Nastran SOL400/RC Network Solver thermal input file
QT14_sat_tran.dat MD Nastran SOL400/RC Network Solver thermal input file
QT39_sat_3arcs.dat MD Nastran SOL400/RC Network Solver thermal input file
QT40_sat_tran_3arcs.dat MD Nastran SOL400/RC Network Solver thermal input file
QT13_14_satellite.TRJINP Thermica v3 orbit input file for case 1
QT13_14_satellite.PNTINP Thermica v3 pointing input file for case 1
QT39_40_sat_3arcs.TRJINP Thermica v3 orbit input file for case 2
QT39_40_sat_3arcs.PNTINP Thermica v3 pointing input file for case 2
Chapter 67: Thermal Contact on Surface, Edge and Solid Face
Thermal Contact on Surface,

67 Edge and Solid Face

Summary 1235

Introduction 1236



Results 1238

Modeling Tips 1239

Input File(s) 1239

Video 1240
CHAPTER 67 1235
Thermal Contact on Surface, Edge and Solid Face
Summary
Title Chapter 67: Thermal Contact on Surface, Edge and Solid Face
Features: Thermal Contact
Geometry & Boundary 100 ºC
Conditions Diameter = 0.4m
Height = 0.6 m
Mat 1 0.7 m x 1 m x 0.2 m
Mat 2
20 ºC
0 ºC
1 m x 1 m x 0.1 m
Mat 1
2 m x 1 m x 0.1 m
0 ºC Mat 1
Mat 1: K = 1.25 W/m/°C, Cp = 920 J/Kg/°C, ρ = 2500 Kg/m³

Material properties
Mat 2: K = 12.5 W/m/°C, Cp = 920 J/Kg/°C, ρ = 2500 Kg/m³
Analysis characteristics Solution 400 / RC Network solver.
Applied Loads Heat flux, thermal contact
Element type CQUAD4, CTETRA
FE results
CHAPTER 67
Introduction
This problem demonstrates the thermal contact feature of SOL 400 RC Network Solver.
Modeling Details
This problem has three surfaces and one cylinder solid. These surfaces and solid do not really touch each other. The
cylinder and vertical surface are above the two horizontal surfaces, with a gap of 0.2 m distance. The two horizontal
surfaces have a 0.2 m distance gap between them.
100 ºC
Diameter = 0.4m
Height = 0.6 m
Mat 1 0.7 m x 1 m x 0.2 m
Mat 2
20 ºC
0 ºC
1 m x 1 m x 0.1 m
Mat 1
2 m x 1 m x 0.1 m
0 ºC Mat 1
Figure 67-1 three Surfaces and Solid Contact Model
RC Network Solver simulates the thermal contact with a “projection” algorithm. When two surfaces or edges are
connected together, they do not need to match their meshes each other. The slave entities project to the master entities
to determine the contact hooks. This is done automatically by the translator during the running time. If the cylinder or
surface is moved, the new contact hooks will be created accordingly.
Solution Highlights
RC Network Solver uses PRJCON entry to simulate the thermal contact. SET 3 entry is used to define the master and
slave entities.
CHBDYE 8282 8140 5
CHBDYE 8283 8146 5
SET3 8 ELEM 8273 8274 8275 8276 8277 8278+
+ 8279 8280 8281 8282 8283
...
CHBDYE 8289 7800 5
CHBDYE 8290 7807 5
SET3 9 ELEM 8284 8285 8286 8287 8288 8289+
+ 8290
PRJCON 2184
HEAT1 8 9 111.
CHAPTER 67 1237
Format HEAT1
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
+ HEAT1 SET3 SET3 Slave h
Master
Format HEAT2
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
+ HEAT2 SET3 SET3 Slave PID
Master
Format HEAT3
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
+ HEAT3 SET3 SET3 Slave F Emis Emis Slave
Master Master
Format HEAT4
1 2 3 4 5 6 7 8 9 10
PRJCON BID +
+ HEAT4 SET3 SET3 Slave F RADC id RADC id
Master Master Slave

for HEAT1
for HEAT2
CHAPTER 67

F View factor between parts. 0.0  R  1.0 Required
for HEAT3
& HEAT4
for HEAT3
for HEAT4
value.
value.
Remarks
1. This “HEATx” and the later parameters are for RC Network solver only.
Results
Figure 67-2 Temperature Contour of Thermal Contact Model
The vertical surface is just above the middle of the horizontal surface. The projection of the element edges hit at the
middle of center 2D elements. Form the top view of the model, you can see the vertical surface does not really contact
CHAPTER 67 1239
with the smaller horizontal surface. The higher temperature on the smaller horizontal surface is actually caused by the
contact through the mismatched meshes between the two horizontal surfaces. You can clearly see that all the meshes
are mismatched.
Figure 67-3 Temperature Contour of Thermal Contact Model (top view)
Modeling Tips
RC Network Solver SSSPM is used for a better accuracy in this problem. SSSPM is a direct linear equation solver
(sparse matrix method or method of quasi-minimized residuals). The bigger horizontal surface is meshed with odd
number elements so that the vertical surface is just above the middle of some center 2-D elements.
Input File(s)
Files Description
QT18_contact.dat MD Nastran SOL400/RC Network Solver thermal input file
CHAPTER 67
Video
100 ºC
Diameter = 0.4m
Height = 0.6 m
Mat 1 0.7 m x 1 m x 0.2 m
Mat 2
20 ºC
0 ºC
1 m x 1 m x 0.1 m
Mat 1
2 m x 1 m x 0.1 m
0 ºC Mat 1

Chapter 68: Collection and Primitives Radiation
Collection and Primitives

68 Radiation

Summary 1242

Introduction 1243



Results 1250

Modeling Tips 1251

Input File(s) 1252

Video 1252
CHAPTER 68
Summary
Title Chapter 68: Collection and Primitives Radiation
Features: • Enclosure Radiation
• Primitive modeling
• Small facet, Collection (Super Element), and Primitive radiation
Geometry & Boundary Radiation insulated
Conditions Space T = -273.15 oC upper side
Plate: 1.5 m x 1.5 m x 1 mm

Normal Flux Sphere: 1 m dia, t = 1 mm
1000 W/m2 Distance from Sphere center
Inner Side to plate = 1 m
Radiation insulated
Inner side
Material properties K = 0.001 W/m/oC, Emissivity,  = 1.0, Absorptivity,  = 1.0

Analysis characteristics Solution 400 / RC Network solver. Steady and transient thermal analysis.
Element type 4-node shell element CQUAD4
FE results Temperatures
104.8 104.6 104.3
Small Facets Collection (Super Element) Primitives

(1113 sec) (6 sec) (3 sec)
CHAPTER 68 1243
Collection and Primitives Radiation
Introduction
This problem demonstrates three enclosure radiation loads of SOL 400 RC Network Solver: Small Facets, Collection
(Super Element), and Primitives. Three methods will be used to solve the same model - small facet method, super
element method and primitive method. You can compare the speed and accuracy among the three methods.
Modeling Details
This model consists of a hemi-sphere and a plate. They are all primitive surfaces. The hemi-sphere and plate radiate
to each other, the other sides are radiation insulated. A heat flux 1000 W/ m² is applied to the inner side of the hemi-
sphere. A black coating is applied on the surface of both hemi-sphere and plate. An extremely low conductivity
material and extremely thin 2-D shell property are used to show the “pour” radiation effect.
Radiation insulated
Space T = -273.15 oC upper side
12x12 mesh
Normal Flux Plate: 1.5 m x 1.5 m x 1 mm

Sphere: 1 m dia, t = 1 mm
1000 W/m2
Distance from Sphere center
AxB mesh = 1x1
Radiation insulated K= 0.001 W/m/oC
Inner side Cp = 1 J/Kg/oC
ρ = 1 Kg/m3
Emissivity = 1
Absorptivity = 1
Figure 68-1 Model Geometry and Materials
Solution Highlights
Enclosure Radiation has three options: Small Facets, Collection (Super Element), and Primitives. The small facets
method is the traditional way of FEM modelers to calculate radiation view factors. The collection and primitives are
the unique methods for speeding up radiation calculation in RC Network Solver. All the facets in the application region
will be treated as one radiation node. This makes the radiation analysis much faster and more efficient. The primitive
method also utilizes “true geometric shapes” for radiation analysis. A special algorithm is developed to match the
radiation results back to the finer conduction mesh. More details on collection and primitives can be referenced in
MSC Sinda for Patran user's guide.
RC Network Solver uses VIEWEX entry to simulate the enclosure radiation loads. RADC entry is used to represent the
MLI or Coating materials. These two entries are introduced in Chapter 66: Satellite in Orbit. The SET3 and RADCOL
cards are used to represent the collection (Super Element). The SET3 and PRIMx cards are used to represent the
primitives.
CHBDYE 9346 8735 1 2 2
CHBDYE 9347 8736 1 2 2
CHAPTER 68
$!
SET3 2 ELEM 9043 9044 9045 9046 9047 9048+
+ 9049 9050 9051 9052 9053 9054 9055 9056+
...
$! Radiation Collection
RADCOL 3 2 2 2
...
CHBDYE 9746 930 1 3 2
CHBDYE 9747 931 1 3 2
$!
SET3 4 ELEM 9348 9349 9350 9351 9352 9353+
+ 9354 9355 9356 9357 9358 9359 9360 9361+
...
$! Primitive Shape
$!----------------------------------------------------------------------------!$
PRIM1 2 3 2 3
-0.75 -0.75 1. 0.75 -0.75 1.
-0.75 0.75 1. 1 1
CHAPTER 68 1245
RADCOL Radiation Collective Entity
Specifies a collection of boundary elements to be used as a single face in the radiation calculation. This will decrease
computation time at the small cost of accuracy. Computational savings and accuracy are dependent on the coarseness
of the collection versus the constituents. View factors of the collection are redistributed across the elements for
calculation of the radiative energy transfer.
Format
1 2 3 4 5 6 7 8 9 10
RADCOL RADCOLID 701 2 1.0
Example
1 2 3 4 5 6 7 8 9 10
RADCOL 101 5 6 2 3 7

RADCOLID Radiation Collection identification number. I0 Required
IVIEWF A VIEW entry identification number for the front face. I  0 0
IVIEWB A VIEW entry identification number for the back face. I  0 0
RADMIDF RADM identification number for the front face I0 0
RADMIDB RADM identification number for the back face. I0 0
SET3 idn ID of the element collection to be considered a super I0
element.
Remarks
2. IVIEWF/IVIEWB will default to 0 if left blank. This would indicate that the corresponding front and/or back do
participate in the radiation.
3. IF an IVIEWF is specified, there must also be a RADMIDF for surface material properties. If an IVIEWB is
specified there must also be a RADMIDB for surface material properties.
CHAPTER 68
PRIMx Thermal Geometric Primitives for RC Radiation
Specifies the properties of geometric primitives to be used in radiation calculations in place of elements.
Format
1 2 3 4 5 6 7 8 9 10
PRIM1 PRIMID IVIEWF IVIEWB RADMIDF RADMIDB SET3ID +
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) P4(1) P4(2) P4(3) A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) Diam1 Diam2 Angle1 Angle2
A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) Diam1 Angle1 Angle2 A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) Diam1 Diam2 Angle1 Angle2
A_mesh B_mesh
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) Diam1 Angle1 Angle2 Trunc1 Trunc2
A_mesh B_mesh
CHAPTER 68 1247
1 2 3 4 5 6 7 8 9 10
+ P1(1) P1(2) P1(3) P2(1) P@(2) P2(3) +
+ P3(1) P3(2) P3(3) Diam1 Angle1 Angle2 Trunc1 Trunc2
A_mesh B_mesh

