®

COSMOSWorks 2005

Basic Nonlinear

Structural Research and Analysis Corporation

#700, 12121 Wilshire Blvd.,
Los Angeles, California 90025
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Document Number:
COSMOSWorks Nonlinear Training Manual

Table of Contents

Introduction to Nonlinear Structural Analysis

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Types of Non-Linearities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Geometric Non-linearities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Material Non-linearities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Linear Versus Nonlinear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Incremental Loading and Time curves . . . . . . . . . . . . . . . . . . . . . 11
Lesson 1:
Garden Hose Clamp
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Discussion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Q & A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Numerical Procedures for Nonlinear Finite Element Analysis
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Incremental Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Force Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Displacement Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Arc-length Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
When to use Arc-length control . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Iteration Solution Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Standard Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Newton-Raphson (NR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Modified Newton-Raphson (MNR) . . . . . . . . . . . . . . . . . . . . . . . 40
Quasi-Newton (QN) scheme (the BFGS update) . . . . . . . . . . . . . 41
Line Search Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Termination Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Convergence Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Divergence Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Bad Divergence Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adaptive Automatic Stepping Technique . . . . . . . . . . . . . . . . . . . . . . 42
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lesson 2:
Cylindrical Shell
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Discussion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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Q & A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Geometric Nonlinear Analysis
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Small Displacement Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Large Displacement Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Total Lagrangian (T.L.) formulation . . . . . . . . . . . . . . . . . . . . . . 67
Updated Lagrangian (U.L.) formulation. . . . . . . . . . . . . . . . . . . . 68
Partially Updated Lagrangian (P.U.L.) formulation . . . . . . . . . . . 68
Finite Strain Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Large Deflection Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Stress stiffening and P-delta effects . . . . . . . . . . . . . . . . . . . . . . . . . . 70
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Lesson 3:
Trampoline
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Q & A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Material Models and Constitutive Relations
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Elastic Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Linear Elastic Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Nonlinear Elastic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Hyperelastic models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Elasto - Plastic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Linear Elastic Viscoelastic model. . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Creep. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Lesson 4:
Paperclip
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Lesson 5:
Crankarm
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Q & A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Lesson 6:
Rubber Diaphragm
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Q & A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Lesson 7:
Beam
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3D Contact
Global Contact/Gap Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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COSMOSWorks Nonlinear Training Manual

Global Contact Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Local Contact/Gap Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Additional Local Contact Types . . . . . . . . . . . . . . . . . . . . . . . . . 181
Contact Hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Contact Definition and Meshing. . . . . . . . . . . . . . . . . . . . . . . . . 182
Solving Contact Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Hybrid Technique for Gap/Contact Problems: General Description 182
Hybrid Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Gap Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Contact Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
GAP Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Troubleshooting for Gap/Contact Problems . . . . . . . . . . . . . . . . 188
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Lesson 8:
3D Contact
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Lesson 9:
Fatigue
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

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COSMOSWorks Nonlinear Training Manual

Introduction to Nonlinear
Structural Analysis

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COSMOSWorks Nonlinear Training Manual

Introduction If the behavior of a structural system depends on its current state (i.e.,
current displacement, stress-strain relation, and/or force), the force-
displacement relationship becomes nonlinear.

Generalized
Force
Non-Linear

Linear

Generalized
Displacement

Types of Non- There can be different type of non-linearities in a model which are
Linearities listed below:
n Geometric nonlinearities
n Material nonlinearities
n Boundary nonlinearities

Each type of such nonlinearities can be present separately or in

conjunction with the other types.
Geometric Non- This class of nonlinear behavior arises from the effect of large
linearities displacements on the overall geometric configuration of the structure.
The large displacements can lead the structure to respond in a stiffening
and/or softening manner.

