FENET Copenhagen Feb2002 DLE Konter PDF

Netherlands Institute
for Metals Research
Finite Element Modelling of contact

phenomena in structural analysis
Albert Konter
for Metals Research
NIMR College NAFEMS Contact Workshop: 1

Netherlands Institute for Metals Research
for Metals Research
www.nimr.nl
NIMR College NAFEMS Contact Workshop: NIMR 2

for Metals Research
Welding
Sysweld
www.nimr.nl

for Metals Research
Steel production
MSC.Marc
www.nimr.nl

for Metals Research
Aluminium production
MSC.Marc
www.nimr.nl

for Metals Research
Fundamentals of forming
cutting process
www.nimr.nl

for Metals Research
Sheet metal forming
DiekA
A Benchmark on Hydro Mechanical forming shows

that modelling contact/friction is still a critical issue

Contents
for Metals Research
• Overview of contact analysis using FE

• Contact comparisons
– MSC.MARC & Abaqus
• Seminar themes
– FE contact benchmarks
– difficulties by FE users in modeling contact problems
– current limitations of commercial FE codes
– desirable contact features not currently offered by FE software
– need for further research in application of contact problems
• Concluding remarks
NIMR College NAFEMS Contact Workshop: Contents 8

Shock absorber
for Metals Research
• Rubber-steel assembly
• Self contact rubber
• Rigid steel insert
• Large deformations
NIMR College NAFEMS Contact Workshop: Some examples 9

Bio medical
for Metals Research
FE simulation experiment

Sheet metal forming
for Metals Research
deformable body
• blank
rigid bodies
• blank holder
– binder
• punch
• die
constraints
• friction
• drawbeads Optris

Bulk metal forming
for Metals Research
• thermal contact
• rigid tools
• remeshing
contact redefined
during analysis

Ship collision experiment
for Metals Research
Royal Schelde

Information for a contact analysis
for Metals Research
• what are the various contact bodies?

– can some bodies be considered as rigid?
– what is the outline of the body?
• surface description
• nodes and segments
– are the (undeformed) boundary contours curved or initially
straight?
• which bodies can contact each other during the
analysis?
• what are contact properties at the interface
– normal contact
– tangential contact
NIMR College NAFEMS Contact Workshop: Contact methodology 14
Information for a contact analysis
(continued) Netherlands Institute
for Metals Research
• Can a body get in contact with itself ?

• Is there an initial overlap (shrink fit simulations) or a
discrete clearance?
• When are nodes considered to be in contact?
– tolerance values
• If contact, how is this modelled?
– node to node
– node to segment
– segment to segment
• When are nodes considered to separate?

FEM contact phenomena
for Metals Research
1 1 1 K 2 ∆u 2 = ∆F 2 Contact description
K ∆u = ∆F
• special action needed
– non-linear springs
– contact elements
– contact procedures
• method of contact
– node to curve/surface
– node to segment
– segment to segment
K1 0   ∆u1   ∆F 1 
 ⋅
2  2 
= 2
0 K  ∆u  ∆F  careful with rigid body modes if no contact

Approaches (1)
for Metals Research
node to node contact r

n
Only if limited sliding contact

• mesh generation requires opposite nodes
• specify normal direction
• from position of nodes
• manually if nodes initially very close
NIMR College NAFEMS Contact Workshop: Approaches 17

Simplified beam model
for Metals Research
• collapse element
F
• gap element
• springs
• mass distributions
Question:
How is characteristic of collapse element determined?

Approaches (2)
for Metals Research
node to segment contact

r r
n n
r
n
Frequently applied
• line or surface segment
• allows unequal number of elements at both sides of contact surface
• problem with normal definition near corners
• nodes sliding to a next segment: additional action needed

Example node to segment contact
for Metals Research
top rigid surface is

load controlled

Example node to segment contact
for Metals Research
mesh test section
Royal Schelde
The Netherlands

for Metals Research
Motion
Motionbulb:
bulb:displacement
displacementcontrolled
controlled

Approaches (3)
for Metals Research
segment to segment contactr

n
Beam to beam contact problems

• useful if large amount of sliding present
• specify normal direction
• cross-sections can be accounted for in
closure distance determination

Beam contact
for Metals Research

Beam contact
for Metals Research
frictional forces

Surface to surface contact
for Metals Research
• surface penetrates
• contact satisfied for node with segment