PRIMID Primitive identification number; unique to all I0 Required
other PRIMx
SET3 ID ID of the element collection to which this I>0 Required
primitive describes. This collection acts as the
elements that will exist in the thermal model,
but the collection will be absent from the
radiation model. Instead, the primitive will be
used to calculate radiation and be
redistributed back onto the elements. All
radiation properties for the primitive will be
applied to the element collection and must be
consistent across.
RADMID ID of the radiation material properties used to
describe this primitive for analysis.
Pi(a) The position of point i in the a axis as R Required
described in the correlating picture. For
example, P2(2) denotes the y coordinate of
the second point. Position is always described
in global coordinates.
Diamx Diameter x of the primitive if applicable and R  0.0 Required
as described in the correlating picture.
Anglex Angle x of the primitive if applicable and as 0 R  360.0 Required
described in the correlating picture.
Truncx Truncation x of the primitive if all are R  0 for PRIM8 Required
pickable and as described in the correlating
picture.
-0.5*Diam1  R 0.5*Diam1 for PRIM7
A-mesh Number of mesh spaces in parametric I0 Required
direction-1 as described in the correlating
picture.
B_mesh Number of mesh spaces in parametric I0 Required
direction-2 as described in the correlating
picture.
CHAPTER 68
Remarks
2. SET3 should include all the elements which belong to this primitive. It will cause wrong results if only a partial
of the elements are included.
3. PRIMID should be unique across all primitives (PRIMx) in the model.
4. About the primitives:
PRIM1: Rectangle
PRIM2: Quad
PRIM3: Triangle
CHAPTER 68 1249
PRIM4: Disc
PRIM5: Cylinder
PRIM6: Cone
CHAPTER 68
PRIM7: Sphere
PRIM8: Parabolic
Results
Temperatures
104.8 104.6 104.3
Small Facets Collection (Super Element) Primitives

(1113 sec) (6 sec) (3 sec)
Figure 68-2 Temperature contour of Model for Case 1 (Steady State)
CHAPTER 68 1251
The following form illustrates the Thermica execute times and temperature results. (Windows XP v2002 SP3, Dell
Precision | M65 laptop, Intel® Core(TM) 2 CPU, T7200@2.00GHz, 997MHz, 3.25GB of RAM).
Table 1-1 Speed and Result Comparison among the Three Methods (Ray count: 500,000)
Radiation Executing Time (s) Temperature Result (ºC)
Small facets method 1113 -79.74 to 104.8
Collection method 6 -79.67 to 104.6
Primitives method 3 -79.53 to 104.3
Modeling Tips
As you can see, the temperature results are about the same, but the collection and primitives methods are much faster
then the traditional small facets method. Because of the feature of the re-match algorithm, no obstructions between the
two collections or primitives are allowed; otherwise we may lose some accuracy.
The parabolic primitive has not been supported yet in SimXpert, but MD Nastran/RC Network Solver supports that.
In MSC Sinda for Patran, you can put multiple primitives inside one application region, the translator will
automatically separate them to be multiple single- primitive loads, but SimXpert does not support this feature, one
single primitive is required for one primitive load.
You can preview the AB mesh of the primitive (Figure 68-3). These AB mesh is used to form the radiation model in
Thermica or other external radiation codes. The AB mesh does not have to be congruent with the conduction mesh.
Figure 68-3 AB mesh preview in SimXpert

CHAPTER 68
Input File(s)
Files Description
QT16_hemi_sph_sf.dat MD Nastran SOL400/RC Network Solver thermal input file
QT33_hemi_sph_se.dat MD Nastran SOL400/RC Network Solver thermal input file
QT32_hemi_sph_pr.dat MD Nastran SOL400/RC Network Solver thermal input file
Video
Radiation insulated
Space T = -273.15 oC upper side
Plate: 1.5 m x 1.5 m x 1 mm

Normal Flux Sphere: 1 m dia, t = 1 mm
1000 W/m2 Distance from Sphere center
Radiation insulated
Inner side

Chapter 69: Simulation of Fuel Tank Filling
69 Simulation of Fuel Tank Filling

Summary 1254

Problem Description 1255

MD Nastran SOL700 Model 1255

Results 1266

Input File(s) 1268
CHAPTER 69
Summary
Title Chapter 69: Fuel Tank Filling
Features Multiple Adaptive Euler Domains for Multiple Material
Geometry
Material properties • Fuel:

Density: 8.5E-7 Kg/ mm3
Bulk modulus: 2.0E+4 kPa
• Air:
Density: 1.29E-9 kg/mm3
Gamma 1.4
Specific internal energy 1.938E11 Kg-mm2/s2
• Tank and pipes are modeled as rigid materials
Analysis characteristics Transient explicit dynamic analysis (SOL700) – Fluid Structure Interaction (FSI)
Boundary conditions The tank is fixed in position by defining zero velocity in all directions and zero rotation in
all directions.
Applied loads Flow velocity of fuel at inlet of fuel pip: the velocity is defined such that the flow rate
keeps 2.0 liter/second over 2 seconds
Element type • The Euler domains in this model handle multiple hydrodynamic materials (air and fuel).
• Dummy shell elements for fuel tank structure.
FE results FMATPLT Material fraction of material times the volume uncovered fraction
CHAPTER 69 1255
Simulation of Fuel Tank Filling
Problem Description
The process of filling up an automobile fuel tank must be safe and comfortable for the customer. Effects like premature
switch off of the gasoline pump or the back splash of fuel must be avoided. Furthermore, the legal and government
regulations must be met. The space available for the whole system is constantly minimized, leading to additional
complications in fulfilling the above criteria. Costly and time-consuming experiments are usually necessary for this
optimization. Numerical simulation is a desirable tool to avoid excessive experimental testing.
This example demonstrates the application of Multiple Adaptive Euler Domains with Multiple Material to predict fuel
tank filling process. The problem simulates a fuel tank that contains a filling pipe and a vent pipe. The tank is filled
with fuel up to 80 mm from the bottom. The rest is filled with air. In the simulation, the fuel is made to flow into the
tank through the inlet of the filling pipe. The air and the fuel escape out of the tank through the outlet of the vent pipe.
MD Nastran SOL700 Model

The tank and pipes are modeled as rigid bodies. The fuel/air region is modeled by three Euler meshes. The first domain
models the inside of the tank, the second domain models the inside of the filling pipe, and the third domain models the
inside of vent pipe. For the interaction between the structure and Euler domains, three coupling surfaces are needed.
• Units
• Length = mm, Mass = Kg, and Time = second
• Tank and Pipes
Figure 69-1 shows the structure mesh. All elements are defined as dummy shell elements. A surface is created and
defined as a rigid body. The tank is fixed in position by defining zero velocity in all directions and zero rotation in all
directions.
Figure 69-1 Tank and Piping Structure Mesh

CHAPTER 69
Euler Domain 1
The first Euler domain has the fuel and air inside of the tank.
The properties of fuel are:
Density 8.5E-7 Kg/mm3

Bulk modulus 2.0E+4 KPa
This is a reduced bulk modulus (1/100) to increase the time step and reduce CPU time.
In the input file:
MATDEUL 2 8.5E-7 2
EOSPOL 2 20000
The air properties are:
Density 1.29E-9 Kg/mm3

Gamma 1.4
Specific internal energy 1.938E11 Kg-mm2/s2
In the input file:

MATDEUL 1 1.29E-9 1
EOSGAM 1 1.4
TICVAL,21,,DENSITY,1.29E-9,SIE,1.938E11
The Euler region is modeled by using the MESH entry. The ADAPT option is used:
PEULER1,1,,MMHYDRO,100
MESH,1,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,1
To initialize the whole first Euler mesh, a TICEUL entry is defined. Tank is full with fuel up to 80mms from the bottom.
The rest is full with air. The initial air pressure is set to 100 KPa. Fuel hydrostatic pressure is defined starting from 100
KPa at the surface and increasing going down. The four layers with different pressures are defined:
TICEUL1,100,1
TICREG,1,1,CYLINDER,31,1,21,1.0
$
CYLINDR,31,,-350.,150.,-10000.,50.,150.,-10000.,+
+,20000.
CYLINDR,32,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10020.
CHAPTER 69 1257
CYLINDR,33,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10040.
CYLINDR,34,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10060.
CYLINDR,35,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10080.
$
TICVAL* 22 DENSITY 8.54254E-7*
* SIE 0.
* SIE 0.
* SIE 0.
* SIE 0.
Euler Domain 2
The second Euler region represents the fuel and air inside the filling pipe. For smooth start of the simulation, the part
near the inlet of the filling pipe is initially filled with fuel. The rest is full with air. For the second Euler region, a MESH
entry is used:
$
MESH,2,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,2
$
TICEUL1,200,2
CYLINDR,51,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10260.
CYLINDR,52,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10205.
$
$
TICVAL,41,,DENSITY,8.5425-7,SIE,0
Euler Domain 3
The third Euler region represents the fuel and air inside the vent pipe. The vent pipe is initially full with air. For the
third Euler region, a MESH entry is used:
$
MESH,3,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,3
CHAPTER 69
$
TICEUL1,300,3
Fluid Structure Interaction

For each Euler domain, a separate surface is required. The surface definition makes use of the properties of the
elements.
1. Tank surface:
BCPROP,101,7,8,12,THRU,16
The surface has been closed to constitute valid coupling surface (Figure 69-2).
Holes
Outside of Tank Inside of Tank

Figure 69-2 Coupling Surface of Euler Domain 1
The Euler domain 1 is constrained by surface 101. All elements outside the volume are not active. The covered
option is, therefore, set to OUTSIDE. Attached to this surface is the first Euler MESH:
+,,,,,,,,,+
+,,1
$
CHAPTER 69 1259
2. Filling pipe surface:

BCPROP,201,4,THRU,8
Figure 69-3 Coupling Surface of Euler Domain 2 (filling pipe)
The Euler domain 2 is constrained by surface 201. For this volume, the outer Euler elements are covered:
COUPLE,2,201,OUTSIDE,,,22,,,+
+,,,,,,,,,+
+,,2
Surface 101 and surface 201 share some elements (with property number 7, 8). A hole is modeled as a
subsurface consisting of quads (with property number 8) that are fully porous. The elements in this subsurface
connect the two coupling surface and are included in the definition of both coupling surfaces.
A flow definition is required for one of the coupling surfaces. The flow entry is referenced from the second
coupling surface. The input to define flow between the two regions:
BCPROP,2,8
CHAPTER 69
3. Vent pipe surface:

BCPROP,301,9,THRU,14
Figure 69-4 Coupling Surface of Euler Domain 3 (vent pipe)
The Euler domain 3 is constrained by surface 301. For this volume, the outer Euler elements are covered:
+,,,,,,,,,+
+,,3
Surface 101 and surface 301 share some elements (with property number 12, 13, 14). A hole is modeled as a
subsurface consisting of quads (with property number 14) that are fully porous.
The elements in this subsurface connect the two coupling surface and are included in the definition of both
coupling surfaces.
A flow definition is required for one of the coupling surfaces. The flow entry is referenced from the third
coupling surface. The input to define flow between the two regions:
BCPROP,3,14
Inlet and outlet

Two flow boundaries are defined to the coupling surface (pipe ends, see Figure 69-5). The first is to define fuel flow
into the tank at a predefined flow rate (velocity × area). The second is to allow air (or fuel) to escape out of the tank.
Pressure at the second boundary is defined as 1.0 at (100 kPa).
CHAPTER 69 1261
Inlet Outlet
Figure 69-5 Flow Boundaries
1. Inlet
The flow entry of inlet is referenced from the second coupling surface. As input, the velocity is defined such
that the flow rate keeps 2.0 liter/second over two seconds. Since the area of the inlet hole is 1256 mm2, the
velocity is 1592 mm/s.
LEAKAGE,21,22,21,PORFLOW,21,,1.0
PORFLOW,21,,XVEL,-1592.,DENSITY,8.5425-7,FLOW,IN,+
+,YVEL,0.,ZVEL,0.,MATERIAL,2,,,+
+,SIE,0
BCPROP,21,4
Note: 1. In the case of material flow into a multi-material Euler mesh, the density and specific energy
has to be set.
2. Prescribing both pressure and velocity may lead to the instabilities.
2. Outlet
The flow entry of outlet is referenced from the third coupling surface.
PORFLOW,31,,MATERIAL,1,DENSITY,1.29e-9,SIE,1.938e+11,+
+,PRESSURE,100.
BCPROP,31,9
CHAPTER 69
Note: a) Since tank flow is in general subsonic, a prescribed pressure condition to the flow condition
is necessary. The boundary condition without the prescribed pressure actually assumes that
flow is supersonic.
b) When material flows out of a multi-material Euler mesh, it is assumed that each of the
materials present in the outflow Euler element contributes to the out flow of mass. The
materials are transported in proportion to their relative volume fractions.
Miscellaneous
1. Fast coupling is to used:
DYPARAM,FASTCOUP,
2. Gravity is applied to the whole model:

TLOAD1 1 444 0
GRAV 444 -9800. 1.
3. In order to output results of the flow boundaries, a history request is created:

