Seminar Linear Contact Analysis Notes

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LinearContactAnalysis: Demystified
withFemapV10.1.1andNastran 7.0
AdrianJensen MechanicalEngineer Adrian.Jensen@PredictiveEngineering.com
2010 AllRightsReserved
LinearContactAnalysis:Demystified WORKINPROGRESS
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TableofContents
1. 2. Introduction......................................................66 Regions.........................................................66 a) Solids........................................ . .............66 i. BySurfaces..............................................66 ii. ByElements...................................... . .......66 b) Plates.....................................................66 i. BySurfaces...................................... . .......66 ii. ByElements...................................... . .......66 Connectors.......................................................66 Connectors 66 a) SourceTarget...................................... ...........66 Properties....................................... . ................66 a) Friction....................................... . .............66 b) ContactSearchDistance.................................. . ........66 c) InitialPenetration...............................................66 ) d) Refinement....................................... . ...........66 i. EvaluationOrder..................................... . ......66 ii. RefineSource.............................................66 e) PenaltyFactor..................................... . ...........66 i. PenaltyFactorUnits..........................................66 ii. Autovs.ManualPenaltyFactor...................................66
3. 3 4.
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Introduction
Frustrated? Usinglinearcontactcanbefrustrating.Infact,itisprobablyoneofthemostfrequentsubjectsofcallsfortechsupportstaff.But Using linear contact can be frustrating. In fact, it is probably one of the most frequent subjects of calls for tech support staff. But whenyoubreakitdownintoitsmostsimplecomponents,itdoesnthavetobefrustrating.Itcanbeaquick,easyanduseful techniqueinyourFEAtoolbox.Itallboilsdowntoelementfacesintersectingotherelementfaces.Ifyoucorrectlyspecifythe contactregionsandtheinitialcontactconditionsyouwillhavesuccesswithlinearcontactanalysis. Whatislinearcontact? Linearcontactiscalledsuchbecausethereisnogeometricormaterialnonlinearityintheanalysis.Thatis,thestiffnessmatrixis notupdatedandthematerialbehavesinalinearelasticfashion.Takeforexampleasmallsteelpunchpressingagainstasurface. Letsassumeanominalelasticmodulusof29,000,000andayieldstrengthof60,000psi.Whenthesteelreachestheyieldstress, ithasastrainof0.2%(60,000psi/29,000,000psi).Ifthatpunchwasoriginally1long,ithascompressed0.002.Onecould safelyassumethatthebehaviorofthesystemhaschangedverylittle.Whatdoesthisallmean?Forproblemswithstiff engineeringmaterials(e.g.steel)wherethematerialisnotstressedbeyondtheyieldstrength,linearcontactisareasonable engineering materials (e g steel) where the material is not stressed beyond the yield strength linear contact is a reasonable analysismechanism. Howdoesitwork? Thiswhitepaperwillcoverawiderangeoflinearcontactproblemsfromthesimpletaskofsettingupcontactregionstothe more dauntingchargeofmanuallyadjustingthepenaltyfactors.Thekeytoanylinearcontactproblemittostartsimple.Beforeyoutry g g y j g p y y y p p y y torunthat500,000nodemodelwith20contactregions,buildsmall,manageablemodelsofthedifferentcontactscenariosfor easydebugging.
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ConnectionRegions
Whenyoubreakalinearcontactproblemdownintoitsmostsimplecomponent,youhaveaConnectionRegion.Itmightseem likeanelementarystepintheanalysisbutifitisnotdonecorrectly,therewillbeproblemsthatcantbefixedbytoying withthe moreadvancedcomponentsoflinearcontact.
ConnectionRegions:Solids,bySurfaces
Theeasiestlinearcontactanalysistosetupisforasimplesolidmodelusingsurfaces.WhencreatingyourConnectionRegionby surfacesyoullnoticeanoptiontoselectthepositiveornegative.Forsolidmodels,thisoptionisnotnecessary.Ifyoucheckthe normalsofthesurfacesofthesolidbody,theyreallfacingoutward.Theoptiontomodifysurfacenormalsonlyworksforsheet solids.Additionally,evenifyoudoselectthenegativefaceofasurface,yourresultswillchangenegligibly.