Normal contact methodology
for Metals Research
• visual inspection incremental displacements occurring

during analysis of problem defined without contact
methodology and adaptation of the boundary conditions
not practical
• non-linear springs
limited application
• contact elements
academic literature
– Lagrange multipliers
– Penalty function often in finite element codes
• contact procedures MARC & Abaqus

Simple contact example
for Metals Research
Contact:
0.2
u = 0.3 ur < 0.2 no stiffness
ur = 0.2 stiffness
ur
Elastomer:
C10 = 1

Spring method
for Metals Research
Question?
• which nodes contact?
Introduce :
• 3 extra nodes
• constrain extra nodes
• 3 non-linear springs
– closure distance
– initial stiffness
F
– contact stiffness
– spring force
C closed
C open
u closure u

Deformed structure
for Metals Research
Nodal penetration
Copen = 1e − 3
Cclosed = 1

Vector plot of reaction forces
for Metals Research

Deformed structure plot
for Metals Research
Repeat with larger stiffnes
Copen = 1e − 3
Cclosed = 1e5

Vector plot of reaction forces
for Metals Research

Consequences
for Metals Research
• which stiffness
– too low penetration
– too large convergence problems
• extensions:
– normal to contact surface not constant
– direction to contact surface not constant
r r r
n u A ⋅ n − uclosure ≤ 0
A
uclosure
Solution procedures
for Metals Research
• Penalty stiffness K ⋅ ∆u = ∆F
• Lagrange multipliers K11 K12 ∆u ∆F

⋅ =
K 21 0 ∆λ 0
operate on stiffness and forces

• Constraint procedures uT = ureduced
T T
uconstrained
K rr K rc ∆ur ∆F
⋅ =
K cr K cc ∆uc 0
operate on displacements

Constraint equation
for Metals Research
typical gap function

r r r
g = ( xl − x A ) ⋅ n ≤ 0 no contact
g >0 contact
where
r
x A point for which contact has to be considered
r
xl point of intersection with surface

Lagrangian multipliers
for Metals Research
• add constraint equation through Lagrangian

multiplier
– accurate satisfaction of contact
– at the cost of extra degrees of freedom
• often direct determination of contact stresses/forces
• potentially zero’s on the diagonal matrix
Introduction of gap or contact elements
• node to node contact
• node to segment contact

Compression of circular segment
for Metals Research
closure distance is
function of position

Deformable rigid contact
for Metals Research
normal direction to surface

for each node different

Penalty stiffness
for Metals Research
• contact element with same technology as

non-linear spring
– no extra degrees of freedom
– user defined or default penalty stiffness
• high stiffness: convergence problems

sometimes overcome through damping mechanisms
• low stiffness: nodal penetration
“forgiving” for bad contact detection

Contact elements or contact procedures
for Metals Research
Aspects
contact element
• node to node contact
• sliding?
• node to segment contact

• which segment ?
gap element
• single versus double sided
contact checking

Deformable - deformable contact
for Metals Research
sliding contact:
• node to node contact ?
• node to segment contact ?

Contact procedures
for Metals Research
r
n
deformable - rigid
A
C
B
• determine normal to (moving) segment
• create local coordinate system
• apply constraint in normal direction
• prescribed displacement increment
• tangential component free or defined by friction
• make this completely automatic

Contact procedures
for Metals Research
r
n
deformable - deformable
A
C
• determine normal to segment

• create local coordinate system
• apply constraint equation in normal direction
∆v A = 12 (1 − ξ A )∆vB + 12 (1 + ξ A )∆vC
• make this completely automatic

Observations
for Metals Research
• Academic literature often concentrates on

improvement of convergence behaviour normal
contact methodology
• Commercial fe codes concentrate on improvement
of tangential behaviour
– sliding to next segment
– behaviour near corners
– multi-body contact
– improved boundary contour approximation

A typical example
for Metals Research
2 deformable solids
• circular ring rotates
• segments held fixed
Analytical solution:
• tangential displacement
function of radius
• stress free
NIMR College NAFEMS Contact Workshop: A typical example 46

2D approximation
for Metals Research
2 deformable contact bodies

1 rigid rotating contact body
“glued contact”
node in contact with wrong segment

Improved solution
for Metals Research
Remedy:
exclude segments from
automatic contact detection
Stress concentrations
due to contact with
straight segment