DYTIMHS,,1E-4,,,,,,,+
+,SUBSOUT

$ UNIT: mm/kg/s/K
CEND
SUBCASE 1
$ for QA purpose, run shorter time
TITLE= Jobname is: tank_filling
DLOAD=1
IC=1
SPC=1
TSTEPNL=1
$
BEGIN BULK
TSTEPNL 1 10 2.E-01 1
DYPARAM,FASTCOUP,
PARAM*,DYINISTEP,1E-7
PARAM*,DYMINSTEP,1E-8
$
DYTIMHS,,1E-4,,,,,,,+
+,SUBSOUT
$
CHAPTER 69 1263
$
TLOAD1 1 444 0
GRAV 444 -9800. 1.
$
$ ========== PROPERTY SETS ==========
$
$ * Shell_1 *
$
PSHELL,4,888,1E-3
PSHELL,9,888,1E-3
$
PSHELL,5,999,1E-3
PSHELL,6,999,1E-3
PSHELL,7,999,1E-3
PSHELL,8,999,1E-3
PSHELL,10,999,1E-3
PSHELL,11,999,1E-3
PSHELL,12,999,1E-3
PSHELL,13,999,1E-3
PSHELL,14,999,1E-3
PSHELL,15,999,1E-3
PSHELL,16,999,1E-3
$
MATD009,888,1E-20
$
MATRIG,999,,,,1.0E1,0.00,0.00,0.00,+
+,1.E10,0.0,0.0,1.E10,0.0,1.E10,,,+
+,,,,,,,,,+
+,,,,1,7,7
$
$ -------- Material air_mat id =1
$
MATDEUL 1 1.29E-9 1
$
$ -------- Material oil_mat id =2
$
MATDEUL 2 8.5E-7 2
EOSPOL 2 20000
$
$ ======== Load Cases ========================
$
$
$-----------------------------Domain 1------------------------------
$
MESH,1,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,1
$
+,,,,,,,,,+
+,,1
$
BCPROP,101,7,8,12,THRU,16
$
CHAPTER 69
$---------Euler initial condition---------------

TICEUL1,100,1
$
EOSGAM 1 1.4
$
CYLINDR,31,,-350.,150.,-10000.,50.,150.,-10000.,+
+,20000.
CYLINDR,32,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10020.
CYLINDR,33,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10040.
CYLINDR,34,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10060.
CYLINDR,35,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10080.
CYLINDR,51,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10260.
CYLINDR,52,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10205.
$
$2345678$234567812345678$234567812345678$234567812345678$234567812345678$2345
678
* SIE 0.
* SIE 0.
* SIE 0.
* SIE 0.
$
$-----------------------------Domain 2------------------------------
$
MESH,2,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,2
$
+,,,,,,,,,+
+,,2
$
BCPROP,201,4,THRU,8
$
CHAPTER 69 1265
BCPROP,2,8
$
PORFLOW,21,,XVEL,-1592.,DENSITY,8.5425-7,FLOW,IN,+
+,YVEL,0.,ZVEL,0.,MATERIAL,2,,,+
+,SIE,0
BCPROP,21,4
$
TICEUL1,200,2
$
$
TICVAL,41,,DENSITY,8.5425-7,SIE,0
$-----------------------------Domain 3------------------------------
$
MESH,3,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,3
$
+,,,,,,,,,+
+,,3
$
BCPROP,301,9,THRU,14
$
BCPROP,3,14
$
PORFLOW,31,,MATERIAL,1,DENSITY,1.29e-9,SIE,1.938e+11,+
+,PRESSURE,100.
BCPROP,31,9
$
TICEUL1,300,3
$
$INCLUDE tank.bdf
$
$ --- Define 1335 grid points ---
$
GRID 1 .00000 .00000 200.000
GRID* 2 .00000 -2.8e-14*A000001
*A000001 1.42e-14
GRID* 3 .00000 -3e-06*A000002
*A000002 180.000
GRID* 4 .00000 2.84e-14*A000003
*A000003 160.000
GRID* 5 .00000 -2.8e-14*A000004
………………………………..
………………………………..
CHAPTER 69
$ --- Define 1350 elements

$
$ -------- property set pshell.1 ---------
CQUAD4 1248 4 1121 1259 1258 1120
CQUAD4 1249 4 1122 1260 1259 1121
CQUAD4 1250 4 1123 1277 1260 1122
…………………………………
…………………………………
$ -------- property set pshell.2 ---------

CQUAD4 1103 5 1120 1140 1141 1121
CQUAD4 1104 5 1121 1141 1142 1122
CQUAD4 1105 5 1122 1142 1143 1123
…………………………….
…………………………….
CQUAD4 1099 16 1116 415 416 1117

CQUAD4 1100 16 1117 416 417 1118
CQUAD4 1101 16 1118 417 418 1119
CQUAD4 1102 16 1119 418 419 914
$
ENDDATA
Results
Figure 69-6 shows isosurfaces of the fuel and air. The images are created with CEI.Ensight.
Figure 69-7 shows time history curves of the velocities on the flow boundaries. XVEL-SUB21 is the X-Velocity of
the inlet and XVEL-SUB31 is the X-Velocity of the outlet. The outflow velocity is much higher because the outlet
vent is small. At 1.45 seconds, fuel starts to vent out.
CHAPTER 69 1267
Figure 69-6 Isosurfaces of FMAT

CHAPTER 69
Figure 69-7 Velocities on the Flow Boundaries
Input File(s)
Files Description
EP4_11_tankfill_2s.dat MD Nastran input.Time period reduced to 0.25 seconds
Chapter 70: User-defined Subroutines for Heat Transfer Coefficient
User-defined Subroutines for

70 Heat Transfer Coefficient

Summary 1270

Introduction 1271


Results 1280

Modeling Tips 1280

Input File(s) 1281
CHAPTER 70
Summary
Title Chapter 70: User-defined Subroutines
Features: User-defined Subroutines (Fortran, C, and Sinda SSK file)
Geometry & Boundary Convection to ambient temperature Tamb = 300 K
Conditions
Heat Flux 1000 W/m2
Dimension: 1m x 10m Unit Thickness Material: Iron
Convection coefficient H = (T1 + 100)/RL computed in user subroutine

Where: T1 is the wall temperature on each node
RL is the average distance to the leading edge to node
Material properties 1000 Conductivity (W/m/K)
800 Specific Heat = 477.3 W/Kg/K

Density = 7870 Kg/m3
600
400
200
Temperature (K)
0
0 500 1000 1500 2000
Analysis characteristics Solution 400 / RC Network solver. Steady state analysis. User-defined Subroutines
(UDS) and SCA service.
FE results Temperature result (User defined Fortran Subroutine)
Temperature result (User defined C Subroutine)
Temperature result (MSC Sinda Skeleton SSK file)

CHAPTER 70 1271
User-defined Subroutines for Heat Transfer Coefficient
Introduction
This example shows the basic steps to add user defined subroutines to MD Nastran solution 400/RC Network Solver.
The same model and convection correlation are used with P/Thermal's workshop 15, so that users can easily compare
the Fortran or C logics and temperature results. A Fortran or C user defined subroutine is used to calculated the
convection coefficients. We also show the MSC Sinda's SSK file to add the same Fortran logic to the sin file.
Convection coefficients are computed by the following formula
H = (T1 + 100)/RL
where
H Convection coefficient for each node.

T1 Temperature values on each node.
RL The average distance from the leading edge to node
In this problem, we are going to use a text file from P/Thermal to calculate the RL values. RL = (GP2+GP3)/2. Where:
GP2 and GP3 are the distance from each node control area's leading and trailing edges. GP2 and GP3 are added 1.0
according to the requirements of the specific convection correlation.
GP1 is the control area of the nodes. They can be found in the text file from P/Thermal. Users can create this text file
by themselves with any format they like. It contains the nodal control area GP1, and the two distances GP2 and GP3
of this control area.
We also need the conductor numbers in the sin file. You can get these conductor ids by running the model with a
constant dummy convection coefficient.
Modeling Details
A 1m x 10m unit thickness iron slab is meshed 5 x 50. The ambient temperature is set to be 300K, and a heat flux 1000
W/m² is applied to the bottom edge of the surface. A convection to ambient load is applied to the top edge of the plate.
A constant dummy convection coefficient is used for an initial run. We will need an initial run for the convection
conductor ids. Later, we will use a Fortran or C user defined subroutine to calculate the real h values, and replace the
convection conductors in the sin file.
Convection to ambient temperature Tamb = 300 K
Heat Flux 1000 W/m2

Figure 70-1 Boundary Conditions
CHAPTER 70
Solution Highlights
MD Nastran Solution 400/RC Network Solver supports user defined subroutines to modify any parameters in the
solver input (.sin) file. EntUDS is used to merge user's own subroutines into the 4 entry points of the solution sequence.
1. RCEnt1 ---- Beginning of nonlinear loop before temperature update
2. RCEnt2 ---- End of nonlinear loop after temperature update
3. RCOut1 ---- Beginning of output routine
4. RCExec1 - Beginning of Execution block
In this model, we will use RCEnet1 and RCExec1 entry points. We need to add three lines of command in the bdf file.
At the beginning of the bdf file:
CONNECT SERVICE MYGN1 'SCA.MDSolver.Obj.Uds.DefEnt'
At the end of the bdf file:
ENTUDS 1 RCENT1 MYGN1
ENTUDS 2 RCEXEC1 MYGN1
The following is the example Fortran code in the UDS.f file in the server's folder.
In the MODULE RCDATA block,
MODULE RCDATA
C GP Array, Conductor ID array, and Node ID array definition

DOUBLE PRECISION, DIMENSION(51,3)::GP
INTEGER(8), DIMENSION(51)::IDS_G,NODEIDS
In the Subroutine Variables1 block,
SUBROUTINE VARIABLES1( iarray, ia_cnt, farray, fa_cnt )

USE RCDATA
IMPLICIT NONE
INTEGER(KIND=4), DIMENSION(*):: iarray(*)
REAL(KIND=4), DIMENSION(*):: farray(*)
INTEGER ia_cnt, fa_cnt
DOUBLE PRECISION::RL,AREA
REAL(8)::Hconv
INTEGER(8)::IRESIS
CALL ARRAYS64( tptr,cptr,qptr,gptr,aptr,kptr,xptr )
DO 400 IRESIS=1,51
RL = (GP(IRESIS,2)+GP(IRESIS,3))/2.0
AREA = GP(IRESIS,1)
Hconv = (T(NR(NODEIDS(IRESIS)))+100)/RL
G(NGR(IDS_G(IRESIS))) = Hconv*AREA
END DO
END SUBROUTINE
CHAPTER 70 1273
In the Subroutine Execution block,
SUBROUTINE EXECUTION( iarray, ia_cnt, farray, fa_cnt )

USE RCDATA
IMPLICIT NONE
INTEGER(KIND=4), DIMENSION(*):: iarray(*)
REAL(KIND=4), DIMENSION(*):: farray(*)
INTEGER ia_cnt, fa_cnt
INTEGER(8)::IRESIS
C Get NODEIDS and GP(51,3) data by reading "convec.dat"
OPEN(11,FILE = 'convec.dat')
DO 100 IRESIS=1,9
READ(11,*)
100 END DO
DO 200 IRESIS=1,51
IF(IRESIS==1 ) THEN
READ(11,800) NODEIDS(IRESIS)
READ(11,1000) GP(IRESIS,1),GP(IRESIS,3),GP(IRESIS,3)
GP(IRESIS,2)=1.0
READ(11,*)
READ(11,*)
ELSE IF(IRESIS==51) THEN
GP(IRESIS,3)=11.0
READ(11,*)
READ(11,*)
ELSE
READ(11,*)
READ(11,*)
READ(11,*)
READ(11,1000) GP(IRESIS+1,1),GP(IRESIS,3),GP(IRESIS,3)
READ(11,*)
READ(11,*)
GP(IRESIS,1) = GP(IRESIS,1) + GP(IRESIS+1,1)