Generalized Stiffening
Force

Softening

Generalized
Displacement

Introduction 7
 COSMOSWorks Nonlinear Training Manual

Material Non- This class of nonlinear behavior stems from the nonlinear relationship
linearities between the stress and strain.
Force

Time

Beam Column Stress-Strain curve

Connection

Several factors can affect the stress-strain relationship such as:

n Load History : Plasticity problems
n Load Duration : Creep analysis, Viscoelasticity
n Temperature : Thermo-plasticity
Boundary Non- This class of nonlinear behavior results from the changing nature of the
Linearities boundary conditions (kinematic and/or force) of the structures involved
in the analysis during motion.
n Contact Problems
n Pounding of structures
n Fitting problems
n Gear-tooth contacts

Seismic
Motion

Displacement-dependent loads - The applied loads vary with the

displacements of the structure leading to either a conservative or a non-
conservative loading.
Types:
n Pressure
n Centrifugal

8 Types of Non-Linearities
COSMOSWorks Nonlinear Training Manual

Water gate under Circular ring under

Hydrostatic pressure Uniform Pressure
CONSERVATIVE
P P

Beck’s Column

NON-CONSERVATIVE

Theory In FEA, the expression of the force-displacement relationship for a

nonlinear structural problem can be expressed as:
[K({u},{R({u})})] {u} = {R({u})}
where,
{u} = Displacement vector
[K({u},{R({u})})] = Stiffness matrix
{R({u})} = Vector of externally applied loads
Linear Versus A nonlinear problem cannot be simulated mathematically as a system
Nonlinear of linear equations.
A nonlinear problem can only be formulated as a system of nonlinear
equations.
A nonlinear system of equations does not necessarily have a unique
solution or even a solution.
Linear analysis is a subset of nonlinear analysis.
Principle of super- The principle of superposition is not applicable for nonlinear analysis.
position

Theory 9
 COSMOSWorks Nonlinear Training Manual

F1 F2 F1 F2

(F1 + F2) F1 F2

(Pressure + Pressure Temperature

Temperature Loading Loading
Loadings)
Applications of the superposition
Principle in Linear Problems

Solution of nonlinear problems requires incremental (step-by-step)

techniques and often iterations within each increment (step) to ensure
equilibrium at the end of each increment (step).
An incremental solution is performed by incrementing the applied
loads (from one step to the next) until a certain level of loading is
reached.
A pure incremental technique can cause error accumulation from one
increment to the next leading to incorrect solution.
Equilibrium iterations should be performed in order to enforce the
solution to lie on the equilibrium path within a preset tolerance.

10 Theory
COSMOSWorks Nonlinear Training Manual

Incremental The “time” variable (along with time curves) is used to prescribe the
Loading and Time loading magnitude at every step. Each step is associated with a specific
curves time. (See the loading curve shown in the next slide.)
At any given time, the multipliers by which the loads are to be varied
are represented by “time” curves.
In static analysis, in absence of time-dependent loadings and material
properties, the “time” variable represents a pseudo variable.

Theory 11
 COSMOSWorks Nonlinear Training Manual

12 Theory
COSMOSWorks Nonlinear Training Manual

Lesson 1
Garden Hose Clamp

Upon successful completion of this lesson, you will be able to:

n Perform a nonlinear large-deformation static analysis on a CAD
model
n Retrieve the model
n Define a linear static study - apply material, loads and restraints,
and mesh
n Run static analysis and visualize static analysis results
n Define a nonlinear study
n Define pseudo-time curves for loading.
n Copy material, loads and restraints and mesh from the static
analysis study.
n Edit the loading in order to follow the time curve.
n Run nonlinear analysis and visualize the stress and displacement
results.

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Lesson 1 COSMOSWorks Nonlinear Training Manual

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COSMOSWorks Nonlinear Training Manual Lesson 1

Objective The Hose Clamp shown is analyzed for stresses and displacements
subject to the loading and boundary conditions specified in the figure
below. This part is made of stainless steel. The Hose Clamp is 6 inches
long, 0.5 inches wide and 0.01 inches thick. It is fixed on one end and a
360 degree rotation is applied on the other.