Smoothened contact
for Metals Research
discontinuity in smoothening

Final solution and 3D extension
for Metals Research
extension to 3D
• curve smoothening > surface smoothening
• nodes falling of segment

Friction modeling
for Metals Research
• Classical friction models

– Coulomb friction
– Shear friction
– mixture of both
• Numerical implementation
– force controlled method
– often smoothening
• Consequences for analysis
NIMR College NAFEMS Contact Workshop: Friction modelling 51

Coulomb friction
for Metals Research
• friction coefficient µ
σn
pt vr
• distributed load in opposite direction of vr : pt = µσ n
high contact pressure causes high shear load

Ring compression
for Metals Research
• inner radius 0.02 m

• outer radius 0.03 m
• height 0.01 m
• friction coefficient 0.15
• elastic-plastic with worhardening
NIMR College NAFEMS Contact Workshop: Friction example 53

Ring compression
for Metals Research
2.00E+06
1.50E+06
Force [N]
MARC_Coulomb
1.00E+06
Abaqus_Coulomb
5.00E+05
0.00E+00
0.00E+00 1.00E-03 2.00E-03 3.00E-03 4.00E-03
Displacement [m]

Shear friction
for Metals Research
• friction coefficient µ
σn
equivalent shear stress:

pt vr
kn = σ vonMises / 3
• distributed load in opposite direction of vr : pt = µkn

Ring compression
for Metals Research
2.00E+06
1.50E+06
MARC_Coulomb
Force [N]
Abaqus_Coulomb
1.00E+06
MARC_shear
Abaqus_shear
5.00E+05
Abaqus ignores
hardening in shear limit
0.00E+00
0.00E+00 1.00E-03 2.00E-03 3.00E-03 4.00E-03
Displacement [m]

Friction smoothening
for Metals Research
• Replace strong non-linearity by continuous curve
– improves convergence behaviour at the cost of modified friction

• rubber: often stick-slip model required
• metal forming: often slipping model required
– rolling analysis ????
– higher temperatures friction displays increased sticking tendency

Additional non-linearity controls
for Metals Research
• Penalty, Lagrange multiplier or constraint approach?

• When are additional nodes in contact?
• Have nodes separated?
– separation forces/stresses
• Are separating nodes in contact again?
• Have the frictional forces converged?
What default convergence criteria

have been set by the program?
NIMR College NAFEMS Contact Workshop: Solution controls 58

Quasi-static analysis (elastic-plastic)
for Metals Research
Bow shape can not be treated in Abaqus

as analytical surface
Workaround: generate surface mesh
NIMR College NAFEMS Contact Workshop: Comparison MARC and Abaqus 59

Load displacement curve
for Metals Research
Plate indent
1.00E+07
8.00E+06
6.00E+06
force
MARC
Abaqus
4.00E+06
2.00E+06
0.00E+00
0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700
displacement

Displacement along section
for Metals Research
0
0 0.5 1 1.5 2 2.5
-0.1
Abaqus/Standard ignores shell
-0.2 thickness in contact
Y displacement [m]
-0.3
MSC.MARC
Abaqus/Standard
-0.4 0.07
-0.5 0.06
-0.6 0.05
Z displacement [m]
-0.7 0.04
MSC.MARC
Distance from center [m]
Abaqus/Standard
0.03
normal 0.02
0.01
0
0 0.5 1 1.5 2 2.5
distance from center [m]
tangential
Conclusion
for Metals Research
• Within engineering accuracy:

– identical results
– small differences in node projection on surface
• Abaqus: surface of revolution
• MARC: NURB surface
Statement:
Two users and 2 fe programs: at least 3 different fe solutions
Replaced statement:
One user and 2 fe programs: one good fe solution
Requirements dynamic contact analysis
for Metals Research
• Which method for time integration?