END IF
200 END DO
CLOSE(11)
800 FORMAT(7x,I3)
1000 FORMAT(3(E20.11))
C Get IDS_G(51) data by reading conductors.txt
OPEN(11,FILE = 'conductors.txt')
READ(11,*)
DO 300 IRESIS=1,51
READ(11,1010) IDS_G(IRESIS)
300 END DO
CLOSE(11)
1010 FORMAT(12x,I4)
END SUBROUTINE
CHAPTER 70
The following is the example C code in the DefEnt.cpp file in the server's folder.
In the beginning of the DefEnt.cpp
#include "DefEnt.h"
#include "RCDefEnt.h"
#include <fstream>
#include <iostream>
namespace SCA { namespace MDSolver { namespace Obj { namespace Uds { namespace Entry
{
using namespace std;
const int cnt = 51;

int nodes[cnt];
double gp[cnt][3];
int ids_g[cnt];
CHAPTER 70 1275
In the RCEXec1 function
SCAResult DefEnt::RCExec1(const SCAInt32Sequence& IData, const SCAReal32Sequence& R

const SCAStringSequence& CData)
{
int i;
char bin[256];
// get convection values

ifstream conv( "convec.dat" );
char blank;
for( i=0; i<9; i++ )
conv.getline( bin, 256 );
// first one
conv >> blank >> nodes[0]; conv.getline( bin, 256 );
conv >> gp[0][0] >> gp[0][2] >> gp[0][2]; conv.getline( bin, 256 );
gp[0][1] = 1.0;
for( i=1; i<50; i++ )
{
// read first
conv >> blank >> nodes[i]; conv.getline( bin, 256 );
conv >> gp[i][0] >> gp[i][1] >> gp[i][1]; conv.getline( bin, 256 );
// read second
conv >> gp[i+1][0] >> gp[i+1][2] >> gp[i+1][2]; conv.getline( bin, 256 );
gp[i][0] += gp[i+1][0];
}
// last one
conv >> blank >> nodes[i]; conv.getline( bin, 256 );
conv >> gp[i][0] >> gp[i][1] >> gp[i][1]; conv.getline( bin, 256 );
gp[50][2] = 11.0;
// get conductor ids
ifstream cond( "conductors.txt" );
cond.getline( bin, 256 );
for( i=0; i<cnt; i++ ) {
cond >> ids_g[i]; cond.getline( bin, 256 );
}
return SCASuccess;
}
CHAPTER 70
In the RCEnt1 function
SCAResult DefEnt::RCEnt1(const SCAInt32Sequence& IData, const SCAReal32Sequence&

const SCAStringSequence& CData)
{
int i;
SCAReal64 rl, area, hconv;
SCAInt32 idr;
// Get the model data from the Solver service

DynReal64 T( NULL, 0, 0 ); DynReal64 C( NULL, 0, 0 ); DynReal64 Q( NULL, 0, 0
DynReal64 G( NULL, 0, 0 );
DynReal64 A( NULL, 0, 0 ); DynReal64 K( NULL, 0, 0 ); DynReal64 X( NULL, 0, 0
Solv->Arrays64( T, C, Q, G, A, K, X );
// Adjust Conductors
for( i=0; i<cnt; i++ ) {
rl = ( gp[i][1] + gp[i][2] ) * 0.5;
area = gp[i][0];
idr = Solv->ActRel( "NR", nodes[i] );
hconv = (T[idr]+100.0) / rl;
idr = Solv->ActRel( "NGR", ids_g[i] );
G[idr] = hconv*area;
}
return SCASuccess;
}
The following is the example SSK file in the working directory.
In the MODULE block
BCD 3MODULE
DOUBLE PRECISION, DIMENSION(51,3)::GP
INTEGER(8), DIMENSION(51)::IDS_G,NODEIDS
END
CHAPTER 70 1277
In the EXECUTION block
BCD 3EXECUTION
F INTEGER(8)::IRESIS
C Get NODEIDS and GP(51,3) data by reading "convec.dat"
F OPEN(11,FILE = 'convec.dat')
F DO 100 IRESIS=1,9
F READ(11,*)
F100 END DO
F DO 200 IRESIS=1,51
F IF(IRESIS==1 ) THEN
F READ(11,800) NODEIDS(IRESIS)
F READ(11,1000) GP(IRESIS,1),GP(IRESIS,3),GP(IRESIS,3)
F GP(IRESIS,2)=1.0
F READ(11,*)
F READ(11,*)
F ELSE IF(IRESIS==51) THEN
F GP(IRESIS,3)=11.0
F READ(11,*)
F READ(11,*)
F ELSE
F READ(11,*)
F READ(11,*)
F READ(11,*)
F READ(11,1000) GP(IRESIS+1,1),GP(IRESIS,3),GP(IRESIS,3)
F READ(11,*)
F READ(11,*)
F GP(IRESIS,1) = GP(IRESIS,1) + GP(IRESIS+1,1)
F END IF
F 200 END DO
F CLOSE(11)
F 800 FORMAT(7x,I3)
F1000 FORMAT(3(E20.11))
C Get IDS_G(51) data by reading conductors.txt

F OPEN(11,FILE = 'conductors.txt')
F READ(11,*)
F READ(11,1010) IDS_G(IRESIS)
F300 END DO
F CLOSE(11)
F1010 FORMAT(12x,I4)
SNSOR
END
CHAPTER 70
In the VARIABLE 1 block
BCD 3VARIABLES 1
F DOUBLE PRECISION::RL,AREA
F REAL(8)::Hconv
F INTEGER(8)::IRESIS
F RL = (GP(IRESIS,2)+GP(IRESIS,3))/2.0
F AREA = GP(IRESIS,1)
F Hconv = (T(NR(NODEIDS(IRESIS)))+100)/RL
F G(NGR(IDS_G(IRESIS))) = Hconv*AREA
F400 END DO
END
CHAPTER 70 1279
ENTUDS User-defined Logic at Entry Point
Calls user defined logic within a SCA service at the point specified within the solution sequence.
Format
1 2 3 4 5 6 7 8 9 10
ENTUDS ENTID ENTPNT GROUP +
+ “INT” IDATA1 IDATA2 IDATA3 IDATA4 IDATA5 IDATA6 IDATA7 +
+ IDATA8 IDATA9 ... ... IDATAn +
+ “real” RDATA1 RDATA2 RDATA3 RDATA4 RDATA5 RDATA6 RDATA7 +
+ RDATA8 RDATA9 ... ... RDATAn
+ “CHAR” CDATA1 CDATA2 ... ... CDATAn
Example
1 2 3 4 5 6 7 8 9 10
ENTUDS 1 RCENT1 MY_FUNC +
INT 2 17 +
REAL .5 .25

ENTID Entry point identification number. I0
ENTPNT The point of entry in the solution sequence. Acceptable C Require
values for now: “RCENT1”, “RCENT2”, “ROCOUT1”, d
“RCEXEC1”.
GROUP The SCA group name used to identify the service C Require
d
“INT” Keyword indicating that the following data is integer. C
IDATAi Additional user supplied Integer data not already I
existing on the specified MAT entry.
“READ” Keyword indicating that the following is real. C
RDATAi Additional user supplied Read data not already existing R
on the specified MAT entry.
“CHAR” Keyword indicating that the following data is Character. C
CDATAi Additional user supplied Character data not already C 2
existing on the specified MAT entry.
CHAPTER 70
Remarks
2. In SINDA input file, there are four entry points for users to input customized logics
a. RCENT1 Variable 1 block

b. RCENT2 Variable 2 block
c. RCOUT1 Output block
d. RCEXEC1 Execution block
Results
P/Thermal Temperature result: (303.4 K ~ 336.7 K)
MD Nastran / RC Network Solver: UDS.f temperature result: (303.3 K ~ 336.7 K)
MD Nastran / RC Network Solver: DefEnt.cpp temperature result: (303.3 K ~ 336.7 K)
MSC Sinda: SSK file temperature result: (303.3 K ~ 336.7 K)
Figure 70-2 Results
Modeling Tips
In UDS.f file, M type Fortran is not supported, and you do not need to mark F either. If you want to define a global
variable in the Module RCDATA, you need to insert a USE RCDATA command in the Entry blocks.
CHAPTER 70 1281
In DefEnt.cpp file, you will need to use SCA*32 or 64 type variables if they are used by the Solver routines. If you
want to add the C logic in the original DefEnt.cpp file, you need to remove the Return Call command in each block.
They are used to call the UDS.f file.
In the UDS.f or DefEnt.cpp, if you want some output messages or variables, you will need to use call msg (bin) or msg
(bin) command which outputs to the f06 file. SCA service does not output messages to the console window.
Input File(s)
Files Description
exercise_15_sca_sca.bdf BDF file with SCA Entry interfaces
UDS.f Fortran logic for the SCA service
DefEnt.cpp C++ logic for the SCA service
exercise_15_sin.sin MSC Sinda input file
exercise_15_sin.SSK MSC Sinda's SSK (skeleton) file contains Fortran logic
Chapter 71: Impact of a Rigid on Composite Laminate using GENOA PFA Material
Impact of a Rigid on
71 Composite Laminate using
GENOA PFA Material

Summary 1283

Introduction 1284


Model Details of Part 1 – Composite Shells 1284

Results 1285

Test versus Simulation 1286

Input File(s) 1286

Part 2 - Rigid Impact on Composite Foam Laminate using Genoa
Material 1287

Model Details – Composite shells and Solid Foam Material
1287
 Results of Part 2: 1288

Test versus Simulation 1288

Input File(s) 1288
CHAPTER 71 1283
Impact of a Rigid on Composite Laminate using GENOA PFA Material
Summary
Title Chapter 71: Impact of a Rigid Body on Composite Laminate using GENOA PFA
Material
Features Using Genoa composite shell material for impact simulation
Geometry
Impactor
Plate
Material properties • Impactor (Rigid)

Mass = 0.138 lbf-s2/inch = 53.2 lbm
Diameter = 1 inch
• Plate (Deformable, GENOA 2D material)
G30-500/45 R6367: /-45/0/90/0/90/0/90/0/90/-45/45
12 layers (Details will be explained)
Analysis characteristics Transient explicit dynamic analysis (SOL700)
Boundary conditions Fixed boundary at sides of the plate
Applied loads Initial velocity of a rigid body
FE results 1. Displacement and contact force time histories
2. Stress Distribution plot at the end
CHAPTER 71
Introduction
MD Nastran predicts complex, large deformation composite behavior with extensive material degradation. GENOA
PFA (Progressive Failure Analysis) material model available in MD Nastran SOL700 allows prediction of complex
composite material behavior and degradation of the plies and laminates at micro-mechanical level. In the following
example which includes two parts, the simulation results are compared and correlated closely to those of test results
during a high velocity impact event. In part 1, the plate material is a composite laminate using shell elements while in
part2, the plate material is a combination of laminate composites and solid foam material.
Requested Solution
The displacement and contact force time histories are computed and compared with the test results.
Model Details of Part 1 – Composite Shells

The 10-inch width by 11-inch length composite panel is sandwitched by two supporting plates during impact
(Figure 71-1). The one-inch diameter impactor has a mass of 53.75 lbs with an impact velocity of 3.01 ft/sec resulting
in a impact energy of 7.58 ft-lbs. The panel was made with six layers of G30-500/R3676 fabric (in which the fiber
volume was 60 percent) with the ply lay-up of (45,-45), 4x(0,90),(45,-45). Each fabric ply is 0.014 inches thick and
the total thickness of the panel is 0.084 inches. For details of the test results, please refer to the paper, “Impact, and
Tension After Impact of Composite Launch Space Structure” (Frank Abdi, at al, Conference Paper 2001.).
Impactor
Fixture plate
A A
5.0 inch
11.00 inch
5.0 inch
10.0 inch Impacted panel
Figure 71-1 Test and Simulation Setup
The composite shell panel is modeled using PCOMP entry. The panel has 12 layers and the thickness of each layer is
0.007 inch. The panel is made with the ply lay-up of (45,-45), 4x(0,90),(45,-45) which is the same as the test model.
PCOMP 1
+ 1 .007 45.00000 1 .007 -45.
+ 1 .007 0.0 1 .007 90.00000
CHAPTER 71 1285
+ 1 .007 0.0 1 .007 90.00000

+ 1 .007 90.00000 1 .007 0.0
+ 1 .007 90.00000 1 .007 0.0
+ 1 .007 -45. 1 .007 45.00000
The composite material is modeled using MAT1, MAT8, and MATM entries. MAT1 and MAT8 represent general isotropic
and orthotropic material properties, respectively. Both materials are referred by MATM material where the fiber/ply
and matrix properties of composite materials can be assigned. In addition, the failure criteria can also be defined in the
MATM material model.
MAT1 333 560000.0 0.33 1.962E-3