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ConnectionRegions:Solids,byElements
InsomecasesyoubeunabletoselectyourConnectionRegionsbysurfaces.Theotheroptionistoselectyourregionsby elements.ThistechniquegivesyoumorecontroloverselectingyourConnectionRegion,butalsoopensupthepossibilityfor error.StarttocreateyouConnectionRegionbyselectingtheElementsradiobuttonundertheDefinedBysectionofthe ConnectionRegiondialoguebox. Assumingyoudontwanttoselectelementsonebyone,clicktheMultiplebutton.Therearetwostagestotheregionselection A i d t tt l t l t b li k th M lti l b tt Th t t t th i l ti byelements:theelementselectionandtheelementfaceselection.Theelementselectionissimple;graballelementsthathave facesyouwanttoincludeintheConnectionRegion.
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Regions:Solids,byElements
Theelementfaceselectionisabittrickier.Onceyouhaveselectedtheelementsyouwant,youarepresentedfiveoptionsforface The element face selection is a bit trickier Once you have selected the elements you want you are presented five options for face selection.Thefollowingpagesprovidesexamplesofeach. FaceID: Eachfaceofanelementhasafaceid.Plateelementsusefaces1&2,tet elementsusefaces14andhexelementsusefaces16. Thisoptionisgenerallytheleastusefulforasolidmodelbecausetheelementfacesonthesurfaceofthesoliddonotnecessarily shareacommonfaceID.ThegraphicsbelowshowtheConnectionRegionscreatedbyselectingalloftheelementsandusingthe FaceIDfaceselectionmethod.Thefirstgraphicshowsface1,thesecondshowsface2andsoforth.
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NearSurface: ThisoptionisusefulifyouhavegeometrytoworkwithbutyoudontwanttolimittheelementsinyourConnectionRegion.The graphicsbelowshowtheConnectionRegionscreatedbyselectingaclusterofelementsinthecorneroftheblockandusingthe NearSurfacefaceselectionmethod.
NearCoordinates: TheNearCoordinatesmethodisverysimilartoNearSurface.Insteadofspecifyingasurface,however,youchoosea coordinatesystem,directionandposition.Thisdefinesaplanarsurface,whichisusedalongwiththetolerancetofindtheclosest faces.
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AdjacentFaces: Apowerfulmethodforchoosingfaces,especiallyforcomplexsolidandplanarelementmodels.Youchoosejustoneinitialface (andtheassociatedelementID).Thiscanbedoneveryeasilybygraphicallyselectingtheface.Youthenspecifyatolerance angle. FEMAPwillsearchallselectedelementsforfacesthatareconnectedtothefacethatyouchoseandthatarewithinthespecified tolerancefrombeingcoplanarwithanalreadyselectedface.
ModelFreeFaces TheModelFreeFaces methodsimplyincludesevery"freeelementface"inyourelementselection.Agoodtechniqueifyoucan g grabexactlytheelementsyouwantwithintheelementselectiondialoguebox. y y g
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ConnectionRegions:Plates,bySurfaces
Platemodelsaregenerallyrequiremorecarewhenselectingyour regions.WhenselectingyouplatemodelConnectionRegionsby surfaces,youneedtopayspecialattentiontothesurfacenormals andelementnormals.Sincebothfacesofaplateelementare linkedtothesamesurface,youwillneedtoturnthePositive Sideoptiononandoffwhereappropriate. Sid ti d ff h i t Thesurfacenormalsareshownintheuppermostgraphiconthe right.ThemiddleimageshowsthefirstConnectionRegion.The surfacewasselectedwiththePositiveSideoptionunchecked. ThebottomimageshowsthesecondConnectionRegion.The The bottom image shows the second Connection Region The surfacewasselectedwiththePositiveSideoptionchecked. NotethattheConnectionRegiondirectionsfaceeachotherina properlyconfiguredcontactanalysis.Youcancheckthisbyusing Window>ShowEntities.SelectRegionforyourentitytypeand checktheShowNormalsstyleoption.
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ConnectionRegions:Plates,byElements
InsomecasesyoubeunabletoselectyourConnectionRegionsbysurfaces.Theotheroptionistoselectyourregionsby elements.ThistechniquegivesyoumorecontroloverselectingyourConnectionRegion,butalsoopensupthepossibilityfor error.StarttocreateyouConnectionRegionbyselectingtheElementsradiobuttonundertheDefinedBysectionofthe ConnectionRegiondialoguebox.Youprobablydontwanttoselectelementsonebyone.UsetheMultiplebuttontospeed thingsup.
