Ansys Manual Combines

Chapter 2
Nonlinear Structural
Nonlinear Structural Analysis
Chapter Overview Training Manual
ANSYS Workbench Simulation

The following will be covered in this Chapter:
General Background on Nonlinear Theory
Setting Up Nonlinear Analyses
Metal Plasticity
Solving Nonlinear Models
Reviewing Results
The capabilities described in this section are generally

applicable to ANSYS Structural licenses and above.
Exceptions will be noted accordingly
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A. Background on Linear Analysis Training Manual

In Chapter 4 of the Workbench Simulation Intro course,
the assumptions and restrictions related to performing
linear static structural analysis were covered:
The matrix equation solved for is Hookes Law:
K x F F
Because [K] is assumed to be constant,
essentially only linear behavior is allowed K
As shown on the figure on the right, if the
force doubles, the displacement (and stresses) x
are assumed to double in linear analysis
In many real-world situations, however, this small-
displacement theory may not be valid. In these situations,
nonlinear analysis may be required.
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Background on Nonlinear Analysis Training Manual

There are three main sources of nonlinearities:
Geometric nonlinearities: If a structure
experiences large deformations, its
changing geometric configuration can
cause nonlinear behavior.
Material nonlinearities: A nonlinear stress-strain

relationship, such as metal plasticity shown on
the right, is another source of nonlinearities.
Contact: Include effects of contact is a type

of changing status nonlinearity, where an
abrupt change in stiffness may occur when
bodies come into or out of contact with each
other.
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In a nonlinear static analysis, the stiffness [K] is dependent
on the displacement {x}:
K x x F
The resulting force vs. displacement curve
may be nonlinear, as shown on the right, so
doubling the force does not necessarily
F
result in doubling of the displacements
and stresses
A nonlinear analysis is an iterative solution
because this relationship between load (F)
and response (x) is not known beforehand
x
No time-dependent effects are considered.
It is important to remember these assumptions related to

performing nonlinear static analyses in Simulation.
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Newton-Raphson Method Training Manual

Nonlinear solutions require several iterations
The actual relationship between load and
displacement (shown with a yellow dotted line) is not
known beforehand
Consequently, a series of linear approximations with
corrections is performed. This is a simplified
explanation of the Newton-Raphson method (shown
as solid red lines)
In the Newton-Raphson Method, the total Newton-Raphson Method
load Fa is applied in iteration 1. The result Fa
is x1. From the displacements, the internal 4
forces F1 can be calculated. If Fa F1, then 3
the system is not in equilibrium. Hence, F1
2
a new stiffness matrix (slope of red line) is
calculated based on the current conditions. 1
The difference of Fa - F1 is the out-of-balance
or residual forces. The residual forces must
be small enough for the solution to converge. x1 x
This process is repeated until Fa = Fi. In this example,
after iteration 4, the system achieves equilibrium and the
solution is said to be converged. February 4, 2005
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Nonlinear Solution Training Manual

It is useful to understand how loads are managed
Load steps are changes in general loading.
Simulation usually solves all nonlinear models with one load step,
but, in the case of Pretension Bolt Loads, this is done in two load
steps. The bolt preload is applied first, then all other loads are
applied next. These load steps can be thought of as Fa and Fb.
Substeps apply the loads in an incremental fashion
Because of the complex response, it
may be necessary to apply the load Fb
incrementally. For example, Fa1 may be Fb2
near 50% of the Fa load. After the load Fb1
for Fa1 is converged, then the full Fa load
Fa
is applied. Fa has 2 substeps while Fb
has 3 substeps in this example Fa1
Equilibrium iterations are the corrective

solutions to obtain a converged substep
xa xb
In the example on right, the iterations between the dotted white lines
indicate equilibrium iterations. February 4, 2005
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In Simulation, the following types of nonlinear static structural
analyses are directly available via the GUI:
Large deflection effects
Nonlinear contact (I.e. frictionless, frictional, no separation)
Metal plasticity (Bi-linear or Multi-linear Isotropic Hardening).
Many more advanced nonlinear features are not available

directly in the Simulation interface.
These items can be added with Command Objects
Advanced Nonlinear material models (i.e. Creep, Hyperelasticity)
Nonlinear solution options, element formulations, and advanced
contact options
Advanced time-history postprocessing
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B. Nonlinear Analysis Setup Training Manual

The procedure for nonlinear static analysis is very similar
to performing a linear static analysis, so not all steps will be
covered in detail. The steps in yellow italics include
options that are specific to nonlinear analyses.
Attach Geometry
Assign Material Properties (with metal plasticity, if applicable)
This will be covered in detail in Section C
Define Contact Options (if applicable)
Define Mesh Controls (optional)
Include Loads and Supports
Request Results
Set Nonlinear Solution Options
Solve the Model
Review Results
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Geometry (Solid Bodies) Training Manual

Solid bodies are supported for large-deflection analyses
with ANSYS Structural licenses and above.
Advanced users can change the Brick Integration Scheme
from Full to Reduced, which may be useful for large-
deformation problems.
ANSYS License Availability

DesignSpace Entra
DesignSpace February 4, 2005
Professional Inventory #002177
Structural x
Mechanical/Multiphysics x 2-10
Geometry (Line/Surface Bodies) Training Manual

ANSYS Professional licenses and above support large-
deformation analyses with surface or line bodies.
Note that ANSYS Professional does not support a combination
of line and surface bodies. ANSYS Structural and above must
be used in these cases.

DesignSpace Entra
Professional x Inventory #002177
Structural x
Solid Body Contact Options Training Manual

All of the contact options available in linear static analyses
are also available for nonlinear, large-deflection analyses in
ANSYS Structural licenses and above:
Contact Geometry Solid Body Face Solid Body Edge Surface Body Face Surface Body Edge
Solid Body Face All types Bonded, No Separation Bonded, No Separation Bonded only
All formulations All formulations All formulations MPC formulation
Symmetry respected Asymmetric only Symmetry respected Asymmetric only
Solid Body Edge Bonded, No Separation Bonded, No Separation Bonded only
All formulations All formulations MPC formulation
Asymmetric only Asymmetric only Asymmetric only
Surface Body Face Bonded, No Separation Bonded only
All formulations MPC formulation
Symmetry respected Asymmetric only
Surface Body Edge Bonded only
MPC formulation
Asymmetric only
In general, face-to-face contact for solid bodies is the only

type of contact which supports advanced nonlinear options
Most other contact involving surface bodies or solid edges
support bonded (and no separation) contact only
DesignSpace Entra
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Professional / Inventory #002177
Structural x
Meshing Controls Training Manual

Meshing considerations are usually the same in nonlinear
analyses. However, if large strains are expected, the shape
checking option may be changed to Aggressive
For large-deflection analyses, if elements may undergo some
change in shape, this may reduce the fidelity of the solution
By using Aggressive shape checking, Simulation will ensure
that the element quality is much better prior to solution in
order to anticipate distortion of the element in the course of a
large-strain analysis.
The quality of the Standard shape checking is suitable for linear
analyses, so it does not need to be changed in linear analyses
With aggressive shape checking set,
some mesh failures may be more likely.
See Ch. 3 from the Workbench Simulation -
Intro course for some ways to detect and
remedy mesh failures.
DesignSpace Entra /
DesignSpace / February 4, 2005
Structural x
Loads and Supports Training Manual

Most loads and supports used in linear analyses may also
be used in large-deflection analyses
Thermal-stress analyses are supported for large-deflection
analyses.
See Chapter 6 of the Workbench Simulation Intro course on
details of performing thermal analyses
ANSYS Structural licenses do not support any thermal loads
Recall that ANSYS Professional does not support large-
deflection analyses for solid bodies
Two unique items for loads and supports in large-deflection

analyses will be covered next
Orientation of loads for large-deflection
Pretension Bolt Load

DesignSpace Entra
Structural /
Load Orientation Training Manual

It is important to note the orientation of loads and its effect
on the structure in large-deflection analyses:
Direction Before Direction After
Load Deflection Deflection
Acceleration
(constant direction)
Force, Moment,
Bolt Load
(constant direction)
Pressure
(always normal to
surface)

DesignSpace Entra
Structural x
Pretension Bolt Load Training Manual

A Pretension Bolt Load is available in ANSYS Structural
Pretension Bolt Load is applied on a single cylindrical surface
Each load must be applied to only one set of cylindrical surface(s)
For multiple loads, add separate Pretension Bolt Loads branches
Usually, a preload value is input in the Details view
If the torque is known, this can be converted to a preload force
If known, an initial adjustment can be directly applied
Internally, preloads are applied in two steps
The preload value is applied first, which shortens the grip length
The grip length is then fixed, and any other loads are then applied

DesignSpace Entra
Structural x

A Pretension Bolt Load is useful to account for the effect of
the preload in bolts, which is caused by their tightening
The loss of preload and the effect the preload has on contact
regions can be included in this manner, enabling for more
complex simulation of real-world assemblies.
Contact options for parts connected with fasteners should be set
separately in the Contact branch. The Pretension Bolt Load only
controls the load on the cylindrical surface representing the bolt.
The adjustment or preload is applied in two steps.
In real life, if the fastener is tightened, its grip length changes.
Simulation mimics this the same way by first applying only the
preload or adjustment. If the preload is defined, the adjustment
(shortening of the grip length) is calculated. The given or
calculated adjustment shortens the grip length of the bolt.
All other external loads are then applied in the second load step,
once the grip length is shortened.
DesignSpace Entra
Structural x

In large-deflection analyses, the orientation of the
Pretension Bolt Load is not updated
The Pretension Bolt Load should not be applied on any part
that undergoes large rotation
The Pretension Bolt Load is applied in the center of the

solid body containing the cylindrical surface
Verify the mesh, and ensure that no constraints or bonded
contact is present near the center of the bolt solid body.
Otherwise, the preload may be overconstrained.
The Adjustment and Working Load can be reviewed

After the solution, in the Details view, the
adjustment caused by the preload is shown.
Also, the working load is provided, so the user
can determine how much preload was lost.
DesignSpace Entra
DesignSpace
The Adjustment and Working Load information is also February 4, 2005
Professional
x
available in the Worksheet tab of the Environment branch Inventory #002177
Structural
C. Metal Plasticity Training Manual

What is plasticity?
When a ductile material experiences stresses beyond the
elastic limit, it will yield, acquiring large permanent
deformations.
Plasticity refers to the material response beyond yield.
Plastic response is important for metal forming operations.
Plasticity is also important as an energy-absorbing
mechanism for structures in service.
Materials that fail with little plastic deformation are said to be
brittle.
Ductile response is safer in many respects than is brittle response.
This section will review some basics of plasticity by

defining certain terminology.
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Elasticity Training Manual

Review of Elasticity:
Before proceeding to a discussion on plasticity, it may be
useful to review elasticity of metals.
In elastic response, if the induced stresses are below the
materials yield strength, the material can fully recover its
original shape upon unloading.
From a standpoint of metals, this behavior is due to the
stretching but not breaking of chemical bonds between atoms.
Because elasticity is due to this stretching of atomic bonds, it
is fully recoverable. Moreover, these elastic strains tend to be
small.
Elastic behavior of metals is most commonly described by the
stress-strain relationship of Hookes Law:
E
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Plasticity Training Manual

Review of Plasticity:
Plastic deformation results from slip between planes of
atoms due to shear stresses (deviatoric stresses). This
dislocation motion is essentially atoms in the crystal
structure rearranging themselves to have new neighbors
results in unrecoverable strains or permanent deformation
after load is removed.
slipping does not generally result in any volumetric strains
(condition of incompressibility), unlike elasticity
Yield Strength y
Unloading
Elastic Plastic
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Rate-Independent Plasticity Training Manual

Rate-Independent Plasticity:
If the material response is not dependent on the rate of
loading or deformation, the material is said to be rate-
independent.
Most metals exhibit rate-independent behavior at low
temperatures (< 1/4 or 1/3 melting temperature) and low strain
rates.
Engineering vs. True Stress-Strain:

While engineering stress-strain can be used for small-strain
analyses, true stress-strain must be used for plasticity, as
they are more representative measures of the state of the
material.
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True Stress and Strain Training Manual

Engineering vs. True Stress-Strain (contd):
If presented with engineering stress-strain data, one can
convert these values to true stress-strain with the following
approximations:
Up until twice the strain at which yielding occurs:
eng eng
Up until the point at which necking occurs:
eng 1 eng ln 1 eng
Note that, only for stress conversion, the following is assumed:
Material is incompressible (acceptable approximation for large strains)
Stress distribution across cross-section of specimen is assumed to be
uniform.
Beyond necking:
There is no conversion equation relating engineering to true stress-strain at
necking. The instantaneous cross-section must be measured.
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Yield Criterion (Yield Point) Training Manual

Yield Criterion:
The yield criteria is used to relate multiaxial stress state
with the uniaxial case.
Tensile testing on specimens provide uniaxial data, which can
easily be plotted on one-dimensional stress-strain curves,
such as those presented earlier in this section.
The actual structure usually exhibits multiaxial stress state.
The yield criterion provides a scalar invariant measure of the
stress state of the material which can be compared with the
uniaxial case.
A common yield criterion is the von Mises yield criterion

(also known as the octahedral shear stress or distortion
energy criterion). The von Mises equivalent stress is
defined as:
o
1
2

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Mises Yield Criterion Training Manual

If plotted in principal stress space, the von Mises yield
surface is a cylinder.
Inside the yield surface, as noted earlier, behavior is elastic. Note that the
multiaxial stress state can exist anywhere inside of the cylinder. At the edge
of the cylinder (circle), yielding will occur. No stress state can exist outside of
the cylinder. Instead, hardening rules will describe how the cylinder changes
with respect to yielding.
Plastic
y
Elastic
2 Principal Stress Space