1 Open SolidWorks.

2 COSMOSWorks Add-Ins.
Once installed, COSMOSWorks can be activated in SolidWorks using
the Tools, Add-Ins... menu.
Check COSMOSWorks 2005 to
use this Add-In.

Click OK.
3 Open Assembly
Click File, Open to open the assembly file hose-clamp.sldprt
from the Lesson 1 folder.
4 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.

Objective 15
Lesson 1 COSMOSWorks Nonlinear Training Manual

5 Create Study.
From the
COSMOSWorks
FeatureManager tree,
right-click the hose-
clamp icon and left-
click on Study from
the context-sensitive
pop-up menu to open
the study dialog box.

6 Enter Study Name and properties.

In the Study dialog
box, type Linear in
the text box under
Study Name.i
In the list box for
Analysis Type select
Static.
Under Mesh type
select Shell mesh using mid-surfaces.
Click OK.
7 Apply fixed restraint.
In the COSMOSWorks
FeatureManager, right-click
Linear, Load/Restraint and
select Restraints... from the context
sensitive pop-up menu.

16 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

Select the face in the model to

apply a fixed restraint.

Click the green check to apply the restraint.

8 Apply rotation restraint.
In the COSMOSWorks FeatureManager, right-click Linear,
Load/Restraint and select Restraints... from the context
sensitive pop-up menu.

Objective 17
Lesson 1 COSMOSWorks Nonlinear Training Manual

Select the face in the model to

apply a rotational restraint.

In the COSMOSWorks FeatureManager,

select On flat face under the Type list
box.
Under Translations, set the units to in.
Under Rotations, type 0 rad for Set
plane dir 1.
Under Rotations, type 6.25 rad for Set
plane dir 2.
Under Rotations, type 0 for Normal to
plane.
Click the green check to apply the
restraint.

18 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

9 Create mesh.
In the COSMOSWorks
FeatureManager, right-click Linear,
Mesh and select Create... from the
context sensitive pop-up menu.

In the Mesh property box, click Options.. button to set the mesh
options.
In the Options dialog box, set the mesh
quality to Draft.
Click OK.

10 Set Mesh size and tolerance.

Type 0.1 in the text box for mesh
size. Take the default tolerance of
0.005 inch.
Click on the green check mark to
create mesh.

Objective 19
Lesson 1 COSMOSWorks Nonlinear Training Manual

11 Run analysis.
In the
COSMOSWorks
FeatureManager,
right-click Linear
and select Run...
from the context
sensitive pop-up
menu.
OR
In the COSMOSWorks Main
toolbar, left-click Run button.

12 Plot displacement results.

In the COSMOSWorks FeatureManager, under Linear,
Displacement, double-click Plot1... to display the displacement
on the graphics screen.

20 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

13 Change displacement view scale.

We will change the displacement plot’s
view scale. In the COSMOSWorks
FeatureManager, under Linear,
Displacement, right-click
Plot1.... and select Edit Definition
from the context-sensitive pop-up
menu.

In the Displacement plot property box,

under Deformed shape select Defined. Enter
1 in the text box for Scale Factor.
Click green check mark to accept changes.

Objective 21
Lesson 1 COSMOSWorks Nonlinear Training Manual

14 Superimpose original model with deformed model.

WIn the COSMOSWorks
FeatureManager, under Linear,
Displacement, right-click
Plot1.... and select Settings from
the context-sensitive pop-up menu.

Under deformed plot options, check

the option Superimpose model on the
deformed shape.
Click the green check mark to accept changes.

The figure below shows the final displacement plot with all the above
settings.