MATM 1 1 1 0 .6 0.0
+ PLY 1 33 333000.0266000.0333000.0266000.0333000.0
+ 266000.03846.0003846.0003846.000
+
+ MATRIX 333 11000. 55000. 21000. 2.00E-02 .05 4.00E-02
+ CRITICALS11T
+ NONCRIT S11C S22C S33T S33C S12S S23S S13S
+ MDE RROT CRSH DELM FMBK S22T
MAT8 33 3.400E+72500000.0.2 2500000.2500000.1000000.1.962E-3
Results
The results of the simulation were compared with those of the test. MD Nastran SOL700 generates Lagrangian time
history results into the binout binary and d3plot files while the Eulerian time history results are output in the THS file.
The following displacement time history is generated using SimXpert reading the results from d3plot.
Figure 71-2 shows the displacement time history result at node 1 which is located in the center of the panel and shows
the maximum displacement of 0.22 inches which correlates very closely to the maximum displacement from the test
of 0.20 inches.
Figure 71-2 Displacement Time History at Node 1

CHAPTER 71
To generate the contact force time histories, an ASCII file is generated. This is because XY plots generation from
binout binary file is not currently supported in SimXpert or Patran at this time. Alternatively, LS-Post can be used to
generate the XY plot by reading the binout file directly.
To generate the ASCII file from binout file, a convertor tool called I2a is used. l2a is an executable that resides in
the MD Nastran SOL 700 installation directories and reads in the binout binary file and generates an equivalent ASCII
file. The command is:
l2a filename.dytr.binout0000
After running this command, several ASCII files are generated that include nodal forces (ncforc), contact forces (rcforc), element
forces (elout), etc.
In the rcforc file, the slave and master time history contact forces are recorded. The magnitude of contact forces on
slave and master bodies are the same but with opposite signs. Using a contact force time history of the master contact
body, the Figure 71-3 is generated by sorting the data first and then using MS xl for actual plot. The maximum
z-contact force is 878.6 lbf compared to 897 lbf from the test results.
Figure 71-3 Contact Forces in Z-direction
Test versus Simulation

Test Simulation
Maximum displacement (in) 0.20 0.22
Maximum contact force (lbf) 897 878.6
Input File(s)
Files Description
E1-Impact.bdf MD Nastran input for composite shells
CHAPTER 71 1287
Part 2 - Rigid Impact on Composite Foam Laminate using

Genoa Material
Model Details – Composite shells and Solid Foam Material

The 10-inch wide by 11-inch high panel was fully fixed at each side. The one-inch diameter impactor had mass of
53.75 lbs and impact velocity of 62.04 inch/sec. The panel was made with a composite foam, adhesive and skin
composite fabric (Skin: G30-500/R3676, adhesive; FM-300, foam core: Rohacel 200WF.) The panel was laid up by
skin, adhesive, foam core, adhesive and skin from the bottom surface. Each skin fabric ply is 0.014 inch thick and the
total thickness of the skin ply is 0.056 inches (upper skin ply lay-up angle: -45, 45, 90, 0 and lower skin ply lay-up
angle: 0, 90, 45, -45). The thickness of the FM300 adhesive layer is 0.01 inch and the thickness of the core foam is
0.37 inch. To get the test results, please refer the report, (Dade Huang, Frank Abdi, Mohsen Khatiblou “Progressive
Failure Analysis (PFA) and Verification of Composite Test Panel Under Impact and Compression After Impact (CAI)
Loading Using GENOA”. Alpha STAR Technical Report to Boeing 12/14/1999. Filename: 2-99_Report-
impact_compression.)
The composite shell is modeled using PCOMP entry and the solid composite foam is modeled using PCOMPLS entry.
PCOMP 8
+ 1 1.4E-02 0.00 1 1.4E-02 90.0
+ 1 1.4E-02 45.0 1 1.4E-02 -45.
PCOMPLS 6
+ 1 2 1.0E-02 0.00
+ 2 3 2.4E-02 0.00
+ 3 3 2.4E-02 0.00
+ 4 3 2.4E-02 0.00
+ 5 3 2.4E-02 0.00
+ 6 3 2.4E-02 0.00
To predict the progressive fracture, the material is modeled using MAT1, MAT8, and MATM entries. MAT1 and MAT8
represent general isotropic and orthotropic material properties, respectively. Both materials are referred by MATM
material. The fiber/ply and matrix properties of composite materials and their failure criteria can be assigned by using
the MATM entry shown below:
MAT1 333 560000.01 0.33 1.308-4
MATM 1 1 0 .6 0.01
+ PLY 1 33 333000. 266000. 333000. 266000. 333000.
+ 266000.03846.0003846.0003846.0001.00E-021.00E-021.00E-02
+ 1.00E-021.00E-021.00E-021.00E-021.00E-021.00E-02
+ 0.03 0.03
+ MATRIX 333 11000. 55000. 21000. 1.00E-02 .01 1.00E-02
+ CRITICALS11T
+ NONCRIT S11C S22C S33T S33C S12S S23S S13S
+ MDE RROT CRSH DELM FMBK S22T
MAT8 33 3.400E+72500000.0.2 2500000.2500000.1000000. 1.632-4
CHAPTER 71
Results of Part 2:
The results of the simulation were compared with those of the test. To plot the results, same methodology as Part 1
was followed.
Figure 71-4 Contact Force Time History
The maximum z-contact force is 1510 lbf compared to 1514 lbf from the test results.
Test versus Simulation

Test Simulation
Maximum contact force 1510 lbf 1514 lbf
Input File(s)
Files Description
E2-Impact-Foam.bdf MD Nastran input for composite shells and solid foam material
Chapter 72: Automated Bolt Modeling
72 Automated Bolt Modeling

Summary 1290

Introduction 1291


Results 1296

Input File(s) 1299

Video 1300
CHAPTER 72
Summary
Title Chapter 72: Automated Bolt Modeling
Features Automated Bolt Modeling and Segment to Segment Contact
Geometry & Boundary
Fixed End
Conditions Control Grid Points
Bolt 1
Bolt 2
3,000 lbf Applied
• Linear elastic material for flanges and bolts

Material properties
• Flanges: E = 1e+007 psi,  = 0.3, Bolts: E = 3e+007 psi,  = 0.3
Analysis characteristics Nonlinear static analysis
Both bolts are glued and touching to the left flange and right flange respectively. Both
Contact Properties
plates are touching together.
Element type 3-D 4-noded tetrahedron (CTETRA) elements and RBE2 element
FE results
Load step-4; stress-SZZ

CHAPTER 72 1291
Automated Bolt Modeling
Introduction
Bolt modeling is important in analyses of engine assemblies. Gasket joints, which are used in such assemblies to
prevent steam or gas from escaping, are often fastened by a number of bolts. In a typical loading sequence of an engine
assembly, the bolts are first fastened until a certain pre-tension force is present in the bolts. This can be achieved by
shortening the bolts until the desired force is reached. Next, the bolts are “locked”, that is, the amount of shortening
remains fixed, while the assembly is subject to other (thermo-) mechanical loads. Finally, the bolts are loosened again,
either by decreasing the shortening or by releasing the bolt forces.
Modeling Details
The geometry of the model, shown in Figure 72-1, is a structure having two flanges connected through two bolts. The
materials of bolts and the flanges are different. The left end of the left side flange is clamped and force of 3000 lbf is
applied via RBE2 element. In order to apply pre-tensioning on the bolts, automatic bolt creation and assisted bolt
creation option is used for Bolt-1 and Bolt-2 respectively, where the pre-tension force (2000 lbf) has been applied at
each bolt location via control nodes.
Fixed End Control Grid Points
Bolt 1
Bolt 2
3,000 lbf Applied
Figure 72-1 Model of the Flange
Element Modeling
Four-noded tetrahedron elements (CTETRA) have been used for flanges and bolts. Properties of the elements are
defined trough PSOLID entry. Additional nonlinear properties for the solid elements corresponding are specified using
the PSLDN1 entry.
PSOLID 1 1 PSOLID_b
PSLDN1 1 1 +
+ C4 SOLID L PSOLID_b
CHAPTER 72
Material Modeling
Linear isotropic material properties are defined using MAT1 entry. Elastic modulus and Poisson’s ratio are the material
constant input for this analysis.
MAT1 1 3.E+7 0.3 Iso_bolt
MAT1 2 1.E+7 0.3 Iso_flan
Bolt Modeling
In various engineering applications, it is necessary to define a pre-stress in, for example, bolt or rivets before applying
any other structural loading. A convenient way do this is via the BOLT entry. The key idea is to split the element mesh
of the bolt across the shank in two disjoint parts, such that duplicate grid points appear at the cut, and to create an
overlap or gap between the two parts via multi-point constraints, which is done internally using the BOLT entry. If the
motion of these parts is somehow constrained in the direction in which the gap or overlap is created, then an overlap
(shortening) will introduce a tensile stress in each of the parts and a gap (elongation) will result in a compressive stress.
In this exercise, one coordinated systems (LCS4) is created automatically when automatic bolt creation option is used
for Bolt-1 and other local coordinated systems is created manually (LCS6) using 3 points when assisted bolt creation
option is used for Bolt-2.The local C/S is described through CORD2R entry.
CORD2R 6 0 1.625 0.75 3.04E-8 1.625 0.750.189808+
+ 1.542650.921013 3.04E-8 BOLT_2
The BOLT entry is described below:
1 2 3 4 5 6 7 8 9 10
BOLT ID GRIDC +
+ TOP GT1 GT2 GT3 GT4 GT5 GT6 GT7 +
+ GT8 GT9 etc. +
BOTTOM GB1 GB2 GB3 GB4 GB5 GB6 GB7 +
GB8 GB9 etc.
• New bulk data entry creates MPCs internally to all six degrees of freedom
• (GTi,GBi) are pairs of (usually are coincident) grids on top and bottom
• Same number of grid points should be in TOP and BOTTOM
• GRIDC is the control grid point (usually not connected to any element)
• Bolt loads prescribed on GRIDC
• Global Coordinate System has to be defined at the Control Node if the bolt direction is not a Basic Coordinate
direction
• Loads in directions other than the bolt direction are possible
• The BOLT force can be output by MPCFORCE request output at each Control Node (GC)
• The new bulk data option, BOLT, supports only small rotations in this release. Since it is targeted to analyses
of engine gasket joints, this is not considered a severe limitation
CHAPTER 72 1293
• Sufficient boundary conditions must be applied on the control grid to suppress any rigid body modes if the
two parts of the structure are not constrained
• In a contact analysis, the amount of shortening is limited to the sum of the sizes of the elements in the
direction in which the shortening is prescribed. If the shortening exceeds this limit, the contact surface patches
will start to overlap each other, leading to problems with sliding.
BOLT 24910 6129
TOP 6130 6131 6132 6133 6134 6135 6136+
+ 6137 6138 6139 6140 6141
BOTTOM 5705 5706 5708 5764 5765 5767 5790+
+ 5792 5793 5861 5798 5795

Figure 72-1 shows the loading and boundary conditions applied on the finite element model of the solid structure.
Analysis is done in 5 load steps explained below.
Load step-1: Pre-tension force of 2000 lbf applied to Bolt-1
Load step-2: Pre-tension force of 2000 lbf applied to Bolt-2 and locking of the Bolt-1 using the SPC1 entry.
Load step-3: Locking of the Bolt-1 and Bolt-2 using SPC1 entry.
Load step-4: Load step-3 + point load of 3000 lbf applied to right face of the right flange via RBE2.
Load step-5: Remove the point load from load step-4.
SPCADD and LOAD cards define the single point constraint set and load set respectively. Displacement constraints and
concentrated nodal forces are specified using SPC1 and FORCE cards, respectively.
Step-1
SPCADD 49 6 8 11 12
LOAD 50 1. 1. 7
Step-4
SPCADD 52 6 8 11 12 13 14
LOAD 52 1. 1. 10
$Force (2000lbf) applied on ‘control grid point’ of the Bolt-1 in automatically created coordinate
system.
FORCE 7 6129 4 1999.999 0.0 0.0 1
$Force (2000lbf) applied on ‘control grid point’ of the Bolt-2 in manually created coordinate
system.
FORCE 9 6142 6 1999.999 0.0 0.0 1.
$Force (3000lbf) applied on master node of the RBE2 element