3 Uniaxial Stress-Strain
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Hardening Rules Training Manual

Hardening Rules:
The hardening rule describes how the yield surface
changes (size, center,shape) as the result of plastic
deformation.
The hardening rule determines when the material will yield
again if the loading is continued or reversed.
This is in contrast to elastic-perfectly-plastic materials which
exhibit no hardening -- i.e., the yield surface remains fixed.
Plastic
Yield Surface after Loading

Elastic
Initial Yield Surface
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Isotropic Hardening Training Manual

Isotropic Hardening:
Isotropic hardening states that the yield surface expands
uniformly during plastic flow. The term isotropic refers to
the uniform dilatation of the yield surface and is different
from an isotropic yield criterion (i.e., material orientation).
Subsequent
Yield Surface '
y
'
Initial Yield
Surface
2 3
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Isotropic Hardening Training Manual

Plotting the stress-strain curve enables an understanding
of what occurs during a loading and reverse loading cycle:
Note that the subsequent

yield in compression is
y equal to the highest stress
attained during the tensile
phase.
2

Isotropic hardening is often
used for large strain or
proportional loading
simulations. It is usually
not applicable cyclic
loading.
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Stress-Strain Curve Representation Training Manual

Curve shapes
Two different type of stress-strain curve representations are
possible:
Bilinear Multilinear
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Summary of Plasticity in Simulation Training Manual

In Simulation, metal plasticity can be included as part of the
model. The following points should be remembered:
Metal plasticity deals with elastic and inelastic (permanent)
deformation. Inelastic or plastic deformation occurs when the
stress is higher than the yield strength. There will always be
some recoverable strain (elastic strain) upon unloading.
A stress-strain curve is based on scalar data, usually from a
uniaxial test. A system may undergo a multiaxial stress state,
so Simulation uses the Mises yield criterion to relate a
multiaxial stress state with scalar test data. In this situation,
true stress vs. strain data should be supplied.
After yielding occurs, the yield point may increase due to
strain hardening. This changes the yield surface, and the way
in which it evolves in Simulation is determined by isotropic
hardening assumption.
The stress-strain curve can be represented by a bilinear or
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Material Properties Training Manual

Linear elastic material properties must be supplied
The same requirements exist for linear static structural
analyses, namely that Youngs Modulus and Poissons Ratio
must be defined as a minimum.
Metal plasticity is available as a nonlinear material model.

This will be discussed next.
Other nonlinear constitutive models may be added with the
Preprocessing Command Builder
However, note that only ANSYS Structural licenses and above
support nonlinear material laws.
ANSYS Professional supports large-deflection analyses of surface
or line bodies, but it does not support any material nonlinearities

DesignSpace Entra
Structural x
Metal Plasticity Training Manual

To add metal plasticity, first navigate to the specific part or
parts under the geometry branch. In the Details window,
highlight the material you wish to modify

DesignSpace Entra
Structural x

Right side of the Engineering Data application shows the
currently defined properties. Choose Add/Remove
Properties to continue.
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Select either Bilinear or Multilinear Isotropic Hardening
under Nonlinear > Plasticity.
Multilinear representation usually provides a more accurate
description of stress-strain curve than Bilinear.
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To enter or modify the plasticity definition click either chart
icons for the property.
Chart Icons
To return to the general material property display use the

Close Curve icon.
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Bilinear Stress-Strain Training Manual

The Bilinear Stress-Strain requires two input values:
The Yield Strength and Tangent Modulus is input in the
Details view.
The yield strength is the value at

which plastic straining occurs.
The tangent modulus is the slope
of the stress-strain curve after
yielding.
As the name implies, the Bilinear
Stress-Strain provides a simple
representation of metal plasticity

DesignSpace Entra
Structural x
Multilinear Stress-Strain Training Manual

The Multilinear Stress-Strain allows stress-strain input:
Right-click on the spreadsheet to add rows
Input as many Strain and Stress values as needed
The stress-strain plot will be displayed dynamically
The origin (0,0) should be the first

point. Also, ensure that the second
point has the same slope as the
Youngs modulus.
Simulation assumes perfect plasticity
(zero slope) beyond the defined
stress-strain values.

DesignSpace Entra
Structural x
Workshop 2A
Large Deflection with Metal
Plasticity
D. Workshop 2A Metal Plasticity Training Manual

Goal
Compare and contrast results using small deflection, large deflection and large
deflection with metal plasticity on a model with identical loads and boundary
conditions.
Model Description
3D large deflection of spring plate
Spring plate
Ductile steel
Loads and Boundary Conditions:

Fixed support
3 Mpa Pressure load at opposite end
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Workshop 2A Metal Plasticity Training Manual

Steps to Follow:
Start an ANSYS Workbench session. Browse for and open Spring_ws01.wbdb
project file.
This project contains a Design Modeler (DM) geometry file Spring_ws01.agdb and a
Simulation (S) file Spring_ws01.dsdb.
Highlight the the Model, Small Deflection-Linear Matl (Spring_ws01.dsdb) file and
open a Simulation Session.
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Review the contents of the model
Highlight geometry Solid branch and

examine the Details of Solid Window
(lower left corner of screen). Note we
will start with a structure steel and
Nonlinear Material Effects off.
The boundary conditions and load

(3Mpa Pressure) have already been
defined.
Highlight the Solution branch.

Note: We accept the default settings,
including Large Deflection Off
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Add a Solution Information Folder to the
Solution Branch
Run the Solution

Solution, RMB SOLVE
After solution run is complete, open the

Solution Information folder and scroll to
near the bottom of the output. As
expected, this solves in one iteration.
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Review the displacement and stress results from this first run.
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Highlight the Small Deflection- Linear
Matl Branch at the top of the Project
Tree, and duplicate this Branch with
RMB=> Duplicate.
Change the new branch name to Large
Deflection - Linear Matl
Highlight Solution Branch and turn Large
Deflection ON
The Project tree should look as shown in
figure to the right.
Execute a Solve on this new Solution
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After solution run is complete, open the Solution Information folder and scroll to near
the bottom of the output. Note the solution still solves in one substep, but 9 iterations
were made on the stiffness matrix during the run to account for large deflection effects.
Change Solution Output to Force Convergence to review the Newton-Raphson History.
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Review the large deflection analysis displacement and stress results and compare with the
first run. Note: Total Deformation is larger, but max equivalent stress is actually slightly
lower and in a different location then the linear run.
Extra Credit: To better understand the differences, try post processing x and y deflections
and equivalent strains separately for both runs. Note the dramatic increase in the y
deflections especially and the different distributions of strain energies.
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Highlight the Large Deflection- Linear Matl
Branch and duplicate this Branch with RMB=>
Duplicate.
Change the new branch name to Large
Deflection-NonLinear Matl
Add metal plasticity:
Highlight Geometry Solid branch
Activate Nonlinear material effects (YES)
RMB on Structural Steel
Select Edit Structural Steel
Select Add/Remove Properties
Activate Bilinear Isotropic Hardening

Plasticity
[OK]
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Click on the ICON to the right of Bilinear Isotropic Hardening
Define Yield Strength of 250Mpa and a Tangent Modulus of 10000Mpa.
Select Close Curve
Return to project tree

and execute a solve on
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This last solution run can take up to two minutes depending on machine.
Review the Solution Convergence History as before.
It now takes 42 iterations in eight substeps, including two bisections.
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Review the displacement and stress results and compare with the large deflection run.
Note: Total Deformation is considerably larger and stresses come down due to the
dramatic loss of stiffness as part goes plastic.
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Add Equivalent Plastic Strain to the solution branch for a better picture of where most of
the yielding occurs.
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E. Solving Nonlinear Models Training Manual

The solution options for nonlinear analyses are the same
for linear analyses. However, for large-deflection problems,
the user has an additional option of turning on Large
Deflection
Use of the Large Deflection option accounts for changes in the
geometry during the course of the analysis.
ANSYS Professional only supports large-deflection analyses
for surface or line bodies.
The Newton-Raphson method is employed in nonlinear
solutions (see next slides)

DesignSpace Entra
Structural x

Simulation automates nonlinear solutions by automatically
determining the number of load steps, substeps, and
equilibrium iterations
In this way, the user does not have to worry about these
settings. However, as will be shown later, it is very useful to
understand these concepts in dealing with nonlinear solutions
During the course of the analysis, if Simulation has trouble
converging, it will bisect the solution.
This means that Simulation will apply the load in smaller
increments (more substeps). This usually helps for difficult
problems since the response will be easier to converge if a smaller
load is applied. The final, total load will be solved for in the end.
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The number of load steps is usually set to 1
If Pretension Bolt Loads are present, there will be 2 load steps
For thermal-stress analyses, the thermal analysis is performed first
as a separate analysis. Hence, this part is not considered a load
step since it is a different type of analysis.
The initial number of substeps is usually set to 1
If frictional contact with a Friction Coefficient 0.2 is present, this
results in 5 initial substeps
The max number of equilibrium iterations is usually around 20
The type of contact will dictate the maximum number of
equilibrium iterations
If a substep cannot be converged within the specified number of
equilibrium iterations, Simulation will bisect the solution. It will
apply half of the current load and run equilibrium iterations again
to converge. Usually, this is repeated until 10% of the load is
applied. If the solution still does not converge, Simulation will
stop and produce an error message.
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Auto Time Stepping specifications can be changed within
Simulation in the Details of Solution Window:
Change Auto Time Stepping from Program Controlled to On
Manually define the initial, minimum and maximum values.
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Nonlinear Solution Output Training Manual

Nonlinear solution output from the ANSYS solver
is requested with the Solution Information branch
When requested, the Solution Information branch
may be used to display Solver Output or Force
Convergence progress, among a number of other
options from the pull-down menu
The Update Interval allows users to specify (in seconds) how
frequency this output is updated
The Solver Output and Force Convergence provide details
on the nonlinear solution progress.

DesignSpace Entra x
DesignSpace x February 4, 2005
Structural x
Nonlinear Solver Output Training Manual

Nonlinear solutions, especially those dealing with
frictionless or frictional contact, can be difficult to solve
During the solution, it is useful to become familiar with
reading the ANSYS solver output
In the Solution Information branch, informative messages
about the solution, solver, and contact settings are usually
printed first when solution is initiated
It may be useful to browse through the contact information
(sample below) to ensure that initial gaps or initial penetration is
not very large. If an initial gap is automatically closed, this will
also be printed in the output.
In this example, the initial penetration 7e-5 may be very small compared
to the dimensions of the model, so it can be ignored. These small values
of penetration or gaps may be caused by the mesh discretization.
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As the nonlinear solution progresses, the equilibrium iteration
information is shown (sample below)
Note that for each equilibrium iteration, the residual forces (FORCE
CONVERGENCE VALUE) must be lower than the CRITERION
Ideally, the residual or out-of-balance forces should be zero for a
system to be in equilibrium. However, because of machine
precision and practical concerns, Simulation determines a value
small enough to result in negligible error. This value is the
CRITERION, and the FORCE CONVERGENCE VALUE must be
smaller than the CRITERION for the substep to be converged.
In the example below, after 3 equilibrium iterations, the residual
forces are lower than the criterion, so the solution is converged.
Informative messages (such as convergence or bisection) are
noted with >>> and <<< in the output.
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By understanding how to read the solution output, potential
problems can be detected early on
In the contact output below, there are notes of initial
penetration and initial gaps.
One should always verify automatically-generated contact regions
The improper specification of contact may cause convergence
difficulties, so reading the contact output would be helpful in
determining if any contact region is problematic
Initial penetration/gaps are reported in active length units
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During the equilibrium iterations, reviewing the pattern of the
residual forces will help determine if a solution is diverging
In the example below, the residual forces (FORCE CONVERGENCE
VALUE) initially decreases but then starts to increase dramatically.
In this situation, the user can abort the solution and check his/her
model to see what caused the high residual forces. Otherwise,
Simulation may continue for several more iterations (and even
bisect the solution) until it diverges, which would take longer.
Some causes of high residual forces include excessively large
loading (verify units), high contact stiffness (especially for thin,
bending-dominated behavior), or high friction coefficient values.
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Warning and error messages will also be printed in the output
When contact status changes abruptly, this is just a warning
indicating that the contact elements enter or exit the pinball
region drastically. This may be due to parts sliding or separating
drastically if the load is too high. Simulation may automatically
bisect the solution, if necessary.
Element distortion messages are usually severe problems due to
excessive loading or over-constraints. Bisection of the load is
automatically performed, but sometimes corrective measures may
need to be taken to fix the problem.
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Nonlinear Force Convergence Training Manual

The Solver Output option shows detailed text information.
If Solution Output is changed to Force Convergence,
the force convergence behavior is shown graphically:
Graphical Output
Text Output
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Nonlinear Force Convergence Training Manual

The Force Convergence view shows what the force
criterion and residual forces (force convergence) are.
When the residual forces are less than the criterion, the
substep is assumed to be converged.
Additional useful features

include the fact that
converged substeps and
loadsteps are also indicated
on the chart with a green and
blue dotted line, respectively.
For this model, because
Pretension Bolt Loads are
present, it is a two-load step
analysis. Time is the same
as load step number in this
case. The current time is
1.2, so it is 20% complete
with the second load step.
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Results Tracker Training Manual

Besides monitoring the out-of-balance forces, a
Results Tracker is available from the Solution
Information branch
The Results Tracker enables users to monitor
deformation at a vertex and/or contact region
information during the solution.
For Results Tracker > Deformation, select a
vertex of interest and specify whether x, y, or z
deformation is to be monitored.
For Results Tracker > Contact, a pull-down
menu enables users to select a contact region.
Then, the quantity to track (such as number of
contacting elements) can be displayed.

DesignSpace Entra
Structural x
Results Tracker Training Manual

After the Results Tracker items are requested and solution
initiated, users may track the deformation or contact
results during the course of the solution.
In this example, the number of

contacting elements is
monitored for a particular
contact region. As is apparent
in the graph on right, between
Time=1.4 and 1.7, the number of
contacting elements jumps from
zero to 29. Since Time is a
placeholder in a nonlinear
static analysis, this means that,
after the first load step
(Time=1.0), between 40% and
70% of the load, contact is
established.