– Explicit
• High number of steps
– Implicit
• Newmark - Beta can not sufficiently filter higher order
frequencies caused by nodes coming in contact
• Standard Houbolt does not allow time step changes
• Single step Houbolt more effective
• local assumption on velocities and accelerations
during contact
• startup conditions
NIMR College NAFEMS Contact Workshop: Dynamic contact 63

Two Stroke Engine
for Metals Research

Dynamic contact
for Metals Research
NIMR College NAFEMS Contact Workshop: Dynamic contact 65

Test section
for Metals Research

Dynamic contact analysis
for Metals Research

Dynamic impact (Newmark Beta)
for Metals Research
v = 2 m / sec
m = 4 * 25000 kg
Elastic contact
1.8
1.4
Displacement [m]
1
Bulb
Plate_center
0.6
elastic material behaviour 0.2
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

-0.2
Time [sec]
NIMR College NAFEMS Contact Workshop: Comparison of MARC and Abaqus 68

Velocities (Newmark Beta)
for Metals Research
Elastic contact
2
Velocity [m/sec]
Bulb
0
Plate center
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
-2
-4
-6
Time [sec[

Accelerations (Newmark Beta)
for Metals Research
Elastic contact
10000
8000
6000
Acceleration [m/sec2]
4000
2000
Bulb
Plate center
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
-2000
-4000
-6000
-8000
Time [sec]

Center plate displacement
for Metals Research
Elastic contact
0.05
0
0 0.2 0.4 0.6 0.8 1
Displacement [m]
-0.05 Center_MARC
Center_Abaqus
Center_Aba/Exp
-0.1 Center_Aba/damp
-0.15
-0.2
different transient operators
Time [sec]

Center plate velocities
for Metals Research
Elastic contact
1
Velocity [m/sec]
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
-1
-2
-3
-4
Time [sec]
Center_MARC Center_Abaqus Center_Aba/Exp Center_Abaqus_damp

Center plate accelerations
for Metals Research
Elastic contact
1000
800
600
400
Acceleration [m/sec2]
200
Center_MARC
0 Center_Abaqus
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Center_Aba/Exp
-200
-400
-600
-800
-1000
Time [sec]

Car boot - self contact
for Metals Research
self contact
simulation experiment
NIMR College NAFEMS Contact Workshop: Workshop themes 74

Difficulties encountered
for Metals Research
MARC Abaqus
Model file transfer between codes and interfaces hopeless

Difficulties encountered
for Metals Research
• symmetry contact surfaces

– MARC: does not handle rotation symmetry conditions
– Abaqus: not present/found
• self contact of complex shell structure
– MARC: possible but potentially expensive
– Abaqus: not possible in 3D
• subdivide body into multiple contact surfaces
– both MARC and Abaqus do not allow nodes in more than one surface
• shell to shell contact
– MARC: initially error if branched shell - fixed
– Abaqus/Standard: ignores shell thickness
– Abaqus/Explicit: includes shell thickness

Final result of comparison
for Metals Research
Reaction force versus displacement

Force Displacement (Case 1) of rigid surface
1.E+07
8.E+06
6.E+06
Force [N]
MARC
Linear buckle estimate
Abaqus
4.E+06
2.E+06
0.E+00
0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700
displacement [m]

Deformation MARC
for Metals Research
NIMR College NAFEMS Contact Workshop: Example 78

Deformation Abaqus
for Metals Research
NIMR College NAFEMS Contact Workshop: Example 79

Desirable features
for Metals Research
Basic requirements
• capability to define bodies
– rigid
– deformable
• identification of surfaces and contact nodes
• verification mechanism for contact direction
• arbitrary motion definition of rigid surfaces
• can loads (and moments) and springs be applied to
rigid surfaces?
• can contact elements be visualized?

Example
for Metals Research
incorrect contact
definition

Example
for Metals Research

Desirable features
for Metals Research
Useful requirements
• identification of nodes in contact
– initially
– during analysis
• initial contact detection
– move deformable or rigid contact bodies until
first contact
• activation or deactivation of contact
checking during load history?

Desirable features
for Metals Research
Requirements post processing

• deformed structure plotting
– animation mechanism
• display of reaction forces on rigid surfaces
• display of contact forces and stresses
• display of frictional forces and stresses
• display of slip
• display of distance to a surface
• display of nodes in contact

Needs in commercial fe software
for Metals Research
• Robustness improvement
– symmetry surfaces
– multiple body contact
– intuitive selection of best method for a specific problem
• more visualization
– error recognition
• algorithms
– improved quadratic contact
– surface smoothening
– speed of convergence for friction