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Regions:Plates,byElements
Onceyouhaveselectedtheelementsyouwant,youarepresentedfiveoptionsforfaceselection.Whenworkingwithplate Once you have selected the elements you want you are presented five options for face selection When working with plate elements,onlytheFaceIDandAdjacentFacesoptionsshouldbeused. FaceID: Asmentionedearlier,plateelementsusefaces1&2forConnectionRegions.Beawarethatafoursidedplateelementhassix facesandFemapwillallowyoutoselectanyofthesefacesbutonlyfaces1&2aresupportedforcontact.TheFaceIDmethod allowsyoutoenterthefaceIDnumericallyorselectafacefromthemodel.Thismodelismoreeffectivewithplatemodels becausethefacesoftheelementsaremorecommonlyaligned. AdjacentFaces: ThismethodisusefulforcreatingConnectionRegionswhenelementsdonothaveconsistentorientationorwhenthemodelhas complexgeometry(seeAdjacentFacesinthesolidelementsection). l t ( Adj tF i th lid l t ti )
Hint:TurnonelementthicknesstohelpyouchecktheConnectionRegionyouhavecreated.
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Connectors
OnceyouhaveproperlysetupyourConnectionRegions,youmustestablishcontactpairs,calledConnectorsintheFemap interface.AConnectorspecifiesacontactmechanisminthemodelwithaSourceConnectionRegion,aTargetConnection RegionandaConnectionProperty.
SettingupaConnectorisquitesimple,selectaConnectionPropertyfromthedropdownlistorusethequickbuttontotheright tocreateanewone.LeavethefieldsoftheConnectionPropertyblankfornow.ConnectionPropertieswillbediscussedingreater detaillaterinthiswhitepaper.Next,selectMaster(Target)andSlave(Source)ConnectionRegionsfromthedropdownlistsor selectbyclickingonthedesiredConnectionRegionsinthemodel.TheConnectionRegionswillhighlightasyouplacethecursor overthemtomaketheselectionprocesseasier(seethegraphicabove).
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Connectors:SourceRegionsandTargetRegions,fromtheNXNastran7UsersGuide
It'simportanttounderstandhowcontactelementarecreatedwhenselectingwhichregionwillbethesourceandwhichthe target,sincethetwocanbeinterchangeable.Thesolverprojectsvectornormalsfromthesourceregiontothetargetregion. It thencreatescontactelementswhenthesenormalsintersectelementsinthetargetregionandarewithinthesearchdistance criteriaforthecontactpair.Thismeansthatwhenthetworegionsofapairdonothavecorrespondingonetooneelements,the numberofcontactelementsthatthesolvercreatescanchangedependingonwhichregionitprojectstheelementsfromand whichregionitprojectsthemto. Ingeneral,ofthetwocontactregionsyouuseforthepair,choosetheonewiththefinermeshforthesourceregion.Whenthe sourceandtargetregionshavedifferentmeshdensities,moreelementsonthesourceregionwillmeanthatmorecontact elementsarecreated,whichwillproduceamoreaccuratesolution. Forexample,thetworegionsbelowarebothcomposedoflinearshells.Thesourceregion(A)hasoneelementandthetarget For example, the two regions below are both composed of linear shells. The source region (A) has one element and the target region(B)hasfourelements.
Whencreatingthecontactelementsbetweentheseregions,thesoftwareprojectscontactelementsfromthesingleelementon the source region to the four elements in the target region This results in the creation of a single contact element (see the graphic thesourceregiontothefourelementsinthetargetregion.Thisresultsinthecreationofasinglecontactelement(seethegraphic ontheleft). However,ifyouweretousetheregionwithfourelementsasthesource(C)andtheregionwithoneelementasthetarget(D),the solutionwillcreate4contactelements(seethegraphicontheright).