DesignSpace Entra
Structural x

It is the users responsibility to determine whether or not
large deformation effects are significant and need to be
considered.
Simulation has some basic checks after the solution, where if
the deformation is large compared to the overall geometry
size, the warning below will appear:
This, however, occurs for obvious, exaggerated cases. It does

not mean that if the warning does not appear in a linear
analysis that large deformation effects may not be significant.
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Newton-Raphson Residuals Training Manual

As emphasized earlier, the Newton-Raphson method
employs multiple iterations until force equilibrium is
achieved. For debugging purposes, it may be useful to
request the Newton-Raphson Residuals (i.e., residual
forces) to see what locations have high residuals which
may be the cause of force equilibrium not being satisfied.
In the Solution Information details view, enter the number of
equilibrium iterations to retrieve Newton-Raphson Residuals.
For example, if 3 is entered, the residual forces from the last
three iterations will be returned if the solution is aborted or
does not converge.

DesignSpace Entra
Structural x
Newton-Raphson Residuals Training Manual

After solution is stopped or fails to converge, residuals will be
available under the Solution Information branch, as shown
below.
If a solution fails to
converge or is aborted by
the user, the requested
number of residuals will be
available.
By looking at the residuals,
one can example at which
locations out-of-balance
forces are high. This helps
users identify possible
problematic locations, so
that corrective action may be
taken.

DesignSpace Entra
Structural x
F. Reviewing Results Training Manual

Requesting and reviewing results are similar to linear static
structural analyses
In large deformation problems, one usually should view the
deformation with Actual scaling from the Result toolbar
Any of the structural results may be requested, such as
Equivalent Stress, shown below

DesignSpace Entra
Structural x
Mechanical/Multiphysics x
Model shown is from a sample Unigraphics assembly. 2-69
Reviewing Results - Equivalent Plastic Strain Training Manual

If plasticity is defined, equivalent plastic strain can be
requested as output (example shown below)
Total equivalent strain is the sum of equivalent elastic and
equivalent plastic strain. Total equivalent strain is used to
correlate to the stress-strain curve.

DesignSpace Entra
Structural x
Reviewing Results Training Manual

Animations of nonlinear solutions linearly increase from
zero to the final value
The actual load history is not accounted for in the animation
If Pretension Bolt Loads are present, only the second load
step (externally applied loads after adjustment) is animated, as
shown in the example below
This model has Pretension Bolt Loads

applied on the three bolts.
Although the solution consisted of two
load steps simulating the assembly
and loading processes, only the final
result is animated.
This final result is animated in a linear
fashion from zero to the final value.
The actual load history is not
contained in the animation (i.e., if
multiple substeps were solved for, they
are not included in the animation)

DesignSpace Entra
Structural x
Workshop 2B
Bolt Pretension with Contact

G. Workshop 2B Goals Training Manual

Goal:
In this workshop our goal is to investigate the behavior of the pipe
clamp assembly (Pipe_clamp.x_t) shown here. Specifically we wish to
determine the crushing stress and deformation in a copper pipe
section when the bolt in the clamp is torqued down.
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. . . Workshop 2B Assumptions Training Manual

We will assume the material used for the pipe is a copper alloy
while all other parts are steel.
It is assumed the clamp is torqued to 1000 N when placed in
service.
Well assume the coefficient of friction between the clamp and
pipe is 0.4. The other contact regions will be treated as either
bonded or no separation as shown in the accompanying figures.
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. . . Workshop 2B - Start Page Training Manual

From the launcher start Simulation.
Choose Geometry > From File . . .
and browse to the file
Pipe_clamp.x_t.
When Workbench Simulation starts,

close the Template menu by clicking
the X in the corner of the window.
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. . . Workshop 2B Preprocessing Training Manual

Change the working unit system to metric mm.
1. Units > Metric (mm, kg, MPa, C, s)
1.
Insert the material Copper Alloy from the material library.

2. Highlight the Part 2 in the geometry branch (pipe).
3. Click in the Material field and Import.
2.
3.
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4. Select Copper Alloy material.
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5. Expand the Contact branch and use the shift
key to highlight all contact definitions.
6. In the details window change the Formulation

to Augmented Lagrange.
5.
6.
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7. Highlight the first contact branch. This is the
definition for the pipe to clamp contact.
7.
8. In the detail for the definition change the Type to

Frictional.
9. Enter a value for Friction Coefficient of 0.4.
8.
9.
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10. Highlight the second contact branch. This is
the definition for the bolt shaft to clamp hole
contact.
10.
11. From the details window change the Type to
No Separation.
The remaining 2 contact regions will be

modeled using the default bonded type of
contact. 11.
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Create a local coordinate system along the
pipes axis. Note, we will use the local
coordinate system for post processing 12.
later.
12. Highlight the Model branch. 13.
13. RMB > Insert > Coordinate Systems.
Notice the result is a new branch

Coordinate Systems appears in the tree.
Also, the Global Coordinate System is
automatically placed in the branch.
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With the Coordinate system branch highlighted:
14. Select the inside surface of the cylinder.
15. RMB > Insert > Coordinate System.
14.
15.
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16. From the detail for the new coordinate system
change Type to Cylindrical. 16.
17. Click to Change in the Z Direction field to
change the systems orientation.
17.
18. Select the inner surface of the pipe.
19. Apply in the detail window.
18.
19.
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. . . Workshop 2B - Environment Training Manual

20. Highlight the Environment branch.
21. Select one of the end surfaces of the pipe.
20.
22. RMB > Insert > Fixed Support.
21.
22.
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. . . Workshop 2B - Environment Training Manual

23. Select the cylindrical face of the bolt
part.
23.
24. RMB > Insert > Bolt

25. In the detail for the pretension bolt load
enter a Preload value of 1000.
25.
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. . . Workshop 2B Solution Setup Training Manual

26. Highlight the solution branch.
26.
27. RMB > Insert > Stress > Equivalent (von Mises).
27.
28. RMB > Insert > Deformation > Total.
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29. Switch to Body select mode.
29.
30. Select the pipe part.
30.
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31. RMB > Insert > Deformation > Directional.
31.
32. From the detail for the Directional Deformation change to

Coordinate System.
32.
Note we allowed the default name Coordinate System to be used

when the local system was created. We could easily change the
name to a more meaningful one. February 4, 2005
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33. Switch to face select mode. 33.
34. Highlight the outer surface of the pipe.

35. RMB > Insert > Contact Tool > Pressure.
Repeat steps 34 and 35 inserting contact 34.
Frictional Stress.
Solve February 4, 2005

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. . . Workshop 2B Solution Notes Training Manual

The solution for this workshop will take several minutes or more
depending on the available hardware.
The use of frictional contact triggers a nonlinear solution
requiring equilibrium iterations. The solution progress can be
viewed by inserting the Solution Information object.
The use of the pretension bolt load also causes 2 solutions to be

run. The first applies the pretension load and locks it down. The
second applies any remaining loads. February 4, 2005
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. . . Workshop 2B - Results Training Manual

Recall that the solution triggered the use of Weak Spring
stabilization. To insure that the weak springs are not the result of
rigid body motion, highlight the Environment branch and inspect
the weak spring reaction forces.
Here we can see that the reaction in the weak springs is of the
order e-5, a negligible value.
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Highlighting and plotting the Total Deformation for the assembly
shows the plot is not particularly useful for our goal (investigation
of pipes behavior).
The scoped result we placed in the solution branch will be more
instructive.
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Highlight and plot the result Directional Deformation.
In this case the result is scoped only to the pipe section. Also,
since we employed a local cylindrical system at the pipe axis,
the X direction here is displayed in the radial sense.
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Similarly, the behavior of the contact region can be view by
highlighting the contact result objects. Again the use of scoped
results allows a more intuitive plot of the quantity displayed.
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Chapter Four
Static Structural Analysis

Linear Static Structural Analysis

In this chapter, performing linear static structural analyses
in Simulation will be covered:
Geometry and Elements
Contact and Types of Supported Assemblies
Environment, including Loads and Supports
Solving Models
Results and Postprocessing

applicable to ANSYS DesignSpace Entra licenses and
above.
Some options discussed in this chapter may require more
advanced licenses, but these are noted accordingly.
Free vibration, harmonic, and nonlinear structural analyses are
not discussed here but in their respective chapters. March 29, 2005
Inventory #002215
4-2
Basics of Linear Static Analysis Training Manual

For a linear static structural analysis, the displacements {x}
are solved for in the matrix equation below:
K x F
This results in certain assumptions related to the analysis:
[K] is essentially constant
Linear elastic material behavior is assumed
Small deflection theory is used
Some nonlinear boundary conditions may be included
{F} is statically applied
No time-varying forces are considered
No inertial effects (mass, damping) are included

linear static analysis. Nonlinear static and dynamic
March 29, 2005
analyses are covered in later chapters. Inventory #002215
4-3
A. Geometry Training Manual

In structural analyses, all types of bodies supported by
Simulation may be used.
For surface bodies, thickness must be

supplied in the Details view of the
Geometry branch.
The cross-section and orientation of line bodies are defined

within DesignModeler and are imported into Simulation
automatically.
For line bodies, only displacement results are available.

DesignSpace Entra x
DesignSpace x March 29, 2005
Structural x
Point Mass Training Manual

A Point Mass is available under the Geometry branch to
mimic weight not explicitly modeled
A point mass is associated with surface(s) only
The location can be defined by either:
(x, y, z) coordinates in any user-defined Coordinate System
Selecting vertices/edges/surfaces to define location
The weight/mass is supplied under Magnitude
In a structural static analysis, the point mass is affected by
Acceleration, Standard Earth Gravity, and Rotational
Velocity. No other loads affect a point mass.
The mass is connected to selected surfaces
assuming no stiffness between them. This is
not a rigid-region assumption but similar to a
distributed mass assumption.
No rotational inertial terms are present.
DesignSpace Entra x
Structural x
Point Mass Training Manual

A point mass will be displayed as a round, grey sphere
As noted previously, only inertial loads affect the point mass.
This means that the only reason to use a point mass in a linear
static analysis is to account for additional weight of a
structure not modeled. Inertial loads must be present.
No results are obtained for the Point Mass itself.

DesignSpace Entra x
Structural x

The required structural material properties are Youngs
Modulus and Poissons Ratio for linear static structural
analyses
Material input is under the Engineering Data branch, and
material assignment is per part under the Geometry branch
Mass density is required if any inertial loads are present
Thermal expansion coefficient and thermal conductivity are
required if any thermal loads are present
Thermal loading not available with an ANSYS Structural license
Negative thermal expansion coefficient may be input (shrinkage)
Stress Limits are needed if a Stress Tool result is present
Fatigue Properties are needed if Fatigue Tool result is present
Requires Fatigue Module add-on license
Specific loading and result tools will be discussed later
DesignSpace Entra x
Structural /

Engineering Data view of sample material shown below:

DesignSpace Entra x
Structural x
B. Assemblies Solid Body Contact Training Manual

When importing assemblies of solid parts, contact regions
are automatically created between the solid bodies.
Surface-to-surface contact allows non-matching meshes at
boundaries between solid parts
Tolerance controls under Contact branch allows the user to
specify distance of auto contact detection via slider bar

DesignSpace Entra
Structural x
Assemblies Solid Body Contact Training Manual

In Simulation, the concept of contact and target surfaces
are used for each contact region.
One side of the contact region is comprised of contact
face(s), the other side of the region is made of target face(s).
The integration points of the contact surfaces are restricted
from penetrating through the target surfaces (within a given
tolerance). The opposite is not true, however.
When one side is the contact and the other side is the target, this
is called asymmetric contact. On the other hand, if both sides are
made to be contact & target, this is called symmetric contact since
neither side can penetrate the other.
By default, Simulation uses symmetric
contact for solid assemblies.
For ANSYS Professional licenses and
above, the user may change to
asymmetric contact, as desired.
DesignSpace Entra
DesignSpace / March 29, 2005
Structural x

Four contact types are available:
Contact Type Iterations Normal Behavior (Separation) Tangential Behavior (Sliding)
Bonded 1 Closed Closed
No Separation 1 Closed Open
Frictionless Multiple Open Open
Rough Multiple Open Closed
Bonded and No Separation contact are basically

linear behavior and require only 1 iteration
Frictionless and Rough contact are nonlinear
and require multiple iterations. However, note
that small deflection theory is still assumed.
When using these options, an interface treatment
option is available, set either as Actual Geometry
(and Specified Offset) or Adjusted to Touch.
The latter allows the user to have ANSYS close the
gap to just touching position. This is available
for ANSYS Professional and above.
DesignSpace Entra
Structural x

For the advanced user, some of the
contact options can be modified
Formulation can be changed from Pure
Penalty to Augmented Lagrange, MPC, or
Normal Lagrange.
MPC is applicable to bonded contact only
Augmented Lagrange is used in regular ANSYS
The pure Penalty method can be thought of as
adding very high stiffness between interface of
parts, resulting in negligible relative movement
between parts at the contact interface.
MPC formulation writes constraint equations
relating movement of parts at interface, so no
relative movement occurs. This can be an
attractive alternative to penalty method for
bonded contact.