FORCE 10 6156 3000. 0.0 0.0 1.
CHAPTER 72
$ Fix left end

SPC1 12 123456 265 266 323 324 325 427+
$ X and Y translation d.o.f for bolt-1 is fixed (would be generated automatically if automatic
bolt creation is used in SimXpert)
SPC1 6 12 6129
$ X and Y translation d.o.f for bolt-2 is fixed (would be generated automatically even if assisted
bolt creation is used in SimXpert)
SPC1 8 12 6142
$ X, Y translation and all rotation is fixed for master node of RBE2 element
SPC1 11 12456 6156
$ To lock the bolt-1 for the coming load step, Z translation of first bolt is fixed in the coming
load step.
SPC1 13 3 6129
$ To lock the bolt-2 for the coming load step, Z translation of first bolt is fixed in the coming
load step.
SPC1 14 3 6142
Contact
In total, six deformable contact bodies are used. The first and second deformable body consists of all elements of left
and right flange respectively. Third and fourth contact bodies consist of elements of Bolt-1 head and nut respectively.
Fifth and sixth contact bodies consist of elements of Bolt-2 head and nut respectively
$ Contact Body: Deform_left_flange
$ Contact Body: Deform_right_flange
The BCTABLE entries shown below identify the admissible contact combinations, select the slave and master body for
each combination, and set associated parameters. It is important to note that:
• The shaft part of the BOLT-1 and BOLT-2 have not been defined as a contact body to avoid the touching
condition between shaft part of the BOLT-1 and BOLT-2 with holes of the left and right flange. If this
touching condition will arises then correct magnitude of bolt pretension force will not be applied on the
flanges and we will not get proper response of the bolt tightening/loosening.
• The ISEARCH entry is set to 0 (Double orders search, Default) the search order is from lower BCBODOY ID’s to
higher ones first. If no contact is detected, then it searches the opposite order to force search order from the
slave body to the master.
• Both bolts can touch the right flange and the both flanges can touch each other.
• The IGLUE entry is set to 1 for contact between both bolts and left flange to activate glued contact conditions
(that is, no sliding and no separation) between these two contact bodies.
CHAPTER 72 1295
BCTABLE 1 5 +
$ Pair: Deform_bolt1_head / Deform_left_flange
+ SLAVE 3 1 +
+ MASTERS 1 +
$ Pair: Deform_bolt1_nut / Deform_right_flange
+ SLAVE 4 +
+ MASTERS 2 +
• Segment-to-segment contact algorithm is used for this analysis, as compared to node-to-segment algorithm,
the segment-to-segment algorithm will provide more accurate results in the contact area (specifically focusing
on continuous contact stresses) and to make the results effectively independent of the numbering of the
contact bodies and the contact detection order.
BCPARA 0METHOD SEGSMALL
Contact Body 1 2 3 4 5 6
1-Def-Deform_bolt1_head G
2-Def-Deform_bolt1_nut T
3-Def-Deform_bolt2_head G
4-Def-Deform_bolt2_nut T
5-Def-Deform_left_flange G G T
6-Def-Deform_right_flange T T
3 4
5 1 2 6
Figure 72-2 Contact Table
Solution Procedure
The problem is analyzed in MD-Nastran using the SOL 400 routine which is an implicit nonlinear solution
procedure. Control parameters for the nonlinear solution scheme are described through the NLSTEP entry. Total five
NLSTEP have been used corresponding to each load-step.
NLSTEP 2 +
+ FIXED
CHAPTER 72
Results
Radius of the shaft (r) = 0.125 in; Pretension= 2000 lbf: Stress=2000/ (pi*r*r) = 40743.66 lbf/in2
Stress ZZ at nodes marked
45,841
46,997
45,214
44,140
44,801
45,130
Load step-1; stress-ZZ
Load step-2; displacement Z

Figure 72-3 Stress Component ZZ Load Steps 2 and 4
CHAPTER 72 1297

CHAPTER 72

CHAPTER 72 1299

Input File(s)
Files Description
nug72.bdf MD input file
nug72.simxpert SimXpert Model file
CHAPTER 72
Video
Fixed End Control Grid Points
Bolt 1
Bolt 2
3,000 lbf Applied

Chapter 73: Cylinder Upsetting with Plastic and Friction Heat Generation
Cylinder Upsetting with Plastic

73 and Friction Heat Generation

Summary 1302

Introduction 1303


Results 1307

Modeling Tips 1309

Input File(s) 1310

Video 1310
CHAPTER 73
Summary
Title Chapter 73: Cylinder Upsetting with Plastic and Friction Heat Generation
Features Plastic and friction heat generation, coupled analysis and user subroutine 'motion'
Geometry & Boundary
Cylinder: Diameter 20mm x height 30mm
Conditions
Punch : Diameter 32mm x height 10mm
Initial Temp 293K
Symmetry Boundary Conditions - Axisymmetric
Punch velocity V = 12*sqrt(H-20) mm/s
Linear elastic material for the cylinder

Material properties E = 2.0e5 N/mm2;  = 0.3; with yield stress σ y = 275 N/mm2,  = 7220.262 N/mm2
k = 36 N/s/K, Cp = 3.77 N/mm2/K
Analysis characteristics Punch is modeled as a rigid body at fixed room temperature.
Contact Properties Touching contact with shear friction is defined between cylinder and punch.
Element type 3 node axi-symmetric triangle
FE results
Temperature (305 to 364 K)

CHAPTER 73 1303
Cylinder Upsetting with Plastic and Friction Heat Generation
Introduction
This example demonstrates the thermal-mechanical coupling capability and the use of 'user subroutine' feature in MD-
Nastran. It simulates a cylinder upsetting process considering the heat generation due to plastic heating and frictional
effects. The mechanical and heat transfer analysis are handled in a staggered manner. While the mechanical analysis
computes the deformation behavior considering the frictional effects and the plastic heating, the thermal behavior of
the problem is analyzed in the heat transfer analysis. The model is created based on the literature (please see reference
[1.]) and the results are compared with the experiments.
Modeling Details
The model is set up as an axi-symmetric, thermal-mechanical coupled problem. The cylinder is modeled using axi-
symmetric elements and half symmetry is considered in modeling (shown in Figure 73-2). Punch is assumed to be a
rigid body. The model will be analyzed with friction to show the combined effect of heat generation due to plastic
deformation and the friction between punch and workpiece. The conversion factor from plastic work and friction work
to the heat source is 0.9. Some heat loss due to the release of dislocations and due to the lubrication is considered.
Element Modeling
The cylinder is modeled using nonlinear axi-symmetric element. Axi-symmetric elements are selected using CTRAIX
entry pointing to a PLPLANE entry which in turn, points to an auxiliary PSHLN2 entry as shown below. PSHLN2 entry
specifies additional nonlinear properties for axi-symmetric elements. By choosing ISH option, implicit structural and
heat elements are referred. Second line of PSHLN2 entry specifies element behavior and integration scheme for
structural and heat pass. By selecting element structural behavior as IAX, an incompressible axi-symmetric element
formulation is used.
...
CTRIAX 1 1 91 1 92
CTRIAX 2 1 91 92 93
CTRIAX 3 1 94 2 1
...
...
PLPLANE 1 1
PSHLN2 1 1 1
+ C3 IAX L AXSOLID L
Punch is modeled using four 2D NURBS.
BCBODY 101 2D RIGID 0.65 1 0
HEAT 4. 293. 1
RIGID 4 punch
NURBS2D -2 2 50
0.0 15. 16. 15.
1. 1.
0.0 0.0 1. 1.
...
CHAPTER 73
Modeling Contact
The contact bodies are defined as follows: Cylinder as the deformable body and Punch as the rigid body
The contact boundary conditions are as follows:
1. Friction coefficient between the cylinder and the punch with bilinear shear friction law: 0.65
2. Heat transfer coefficient between cylinder and punch: 4 N/s/mm/K
3. Film coefficient to environment: 0.00295 N/s/mm/K
The BCPARA entry used in the model is given below. With ID zero, the parameters defined here belongs to all the
subcases. FTYPE indicates the type of friction model to be used. In this example Bilinear Shear friction is used.
BCPARA 0 FTYPE 7
The definition of the contact bodies consists of the BCBODY bulk data entry which defines the deformable body
including the body ID, dimensionality, type of body, mechanical and thermal properties for the contact body. While
the BSURF identifies the elements forming a part of the deformable body. The following BCBODY entries are used.
BCBODY 1 2D DEFORM 4 0.65 0 +
+ HEAT 0.00295 293. 4. 2+
...
BSURF 4 1 THRU 220
To specify the characteristics of interaction between the contact bodies, the BCTABLE bulk data option is used. The
BCTABLE with ID 1 is used to define the touching conditions between punch and workpiece. It is flagged using
BCONTACT = 1 in the case control section to activate for both the SUBSTEPs in SUBCASE 1. The following BCTABLE
entry is used in the analysis.
BCTABLE 1 1 +
$ Pair: workpiece / punch
+ SLAVE 1 0.65 +
+ MASTERS 101
Material Modeling
All the elements of the structure are modeled with isotropic, elasto-plastic material using the MAT1 and MATEP
options. The yield stress is taken as 275 N/mm2. Thermal material properties are specified using MAT4 entry.
MAT1 1 200000. 0.3
MAT4 1 36. 3.77 1.
MATEP 1 Table 1 Vmises Isotrop Addmean
...
The Young's modulus is 200000 N/mm2 and the Poisson's ratio is 0.30. According to the literature (please see reference
[1]), the flow stress is assumed to be plastic strain dependent only. The flow stress function takes the following form:
 y = 275 N/mm and  y = 722 0.262 N/mm 2 . This is entered in a piece wise linear manner and referred in MATEP entry
2
using the 'Table' option. The TABLES1 bulk data entry is used to enter this data. Third field in the TABLES1 entry
CHAPTER 73 1305
defines the type of stress-strain curve. Option 2 indicates stress verses equivalent plastic strain data. This is shown in
Figure 73-1.
TABLES1 1 2 +
+ 0.0 275. 0.1 394.946 0.2 473.595 0.3 526.675+
+ 0.4 567.907 0.5 602.098 0.6 631.557 0.7 657.586+
+ 0.8 680.999 0.9 702.342 1. 722. 1.4 788.538+
+ ENDT
The heat transfer properties for cylinder are the thermal conductivity and the heat capacity k = 36 N/s/K, Cp = 3.77
N/mm2/K.
Figure 73-1 Stress Versus Equivalent Plastic Strain

The motion of the punch represents a type of mechanical press and is defined as
V = 12  H – 20  mm/s , where H is the current height of the cylinder. This motion is simulated through the use of the
user subroutine motion.f. Constant time increment of 0.01 is used with maximum 50 increments. This reaches 1/3 of
total reduction in height.
CHAPTER 73
Boundary conditions are applied using SPC1 and SPCADD entries. Horizontal displacement along axis of symmetry
(global Y axis) and vertical displacements on XZ plane are constrained. SPC set combination ID is referred in the SPC
case control command.
SPC1 1 2 122 THRU 132

SPC1 2 1 102 103 105 107 109 111+
+ 113 115 117 119 121 132
.
SPCADD 10 1 2
.
SPC = 10
Figure 73-2 Boundary Conditions
Solution Procedure
Simulation is set up as a coupled job in which transient heat transfer analysis is done in the SUBSTEP 1. The
temperature output is passed on to nonlinear structural run in SUBSTEP 2.
SUBCASE 1
TITLE=Coupled Cylinder Upsetting Simulation
BCONTACT = 1
STEP 1
NLSTEP = 3
SUBSTEP 1
IC = 29
ANALYSIS = HTRAN
FLUX(PRINT)=ALL
SUBSTEP 2
SPC = 10
ANALYSIS = NLSTAT
DISPLACEMENT(SORT1,PRINT,REAL)=ALL
CHAPTER 73 1307
NLSTEP entry is used to describe the control parameters for mechanical, thermal and coupled analysis.
NLSTEP 3 0.5
GENERAL 20 2
FIXED 50 1
MECH PV 0.01 PFNT
HEAT P 0.01 PFNT
COUP 0.9 0.9
in this case.
The second line gives the general stepping parameters associated with the analysis. The maximum number of iteration
(=20), minimum number of iteration needed for each increment (=2) and the maximum number of bisections allowed
in current step (=10).
The keyword FIXED defines the uniform time stepping procedure which is followed by the parameters like number of
increments and output interval.
criteria selection followed by the error tolerance for displacement, load and work respectively. PV stands for
convergence criteria checking with respect to load vectors. The PFNT character parameter stands for “Pure Full
Newton Raphson” which is the method for controlling stiffness updates.
The keyword HEAT stands for heat transfer analysis appended with the parameters such as flags for convergence
criteria selection followed by the error tolerance for temperature, heat flux and work respectively. The PFNT character
parameter stands for “Pure Full Newton Raphson” which is the method for controlling stiffness updates.
The keyword COUP defines conversion factor for heat generated due to plasticity and conversion factor for heat
generated due to friction.
Results
The plots for x and y displacements are shown in the Figure 73-3, and Figure 73-4. Temperature distribution in the
cylinder is shown in Figure 73-5. Results of this simulation are compared with the experimental results in Figure 73-6.
CHAPTER 73
Figure 73-3 Plot of X (Radial) Displacement
Figure 73-4 Plot of Y (Axial) Displacement