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ConnectionProperties Connection Properties

AfteryouhavecreatedandcheckedyourConnectionRegionsand ConnectorsyoucansetuptheConnectionProperty. AlthoughaConnectionPropertyisrequiredtocreateaConnector, itisrecommendedthatfullyconfiguringtheConnectionProperty y g g p y shouldbesavedforlast.Thisisbecauseitiseasytoget overwhelmedwiththeoptionsprovidedonaConnectionProperty card.Additionally,unlesstheConnectionRegionsandConnectors areconfiguredcorrectly,noneoftheoptionsoftheConnection Propertywillallowforaaccuratecontactanalysis. TheConnectionPropertycardisdividedintothreesections: ContactPair(BCTSET),ContactProperty(BCTPARAM)and CommonContactParameters(BCTPARAM).CommonGlue Parameters(BGPARAM)andGluedContactProperty(BGSET)will not be covered in this white paper notbecoveredinthiswhitepaper.
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ConnectionProperties:ContactPair(BCTSET)
TheoptionsinthisportionofthedialogboxcanbesetindividuallyforeachConnector(contactpair)thatiscreatedinthemodel. TheseoptionswillbewrittenouttotheBCTSETentryforeachindividualcontactpair.Eachcontactpairwillbedesignatedinthe graphicswindowwithasinglelinegoingfromoneConnectionRegiontoanotherandthislineisacontactelement. Friction EntersavalueintheFRICi fieldontheBCTSETentry.DesignatestheStaticCoefficientoffrictionforcontactpair"i". Note: Ingeneral,ifdifferentfrictionvaluesareNOTneededthenthecontactpairsshouldallreferencethesamecontactproperty. MinContactSearchDist EntersavalueintheMINDi fieldontheBCTSETentry.DesignatestheMinimumsearchdistancefor contactpair"i". Note:Theminimumdistancecanbenegativeandusedforaninterferencefitconditionmodeledasoverlappingsurfaces. MaxContactSearchDist EntersavalueintheMAXDi fieldontheBCTSETentry.DesignatestheMaximumsearchdistancefor Max Contact Search Dist Enters a value in the MAXDi field on the BCTSET entry. Designates the Maximum search distance for contactpair"i". Note: Themaxdistancemustbedefinedforallcontactproblems.ThisisthedistancethatNXNastranwillsearchforcontactfrom theelementnormal.
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ConnectionProperties:ContactProperty(BCTPARM)
Theseoptionsneedtoonlybedefinedonceforacontactanalysis,regardlessofhowmanyConnectors (contactpairs)aredefined inthemodel.EachConnector hasanIDassignedtoitandcanreferenceadifferentConnectionProperty.FEMAPwillusethe ConnectionProperty referencedbytheConnector withthelowestIDtodefinetheBCTPARMentryfortheentiremodel.For example,ifamodelhas2Connectors (contactpairs)withIDnumbers101and102,theConnectionPropertyvaluesdefinedinthe propertyassociatedwithConnectorID101wouldbeusedfortheanalysis. MaxForceIterations C t th MAXF fi ld M F It ti CreatestheMAXFfieldontheBCTPARMentry.Designatesthemaximumnumberofiterationsforaforce th BCTPARM t D i t th i b f it ti f f (inner)loop(Default=10). MaxStatusIterations CreatestheMAXSfieldontheBCTPARMentry.Designatesthemaximumnumberofiterationsforastatus (outer)loop(Default=20). ForceConvergenceTol CreatestheCTOLfieldontheBCTPARMentry.DesignatestheContactForceconvergencetolerance (Default=0.01). ConvergenceCriteriaandNumForConvergence Together,thesetwovaluescreatetheNCHGfieldontheBCTPARMentry.The valueandtypeofnumber(realorinteger)enteredforNumForConvergencedependsontheoptionsetforConvergenceCriteria: 0..NumberofChanges Whenthisoptionisset,NumforConvergence mustbeaninteger>1.Thisvaluedefinestheallowable numberofcontactchanges. 1..PercentageofActive Whenthisoptionisset,NumforConvergence mustbeenteredasapercentage(between1and99, whichwillappearas0.01to0.99intheNXNastraninputfile).Thesolvertreatsthisvalueasapercentageofthenumberofactive contactelementsineachouterloopofthecontactalgorithm.Thenumberofactivecontactelementsisevaluatedateachouter loopiteration.