DesignSpace Entra
DesignSpace March 29, 2005
Structural x

Advanced options (continued):
As explained in Chapter 3, the pinball
region can be input and visualized
The pinball region defines location of near-
field open contact. Outside of the pinball
region is far-field open contact.
Originally, the pinball region was meant to
more efficiently process contact searching,
but this is also used for other purposes,
such as bonded contact
For bonded or no separation contact, if gap
or penetration is smaller than pinball region,
the gap/penetration is automatically
excluded
Other advanced contact options will be
discussed in Chapter 11.
In this case, the gap between
the two parts is bigger than the
DesignSpace Entra pinball region, so no automatic
DesignSpace gap closure will be performed. March 29, 2005
Structural x
Assemblies Surface Body Contact Training Manual

For ANSYS Professional licenses and above, mixed
assemblies of shells and solids are supported
Allows for more complex modeling of assemblies, taking
advantage of the benefits of shells, when applicable
More contact options are exposed to the user
Contact postprocessing is also available (discussed later)

DesignSpace Entra
Structural x

Edge contact is a subset of general contact
For contact including shell faces or solid
edges, only bonded or no separation
behavior is allowed.
For contact involving shell edges, only
bonded behavior using MPC formulation is
allowed.
For MPC-based bonded contact, user can set
the search direction (the way in which the
multi-point constraints are written) as either
the target normal or pinball region.
If a gap exists (as is often the case with
shell assemblies), the pinball region can be
used for the search direction to detect
contact beyond a gap.

DesignSpace Entra
Structural x
Assemblies Contact Summary Training Manual

A summary of contact types and options available in
Simulation is presented in the table below:
Contact Geometry Solid Body Face Solid Body Edge Surface Body Face Surface Body Edge
Solid Body Face All types Bonded, No Separation Bonded, No Separation Bonded only
All formulations All formulations All formulations MPC formulation
Symmetry respected Asymmetric only Symmetry respected Asymmetric only
Solid Body Edge Bonded, No Separation Bonded, No Separation Bonded only
All formulations All formulations MPC formulation
Asymmetric only Asymmetric only Asymmetric only
Surface Body Face Bonded, No Separation Bonded only
All formulations MPC formulation
Symmetry respected Asymmetric only
Surface Body Edge Bonded only
MPC formulation
Asymmetric only
This table is also in the Simulation online help. Please refer to

this table to determine what options are available.
Note that surface body faces can only participate in bonded or no
separation contact. Surface body edges allow MPC-based bonded
contact only.
DesignSpace Entra
Structural x
Assemblies Spot Weld Training Manual
Spot welds provide a means of connecting shell assemblies

at discrete points
For ANSYS DesignSpace licenses, shell contact is not
supported, so spotwelds are the only way to define a shell
assembly.
Spotweld definition is done in the CAD software. Currently,
only DesignModeler and Unigraphics define spotwelds in a
manner that Simulation supports.
Spotwelds can also be created in
Simulation manually, but only at
discrete vertices.
DesignSpace Entra
DesignSpace x
Professional x
Structural x
DesignModeler x
Pro/ENGINEER
Unigraphics x
SolidW orks
Inventor
Solid Edge
Mechanical Desktop
CATIA V4
CATIA V5 March 29, 2005
ACIS (SAT) Inventory #002215
Parasolid
IGES 4-17
C. Loads and Supports Training Manual

There are four types of structural loads available:
Inertial loads
These loads act on the entire system
Density is required for mass calculations
These are only loads which act on defined Point Masses
Structural Loads
These are forces or moments acting on parts of the system
Structural Supports
These are constraints that prevent movement on certain regions
Thermal Loads
Structurally speaking, the thermal loads result in a temperature
field, which causes thermal expansion on the model.

DesignSpace Entra x
Structural /
. . . Time Type Training Manual

A time type option is available at certain license levels.
The default time type for loading is static
Sequence and harmonic time types are available as
options (harmonic analysis is covered in the Advanced WB
training)
Sequence loading allows a series of static time steps to be
set up in advance and solved at once
Sequenced results can be reviewed step by step

DesignSpace Entra
Structural x

Specify the desired number of sequence
steps in the details of the Environment.
Enter the value of the load for each step by
first highlighting the desired step in the
graphics window.
The chart in the graphics window displays the

variation of the load.
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4-20

The worksheet view provides a
graphical representation of each
loads sequence.
Results of a sequenced simulation

can be reviewed by highlighting the
quantity of interest and picking the
desired sequence from the graphics
window.
March 29, 2005

Inventory #002215
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Directional Loads Training Manual

For most loads/supports which have an
orientation, the direction can be defined by
components in any Coordinate System
The Coordinate System (CS) has to be
defined prior to specifying the loading. Only
Cartesian coordinate systems may be used
for loading/support orientation.
In the Details view, change Define By to
Components. Then, select the appropriate
Cartesian CS from the pull-down menu.
Specify x, y, and/or z components, which are
relative to the selected Coordinate System
Not all loads/supports support use of CS:
Load Supports Coordinate Systems
Acceleration No Loads/Supports not
Standard Earth Gravity No listed in the table do not
Rotational Velocity No
Force Yes
have direction
ANSYS License Availability Remote Force Location of Origin Only associated with it, so
DesignSpace Entra x Bearing Load Yes Coordinate Systems are
Professional x
Moment Yes not applicable.
Given Displacement Yes Inventory #002215
Structural x
Acceleration & Gravity Training Manual

An acceleration can be defined on the system
Acceleration acts on entire model in length/time2 units.
Users sometimes have confusion over notation of direction. If
acceleration is applied to system suddenly, the inertia resists
the change in acceleration, so the inertial forces are in the
opposite direction to applied acceleration
Acceleration can be defined by Components or Vector
Standard Earth Gravity can also be applied as a load

Value applied is 9.80665 m/s2 (in SI units)
Standard Earth Gravity direction can only be defined along
one of three World Coordinate System axes.
Since Standard Earth Gravity is defined as an acceleration,
define the direction as opposite to gravitational force, as noted
above.
DesignSpace Entra x
Structural x
Rotational Velocity Training Manual

Rotational velocity is another inertial load available
Entire model spins about an axis at a given rate
Can be defined as a vector, using geometry for axis and
magnitude of rotational velocity
Can be defined by components, supplying origin and
components in World Coordinate System
Note that location of axis is very important since model spins
around that axis.
Default is to input rotational velocity in radians per second.
Can be changed in Tools > Control Panel > Miscellaneous >
Angular Velocity to revolutions per minute (RPM) instead.

DesignSpace Entra x
Structural x
Forces and Pressures Training Manual

Pressure loading:
Pressures can only be applied to surfaces and always act
normal to the surface
Positive value acts into surface (i.e., compressive)
negative value acts outward from surface (i.e., suction)
Units of pressure are in force per area
Force loading:
Forces can be applied on vertices, edges, or surfaces.
The force will be distributed on all entities. This
means that if a force is applied to two identical
surfaces, each surface will have half of the force
applied. Units are mass*length/time2
A force is defined via vector and magnitude or by
components (in user-defined Coordinate System)
DesignSpace Entra x
Structural x
Bearing Load Training Manual

Bearing Load (was called Bolt Load in prior releases):
Bearing Loads are for cylindrical surfaces only. Radial
component will be distributed on compressive side using
projected area. Example of radial distribution shown below.
Axial component is distributed evenly on cylinder.
Use only one bearing load per cylindrical surface. If the
cylindrical surface is split in two, however, be sure to select
both halves of cylindrical surface when applying this load.
Load is in units of force
Bearing load can be defined
via vector and magnitude or
by components (in any
user Coordinate System).

DesignSpace Entra x
Structural x
Moment Load Training Manual

Moment Load:
For solid bodies, a moment can be applied on any
surface
If multiple surfaces are selected, the moment load
gets apportioned about those selected surfaces
A vector and magnitude or components (in user-defined
Coordinate System) can define the moment. The moment acts
about the vector using the right-hand rule
For surface bodies, a moment can also be applied to a vertex
or edge with similar definition via vector or components as
with a surface-based moment
Units of moment are in Force*length.

DesignSpace Entra x
Structural x
Remote Load Training Manual

Remote Load:
Allows the user to apply an offset force on a surface or edge of
a surface body
The user supplies the origin of the force (using vertices, a
cylinder, or typing in (x, y, z) coordinates). A user-defined
Coordinate System may be used to reference the location.
The force can then be defined by vector and magnitude or by
components (components for direction is in Global CS)
This results in an equivalent force on
the surface plus a moment caused by
the moment arm of the offset force
The force is distributed on the surface
but includes the effect of the moment
arm due to the offset of the force
Units are in force (mass*length/time2)
DesignSpace Entra x
Structural x
Supports (General) Training Manual

Fixed Support:
Constraints all degrees of freedom on vertex, edge, or surface
For solid bodies, prevents translations in x, y, and z
For surface and line bodies, prevents translations and
rotations in x, y, and z
Given Displacement:
Applies known displacement on vertex, edge, or surface
Allows for imposed translational displacement in x, y, and z (in
user-defined Coordinate System)
Entering 0 means that the direction is constrained.
Leaving the direction blank means that the entity is free to
move in that direction

DesignSpace Entra x
Structural x
Supports (Solid Bodies) Training Manual

Frictionless Support:
Applies constraint in normal direction on surfaces
For solid bodies, this support can be used to apply a
symmetry plane boundary condition since symmetry plane
is same as normal constraint
Cylindrical Constraint:
Applied on cylindrical surfaces
User can specify whether axial, radial, or tangential
components are constrained
Suitable for small-deflection (linear) analysis only

DesignSpace Entra x
Structural x
Supports (Solid Bodies) Training Manual

Compression Only Support:
Applies a compression-only constraint normal to any given
surface. This prevents the surface to move in the positive
normal direction only.
A way to think of this support is to imagine a rigid structure
which has the same shape of the selected surface. Note that
the contacting (compressive) areas are not known beforehand.
Can be used on a cylindrical surface to model a
(referred to as Pinned Cylinder 7.1)
Notice the example on the right,
where the outline of the undeformed cylinder
is shown. The compressive side retains the shape
of the original cylinder, but the tensile side is free to deform.
This requires an iterative (nonlinear) solution.

DesignSpace Entra x
Structural x
Supports (Line/Surface Bodies) Training Manual

Simply Supported:
Can be applied on edge or vertex of surface or line bodies
Prevents all translations but all rotations are free
Fixed Rotation:
Can be applied on surface, edge, or vertex of surface or line
bodies
Constrains rotations but translations are free

DesignSpace Entra x
Structural x
Summary of Supports Training Manual

Supports and Contact Regions may both be thought of as
being boundary conditions.
Contact Regions provides a flexible boundary condition
between two existing parts explicitly modeled
Supports provide a rigid boundary condition between the
modeled part an a rigid, immovable part not explicitly modeled
Type of Support Equivalent Contact Condition at Surfaces of Part
Fixed Support Bonded contact with a rigid, immovable part
Frictionless Support No Separation contact with a rigid, immovable part
Compression Only Support Frictionless contact with a rigid, immovable part
If Part A, which is of interest, is connected to Part B,

consider whether both parts need to be analyzed (with
contact) or whether supports will suffice in providing the
effect Part B has on Part A.
In other words, is Part B rigid compared to Part A? If so, a
support can be used and only Part A modeled. If not, one may
need to model both Parts A and B with contact. March 29, 2005
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Thermal Loading Training Manual

Temperature causes thermal expansion in the model
Thermal strains are calculated as follows:
thx thy thz T Tref
where is the thermal expansion coefficient (CTE), Tref is the
reference temperature at which thermal strains are zero, T is
the applied temperature, and th is the thermal strain.
Thermal strains do not cause stress by themselves. It is the
constraint, temperature gradient, or CTE mismatch that
produce stress.
CTE is defined in Engineering Data
and has units of strain per temperature
The reference temperature is defined in the
Environment branch

DesignSpace Entra x
Structural
Thermal Loading Training Manual

Thermal loads can be applied on the model
Any temperature loading can be applied (see Chapter 6 on
Thermal Analysis for details)
Simulation will always perform a thermal solution first, then
use the calculated temperature field as input when solving the
structural solution.

DesignSpace Entra x
Structural
D. Workshop 4.1 Training Manual

Workshop 4.1 Linear Structural Analysis
Goal:
A 5 part assembly representing an impeller type pump is
analyzed with a 100N preload on the belt.
March 29, 2005

Inventory #002215
4-36
E. Solution Options Training Manual

Solution options can be set under the Solution branch
The ANSYS database can be saved if Save
ANSYS db is set
Useful if you want to open a database in ANSYS
Two solvers are available in Simulation
The solver is automatically chosen, although some
informative messages may appear after solution
letting the user know what solver was used. Set
default behavior under Tools > Options >
Simulation: Solution > Solver Type
The Direct solver is useful for models containing
thin surface and line bodies. It is a robust solver
and handles any situation.
The Iterative solver is most efficient when solving
large, bulky solid bodies. It can handle large models
well, although it is less efficient for beam/shells.
DesignSpace Entra x
Structural x
Solution Options Training Manual

Weak springs can be added to stabilize model
If Program Controlled is set, Simulation tries to
anticipate under-constrained models. If no
Fixed Support is present, it may add weak springs
and provide an informative message letting the user
know that it has done so
This can be set to On or Off. To set the default
behavior, go to Tools > Options > Simulation:
Solution > Use Weak Springs.
In some cases, the user expects the model to be in
equilibrium and does not want to constrain all
possible rigid-body modes. Weak springs will help
by preventing matrix singularity.
It is good practice to constrain all possible rigid-body
motion, however.

DesignSpace Entra x
Structural x

Informative messages are also present:
The type of analysis is shown, such as Static
Structural for the cases described in this section.
If a nonlinear solution is required, it will be indicated
as such. Recall that for some contact behavior and
compression-only support, the solution becomes
nonlinear. These type of solutions require multiple
iterations and take longer than linear solutions.
The solver working directory is where scratch files
are saved during the solution of the matrix equation.
By default, the TEMP directory of your Windows
system environment variable is used, although this
can be changed in Tools > Options > Simulation:
Solution > Solver Working Directory. Sufficient free
space must be on that partition.
Any solver messages which appear after solution can
be checked afterwards under Solver Messages

DesignSpace Entra x
Structural x
Solving the Model Training Manual

To solve the model, request results first (covered next) and
click on the Solve button on the Standard Toolbar
By default, two processors (if present) will be used for parallel
processing. To set the number, use Tools > Options >
Simulation: Solution > Number of Processors to Use
Recall that if a Solution Information branch is requested, the
contents of the Solution Output can be displayed.