CHAPTER 73 1309
Temperature (305 to 364 K)
Figure 73-5 Plot of Temperatures
Figure 73-6 Temperature History
Modeling Tips
The key aspect in this analysis is the usage of user subroutine feature available in MD Nastran. Following are the inputs
through argument for subroutine motion.
nsurf - rigid body ID
time - the current time
dtime - the current time increment
x(3) - current die defining coordinates:
f(3) - the current surface load:
inc - the increment number
CHAPTER 73
Along with these variables input argument contains INTEGER, REAL, and CHARACTER data specified through
BCONUDS entry. Using above mentioned argument data, at the beginning of each increment, current surface
velocity components are to be computed and returned for rigid bodies referred in BCONUDS entry.
BCONUDS 101 BCBODY CONTACT motion
REAL 5.
…
The above BCONUDS entry points to master body ID 101 which refers to the punch. This entry invokes the flag for
usage of user subroutine ‘motion’ which controls the motion of the punch.
To execute the subroutine, user needs to build Dynamic Link Library (shared objects on Linux) which is loaded by
MD Nastran executable. To simplify this task, MSC_SDK provides ready-made templates for all available user
subroutines along with build utility SCA Scons. With one command it updates all dynamic link libraries.
To invoke User Defined Service, the following File Management Statement is required.
$
CONNECT SERVICE contact 'SCA.MDSolver.Obj.Uds.Contact'
$
References
1. N.Rebelo and S.Kobayashi: “A Coupled Analysis of Viscoplastic Deformation and Heat Transfer – II”,
Int.J.Mech.,Sci. Vol.22, pp.707-718
2. Simulation Component Architecture (SCA) Guide.
3. User Defined Service Guide.
Input File(s)
Files Description
nug_73.dat MD Nastran input for “Cylinder Upsetting with Plastic and Friction Heat Generation”
nug_73.f MD Nastran user subroutine motion
Video
Cylinder: Diameter 20mm x height 30mm

Punch : Diameter 32mm x height 10mm
Initial Temp 293K
Symmetry Boundary Conditions - Axisymmetric
Punch velocity V = 12*sqrt(H-20) mm/s

Appendix A: Getting Started in SimXpert
A Getting Started in SimXpert

Starting SimXpert 1312

SimXpert Graphical User Interface (GUI) 1313

Graphical Picking 1335

Solutions 1342

Workflow 1343
APPENDIX A
Starting SimXpert
You can start SimXpert just as you would any software application. To start SimXpert do one of the following:
• Choose Start  Programs  MSC.Software  SimXpert 2010
• You may start SimXpert by double clicking a desktop icon similar to the one depicted below
Startup Screen
The following startup screen appears upon entering SimXpert.
Create a new database
Select an existing database to open
Select and enter a workspace.

A new database is opened.
Access online help

CHAPTER A 1313
Getting Started in SimXpert
SimXpert Graphical User Interface (GUI)

Figure A-1 shows the screen layout for SimXpert. All windows can be moved and resized. The regions that are
common to all workspaces are shown and described in this section of document.
Main menu bar

Workspace Tool Ribbon Workspace management
Toolbars
Model Browser Message region Graphics Window
Figure A-1 SimXpert GUI

APPENDIX A
Common Workspace Menus
Main Menu Bar

This section covers menus from the Main Menu Bar that are common to every workspace.
File
The File menu allows the manipulation of databases:

• Create a new database
• Open an existing database
• Save an open database or save under a different name.
This menu is also used to print or save images of the graphics window or to exit SimXpert.
Database Manipulation
CAE FILE I/O
Print or Save Image Files of Graphics Window
Exit SimXpert
Figure A-2 File Menu

CHAPTER A 1315
File > Import

Using the Geometry as Parasolid option, directly opens a model or part file generated by the CAD codes as shown in
Figure A-3. SimXpert converts the CAD information ‘on the fly’ to parasolid format. No local licenses for the CAD
software are required for this option.
SimXpert also directly accesses CATIA, Pro/Engineer, and Unigraphics files with no geometry translation involved.
CAD features, parameters, and geometry can be modified within SimXpert with updates then added back to the
original file. This option uses the local CAD installation directly and therefore a license is required.
CAD geometry
translated to
parasolid
No CAD license
required
Direct CAD access

CAD license required
Figure A-3 Supported Geometry Interfaces

APPENDIX A
Edit
As the name implies, the Edit menu allows modification of the model. This menu is also one of the places in SimXpert
where:
• Entities can be deleted, graphically hidden or shown, completely turn collections of entities on or off
• Modify model properties.
• Updates SimXpert entities to reflect changes in the associated CAD file.
• Undo and Redo commands are also available.
Select Finite Element Objects to Delete

Select Geometry Objects to Delete
Graphically Hide or Display Entities
Modify Properties (Pre-select Item First)

Update SimXpert Entities from CAD
Figure A-4 Edit Menu

CHAPTER A 1317
View
The View menu provides tools for displaying models and activating regions in the workspace.
The View menu is used to control

• The appearance of your screen (Figure A-5).
• The appearance of the model in the graphics window which are discussed in more detail in the following
paragraphs.
• Which toolbars and regions are displayed.
Options Affecting Graphics Window Display
Turn Toolbars On or Off

Turn Regions of the SimXpert Display On or Off
Control Entity Display
Figure A-5 View Menu

APPENDIX A
View > Model Views

There are some pre-defined orientations that can be accessed from this menu. The same options are also available from
the Model Views Toolbar. (Figure A-6)
Model Views Toolbar
Figure A-6 Model Subview Menu
More pre-defined views are available using the view region which can be activated by selecting View > Regions >
View.
CHAPTER A 1319
View > Display

The above orientations can fine-tuned by using the Display submenu (Figure A-7). After selecting any of the Rotate,
Pan, or Zoom options, drag the mouse in the window to perform the action. Notice that there are also Hot (Shortcut)
Keys that can be pressed to activate Rotate, Zoom, and Pan. These same options are also available from the View
Manipulation Toolbar.
.
View Manipulation Toolbar
Fit the Model in the Window
Drag a Rectangular Region for Zoom

Zooms with Respect to Window Center
Zooms Around the Point where the Mouse is Clicked
Rotates the Model About Its Center

Rotates About Center specified using the
Define Center Roated Option below
Rotate Around Model Axes
Rotate Around Screen Axes:

X - Horizomtal
Y - Vertical
Z - Points Out of the Screen
Rotate Around Arbitrary Axis Defined Below
Screen Select a Center of Rotation/Zoom

Screen Select Two Points to Define an Axis
to be used with Any Axis Rotate
Figure A-7 Display Subview Menu

APPENDIX A
View > Custom Views

An orientation can be created for recall at a future time by saving the view using Custom Views > Create Custom View
and supplying a name under which to store the view (Figure A-8).
Figure A-8 Custom View Submenu
The view can be recalled at any time by selecting it from the Custom Views Menu or the Model Views Toolbar
(Figure A-9).
Model Views Toolbar
Select Custom View From Either:

Custom Views
Model Views Toolbar
Figure A-9 Recall Custom View
Custom views are saved with the database. They can be exported using File > Export > User Views for import into other
databases.
CHAPTER A 1321
View > Render

The appearance of the finite element model is controlled from the Render option of the View Menu (Figure A-10). The
same commands are also available from the Render Toolbar.
Render Toolbar
Apply to Geometry Model Only
Apply to Finite Element Model Only
Toggles Shaded Images Between

Smooth and Flat Shading
Toggles FE Symbols and Labels
Figure A-10 Render Submenu
Geometry shading is also controlled from the Geometry Graphics Toolbar (Figure A-11).
Toggles Display of Hatch Lines on Geometry
Toggles Geometry Face Shading

Figure A-11 Geometry Graphics Toolbar
APPENDIX A
View > Scenes

A scene consists of the current contents of the window including parts, connections, and boundary conditions. Current
view, graphics, and visibility state are also saved with the scene by default.
To isolate subsets of the model for recall as a group at a future time, they can be saved as a scene using Scenes > Create
Scene and supplying a name (Figure A-12).
Figure A-12 Scenes Submenu

CHAPTER A 1323
The scene can be recalled at any time by selecting it from the Scenes menu or the from the list in the Scenes tab of
the Model Browser (Figure A-13).
Select Scene Name from either:

Scenes Menu or Scenes tab of the Model Browser
Figure A-13 Scene Recall

APPENDIX A
The built-in scene All holds the entire contents of the model with no entities turned off or hidden. The entire model can
be recalled to the display by selecting the Action: Show scene and clicking on All in the list of scenes.
Tools
The Tools menu (Figure A-14) is used to:

1. Report model information and statistics
2. Provides options to move entities.
3. Perform calculations (also available on the Tools Toolbar).
4. Record and run Macros
5. Change appearance or default functionality, establish a system of units for the model. (Options).
6. Configure SimManager Connection information.
7. Access scripts and templates.
Tools Toolbar
Model Information and Statistics
Menu to move/copy entities
Options Editor
Scripts and Templates
Configure SimManager Connection Information
Figure A-14 Tools Menu

CHAPTER A 1325
Tools > Options

The Options Editor (Figure A-15) provides a single dialog to set options for all applications in SimXpert. Options are
presented in a tree view branched by category.
Figure A-15 User Options Menu

APPENDIX A
Mouse Options
The following table shows the default mouse settings (Figure A-16). Notice that the right mouse button in conjunction
with modifier keys is used to transform the image in the graphics window. Mouse settings can be fully customized if
Custom is selected from the View Manipulation Settings. Click the ‘?” in the upper right-hand corner to get help on
available settings.
.
Figure A-16 Mouse Settings

CHAPTER A 1327
Units Manager
SimXpert interprets all dimensions and input data with respect to a system of units. It is important to set the appropriate
units prior to importing any analysis files without units (such as a Nastran Bulk Data file) or creating materials,
properties, or loads. Controlling the system of units can be done from the Options Editor of the Tools menu. When
importing a file that contains units, SimXpert converts them into those specified in the Units Manager (Figure A-17).
Figure A-17 Units Manager
Tools > Customize

Hot (Shortcut) Keys
The first tab of default keyboard shortcuts is shown in Figure A-18. Frequently used commands can be assigned to
function or keyboard keys in conjunction with modifier keys. Click in a key/modifier cell to make it current; then,
simply select the desired action from any menu, toolbar, or tool ribbon.
Figure A-18 Hot Keys

APPENDIX A
Window
The Window menu (Figure A-19) creates new windows or arranges existing windows on the screen.
.
Figure A-19 Window Menu
Help
This menu provides access to:

1. Application online help.
2. Product tutorials.
3. Product support website (SimCompanion).
• Product news and updates
• Documentation
• Technical Articles
• Technical Support Requests
• Multi-media content
• Recorded Webinars + PodCasts
• Known Issues
4. Product version information.
SimXpert Assistant links to
• A search function which allows you to search on specific keywords or topics

• Guides and Example Problems
• Includes links to external web pages (Figure A-20).
CHAPTER A 1329
Links to Web Pages
Figure A-20 Help Menu