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MinContactPercentage CreatestheMPERfieldontheBCTPARMentry.DesignatestheMinimumContactSetPercentage (Default=100). InitialPenetration CreatestheINIPENEfieldontheBCTPARMentry.ControlshowNastranhandlesinitialgaporpenetrationof thegeneratedcontactelements(Default=0). 0..Calculated Usethevaluecalculatedfromthegridcoordinates.Inthecaseofpenetrations,amodelmayexperience"pressfit" behaviorwhenusingthisoption. 2..Calculated/ZeroPenetrations S 2 C l l t d/Z P t ti Sameas0..Calculated,butifpenetrationisdetected,setthevaluetozero. 0 C l l t d b t if t ti i d t t d t th l t 3..ZeroGap/Penetration Setsthepenetration/gaptozeroforallcontactelements. ShellOffset CreatestheSHLTHKfieldontheBCTPARMentry.ShellThicknessOffsetflag.(Default=0) 0..Includeshellthickness Includehalfshellthicknessassurfaceoffset. 1..Donotincludethickness Doesnotincludethicknessoffset. Avg Methods CreatestheAVGSTSfieldontheBCTPARMentry.Determinestheaveragingmethodforcontactpressure/traction results(Default=0). 0..IncludeAllElements TheaveragingofPressure/TractionvaluesforacontactgridwillincludetheresultsfromALLcontact elementsattachedtothegridregardlessofwhethertheyareactiveorinactiveinthecontactproblem 1..IncludeActiveElements TheaveragingofthePressure/Tractionvaluesforacontactgridwillexcludethosecontactelements whicharenotactiveinthecontactsolutionandthushaveazeroPressure/Tractionvalue. ContactStatus CreatestheRESETfieldontheBCTPARMentry.Flagtoindicateifthecontactstatusforaspecificsubcase isto startfromthefinalstatusoftheprevioussubcase.(Default=0) 0..StartfromPrev Subcase Startsfromprevioussubcase. 1..StartfromInitState Startsfrominitialstate. ContactInactive CreatestheCSTRATfieldontheBCTPARMentry.Whensetto 1..RestrictFromInactive prevents all of the Contact Inactive Creates the CSTRAT field on the BCTPARM entry When set to "1 Restrict From Inactive",preventsallofthe contactelementsfrombecominginactive. 0..CanBeInactive(Default) Allcontactelementscanbecomeinactive 1..RestrictFromInactive Solverwillreducethelikelihoodofallofthecontactelementsbecominginactive.Note: Undercertainconditions,allofthecontactelementscouldbecomeinactivewhichmayleadtosingularities.Settingthe p parameterto"1..RestrictFromInactive"willreducethepossibilityofthishappening. p y pp g
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ShellZOffset AllowsyoutochooseiftheZOffsetonshellelementsshouldbeincludedindetermining"GluedContact."Creates ZOFFSETfieldinBGPARMentryandgivesyou2choicesforthecorrespondingValuefield: 0..IncludeZOffset(Default) Zoffsetofshellsisincludedfordetermininggluedsurfaces. 1..NonotIncludeZOffset ZoffsetofshellsisNOTincludedfordetermininggluedsurfaces.Note: TheDefaults buttonwillautomaticallyfillinthedialogboxwiththedefaultvaluessuggestedbyNXNastran.Itmaybehelpfulto tryandruntheanalysiswiththedefaultsandthenrunitagainifanymodificationsareneededtocreatemoreaccurateresults or achieveconvergence. hi AdaptiveStiffness Thisisaflagtoindicatewhetheradaptivestiffnessisactivated.CreatesPENADAPTfieldonBCTPARMentry (Default=0).Whennotchecked,itplacesa"0"(NoAdaptiveadjustment)intothePENADAPTfield,whencheckedplacesa"1" (Adaptivity adjustscontactstiffness)intothePENADAPTfield. PenetrationFactor CreatesthePENETFACfieldontheBCTPARMentry(Default=1.0E4).Designatesthepenetrationfactorfor adaptivepenaltystiffnessadjustment.OnlyusedwhenAdaptiveStiffnessis"on"andshouldusuallyonlybesettoalowervalue toreducetheamountofpenetrationallowedtooccurinananalysis.