DesignSpace Entra x
Structural x
F. Results and Postprocessing Training Manual

Various results are available for postprocessing:
Directional and total deformation
Components, principal, or invariants of stresses and strains
Contact output
Requires ANSYS Professional and above
Reaction forces
In Simulation, results are usually requested before solving,

but they can be requested afterwards, too.
If you solve a model then request results afterwards, click on
the Solve button , and the results will be retrieved. A
new solution is not required if that type of result has been
requested previously (i.e., total deformation was requested
previously but now direction deformation is added).
March 29, 2005
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Plotting Results Training Manual

All of the contour and vector plots are usually shown on the
deformed geometry. Use the Context Toolbar to change the
scaling or display of results to desired settings.

DesignSpace Entra x
Structural x
Deformation Training Manual

The deformation of the model can be plotted:
Total deformation is a scalar quantity:
U total U x2 U y2 U z2
The x, y, and z components of deformation can be
requested under Directional. Because there is
direction associated with the components, if a
Coordinate System branch is present, users can
request deformation in a given coordinate system.
For example, it may be easier to interpret displacement for a
cylindrical geometry in a radial direction by using a cylindrical
coordinate system to display the result.
Vector plots of deformation are available.
Recall that wireframe mode is the easiest
to view vector plots.
DesignSpace Entra x
Structural x
Deformation Training Manual

Deformation results are available for line, surface, and solid
bodies
Note that deformation results are associated with
translational DOF only. Rotations associated with the DOF of
line and surface bodies are not directly viewable
Because deformation (displacements) are DOF which
Simulation solves for, the convergence behavior is well-
behaved when using the Convergence tool
Vector deformation plots cannot useAlert or Convergence
tools because they are vector quantities (x, y, z) rather than a
unique quantity (x or y or z). Use Alert or Convergence tools
on Total or Directional quantities instead.
Total deformation is an invariant, so Coordinate Systems
cannot be used on this result quantity. Also, Vector
deformation is always shown in the world coordinate system.
DesignSpace Entra x
Structural x
Stresses and Strains Training Manual

Stresses and strains can be viewed:
Strains are actually elastic strains
Stresses and (elastic) strains are
tensors and have six components
(x, y, z, xy, yz, xz) while thermal
strains can be considered a vector
with three components (x, y, z)
For stresses and strains, components can be
requested under Normal (x, y, z) and Shear
(xy, yz, xz). For thermal strains, (x, y, z) components are under
Thermal.
Can request in different results coordinate systems
Thermal strains not available with an ANSYS Structural license
Only available for shell and solid bodies. Line bodies currently do
not report any results except for deformation.
Equivalent Plastic strain output is covered in Chapter 11
DesignSpace Entra x
Structural /
Stress Tools Training Manual

Safety Factors can be calculated
based on any of 4 failure theories:
Ductile Theories:
Maximum Equivalent Stress
Maximum Shear Stress
Brittle Theories:
Mohr-Coulomb Stress
Maximum Tensile Stress
Within each stress tool safety factor,
safety margin and stress ratio can be
plotted
Note: see appendix 4 and the

Simulation documentation for more
details
DesignSpace Entra x
Structural x
Contact Results Training Manual

Contact Results:
Contact results can be requested for selected
bodies or surfaces which have contact elements.
Contact elements in ANSYS use the concept of
contact and target surfaces. Only contact surfaces
report contact results. MPC-based contact, the
target surfaces of any contact, and edge-based contact do not
report results. Line bodies do not support contact.
If asymmetric or auto-asymmetric contact is used, then contact
results will be reported on the contact surfaces only. The target
surfaces will report zero values, if requested.
If symmetric contact is used, then contact results will be reported
on both surfaces. For values such as contact pressure, the actual
contact pressure will be an average of both surfaces in contact.
Contact results are first requested via a Contact Tool under
the Solution branch.
DesignSpace Entra
Structural x

The user can specify contact output under Contact Tool
The Worksheet view easily allows users to select which
contact regions will be associated with the Contact Tool
Results on contact or target sides (or both) can be selected
from the spreadsheet (symmetric vs. asymmetric contact)
Specific contact results chosen from Context Toolbar
Select contact regions you want to

review (add more Contact Tool
branches to look at contact region
output separately).
Right-click on the worksheet to see
other available options.
For the Contact Tool, then
request contact output results, and
those results will correspond to
selected contact regions.

DesignSpace Entra
Structural x

Types of Contact Results available:
Contact Pressure shows distribution of normal contact
pressure
Contact Penetration shows the resulting amount of
penetration whereas contact Gap shows any gap
(within pinball radius).
Sliding Distance is the amount one surface has slid with
respect to the other. Frictional Stress is tangential contact
traction due to frictional effects.
Contact Status provides information on
whether the contact is established (closed
state) or not touching (open state).
For the open state, near-field means that it is
within pinball region, far-field means that it is
outside of pinball region.
Contour results are plotted with the
ANSYS License Availability rest of the model being translucent
DesignSpace Entra
DesignSpace
for easier viewing. March 29, 2005
Structural x
Contact Forces Training Manual

If Reactions are requested for Contact Tool, forces and
moments are reported for the requested contact regions
Under the Worksheet tab, contact forces for all requested
contact regions will be tabulated
Under the Geometry tab, symbols will show direction of
contact forces and moments.

DesignSpace Entra
Structural x
Reaction Forces at Supports Training Manual

Reaction forces and moments are output for each support
For each support, look under the Details view
after solution. Reaction forces and moments are
printed. X, y, and z components are with respect
to the world coordinate system. Moments are
reported at the centroid of the support.
The reaction force for weak springs, if used, is
under the Environment branch Details view
after solution. The weak spring reaction forces
should be small to ensure that the effect of weak
springs is negligible.

DesignSpace Entra x
Structural x
Reaction Forces at Supports Training Manual

The Worksheet tab for Environment branch has a
summary of reaction forces and moments
If a support shares a vertex, edge, or surface with another
support, contact pair, or load, the reported reaction forces may
be incorrect. This is due to the fact that the underlying mesh
will have multiple supports and/or loads applied to the same
nodes. The solution will still be valid, but the reported values
may not be accurate because of this.

DesignSpace Entra x
Structural x
Fatigue Training Manual

If the Fatigue Module add-on license is available, additional
post-processing involving fatigue calculations is possible
The Fatigue Tool provides stress-based fatigue calculations
to aid the design engineer with evaluating the life of
components in the system
Constant or variable amplitude loading, proportional or non-
proportional loading is possible
Damage Matrix at Critical Location Contour of Safety Factor

March 29, 2005
Inventory #002215
Fatigue Module x 4-53
G. Workshop 4.2 2D vs 3D Analysis Training Manual
Workshop 4.2 Comparing 2D and 3D Structural Analysis

Comparing 2D and 3D structural analyses.
Shown here are the 3D sector model and the 2D axisymmetric
model.
Pressure Cap
Retaining Ring
March 29, 2005
Inventory #002215
4-54
Chapter Six
Thermal Analysis
Steady-State Thermal Analysis
ANSYS Workbench - Simulation

In this chapter, performing steady-state thermal analyses in
Design Simulation will be covered:
Geometry and Elements
Contact and Types of Supported Assemblies
Environment, including Loads and Supports
Solving Models
Results and Postprocessing

applicable to ANSYS DesignSpace Entra licenses and
above, except for an ANSYS Structural license.
Some options discussed in this chapter may require more
advanced licenses, but these are noted accordingly.
It is assumed that the user has reviewed Chapters 1-3 prior to
this chapter. (Chapters 4-5 are optional)
February 2, 2004
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6-2
Basics of Steady-State Heat Transfer Training Manual

A steady-state thermal analysis is performed to determine
the thermal response under applied steady-state loads
Temperatures and heat flow rate are usually the items of
interest, although heat fluxes can be reported as well.
The general thermal equation is as follows:
C T T K T T Qt , T
where t is time and {T} is temperature, [C] is the specific
heat (thermal capacitance) matrix, [K] is the conductivity
matrix, and {Q} is the heat flow rate load vector.
In a steady-state analysis, all time-dependent terms are
removed. However, nonlinearities are still present:
K T T QT February 2, 2004
Inventory #002010
6-3

For a steady-state thermal analysis in Design Simulation,
the temperatures {T} are solved for in the matrix below:
K T T QT
This results in the following assumptions:
No transient effects are considered in a steady-state analysis
[K] can be constant or a function of temperature
Temperature-dependent thermal conductivity can be input for each
material property
{Q} can be constant or a function of temperature
Temperature-dependent film coefficients can be input for
convective boundary conditions
February 2, 2004
Inventory #002010
6-4

Fouriers Law provides the basis of the previous equation:
This means that the thermal analysis Design Simulation solves
for is a conduction-based equation.
Heat flow within a solid (Fouriers Law) is the basis of [K]
Heat flux, heat flow rate, and convection are treated as boundary
conditions on the system {Q}
No radiation is currently considered
No time-dependent effects are currently considered
Heat transfer analysis is different from CFD (Computational
Fluid Dynamics)
Convection is treated as a simple boundary condition, although
temperature-dependent film coefficients are possible.
If conjugate heat transfer/fluid problem needs to be analyzed, one
must use ANSYS CFD tools instead.

performing thermal analyses in Design Simulation. February 2, 2004
Inventory #002010
6-5
A. Geometry Training Manual

In thermal analyses, most types of bodies supported by
Design Simulation may be used.
Solid and surface bodies are supported by all products which
support thermal analyses.
For surface bodies, thickness must be input in the Details view of
the Geometry branch
Line bodies are only supported under ANSYS Professional
licenses and above.
The cross-section and orientation of line bodies is defined within
DesignModeler and is imported into Design Simulation
automatically. Although the cross-section and orientation is
defined, this information is meant for structural analyses, and the
actual thermal link element will have an effective cross-section
based on the input properties.
No heat flux or vector heat flux output is available with line bodies.
Only temperature results are available for line bodies.
DesignSpace Entra /
DesignSpace /
February 2, 2004
Professional x
Structural Inventory #002010
Geometry Training Manual

It is important to understand assumptions related to using
shell and line bodies:
For shell bodies, through-thickness temperature gradients are
not considered. A shell body should be used for thin
structures when it can be safe to assume temperatures on top
and bottom of surface are the same.
Temperature variation will still be considered across the surface,
just not through the thickness, which is not explicitly modeled.
For line bodies, thickness variation in the cross-section is not
considered. A line body should be used for beam- or truss-like
structures, where the temperature can be assumed to be
constant across the cross-section.
Temperature variation will still be considered along the line body,
just not through the cross-section, which is not explicitly modeled.

DesignSpa ce Entra /
DesignSpa ce /
Professional x
February 2, 2004
Mecha nica l/Multiphysics x 6-7
Elements Used Training Manual

In Design Simulation, the following elements are used:
Solid bodies are meshed with 10-node tetrahedral or 20-node
hexahedral elements
SOLID87 and SOLID90
Surface bodies are meshed with 4-node quad shell elements
SHELL57 using real constants
(SHELL131 or SHELL132 are currently not used.)
Line bodies are meshed with 2-node line elements
LINK33 using real constants
An equivalent cross-sectional area, as defined in DesignModeler, is
used for LINK33
For thermal-stress analyses, a coupled-field element is not

used. The thermal-stress analysis is performed sequentially,
so the above thermal elements are used, then the temperature
field is read into corresponding structural elements.
February 2, 2004
Inventory #002010
Advanced ANSYS Details 6-8

The only required material property is thermal conductivity.
Material input is under the Engineering Data branch, and
material assignment is per part under the Geometry branch
Thermal Conductivity is
input as a sub-branch of
the material property.
Temperature-dependent
thermal conductivity can
be input as a table.
Specific heat can be
input as well, but it is
currently not used.
Other material input
is not used in thermal.
If any temperature-dependent material properties exist, this will
ANSYS License Availability result in a nonlinear solution. This is because the temperatures are
DesignSpace Entra x
DesignSpace x solved for, but the materials are dependent on the temperatures, so
February 2, 2004
Professional x it is not linear. Inventory #002010
Structural

Thermal conductivity is input into ANSYS as MP
commands.
For temperature-dependent thermal conductivity, the
appropriate MPTEMP and MPDATA commands are issued
Although specific heat may be defined in the Engineering

Data branch, it is currently unused and not passed to
ANSYS
No MP,C command is written for specific heat
February 2, 2004
Inventory #002010
B. Assemblies Solid Body Contact Training Manual

When importing assemblies of solid parts, contact regions
are automatically created between the solid bodies.
Surface-to-surface contact allows non-matching meshes at
boundaries between solid parts
Contact enables heat transfer between parts in an assembly

DesignSpace Entra
Professional x
Inventory #002010
Structural
Mechanical/Multiphysics x Model shown is from a sample Inventor assembly. 6-11
Assemblies Contact Region Training Manual

In Design Simulation, the concept of contact and target
surfaces are used for each contact region.
One side of the contact region is comprised of contact
face(s), the other side of the region is made of target face(s).
Heat flow is allowed between contact and target faces (based
on the contact normal direction)
When one side is the contact and the other side is the target, this
is called asymmetric contact. On the other hand, if both sides are
made to be contact & target, this is called symmetric contact.
However, the designation of which side is contact or target is
unimportant in thermal analysis.
By default, Design Simulation uses
symmetric contact for solid assemblies.
For ANSYS Professional licenses and
above, the user may change to asymmetric
contact, as desired.
DesignSpace Entra
Professional x
Structural
Inventory #002010

As noted in the previous slide, heat flows within a contact
region in the contact normal direction
No heat spreading is considered in the contact/target interface
Heat spreading is considered within shell or solid elements at the
contact or target surfaces because of Fouriers Law
Heat flow within the contact region is in the contact normal
direction only
This means that, regardless of the definition of the contact region,
heat flows only if a target element is present in the normal
direction
In the figure on the left, the solid
green double-arrows indicate
heat flow within the contact
region. Heat flow only occurs if a
target surface is normal to a
contact surface.
The light, dotted green arrows
indicate that no heat transfer will
occur between parts.
DesignSpace Entra
Professional x
Structural
Inventory #002010