APPENDIX A
Quick Reference links to menu/command specific help. One can ‘drill down’ or Search to get help on specific menu
items (Figure A-21).
Figure A-21 Quick Reference Menu
Context-Sensitive Help
Context sensitive help can be gotten directly for displayed forms and pick panels by clicking on the question mark icon
in the upper-right or by placing the focus on the form and hitting the F1 function key.
CHAPTER A 1331
Parts
This item is not found on the main menu but parts is used by all SimXpert workspaces so it is briefly discussed here.
1. A part is a collection of entities
2. Entities can be members of only one part
3. Deleting a part deletes its members also.
4. Newly created parts are made current. The current part is indicated in a bold underlined font in the Model
Browser.
5. A part current can be made by right clicking on the part either in the Model Browser or the graphics window
and selecting Set Current from the Context Menu.
Context Menu
Current Part
Parts
Figure A-22 Menu Showing Parts

APPENDIX A
Switching Workspaces
To open a different workspace, simply pull down the menu listing the current workspace then select the desired
workspace.
Available Workspaces
Figure A-23 Workspaces
Toolbars
As seen in previous sections, toolbars provide a quick way to access commonly used commands. The available
toolbars vary depending on the current workspace. To see the function of toolbox icons, pass the cursor over them for
rollover help. Toolbars can be turned on and off from the View > Toolbars menu or from a context menu (Figure A-24)
that can be displayed by right clicking in any blank part of the toolbar region. Uncheck the box next to the toolbar
name to turn off its display.
Figure A-24 Toolbar with Context Menu

CHAPTER A 1333
Workspace Tool Ribbon

Shown below is a tool ribbon for the Motion and for the Structures workspace. The tool ribbons provide commands
and options that are relevant only to the current workspace.
Motion Workspace Tool Ribbons
Structures Workspace Tool Ribbons
Figure A-25 Motion and Structures Workspace Tool Ribbons
Model Browser
The Model Browser lists all the components of the model. When using a command that requires picking, items can be
selected either from the graphics window or the model browser. The current part is shown in bold underlined font. The
Model Browser can be displayed in tree or list view (Figure A-26) by clicking the appropriate tab.
Current Part
Figure A-26 Model Browser Tree or List View

APPENDIX A
Message Region
The message region (Figure A-27) is where SimXpert communicates information. Messages are color-coded as
follows:
• Black: information
• Blue: instructions
• Green: warnings
• Red: errors
Figure A-27 Message Region
You can view a complete history of all SimXpert messages for the current session by clicking the icon in the
lower right corner of the display
.
Context Menu
CHAPTER A 1335
Graphical Picking
Graphical picking uses pick filters with either icons or panels, dynamic highlighting is done by moving the mouse over
the selected types of entities, or pick types with which one can pick multiples entities.
Pick Filters
Forms that require entity selection activate the pick icons. By clicking in the Entity Selection box (Figure A-28) to
activate the pick filters, entities selection is controlled by choosing only the relevant icons.
Pick Filters
Click in the
Entity
Selection
box to
Tool tip for selected icon activate
Pick
Filters.
Figure A-28 Pick Filters
Figure A-28 also shows the Point selection Filters with only the icon at the far left selected. To select multiple filters,
simply click on the desired icon. The function of the icon can be displayed by hovering the cursor over it. A tool tip
is displayed. The icons are toggles; hence, to deselect an active filter, click on its icon.
The icons (Figure A-29) to the right of the separator are available for all picking types. They are:
Clear Selection List removes all entities from the selection box
Reject Last undo last selection
Reverse Selection drops selected entities and picks up unselected entities of the type specified in the
current scene
Select All picks all entities of selected type in the current scene
Clear Selection List Select All
Reverse Selection
Reject Last
Figure A-29 Icons for All Picking Types
APPENDIX A
Pick Panel
Some commands display a pick panel that allows one to control which entities to select. The pick panel lists only
entities that exist in the model and apply to the current command. Figure A-30 is a representative pick panel showing:
Command Buttons
Valid Pick Entities
Advanced... shows a form that allows the selection of picking filters
All picks all the entities of the selected type in the current scene
Displayed picks all the entities of the selected type displayed in the window
Reversed drops selected entities and picks up unselected entities of the specified type
in the current scene
Reject undoes the last selection
Done finalizes the selection
Exit
Command Buttons
Valid Pick Entities
Figure A-30 Pick Panel

CHAPTER A 1337
Extended “Advanced” Picking

In addition to the Pick Filters that appear on the input forms, there is also a Pick Filters toolbar that contains additional
features. Selections can be fine tuned by using the Advanced Pick Dialog button on the Pick Filters toolbar or the
Advanced button on a pick panel. This brings up a form that allows selection of additional picking filters. In
Figure A-31, parts are selected using the form’s Pick Filters. By clicking on the Advanced Pick Dialog button, the
selection of parts that only satisfy a certain condition can be chosen; for instance: contain a specific element type
(shown) or are associated with a certain material or property type.
Pick Filters Toolbar
Pick Panel
Figure A-31 Pick Parts Filters

APPENDIX A
When picking elements, specification to select only a specific element type, only those associated with a particular
surface or node, or other filters that are relevant to your particular procedure (Figure A-32).
Pick Filters Toolbar
Pick Elements Form
Figure A-32 Pick Elements Filters
Dynamic Highlight
While hovering over the mouse in the graphics window, entities of the selected type are highlighted as the mouse
passes over them. In Figure A-33, selected to pick parts are highlighted on the screen as the cursor passes over each
part. Pick parts can also be selected from the Model Browser by name.
Figure A-33 Highlighted Entities of a Selected Type

CHAPTER A 1339
Pick Types
Single/Polygon/Sketch/Rectangular Window
Multiple entities can be picked by changing the pick tool (Figure A-34). The Pick Tool menu can be found on the Pick
Filters toolbar or the Context Menu which is brought up by right clicking in the background of the graphics window.
Pick Filters toolbar
Context Menu
Figure A-34 Picking Types
Single
Pick entities one by one
Polygon
Draw a series of piecewise linear lines by clicking wherever a vertex is desired completely enclosing all necessary
entities. Double-click to close the polygon (Figure A-35).
.
Pick Region Selected Elements

Figure A-35 Polygon
APPENDIX A
Rectangular Window
Drag a box that completely encloses all desired entities (Figure A-36). No pick style selection is required for
rectangular window picking. Simply drag the mouse.
.
Figure A-36 Rectangular Window
Sketch
Drag a freehand region that completely encloses all desired entities (Figure A-37).

Figure A-37 Sketch
Circle
Drag the mouse to draw the outline of your selection region.
CHAPTER A 1341
Note: You can modify the SimXpert’s picking behavior using Tools > Options, General / Navigation and
Selection. You can choose to include only those entities entirely contained in the pick region, or those
that are partially contained.
APPENDIX A
Solutions
SimXpert is a multi-disciplinary simulation environment for the analyst. Different types of simulations can be
performed in each of the four workspaces.
In the Structures Workspace, MD Nastran is used as the solver. The following types of MD Nastran analysis solutions
are available:
• Linear Static Analysis (SOL 101)
• Modal Analysis (SOL 103)
• Linear Buckling Analysis (SOL 105)
• Direct Complex Eigenvalue Analysis (SOL 107)
• Direct Frequency Response Analysis (SOL 108)
• Direct Transient Response Analysis (SOL 109)
• Modal Complex Eigenvalue Analysis (SOL 110)
• Modal Frequency Response Analysis (SOL 111)
• Modal Transient Response Analysis (SOL 112)
• General Nonlinear Analysis (SOL400)
• Implicit Nonlinear Analysis (SOL 600)
In the Thermal Workspace, MD Nastran is used as the solver. The following types of MD Nastran analysis solutions
are available:
• Steady State Heat Transfer Analysis (SOL 153, SOL 600)
• Transient Heat Transfer Analysis (SOL 159, SOL 600)
In the Motion Workspace, the ADAMS C++ solver is used. The user can perform the following types of motion
analysis:
• Dynamic Analysis
• Quasi-Static Analysis
• Static Analysis
In the Crash Workspace, LS-Dyna is used as the solver. The user can perform crash analysis for crash worthiness and
safety applications.
In the MD Explicit Workspace, MD Nastran is used as the solver. Explicit nonlinear analysis (SOL 700) can be
performed.
The Template Builder workspace in SimXpert is a graphical authoring environment for creating and executing
SimXpert Templates. Templates are processes that can automate repetitive tasks, define CAE methods, and perform
simulations.
CHAPTER A 1343
Workflow
The following procedure shows the general recommended workflow for the Structures, Thermal, Crash, and Explicit
workspaces.
1. Designate a system of units. You can open the Units Manager from the Tools menu Or by clicking on the
designated system of units in the lower-right corner of the SimXpert window.
Or
APPENDIX A
2. Import/create geometry
or
3. Create material and element properties
4. Create the finite element mesh
5. Apply loads and boundary conditions

CHAPTER A 1345
6. Set up analysis
APPENDIX A
7. Submit model to solver

CHAPTER A 1347
8. Access results
9. Post-process

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MD Nastran

1 2-D Cylindrical Roller Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2 3-D Punch (Rounded Edges) Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3 3-D Sheet Metal Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4 3-D Loaded Pin with Friction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5 Bilinear Friction Model: Sliding Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

6 Laminated Strip under Three-point Bending . . . . . . . . . . . . . . . . . . . . . . . . 109

7 Wrapped Thick Cylinder under Pressure and Thermal Loading . . . . . . . . 115

8 Three-layer Sandwich Shell under Normal Pressure Loading. . . . . . . . . . 120

9 Bird Strike on Prestressed Rotating Fan Blades . . . . . . . . . . . . . . . . . . . . 126

10 Engine Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

11 Elastic-plastic Collapse of a Cylindrical Pipe under External Rigid Body

12 Thermal/Pressure Loaded Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

13 Ball Joint Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

14 Time NVH Analysis – Chassis Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

15 Tube Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

16 Cup Forming Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

17 Double-sided Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

18 Demonstration of Springback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

19 3-D Indentation and Rolling without Friction . . . . . . . . . . . . . . . . . . . . . . . 312

20 Composite Fracture and Delamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

21 Occupant Safety and Airbag Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . 374

22 Multi-compartment Side Curtain Airbag Deployment . . . . . . . . . . . . . . . . 419

23 Bolted Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

24 Friction Between Belt and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

25 Modal Analysis with Glued Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447

26 Interference Fit Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

27 Large Sliding Contact Analysis of a Buckle . . . . . . . . . . . . . . . . . . . . . . . . 462

28 Model Airplane Engine Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

29 Rapid Road Response Optimization of a Camaro Model using Automatic

30 Paper Feeding Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

31 Wheel Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

32 Pick-up Truck Frontal Crash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

33 Beams: Composite Materials and Open Cross Sections . . . . . . . . . . . . . . 516

34 Topology Optimization MBB Beam and Torsion . . . . . . . . . . . . . . . . . . . . . 526

35 Engine Mount Topology Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541

36 Wheel Topology Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

37 Local Adaptive Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

38 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

39 Brake Squeal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579

40 Multiple Bird-strikes on Box Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589

41 Shaped Charge Penetrating Two Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 656

42 Mine Blast Under a Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715

43 Blastwave Hitting a Bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735

44 Concentric Spheres with Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798

45 Transient Thermal Analysis of Power Electronics . . . . . . . . . . . . . . . . . . . 855

46 Thermal Stress Analysis of an Integrated Circuit Board . . . . . . . . . . . . . . 920

47 Dynamic Impact of a Rigid Sphere on a Woven Fabric . . . . . . . . . . . . . . . 971

48 Shape Memory Analysis of a Stent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 984

49 Shell Edge Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 993

50 Large Rotation Analysis of a Riveted Lap Joint . . . . . . . . . . . . . . . . . . . . . 1037

51 Creep of a Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050

52 Hydro-forming of a Square Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058

53 Chained Analysis: Fan Blade Out with Rotor Dynamics . . . . . . . . . . . . . . 1067

54 Ball Penetration using SPH Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088

55 Square Cup Deep Drawing using Forming Limit Diagram. . . . . . . . . . . . . 1097

56 Hydroplaning Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113

57 Heating and Convection on a Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1131

58 Coupled Advection for Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 1143

59 Shallow Cylindrical Shell Snap-through . . . . . . . . . . . . . . . . . . . . . . . . . . . 1154

60 Deformable Baffle in a Duct using OpenFSI . . . . . . . . . . . . . . . . . . . . . . . . 1163

61 Steady State Heat Transfer due to Natural Convection between Two

62 Girkmann Problem using Axisymmetric Shell Elements . . . . . . . . . . . . . . 1177

63 Beam Reinforced Shell Structure using Offsets . . . . . . . . . . . . . . . . . . . . . 1186