22 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

Discussion We intended to rotate the leading edge of the flat hose Clamp by 360
degrees, but the linear analysis shows that the edge could not really be
rotated completely.
In order to capture the actual large displacement involved in rotating
the Clamp by 360 degrees, we need to run a nonlinear analysis with
geometric nonlinearities. This is what we will do now.
15 Create Nonlinear Study.
Define new study, name it Nonlinear.
Select Nonlinear for
Analysis type.
Select the same Mesh
type as before, Shell
mesh using mid-
surfaces.
Click OK.

16 Create Loads/Restraint.
In the COSMOSWorks FeatureManager,
under the Linear study, select the Load/
Restraint folder. hold in the mouse
button and Drag-and-Drop into the
Nonlinear model of the Load/
Restraint folder.

Drag
and
Drop

Objective 23
Lesson 1 COSMOSWorks Nonlinear Training Manual

17 Edit Rotation restraint.

Verify the rotation
restraint, Restraint-
2, by right-mouse
clicking the icon and
selecting Edit
Definition…

Preview the load variation by selecting

the Graph button.

Discussion The pseudo-time curve defines the path that the load will follow during
the iterative nonlinear solution. It is necessary to describe the pseudo-
time curve in order to scale the load and for the solution to converge at
intermediate steps. In this case, the prescribed 360 degree rotation
follows a linear load path, which is not fully applied until the pseudo-
time curve equals one second. Note that this linear time curve is very
common for when you want to apply the load gradually up to its full
scaling.

24 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

18 Drag and Drop mesh from Linear Study.

Drag-and-drop the Mesh icon from the
Linear study to the Mesh icon for the
Nonlinear study.
Drag
and
Drop

19 Setting properties of the Nonlinear study.

Set the properties for the
Nonlinear model by right-
clicking the study name
and choosing
Properties… from the
context sensitive menu.

Make sure that, Start

time: 0, End time: 1,
Initial time increment:
0.01 and Change Max
increment to: 0.1.

Select Advanced Options… button at the bottom of the box.

Objective 25
Lesson 1 COSMOSWorks Nonlinear Training Manual

Make sure that Control

Method is Force, and
Iterative Method is NR
(Newton-Raphson).
Click on OK at the
bottom to accept
changes.

20 Run Nonlinear Analysis.

Run the Nonlinear
analysis model by
right-clicking the study
name and choosing
Run from the context
sensitive menu.
OR
Left-click on the
Run icon in the
COSMOSWorks
Main toolbar.

Click OK after the solve has completed.

21 Change settings of the plot.
Open Displacement plot by click the + and double-click on the Plot
1 icon to view the plot.

26 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

Right-mouse click the Plot 1 and choose Settings.

Check the option to activate
Superimpose model on the
Deformed shape.

22 Results of the displacement of Nonlinear study.

Objective 27
Lesson 1 COSMOSWorks Nonlinear Training Manual

23 Probe Results.
Select the Probe tool
from either the
COSMOSWorks menu,
Result Tools, Probe…
OR

Select the Probe

icon on the
COSMOSWorks
Result Tools
toolbar.

Notice how the displacement plot Automatically switches off the

Deformed shape view of the model so that you can select the nodes
from the un-deformed model for their nodal values.
Select this vertex from the end of the
clamp where the rotation restraint was
defined earlier.

28 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

Note the node number and

the nodal value.

24 Create Response Graph.

Plot the Response for this node by
clicking on the Response button on
the bottom right of the Dialog box. or
alternatively, you could right-click
the Response folder and select
Define… from the menu.

In the Time History Graph, click on Node 1 to un-

select it, scroll down to Node 61 and click on it to
select.
Choose y-Axis value to be Displacement, URES,
and units inches.
Click on green arrow to accept and plot the
response graph.