In Design Simulation, various contact behaviors exist
In general, the contact type is meant for structural applications
If the parts are initially in contact, heat transfer will occur
between the parts. If the parts are initially out of contact, the
parts will not transfer heat between each other.
Based on the contact type, whether heat will be transferred
between contact and target surfaces is outlined below:
Heat Transfer Betw een Parts in Contact Region?
Contact Type
Initially Touching Inside Pinball Region Outside Pinball Region
Bonded Yes Yes No
No Separation Yes Yes No
Rough Yes No No
Frictionless Yes No No
The pinball region is automatically defined and set to a

relatively small value to accommodate small gaps which may
present in the model. The pinball region will be discussed
next.
DesignSpace Entra
DesignSpace x
x
February 2, 2004
Professional

The pinball region may be input and
visualized in ANSYS Professional
licenses and above.
If the target nodes lie within the pinball region
and the contact is bonded or no separation,
then heat transfer will occur (solid green lines)
Otherwise, no heat transfer will occur between
nodes (dotted green lines)
Pinball Radius
In this figure on the right, the

gap between the two parts is
bigger than the pinball region,
DesignSpace Entra
DesignSpace so no heat transfer will occur February 2, 2004
Professional x between the parts Inventory #002010
Structural
Assemblies Thermal Conductance Training Manual

By default, a high thermal contact conductance (TCC) is
defined between parts of an assembly
The amount of heat flow between two parts is defined by the
q TCC Ttarget Tcontact

contact heat flux q:
where Tcontact is the temperature of a contact node and Ttarget

is the temperature of the corresponding target node located
in the contact normal direction.
By default, TCC is set to a relatively high value, based on the
largest material conductivity defined in the model KXX and the
diagonal of the overall geometry bounding box ASMDIAG.
TCC KXX 10,000 / ASMDIAG

This essentially provides perfect conductance between parts.

DesignSpace Entra
Professional x
Structural
Inventory #002010

Perfect thermal contact conductance between parts means
that no temperature drop is assumed at the interface.
One may want to include finite thermal conductance instead
Two surfaces (at different temperatures) in contact experience
a temperature drop across the interface. The drop is due to
imperfect contact between the two surfaces. The imperfect
contact, and hence the finite contact conductance, can be
influenced by many factors such as:
surface flatness
surface finish
oxides
entrapped fluids T
contact pressure
surface temperature
T
use of conductive grease
x February 2, 2004
Inventory #002010
6-17

In ANSYS Professional licenses and above, the user may
define a finite thermal contact conductance (TCC)
The thermal contact conductance per unit area is input for
each contact region in the Details view, as shown below.
If thermal contact resistance is known, invert this value and
divide by the contacting area to obtain TCC value.
When this is done, there will now be a temperature drop
between the contact and target surfaces for a contact region.
If Thermal Conductance is left

at Program Chosen, near-
perfect thermal contact
conductance will be defined.
The user can change this to
Manual to input finite thermal
contact conductance instead,
which is the same as including
thermal contact resistance at a
DesignSpace Entra
contact interface.
Professional x
Structural
Inventory #002010

If using symmetric contact, the user does
not need to account for a double
thermal contact resistance.
Input values as normal
MPC bonded contact allows for perfect

thermal contact conductance.
In this case, because constraint equations
are used, no thermal contact conductance
is used nor defined.
The contact node and corresponding
target node will have the same
temperature because of perfect contact
conductance.
DesignSpace Entra
DesignSpace
February 2, 2004
Professional x

Internally, thermal contact for solid faces is defined with
CONTA174 and TARGE170 elements.
KEYOPT(1)=2 set for thermal DOF only
KEYOPT(12) is based on contact type used
For example, bonded type is KEYOPT(12)=5. KEYOPT(2),
KEYOPT(5), KEYOPT(9), and FKN are also set. These contact
settings are most critical for structural contact, so the various
default settings are outlined in Chapter 4.
Default thermal contact conductance (TCC) is based on
highest value of thermal conductivity of materials and overall
geometry size
TCC=KXX*10,000/ASMDIAG
KXX is of highest thermal conductivity value of used materials
ASMDIAG is diagonal of overall bounding box of assembly
February 2, 2004
Inventory #002010

For ANSYS Professional1 licenses and above, mixed
assemblies of shells and solids are supported
Allows for more complex modeling of assemblies, taking
advantage of the benefits of shells, when applicable

DesignSpace Entra
Professiona l x1
Structural
Inventory #002010
1 For ANSYS Professional, surface contact supported with ANSYS 8.0 Service Pack 1 and above

Edge contact is a subset of general contact
For contact including shell faces or solid
edges, only bonded or no separation
behavior is allowed.
For contact involving shell edges, only
bonded behavior using MPC formulation is
allowed.
For MPC-based bonded contact, user can set
the search direction (the way in which the
multi-point constraints are written) as either
the target normal or pinball region.
If a gap exists (as is often the case with
shell assemblies), the pinball region can be
used for the search direction to detect
contact beyond a gap.
MPC results in perfect contact conductance
DesignSpace Entra
DesignSpace
February 2, 2004
Professional x1
Structural
Inventory #002010

Internally, any contact including an edge (solid body edge
or surface edge) results in asymmetric contact with
CONTA175 for the edge and TARGE170 for the edge/face
Undocumented KEYOPT(1)=2 is set for thermal contact
Contact involving solid edges default to pure penalty method
Contact involving surface edges use MPC formulation. Instead of
target normal, if search direction is pinball region,
KEYOPT(5)=4 set on companion TARGE170 element.
For bonded contact (default), both
use KEYOPT(12)=5 and
CONTA175 elements
KEYOPT(9)=1.
For surface faces in contact with

other faces, standard surface-to-
surface contact is used, namely
CONTA174 and TARGE170 TARGE170 elements
February 2, 2004
Inventory #002010

Spot welds provide a means of connecting shell assemblies
at discrete points for heat transfer
Although the ANSYS DesignSpace licenses support structural
spot welds, these do not support thermal spot welds.
Spotweld definition is done in the CAD software. Currently,
only DesignModeler and Unigraphics define spotwelds in a
manner that Design Simulation supports.
Spotwelds can also be created in
Design Simulation manually, but
only at discrete vertices.

DesignSpace Entra
DesignSpace Structural
DesignSpace
Professional x
Structural
DesignModeler x
Pro/ENGINEER
Unigraphics x
SolidW orks
Inventor
Solid Edge
Mechanical Desktop
CATIA V4
CATIA V5 February 2, 2004
ACIS (SAT) Inventory #002010
Parasolid
IGES 6-24

Internally, spot welds are defined as a set of LINK33
elements. The spot weld is defined with one link element,
and the top and bottom of the spot weld is connected to the
shell or solid elements with a spider web of multiple links.
The LINK33 elements use
same thermal conductivity
as underlying materials but
with a circular cross-section
with radius=5*thickness of
underlying shells
Figure on right shows two
spot welds between two sets
of shell elements, which are
made translucent for clarity.
February 2, 2004
Inventory #002010
C. Loads Training Manual

There are three types of loads in thermal analyses:
Heat Loads:
These loads pump heat into the system.
Heat loads can be input as a known heat flow rate or heat flow rate
per unit area or unit volume.
Adiabatic Condition:
This is the naturally-occurring boundary condition, where there is
not heat flow through the surface.
Thermal Boundary Conditions:
These boundary conditions act as heat sources or heat sinks with
a known temperature condition.
These can be either a prescribed temperature or a convection
boundary condition with a known bulk temperature.

DesignSpace Entra x
Professional x
Inventory #002010
Structural
Heat Loads Training Manual

Heat Flow:
A heat flow rate can be applied to a vertex, edge, or surface.
The load gets distributed for multiple selections.
Heat flow has units of energy/time (i.e., power).
Heat Flux:
A heat flux can be applied to surfaces only.
Heat flux has units of energy/time/area (i.e., power/area)
Internal Heat Generation:

An internal heat generation rate can be applied to bodies only.
Heat generation has units of energy/time/volume
A positive value for heat load will add energy to the system.
Also, if multiple loads are present, the effect is cumulative.
DesignSpace Entra x
Professional x
Inventory #002010
Structural
Adiabatic Conditions Training Manual

Perfectly Insulated:
Perfectly insulated condition is applied to surfaces
Can be thought of as a zero heat flow rate loading
This is actually the naturally-occurring condition in thermal
analyses, when no load is applied.
Usually, one does not need to apply a perfectly insulated condition
on surfaces since that is the natural behavior for a regular surface.
Hence, this loading is meant to be used as a way to remove
loading on specified surfaces. For example, it may be easier for a
user to apply heat flux or convection on all surfaces, then use the
perfectly insulated condition to selectively remove the loading on
some surfaces (such as those in contact with other parts).

DesignSpace Entra x
Professional x
Inventory #002010
Structural
Thermal Boundary Conditions Training Manual

Thermal boundary conditions present a known local or
remote temperature condition.
At least one type of thermal boundary condition must be present.
Otherwise, the steady-state temperature will be infinite if only heat
is pumped into a system!
Also, Given Temperature or Convection load should not be applied
on surfaces that already have another heat load or thermal
boundary condition applied to it.
If applied on an entity which also has a heat load, the
temperature boundary condition will override.
Perfect insulation will override thermal boundary conditions.
Given Temperature:
This imposes a temperature on vertices, edges, or surfaces.
Temperature is the degree of freedom solved for, but this fixes
the temperature on selected entities to a given value.
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Convection:
Applied to surfaces only.
Convection relates a ambient temperature with the surface
q hATsurface Tambient
temperature:
where the convective heat flux q is related to a film coefficient

h, the surface area A, and the difference in the surface
temperature Tsurface & ambient temperature Tbulk.
Meant to provide a simplified way of accounting for heat
transport from a fluid. h and Tbulk are user-input values.
The film coefficient h can be constant or input from a file (next)

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Temperature-Dependent Convection (continued):
If film coefficent h is input from a file, this can be a constant or
temperature-dependent value h(T).
Select the Engineering branch and use the Convection toolbar to
add or create a new convection file.
Determine what temperature is used for h(T) first, for temperature-
dependent film coefficients. Temperature can be:
Average film temperature
T=(Tsurface+Tbulk)/2
Surface temperature
T= Tsurface
Bulk temperature
T= Tbulk
Difference of surface and
Select the temperature-
bulk temperatures
dependency from the
T=(Tsurface-Tbulk) pull-down menu
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Temperature-Dependent Convection (continued):
After the type of temperature-dependency is selected, the user
may select the Film Coefficient vs. Temperature branch on the
Outline Tree to input the film coefficients and temperatures in a
table. The values are plotted on a graph, as shown below.
If any temperature-dependent convection load is

applied, this will result in a nonlinear solution
since the surface temperature is solved for, but
the film coefficient h is based on a function of the
surface temperature.
The only exception is if the film coefficient h is
based on a function of the bulk temperature only.
In Design Simulation, the bulk temperature is
constant and input by the user, so this load will
not be nonlinear.

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Thermal Loads in ANSYS Training Manual

The internal representation of loads in ANSYS:
Heat flow for an edge or vertex is a heat flow rate (F,,HEAT)
Heat flux or heat flow for a surface is surface load (SF,,HFLUX)
Internal heat generation is applied as a body load (BFE,,HGEN)
Given temperature is applied as a constraint (D,,TEMP)
Perfectly insulated condition internally removes any loads
applied in Design Simulation on those surface(s).
Convection is defined by surface effect SURF152 elements
Bulk temperature and film coefficient is applied on the surface
effect elements (SF,,CONV,film,bulk)
If temperature-dependent film coefficients exist, these are defined
with a temperature-dependent HF material property (MPDATA,HF).
The film coefficient value applied will be HF_number, and
ANSYS knows to use the referenced HF material property number.
KEYOPT(8) is set to be consistent with temperature evaluation of
h(T), such as evaluate h(T) based on surface temperature.
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Thermal Loads Summary Training Manual

For some structural users, it may be useful to provide an
analogy of structural and thermal analyses:
Structural Thermal
Natural Condition No external force Perfectly Insulated
(No heat flow rate)
Boundary Direct Given Displacement Given Temperature
Conditions Indirect Convection
Load Direct Force Heat Flow
Per Area Pressure Heat Flux
Per Volume Thermal Expansion Internal Heat Generation
Inertial Loa ds Acceleration
There are some types of loads that do not have any analogy
There is no thermal equivalent for inertial loads such as rotational
velocity or acceleration
The analogy of convective boundary condition is a foundation
stiffness support in structural terms, similar to a grounded spring
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D. Solution Options Training Manual

Solution options can be set under the Solutions branch:
The ANSYS database can be saved if Save
ANSYS db is set
Useful if you want to open a database in ANSYS
Two solvers are available in Design Simulation
The default solver is automatically chosen. In
thermal analyses, the user usually does not need
to change the solver type.
The Iterative solver can be efficient for solving
large models whereas the Direct solver is a
robust solver and handles any situation.
The ability to change the default solver is under
Tools > Control Panel > Solution > Solver Type
The Weak Springs and Large Deflection
options are meant for structural analyses only,
so they can be ignored for a thermal analysis.
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Informative settings show the user the status of the analysis:
For a regular thermal analysis, the Analysis Type
will be set to Static Thermal. If structural
supports and results are present, then the
analysis type will be Thermal Stress.
A nonlinear solution will be required if
temperature-dependent (a) material properties or
(b) convection film coefficients are present. This
means that several internal iterations will be run
to achieve heat equilibrium.
The solver working directory is where scratch files
are saved during the solution of the equations.
By default, the TEMP directory of your Windows
system environment variable is used, although this
can be changed in Tools > Control Panel >
Solution > Solver Working Directory.
Any solver messages which appear after
solution can be checked afterwards under
DesignSpace Entra x Solver Messages
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To solve the model, request results first (covered next) and
click on the Solve button on the Standard Toolbar
By default, two processors (if present) will be used for parallel
processing. To set the number of processors, use Tools >
Control Panel > Solution > Number of Processors to Use
Recall that under Worksheet tab of the Solution branch,
the details of the solution output can be examined.