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ConnectionProperties:CommonContact(BCTPARM)andGlue(BGPARM)Parameters
ThissectioncontainsoptionsforGluedcontactandseveraloptionsavailableforbothGluedContactandLinearContact. Eval Order Determinesthenumberof"LinearContactorGluePoints"forasingleelementonthesourceregion.CreatesINTORD fieldinBCTPARMorBGPARMentryandgivesyou4choices: 0..Default DoesNOTwritetheINTORDfieldorcorrespondingvaluefieldtotheBCTPARMorBGPARMentry.Simplyusesthe defaultvaluefor"Linear"or"Glued"contactbuiltintotheNXNastransolver. 1..Low L 1 L Lowestorderofpointsonsourceregion. t d f i t i 2..Medium Mediumorderofpointsonsourceregion.Thisisthedefault. 3..High Highestorderofpointsonsourceregion. Thehighertheintegrationorder,thelongerthesolvewilltake. RefineSource Determinesifthesourceregionisrefinedforthe Linear or Glued Contact solution. Creates REFINE field on the Refine Source Determines if the source region is refined for the "Linear"or"Glued"Contactsolution.CreatesREFINEfieldonthe BCTPARMorBGPARMentryandgivesyou2choicesforthecorrespondingValuefield: 0..DoNotRefine Doesnotrefinethe"LinearContact/Glue"sourceregionbasedontargetsurfacedefinition. 1..RefineSourcetoTarget(Default) Refinesthe"LinearContact/Glue"sourceregionbasedontargetsurfacedefinition. 2..NXN7.0Method Refinesthe"LinearContact/Glue"sourceregionusingtheNXNastran7.0method.
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ConnectionProperties:CommonContact(BCTPARM)andGlue(BGPARM)Parameters
PenaltyFactorUnits CreatesthePENTYPfieldontheBCTPARMorBGPARMentry.Specifieshowcontactelementstiffnessis calculated. WhensettingpenaltyfactorsforlinearcontactorgluedcontactwhenGlueType=1..Spring(GLUETYPE=1) 1..1/Length(Default) NormalPenaltyFactor(PENN)andTangentialPenaltyFactor(PENT)areenteredinunitsof1/Length. 2..Force/(LengthxArea) NormalPenaltyFactor(PENN)andTangentialPenaltyFactor(PENT)areenteredinunitsof Force/(LengthxArea). WhensettingpenaltyfactorsforgluedcontactwhenGlueType=2..Weld(GLUETYPE=2) Wh tti lt f t f l d t t h Gl T 2 W ld (GLUETYPE 2) 1..ScaleFactor GlueFactor(PENGLUE)isaunitless value. 2..F/L^2 GlueFactor(PENGLUE)hastheunitsofF/Lengthsquared. AutoPenaltyFactor Thisisaflagtoindicatewhethernormalandtangentialpenaltyfactorswillbeautomaticallycalculated. WhenthisboxischeckedinFEMAP,nospecialfieldwillbewrittentotheBCTPARM.ThisisthedefaultforNXNastran. When this box is checked in FEMAP, no special field will be written to the BCTPARM. This is the default for NX Nastran. NormalFactor CreatesthePENNfieldontheBCTPARMorBGPARMentry.Designatesthepenaltyfactorforthenormaldirection (Default=10.0forBCTPARM,100forBGPARM). TangentialFactor CreatesthePENTfieldontheBCTPARMorBGPARMentry.Designatesthepenaltyfactorforthetangential direction(Default=1.0forBCTPARM,100forBGPARM).
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ConnectionProperties ConnectionProperties:Friction ConnectionProperties:ContactSearchDistance ConnectionProperties:InitialPenetration Connection Properties: Initial Penetration ConnectionProperties:Refinement ConnectionProperties:Refinement,EvaluationOrder ConnectionProperties:Refinement,RefineSource ConnectionProperties:PenaltyFactor ConnectionProperties:PenaltyFactor,Units ConnectionProperties:PenaltyFactor,Automaticvs.Manual

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Seminar Linear Contact Analysis Notes

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NearCoordinates: TheNearCoordinatesmethodisverysimilartoNearSurface.Insteadofspecifyingasurface,however,youchoosea coordinatesystem,directionandposition.Thisdefinesaplanarsurface,whichisusedalongwiththetolerancetofindtheclosest faces.

ModelFreeFaces TheModelFreeFaces methodsimplyincludesevery"freeelementface"inyourelementselection.Agoodtechniqueifyoucan g grabexactlytheelementsyouwantwithintheelementselectiondialoguebox. y y g

ConnectionProperties Connection Properties

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