Objective 29
Lesson 1 COSMOSWorks Nonlinear Training Manual

25 Save and close the part.

30 Objective
COSMOSWorks Nonlinear Training Manual Lesson 1

Q&A In this analysis, we

■ chose __________________________Control method
■ used __________________________ iterative method, as opposed
to ______________ method, because ______________ method is
faster than _____________method per iteration, but
_______________method leads to quicker overall convergence.
■ used __________________ nonlinearity
■ expect the model (to return to its original shape / not to return to its
original shape) when the displacement is released.
■ used __________________type of elements, because the plate has
a length: thickness ratio of ________: 1 which is greater than 20:1

Q&A 31
Lesson 1 COSMOSWorks Nonlinear Training Manual

32 Q&A
COSMOSWorks Nonlinear Training Manual

Numerical Procedures for

Nonlinear Finite Element
Analysis

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COSMOSWorks Nonlinear Training Manual

Overview Different numerical schemes are incorporated in nonlinear FEA

programs. A successful procedure must include the following:
■ Control Techniques: To control the progress of the
computations along the equilibrium path(s) of the system
■ Iterative method: To solve a set of simultaneous
nonlinear equations.
■ Termination Scheme: To end the solution process.
Incremental
Control
Techniques
Force Control ■ Applied loads are used as prescribed variables.
■ Equilibrium state (point) is determined by the intersection of a
surface (F = constant) with the equilibrium path to determine the
deformation parameters..

■ Loads (concentrated, pressure, prescribed displacements, base

motion, thermal, gravity, …) are incrementally applied using
“time” curves.
Displacement ■ A point on the equilibrium path is determined by the intersection of
Control a surface defined by a constant deformation parameter (U =

Overview 35
 COSMOSWorks Nonlinear Training Manual

constant) with the equilibrium path.

■ A pattern of the applied loads is proportionally incremented (using

a single load multiplier) to achieve equilibrium under the control of
a specified degree of freedom.
■ The controlled DOF is incremented through the use of a “time”
curve.
■ The actual loading at any time is proportional to the applied pattern
by a factor called the load factor (given in the output file).
Arc-length Control ■ A parameter is prescribed by means of a constraint equation which
is added to the set of the governing equilibrium equations.
■ The control parameter can be viewed as “arc-length” of the

36 Incremental Control Techniques

COSMOSWorks Nonlinear Training Manual

equilibrium path.

■ A point on the equilibrium path is determined by the intersection of

the equilibrium path with the surface prescribed by the arc-length
constraint.
■ A pattern of the applied loads is proportionally incremented (using
a single load multiplier) to achieve equilibrium under the control of
a specified “arc-length”.
■ The arc-length is internally calculated by the program.
■ No “Time” curve is required.
■ The actual loading at any step is proportional to the applied pattern
by a factor called the load factor (given in the output file).
When to use Arc- ■ Force control fails near a snap-through point.
length control ■ Displacement control fails near a snap-back point.
■ Arc-length control overcomes these difficulties.
■ Snap-through and/or snap-back states can be encountered in
buckling analysis of frame, plate, and shell structures, as noted by

Incremental Control Techniques 37

 COSMOSWorks Nonlinear Training Manual

the load-displacement plots shown below.

Load-displacement plots corresponding to each

control technique

Iteration ■ In nonlinear static analysis, the basic set of equations to be solved at

Solution any “time”
Methods t + ∆t R t + ∆t F
-
where,

t + ∆t R
= Vector of externally applied nodal loads

t + ∆t F
= Vector of internally generated nodal forces

t + ∆t F
Since the internal nodal forces, ,depend on nodal

t + ∆t U
displacements at time t + ∆t , that is, , an iterative method
must be used.
■ The basic outline of an iterative scheme to solve the equilibrium

38 Iteration Solution Methods

COSMOSWorks Nonlinear Training Manual

equations at time step, t + ∆t , can be:

(i – 1) t + ∆t t + ∆t (i – 1)
∆R = R – F

t + ∆t (i) (i) (i – 1)
K ∆U = ∆R

t + ∆t (i) t + ∆t (i – 1) (i)
U = U + ∆U

t + ∆t (0) t t + ∆t (0) t
U = U ; F = F

where,
t + ∆t (i – 1)
F = Vector of internally generated nodal forces at iteration
(i)
(i – 1)
∆R = The out-of-balance load vector at iteration (i)