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To perform a thermal-stress solution, simply add structural
support(s) and request structural results, then solve the
model.
Structural loads are optional but can also be added.
Design Simulation will know that a thermal-stress analysis is
to be performed (under Details view of the Solution branch).
The following will be performed automatically:
A steady-state thermal analysis will be performed
The temperature field will be mapped back onto the structural
model
A structural analysis will be performed
See Chapter 4 for details on Structural Analyses
Design Simulation automates this type of coupled-field
solution, so the user does not have to worry about the above
details.
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Solution Options in ANSYS Training Manual

The solver selection for direct vs. iterative:
The solvers used are either the direct sparse solver
(EQSLV,SPARSE) or the PCG solver (EQSLV,PCG)
The JCG solver is not used in thermal analyses
A simplified discussion between the two solvers:
If given the linear static case of [K]{x} = {F}, Direct solvers factorize [K] to
solve for [K]-1. Then, {x} = [K]-1{F}.
This factorization is computationally expensive but is done once.
Iterative solvers use a preconditioner [Q] to solve the equation [Q][K]{x} =
[Q]{F}. Assume that [Q] = [K]-1. In this trivial case, [I]{x} = [K]-1{F}. However,
the preconditioner is not usually [K]-1. The closer [Q] is to [K]-1, the better the
preconditioning is, and this process is repeated - hence the name, iterative
solver.
For iterative solvers, matrix multiplication (not factorization) is performed. This is
much faster than matrix inversion if done entirely in RAM, so, as long as the number
of iterations is not very high (which happens for well-conditioned matrices), iterative
solvers can be more efficient than sparse solvers.
The main difference between the iterative solvers in ANSYS PCG, JCG, ICCG is
the type of pre-conditioner used.
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Solver working directory:
The ANSYS input file is written as ds.dat in the solver
directory. The output file is solve.out and can be viewed in
the Worksheet tab of the Solution branch.
ANSYS is executed in batch mode (-b) as a separate process.
During solution, the results file .rst is written. The results are
also read in and XML results files are generated in batch
mode. The XML files are then read into Design Simulation.
All associated ANSYS files have default jobname of file and
are deleted after solution, unless changed in Tools > Control
Panel > Solution > Save Ansys Files.
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Some solution options are also defined:
Solution control is used
This is different from structural analyses in Design Simulation
where Solution Control is turned off
ANSYS shape checking is turned off (SHPP,OFF)
If nonlinear, the number of substeps (NSUBST,1,10,1) and
number of equilibrium iterations (NEQIT,20) are defined
CNVTOL also set, where minimum reference heat flow rate is
defined as 1e-6 W
Only Design Simulation-supported results is output with
OUTRES, not everything by default
Results are later written to XML files in /POST1, which are then
read back into Design Simulation. Hence, Design Simulation does
not directly read the results from the .rth file
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E. Results and Postprocessing Training Manual

Various results are available for postprocessing:
Temperature
Heat Flux
Reaction Heat Flow Rate
In Design Simulation, results are usually requested before

solving, but they can be requested afterwards, too.
If you solve a model then request results afterwards, click on
the Solve button , and the results will be retrieved. A
new solution is not required for retrieving output of a solved
model.
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Temperature Training Manual

Temperature contour plots can be requested:
Temperature is the degree of freedom solved for,
and it is the most basic output request.
Temperature is a scalar quantity and, therefore,
has no direction associated with it.

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Heat Flux Training Manual

Heat flux contour or vector plots are available:
Heat flux q is defined as
q KXX T
and is related to the thermal gradient T. The heat flux output
has three components and can aid the user in seeing how the
heat is flowing.
The magnitude plotted as contours: Total Heat Flux
The magnitude & direction as vectors: Vector Heat Flux
Recall that wireframe is best for viewing vectors
Components of heat flux
can be requested with
Directional Heat Flux
and can be mapped on
any coordinate system.
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Reaction Heat Flow Rate Training Manual

Reaction heat flow rates is available for any Given
Temperature or Convection boundary condition
Recall that both given temperature and convection supply a
known temperature, either directly or indirectly. Hence, this
acts as a heat source/sink, and the amount of heat flowing in
(positive) or out (negative) of the support can be output.
For each individual Given Temperature or
Convection load, the Reaction heat flow rate
is printed in the Details view after a solution.

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Reaction Heat Flow Rate Training Manual

The Worksheet tab for Environment branch has a
tabular summary of reaction heat flow rates.
If a thermal support shares a vertex, edge, or surface with
another thermal support or load, the reported reaction heat
flow rate may be incorrect. This is due to the fact that the
underlying mesh will have multiple supports applied to the
same nodes. The solution will still be valid, but the reported
values may not be accurate because of this.

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F. Workshop 6 Training Manual

Workshop 6 Thermal Analysis
Goal:
Analyze the pump housing shown below for its heat transfer
characteristics.
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Chapter 10
Coupled Field Analysis

(with Emphasis on Thermal-Stress)
What is a Coupled-Field Analysis? Training Manual
HEAT TRANSFER 5.7

A Coupled-Field analysis is one in which the interaction (coupling) between
two or more types of phenomena (fields) is considered. Such analyses may
involve direct or indirect coupling of fields.
This is a list of ANSYS elements
When performing a directly coupled that can be used in direct coupled
analysis, DOF from multiple fields field analyses. Not all elements
have thermal DOF.
(e.g., thermal-electric) are computed
simultaneously. This is called the
Direct Method and is only necessary
when the individual field responses of
the model are dependent upon each
other. Directly coupled analyses are
usually nonlinear since equilibrium
must satisfied based on multiple
criteria. With more DOF active per
node, matrix equations are larger and
more costly to analyze than for single-
field models of comparable size.
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What is a Coupled-Field Analysis?
(continued) Training Manual
HEAT TRANSFER 5.7

An indirectly coupled analysis involves the solution of single-field
models in a particular sequence. The results of one analysis are
used as loads for the following analysis. This is also known as the
Sequential Method of coupled analysis.
This method of analysis is applicable when there is one-way
interaction between fields. For example, the field response of a
system (e.g., thermal) may significantly influence the response of
the system to another field (e.g., structural) but not vice-versa. This
method is usually more efficient than the Direct Method, and it does
not require use of special elements.
In this chapter we will only discuss coupling that involves thermal
phenomena. Be aware that some ANSYS products do not support
all kinds of coupled-field element types and analysis options. For
example, the ANSYS Thermal product only supports Thermal-
Electric direct coupling. Refer to the on-line Coupled-Field Analysis
Guide for more information.
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Direct Method - Examples Training Manual
HEAT TRANSFER 5.7

In the context of convection options presented in Chapter 7, the
FLUID66 and FLUID116 thermal-fluid elements were introduced.
These elements featured temperature and pressure DOF, qualifying
them as directly coupled-field elements.
ANSYS has other coupled-field elements which feature combinations
of structural, thermal, electrical, and magnetic DOF. Most practical
problems involve interaction of only a few fields. Here are some
common examples of direct coupled field analysis involving thermal
phenomena:
Thermal-Structural: Hot Rolling of Aluminum Sheet

Temperature of sheet effects elastic-
plastic material properties and thermal
strains.
Mechanical and thermal loads produce

large strains in sheet. New thermal
analysis must be performed to account
for shape change.
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Direct Method - Examples (continued) Training Manual
HEAT TRANSFER 5.7

Thermal-Electromagnetic: Induction Heating of a Steel Billet
An induction coil generates a

magnetic field around the billet. This
field induces an alternating current
within the billet resulting in Joule
heating.
The billet experiences a significant

rise in temperature due to the heating.
Because of the extreme variation in
temperature encountered, the
For a harmonic magnetic analysis such as this, once
temperature-dependence of the
the magnetic vector potential {A} has been solved resistively and relative permeability of
for, the current density vector {J} can be computed.
This is used with resistivity to compute Joule
the billet must be accounted for.
heating in the matrix equivalent of this simple A-C Consequently, the strength and
circuit relationship: 2
I max R direction of the magnetic field
Q j RMS Power
2 changes.
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Direct Method - Preprocessing Training Manual
HEAT TRANSFER 5.7

When preprocessing for a direct coupled-field analysis, remember
the following:
Use coupled-field elements with the appropriate DOF set for the fields
involved. Single-field elements may be used in parts of the model
where coupling is not needed.
Closely study element options, material properties and real constants
for each element type. Coupled-field elements typically have more
limitations than comparable single-field elements (e.g., the PLANE13
does not permit mass transport of heat as does the PLANE55, the
SOLID5 does not permit plasticity or creep as does the SOLID45).
Use consistent units across all fields. For example, when performing
a thermal-electric analysis do not use Btu/s when electrical power
unit is expressed in Watts (Joules/s).
Due to the iterative solution required, thermal coupled-field elements
are not suitable for use within substructures.
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Direct Method - Loading, Solution, and
Training Manual
Postprocessing
HEAT TRANSFER 5.7

When loading, solving, and postprocessing a direct coupled-field model
remember the following:
If a Transient analysis type is selected for coupled-field elements with
temperature DOF:
Transient thermal effects can be modeled by all coupled-field element
types.
Transient electrical effects (capacitance, inductance) are not accounted
for in thermal-electric analyses (i.e., only TEMP and VOLT DOF active).
Coupled-field elements with magnetic vector potential DOF can model
transient magnetic events (e.g., SOLID62). Elements with scalar
potential DOF can only simulate static events (SOLID5).
Study the DOF set and allowable types of loads for each element. Coupled-
field elements allow multiple types (D, F, SF, BF) of loads to be applied at the
same location (node, element face, etc.).
Coupled-field analyses can be highly nonlinear. Consider using the Predictor
and Line Search features to enhance convergence.
Consider using the Multi-Plots feature to display results from different fields
in different windows at the same time.
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Sequential Method Training Manual
HEAT TRANSFER 5.7

The Sequential Method is used to solve indirect coupled-field analysis.
Recall that it involves performing two single-field analyses sequentially
(rather than simultaneously) with the results from the first analysis used as
loads for the second analysis. For example:
Many problems involve significant

thermal-to-structural coupling
Thermal Structural (temperatures cause thermal expansion)
But not Vice-Versa
Thermal Structural the structural-to-thermal coupling is

negligible (strains are small enough that
original thermal solution is unaffected)
When applicable, this approach is usually more desirable than a direct

coupled-field analysis since single-field elements can be used and no
multi-field iteration is required.
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Sequential Method - Examples Training Manual
HEAT TRANSFER 5.7

Here are some common examples of indirect
coupled field analysis involving thermal
phenomena which can be solved using the
Airfoil
sequential method:
Thermal-Structural:
Turbine Blade Attachment Analysis
Platform Temperatures in blade and disk produce

thermal expansion strains. This has
significant impact on stresses.
Root Since strains are small and contact

regions have flat-on-flat geometry,
temperature solution does not have to
be updated.
Disk This kind of analysis is known as a Thermal-Stress analysis. This very

Sector common form of analysis is discussed in more detail later in the Chapter.
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Sequential Method - Examples (continued) Training Manual
HEAT TRANSFER 5.7

Thermal-Electric:
Electrical Heater Embedded in a Glass Plate
An electrical heater embedded in a

thin glass plate has current flowing
through it. This causes Joule
heating within the wire.
The wire and plate experience a rise

in temperature due to the heating.
Because the temperature variation
+V- in the system is not large, the
temperature-dependence of the
Once the voltage {V} has been solved for, it is resistively can be ignored. As a
used with resistivity to compute Joule heating
using the matrix form of this2simple equation:
V
result, the current does not change.
Q j Power
R
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Sequential Method - Procedures Training Manual
HEAT TRANSFER 5.7

There are two basic ways to perform sequential coupled-field
analysis in ANSYS. They are primarily differentiated with regard to
how characteristics from each field are represented:
Physics Environment Approach - One central database is built for use
with all fields. Multiple physics environment files are written describing
characteristics of each field individually.
Manual Method - Multiple databases are created and stored, one for
each field to be studied. All characteristics of an individual field are
stored in database.
We will discuss each of these approaches and their respective
advantages in the following viewgraphs.
Note: The sequential method can use the final analysis results to
loop back to the initial analysis. This is normally accomplished
manually by the analyst.
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Physics Environments Training Manual
HEAT TRANSFER 5.7

To help automate sequential coupled-field analyses, ANSYS allows the
user to define several Physics Environments for a single model. A
Physics Environment represents the model characteristics necessary to
completely describe the behavior of single field. A Physics Environment
File is ASCII-formatted and contains the following information:
Element Types and Options Analysis and Load Step Options
Nodal and Element Coordinate Systems Loads and Boundary Conditions
Coupled Sets and Constraint Equations GUI Preferences and Title
When building a database for use

with physics environments, you Be careful when using
must select element types with degenerate element
shapes. Element types
characteristics that are with similar base
compatible across physics configurations do not
environments. For example 8- no always support the
same degenerate
noded thermal brick elements are shapes.
compatible with 8-noded
yes
structural brick elements, not 10-
noded structural tets:
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Physics Environments (continued) Training Manual
HEAT TRANSFER 5.7