Needs for further research
for Metals Research
• Academic research on new methods

in scientific papers about 6 examples
• Robustness of algorithms
– Estimate:
• MSC.Marc and Abaqus in total 2000 users worldwide
• add other general purpose and e.g. metal forming codes
• per user at least 10 contact analysis per year
– yearly at least 20000-25000 fe contact problems analyzed
– documentation: limitations are not emphasized
– trial and error by user
• experimentally verified friction models and
implementation
Benchmarking software
for Metals Research
• Analysis of existing contact examples

– requires a larger class of well defined problems
and solutions
– requires analysis by the engineer with their
specific software package
– reading of report is not sufficient Perform analyses !
Quote trainee after running NAFEMS geometric non-linear benchmarks:
“I learned that I can never believe the results of a non-linear fe analysis after the
first run; by running parameter studies I could obtain confidence in the results”

Concluding remarks
for Metals Research
• In many structural analyses contact phenomena

can not be avoided
• Commercially available f.e. codes make a contact
analysis simple and straightforward
• Current industrial applications of contact analysis
exceed the academic research applications in
complexity
– more complex benchmarks needed
• Be critical in the evaluation of the results
– errors in penetration can easily be observed
– errors in frictional forces are difficult to detect
NIMR College NAFEMS Contact Workshop: Concluding remarks 88

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Netherlands Institute

for Metals Research

Finite Element Modelling of contact

NIMR College NAFEMS Contact Workshop: 1

NIMR College NAFEMS Contact Workshop: NIMR 2

NIMR College NAFEMS Contact Workshop: NIMR 3

NIMR College NAFEMS Contact Workshop: NIMR 4

NIMR College NAFEMS Contact Workshop: NIMR 5

NIMR College NAFEMS Contact Workshop: NIMR 6

Sheet metal forming

A Benchmark on Hydro Mechanical forming shows

NIMR College NAFEMS Contact Workshop: NIMR 7

• Overview of contact analysis using FE

NIMR College NAFEMS Contact Workshop: Contents 8

• Self contact rubber

• Rigid steel insert

NIMR College NAFEMS Contact Workshop: Some examples 9

NIMR College NAFEMS Contact Workshop: Some examples 10

NIMR College NAFEMS Contact Workshop: Some examples 11

NIMR College NAFEMS Contact Workshop: Some examples 12

NIMR College NAFEMS Contact Workshop: Some examples 13

• what are the various contact bodies?

• Can a body get in contact with itself ?

NIMR College NAFEMS Contact Workshop: Contact methodology 15

NIMR College NAFEMS Contact Workshop: Contact methodology 16

node to node contact r

Only if limited sliding contact

NIMR College NAFEMS Contact Workshop: Approaches 17

NIMR College NAFEMS Contact Workshop: Approaches 18

node to segment contact

NIMR College NAFEMS Contact Workshop: Approaches 19

top rigid surface is

NIMR College NAFEMS Contact Workshop: Approaches 20

mesh test section

NIMR College NAFEMS Contact Workshop: Approaches 21

NIMR College NAFEMS Contact Workshop: Approaches 22

segment to segment contactr

Beam to beam contact problems

NIMR College NAFEMS Contact Workshop: Approaches 23

NIMR College NAFEMS Contact Workshop: Approaches 24

NIMR College NAFEMS Contact Workshop: Approaches 25

NIMR College NAFEMS Contact Workshop: Contents 26

• visual inspection incremental displacements occurring

• contact procedures MARC & Abaqus

NIMR College NAFEMS Contact Workshop: Contact methodology 27

NIMR College NAFEMS Contact Workshop: Contact methodology 28

NIMR College NAFEMS Contact Workshop: Contact methodology 29

NIMR College NAFEMS Contact Workshop: Contact methodology 30

NIMR College NAFEMS Contact Workshop: Contact methodology 31

Repeat with larger stiffnes

NIMR College NAFEMS Contact Workshop: Contact methodology 32

NIMR College NAFEMS Contact Workshop: Contact methodology 33

• Lagrange multipliers K11 K12 ∆u ∆F

operate on stiffness and forces

NIMR College NAFEMS Contact Workshop: Contact methodology 35

typical gap function

NIMR College NAFEMS Contact Workshop: Contact methodology 36

• add constraint equation through Lagrangian

NIMR College NAFEMS Contact Workshop: Contact methodology 37

NIMR College NAFEMS Contact Workshop: Contact methodology 38

normal direction to surface

NIMR College NAFEMS Contact Workshop: Contact methodology 39

• contact element with same technology as