(i)
∆U = Vector of incremental nodal displacements at iteration (i)

t + ∆t (i)
U = Vector of total displacements at iteration (i)

t + ∆t ( i)
K = The Jacobian (tangent stiffness) matrix at iteration (i)

Standard Standard schemes currently employed in the solution of nonlinear

Schemes analysis problems include:
■ Newton-Raphson (NR) scheme
■ Modified Newton-Raphson (MNR) scheme
■ Quasi-Newton (QN) scheme (the BFGS update)
Newton-Raphson ■ The tangential stiffness matrix is formed and decomposed at each
(NR) iteration within a particular solution step.
■ The NR method has high convergence rate (Quadratic).
■ Expensive for large systems.
■ For perfectly plastic or strain-softening materials, the tangential

Standard Schemes 39
 COSMOSWorks Nonlinear Training Manual

stiffness may become singular or ill-conditioned.

Modified Newton- ■ The tangential stiffness matrix is formed and decomposed at the
Raphson (MNR) beginning of each step (or the user-specified reformation interval)
and used throughout the iterations.
■ The MNR method has a lower convergence rate than NR.
■ Inexpensive for large systems.

■ For perfectly plastic or strain-softening materials, the tangential

stiffness may become singular or ill-conditioned.
■ If the stress state is unloaded from a plastic state to an elastic state,
MNR may not lead to a convergent iteration.
■ In some cases, MNR can be more expensive than NR when the
number of required MNR iterations is considerably larger than the
required NR iterations.

40 Standard Schemes
COSMOSWorks Nonlinear Training Manual

Quasi-Newton ■ The QN family of schemes employs a lower-rank matrix to update

(QN) scheme (the the stiffness matrix (or its inverse) to provide secant approximation
BFGS update) from iteration (i-1) to iteration (i).
■ The BFGS (Broyden-Fletcher-Goldfarb-Shanno) update formula
are widely used with the QN algorithm.
■ The BFGS method has a convergence rate lower than NR, but
higher than MNR.

Line Search ■ The performance of an iterative method is very much dependent on

Schemes the choice of the “optimal” step length in the direction of
displacement vector increment (search direction).
■ An estimate of such a step can be calculated by requiring that the
projection of the residual load vector in the search direction vanish
(or to fall within a specified tolerance).
■ The line search operation is expensive because one search process
may involve a large number of re-calculations of the residual
vector.
■ The line search operation is supported with the BFGS method
Termination ■ Termination schemes must be provided at the end of each iteration
Schemes to check if the iteration has converged or if it is diverging.
■ A very loose tolerance can initiate inaccurate results.
■ A very strict tolerance can result in high computational cost.
■ Termination schemes can also be provided at the end of a step to
check if the solution has converged to an unrealizable solution.
Convergence A number of procedures have been introduced as convergence criteria
Criteria for terminating an iterative process.
■ Displacement Convergence Criterion (MNR and NR)

Line Search Schemes 41

 COSMOSWorks Nonlinear Training Manual

■ Energy Convergence Criterion (BFGS method)

Divergence A number of schemes have been described based on:
Criteria ■ Divergence of the residual loads (MNR and NR)
■ Divergence of the incremental energy (BFGS method)
Bad Divergence ■ End the process when the solution is not diverging, or
Criteria ■ Allow the process to continue searching for unrealizable solutions
Adaptive The user has the choice to solve nonlinear problems:
Automatic ■ By directly specifying the load and/or displacement increment
Stepping (through time curve) to be followed.
Technique ■ Or by letting the program select its own increments based on user
specified parameters.

The Adaptive automatic stepping algorithm provides the following:

■ Step size optimization
■ Safeguard against equilibrium iteration failures and stiffness
sigularities
■ Safeguard against converging to incorrect solution.