In addition to similar element order (e.g., shape function polynomial)
and shape, most elements require similar element options (e.g.,
axisymmetric vs. planar 2-D Solids) for compatibility. However,
some types of loads do not require complete compatibility between
environments. For example, 8-noded thermal solids may be used to
supply temperatures for 20-node structural brick elements. Some
elements require special keyoption settings to be compatible with
elements of dissimilar order.
Element attribute numbering (MAT, REAL, TYPE) must be consistent
from environment to environment.
Use the Null Element Type (type # zero) for regions which do not
participate in a particular physics environment (e.g., magnetic
analysis requires modeling of air around objects whereas thermal
and structural do not).
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Physics Environments (continued) Training Manual
HEAT TRANSFER 5.7

Also, make sure the mesh discretization is acceptable for capturing
results you want from ALL physics environments. For example:
This mesh density might be . . . This mesh density is required

suitable for obtaining temperatures to obtain stresses of comparable
in a thermal analysis, but . . . accuracy in a structural analysis
The Physics Environment approach allows up to 9 environments be

defined for a single model. This approach is usually best when
more than two field interactions are to be considered or when the
use of separate databases for each field is infeasible. For more
information about the Physics Environment approach to indirect
problems, refer to Chapter 2 of the on-line Coupled Field Analysis
Guide.
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Thermal-Stress Analysis Training Manual
HEAT TRANSFER 5.7

In the remainder of this Chapter, we will consider what is probably the most
common form of indirect coupled-field analysis; Thermal-Stress analysis.
Thermal-Stress analysis is considered to be an indirect problem because
temperatures from the thermal analysis contribute significantly to the strains
and stresses in the structural analysis, but the structural response of the
model does not strongly impact the thermal solution.
Since thermal-stress analysis involves the sequential interaction of only two
fields, we will use the Manual Method (MM) of sequential coupling rather
than the more elaborate Physics Environment Method (PEM) described
previously. Here are some advantages and disadvantages to the MM:
Advantages to MM:
There are fewer restrictions when building thermal and structural models. For example, the
attribute numbering and mesh discretization may be different for thermal and structural models.
PEM requires same model be used for all.
MM utilizes simplified, robust approach which has been supported by ANSYS and used by
customers for many years.
Disadvantages to MM:
You must maintain both thermal and structural databases and results files. This increases the
amount of disk space required as compared with the single model approach employed by the
PEM.
MM may be cumbersome if you wish to consider interactions with other fields later.
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General Procedure Training Manual
HEAT TRANSFER 5.7

In a Thermal-Stress analysis, Nodal Temperatures from the thermal
solution are used as Body Loads in the structural analysis.
When using the Manual Method of sequential solution there are
two options for applying thermal nodal temperatures to structural
elements. The choice between them depends on whether or not
the thermal and structural models utilize similar meshes:
1 If meshes used for thermal and structural analyses have the SAME
node numbering . . .
The thermal model is automatically Thermal temperatures are read directly

converted to structural by means of the from the thermal results file and applied to
ETCHG command (see table for the structural model using the LDREAD
corresponding element types). command.
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General Procedure (continued) Training Manual
HEAT TRANSFER 5.7

If meshes used for the thermal and structural analyses have
2 DIFFERENT node numbering . . .
Structural mesh is created apart from thermal model using mesh
discretization that is optimized for capturing structural results.
Structural body loads are mapped from the thermal analysis
temperature distribution. This involves a more elaborate procedure
which makes use of the BFINT command to interpolate thermal
results (not available for use with Physics Environments).
The next viewgraph provides a comparison of the procedures when

using the same or different meshes.
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Thermal-Stress Analysis Flow Chart Training Manual
HEAT TRANSFER 5.7

No
5a. Clear thermal Upper and
BEGIN Same (Option 2) lower case
mesh and build letters are used
Mesh?
structural model to differentiate
Options 1 and
Yes 2 in Step 5
1. Build, load, and
(Option 1)
solve thermal model 5b. Write node file
5A. Convert thermal (NWRITE) and save
model to structural structural model
(ETCHG)
2. Postprocess to
identify temps for
structural 5c. Resume thermal
model and perform
5B. Read in temp interpolation
temperature loads (BFINT)
3. Set GUI (LDREAD)
preferences, change END
jobname and delete 5d. Resume
thermal loads, CEs, structural model
CPs and read in body 9. Postprocess
load file (/INPUT) results
4. Define structural 6. Specify analysis 7. Specify reference

material properties type, analysis temperature and 8. Save and
options, and load apply other Solve
step options structural loads.
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Detailed Procedure Training Manual
HEAT TRANSFER 5.7

The following is a step-by-step presentation of the thermal-
stress analysis Flow Chart presented on the previous
viewgraph.
3a
1. Build thermal model and perform
a transient or steady-state thermal 1
analysis to solve for temperatures
2
at nodes.
2. Review thermal results and
identify time-points (or load
steps/substeps) with critical
temperature gradients.
3a. Set GUI preferences to
Structural and Thermal. 3b
3b. Change the Jobname
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Detailed Procedure (continued) Training Manual
HEAT TRANSFER 5.7

3c. Delete all thermal Loads
3d. Delete Coupled Sets and
Constraint Equations
3c
3d
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HEAT TRANSFER 5.7

4. Define structural material properties including the mean (not
instantaneous) coefficient of thermal expansion (ALPX).
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HEAT TRANSFER 5.7

The next two viewgraphs (Steps 5A and 5B) assume that the
thermal mesh will be used again in the structural model
(Option 1).
5A. Change element types from thermal to structural (ETCHG
command):
5A
Check real constants and verify element

options are correct for the new element types
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HEAT TRANSFER 5.7

5B. Apply temperature body loads from thermal analysis (LDREAD command):
Identify result by
time or substep
5B Identify thermal
results file
9. Solve current load step

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HEAT TRANSFER 5.7

The next six viewgraphs (Steps 5a-5d) assume that the
thermal mesh will not be used again in the structural model
(Option 2).
5a. Clear thermal mesh . . .
Delete thermal element

types and define structural
element types . . .
Change meshing controls

and mesh structural model.
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HEAT TRANSFER 5.7

5b. Select all nodes for which temperature body loads are to
be defined and write a node file.
Specify name of
node file to write
5b
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HEAT TRANSFER 5.7

5c. Save structural model, change
jobname back to the thermal jobname,
resume thermal database . . .
enter the General Postprocessor . . .
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HEAT TRANSFER 5.7

Read in desired results set, and . . .
Initiate body load interpolation:
Name of node file
Name of load
file to write
Used for writing
multiple load files
Use solid-to-solid
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Extrapolation with BFINT Training Manual
HEAT TRANSFER 5.7

There may be situations where the thermal mesh and structural mesh do
not occupy the same exact regions of space. In such cases, ANSYS will
extrapolate body loads to structural nodes falling outside the perimeter of
the thermal model.
Using the default tolerance,
EXAMPLE: When the structural mesh includes these two nodes would not
a fillet which is not present in the thermal be assigned a load
model, some nodes may fall outside the
perimeter of the thermal model. If the fillet is Structural Mesh
large enough and the thermal model fine Perimeter
enough, loads may not be written for some
structural nodes in the fillet region. Thermal Mesh
The default proximity criterion used to determine if a structural node is

close enough for extrapolation is 0.5 times the half-width of the nearest
thermal element edge. An undocumented feature was introduced at Rev.
5.4 to allow user control of this tolerance:
BFINT, Fname1, Ext1, Dir1, Fname2, Ext2, Dir2, KPOS, Clab, KSHS, EXTOL
There is no GUI support for the undocumented extra field. Consequently,
the command must be entered manually in the Input Window.
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HEAT TRANSFER 5.7

5d. Exit the General Postprocessor, change the
jobname back to the structural jobname,
resume the structural database . . .
enter Solution . . .
And read input from body load file

to apply temperature loads:
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HEAT TRANSFER 5.7

6a
6a. Define structural analysis type 6b

(default is static)
6b. Specify analysis options (e.g.,

solver choice)
6c. Specify load step options

(e.g., output controls)
6c
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HEAT TRANSFER 5.7

7a. Set the strain free reference
temperature for thermal expansion
calculations (TREF):
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HEAT TRANSFER 5.7

7b. Apply other
structural loads.
7b
9. Postprocess 9
results:
8. Save model and
Solve current
load step.
8
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Module 7
Thermal-Stress Analysis
Thermal-Stress Analysis Training Manual
INTRODUCTION TO ANSYS 5.7 - Part 1

In this chapter, we will briefly describe how to do a thermal-
stress analysis.
The purpose is two-fold:
To show you how to apply thermal loads in a stress analysis.
To introduce you to a coupled-field analysis.
Topics covered:
A. Overview
B. Sequential
C. Direct
D. Workshop
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A. Overview Training Manual

Thermally Induced Stress
When a structure is heated or cooled, it
deforms by expanding or contracting.
Thermal stresses
If the deformation is somehow restricted due to constraints
by displacement constraints or an
opposing pressure, for example
thermal stresses are induced in the
structure.
Another cause of thermal stresses is
Thermal stresses
non-uniform deformation, due to different due to different
materials (i.e, different coefficients of materials
thermal expansion).
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Overview Training Manual

There are two methods of solving thermal-stress
problems using ANSYS. Both methods have their
advantages.
Sequential coupled field
- Older method, uses two element types mapping
thermal results as structural temperature loads
+ Efficient when running many thermal transient time
points but few structural time points
+ Can easily be automated with input files
Direct coupled field
+ Newer method uses one element type to solve both
physics problems
+ Allows true coupling between thermal and structural
phenomena
- May carry unnecessary overhead for some analyses
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B. Sequential Method Training Manual

The Sequential method involves two analyses:
1. First do a steady-state (or transient) thermal

analysis. Thermal
Model with thermal elements. Analysis
Apply thermal loading.
jobname.rth
Solve and review results.
2. Then do a static structural analysis.
Switch element types to structural. Temperatures
Define structural material properties,
including thermal expansion coefficient. Structural
Apply structural loading, including Analysis
temperatures from thermal analysis.
Solve and review results. jobname.rst
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1. Thermal Analysis
The procedure for this is described in Chapter 6.
2. Structural Analysis
a) Move to PREP7 and switch element types from thermal to
structural.
Preprocessor > Element Type > Switch Elem Type
Or ETCHG command
Caution: Switching element types will reset all element options
back to their default settings. For example, if you used 2-D
axisymmetric elements in the thermal analysis, you may need to
respecify the axisymmetric option after the switch. Therefore,
be sure to verify and set the proper element options:
Preprocessor > Element Type > Add/Edit/Delete > [Options]
Or use ETLIST and KEYOPT commands
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b) Define structural material properties (EX, etc.), including the
coefficient of thermal expansion (ALPX). (If you use the ANSYS-
supplied material library, both thermal and structural properties
will be defined, so this step may not be needed.)
Note: If ALPX is not defined or set to zero, no thermal strains
will be calculated. You can use this technique to turn off
temperature effects!
c) Specify static analysis type. This step is needed only if the
thermal analysis was a transient.
Solution > -Analysis Type- New Analysis
Or ANTYPE command
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d) Apply structural loads and include temperatures as part of the
loading.
Solution > -Loads- Apply > -Structural- Temperature > From
Therm Analy
Or use the LDREAD command.
e) Solve.
f) Review stress results.
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C. Direct Method Training Manual

The Direct Method usually involves just one analysis that uses a coupled-
field element type containing all necessary degrees of freedom.
1. First prepare the model and mesh using one

of the following coupled field element types.
PLANE13 (plane solid). Thermal
SOLID5 (hexahedron). Analysis
SOLID98 (tetrahedron). Combined
2. Apply both the structural and thermal loads
and constraints to the model. Structural
3. Solve and review both thermal and Analysis
structural results.
jobname.rst
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Sequential vs. Direct Training Manual

Sequential Direct
For coupling situations which Direct coupling is
do not exhibit a high degree of advantageous when the
nonlinear interaction, the coupled-field interaction is
sequential method is more
efficient and flexible because highly nonlinear and is best
you can perform the two solved in a single solution
analyses independently of using a coupled formulation.
each other. Examples of direct coupling
In a sequential thermal-stress include piezoelectric analysis,
analysis, for example, you can conjugate heat transfer with
perform a nonlinear transient fluid flow, and circuit-
thermal analysis followed by a electromagnetic analysis.
linear static stress analysis.
You can then use nodal
temperatures from ANY load
step or time-point in the
thermal analysis as loads for
the stress analysis.
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D. Workshop Training Manual

Refer to your Workshop Supplement for instructions on:
W4a. Axisymmetric Pipe with Fins (Sequential Coupled Fileld)
W4b. Axisymmetric Pipe with Fins (Direct Coupled Field)
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Chapter 2

ANSYS Workbench Simulation

The capabilities described in this section are generally

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Material nonlinearities: A nonlinear stress-strain

Contact: Include effects of contact is a type

ANSYS Workbench Simulation

It is important to remember these assumptions related to

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Equilibrium iterations are the corrective

ANSYS Workbench Simulation

Many more advanced nonlinear features are not available

ANSYS Workbench Simulation

ANSYS Workbench Simulation

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS License Availability

ANSYS Workbench Simulation

In general, face-to-face contact for solid bodies is the only

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Two unique items for loads and supports in large-deflection

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS Workbench Simulation

The Pretension Bolt Load is applied in the center of the

The Adjustment and Working Load can be reviewed

ANSYS Workbench Simulation

This section will review some basics of plasticity by

ANSYS Workbench Simulation

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Engineering vs. True Stress-Strain:

ANSYS Workbench Simulation

ANSYS Workbench Simulation

A common yield criterion is the von Mises yield criterion

ANSYS Workbench Simulation

2 Principal Stress Space

ANSYS Workbench Simulation

Yield Surface after Loading

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Note that the subsequent

ANSYS Workbench Simulation

ANSYS Workbench Simulation

ANSYS Workbench Simulation

Metal plasticity is available as a nonlinear material model.

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS License Availability

ANSYS Workbench Simulation

ANSYS Workbench Simulation

ANSYS Workbench Simulation

To return to the general material property display use the

ANSYS Workbench Simulation

The yield strength is the value at

ANSYS License Availability

ANSYS Workbench Simulation