Default values of a minimum step size and maximum step size are
provided if not specified.
For complex problems, the minimum and the maximum step sizes
should be reasonably specified.
The maximum step size (time step increment) should be properly
selected to avoid inaccurate results for time-independent static analysis
(creep and viscoelasticity) and dynamic analysis.
References K. J. Bathe - Finite Element Procedures, Prentice Hall, Inc., 1996
M. A. Crisfield - A Fast Incremental/Iterative Solution Procedure That
Handles "Snap-Through“, Comput. Struct., 13:55 - 62, 1980
M. Geradin, S. Idelson, and M. Hogge - Computational Strategies for
the Solution of Large Nonlinear Problems via Quasi-Newton Methods,
Comput. Struct., 13:73 - 81, 1981
H. Mathies and G. Strang - The Solution of Nonlinear Finite Element
Equations Int. J. Numer. Meth. Eng., 14:1613 - 1626, 1979
E. Riks - An Incremental Approach to the Solution of Snapping and
Buckling Problems, Int. J. Numer. Meth. Eng., 15:529 - 551, 1979
O. C. Zienkiewicz - Incremental Displacement in Nonlinear Analysis
Int. J. Numer. Meth. Eng., 3:587 - 588, 1971

42 Adaptive Automatic Stepping Technique

COSMOSWorks Non-Linear Training Manual

Lesson 2
Cylindrical Shell

After successful completion of this lesson, you will be able to

Perform a non-linear large-deformation buckling analysis on a CAD
model using the steps below:
Retrieve the model
Define a linear buckling study - apply material, loads and restraints,
and mesh
Run buckling analysis and visualize buckling analysis results
Define a non-linear study
Define Controls for a Non-linear buckling analysis using ARC
LENGTH CONTROL.
Copy material, loads and restraints and mesh from the static analysis
study.
Run non-linear buckling analysis and visualize the stress and
displacement results.

43
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

44
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Objective The quarter-symmetry model of a cylindrical shell is to be analyzed for

buckling when it is subject to a central point force load.

Dimensions: radius 2540 mm

Thickness 6.35 mm
Width: 508 mm
Theta section: 20 rad (11.46 deg)
Material: Aluminum 1060 Alloy
Reference load: 1000 N center point load
1 Open Assembly
Click File, Open to open
the assembly file
Cylindrical
Shell.sldprt from the
Lesson 2 folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Change configuration.
Pull down Feature manager
window, select
Configuration Manager.
Select Quarter Model
configuration. After
selection, drag Feature
Manager back up.

Objective 45
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Note COSMOSWorks associates analysis studies with SolidWorks

configurations.
4 Create Study.
Define a linear buckling analysis.
Study name: Linear
Analysis type:
Buckling
Mesh type: Shell
mesh using
surfaces.

5 Create shell surfaces.

Right-mouse click Shells and
choose define by Selected
Surfaces…

Select this surface.

Define shell with Thin formulation and

set a thickness of 6.35 mm.

46 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

6 Create Mesh.
Right-mouse click Mesh
and choose Create…

Set mesh parameters to Global

element size: 20 mm, Tolerance: 1
mm (default).
Click on Options…

Make certain Draft is selected under

Mesh quality.
Click on OK for the Options.

Objective 47
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Click on green arrow to accept

and to create the mesh.

7 Hide Mesh.
In the COSMOSWorks FeatureManager, right-mouse click mesh and
select Hide Mesh.
8 Create Restraint.
Right-click Load/
Restraint and choose
Restraints…
OR

Choose Restraints icon in the

COSMOSWorks Loads
toolbar.

Apply Immovable (No translation) on

the Edge associated with the top face.

48 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Select this
edge.

Click green arrow to accept.

9 Create Symmetry Restraint.
Right-click on Loads/Restraints icon and choose Restraints…
Select restraint Type as Use reference
geometry.

Objective 49
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Rotate the model to

view the cut face in
the x-direction. Restraint (select edge)
Choose the edge on
the top surface in the
Restraint dialog and
then click in the
Direction dialog and
select the cut face.

Direction (select Face)

Define translation as 0 in the Normal

to plane direction.
Define rotation as 0 in Along plane Dir
1 and Along plane Dir 2.
Click green check mark to create
restraint.

10 Create Symmetry restraint.

Right-click on Loads/Restraints icon and choose Restraints…

50 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Select restraint Type as Use reference

geometry.

Rotate model to view

the cut face in the z-
direction. Choose the Restraint (select edge)
edge on the top
surface in the
Restraint dialog and
then click in the
Direction dialog and
select the cut face.

Direction (select Face)

Objective 51
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Define translation as 0 in the Normal

to plane direction.
Define rotation as 0 in Along plane Dir
1 and Along plane Dir 2.
Click green check mark to create
restraint.

11 Review and rename symmetry restraints.

Slow double click Restraint-2 and
rename as Symmetry x-dir.
Slow double click Restraint-3 and
rename as Symmetry z-dir.

12 Create Force.
Right-click Load/
Restraint and
choose Force…
OR

Choose Force icon

in the
COSMOSWorks
Loads toolbar.

52 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Apply a force of 250 N to the vertex at

the center of the body and use the edge
just below it to align the direction
normal to the shell face.

Se

Select edge for direction.

Click green check mark to create load.

13 Change the properties of the study.

In the COSMOSWorks
FeatureManager, right-click on
the linear study and select
Properties.

Objective 53
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Set the properties of the

study to make sure that
Number of buckling
modes is 1.
Click OK.

14 Run the buckling analysis.

Run the analysis
either by right-
clicking the
study name or
clicking the icon
on the COSMOSWorks Main Toolbar.
15 Plot Displacement Plot.

16 List Buckling load factor.

List Buckling Load
Factors by right-
clicking the
Deformation
icon and selecting
List Buckling Load Factors... from the menu.

54 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Show buckling factors and click

on Close.

17 Animating the mode shape.

Animate the plot by either
selecting from the
COSMOSWorks Result Tools
toolbar
OR

From the context sensitive

menu by right-clicking the
Plot name and select
Animate.

Objective 55
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Set the number of Frames to 5 and

click the play button.

Discussion We intended to get the cylindrical shell to buckle downwards, but the
linear analysis could not simulate this behavior correctly.
Further, the linear analysis provides only the buckling mode shape and
the buckling load. It does not give us the post-buckling behavior
In order to capture the actual large displacement involved in snap
through buckling, we need to run a nonlinear analysis with geometric
nonlinearities. Such an analysis will also tell us the post-buckling
behavior.
18 Create a Nonlinear Study.
Define a nonlinear analysis.
Study name:
Nonlinear
Analysis type:
Nonlinear
Mesh type: Shell
mesh using
surfaces.

56 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

19 Drag-and-Drop study parameters from Linear buckling study to

nonlinear study.
Left-mouse click Shell from
the Linear analysis and then
hold the shift key down while
selecting the Mesh icon.
Hold in the mouse button and
drag it down to the
Nonlinear Study. This Drag
drag-and-drop technique helps and
to reduce the time to set up the Drop
Nonlinear analysis study.

20 Change study properties.

Right-click the
Nonlinear
study name and
select
Properties…

Objective 57
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Make sure the Initial

time increment is 0.01,
Min step is 1e-008, Max
step is 0.1 and No. of
adjustments is 5.
Start and end times will
not be used for this
Analysis.
Make sure Use large
displacement
formulation is selected.
Select the Advanced
Options… button from
the bottom of the
nonlinear study
properties.

Under Method, select

Control to be Arc
Length and make sure
iterative method is NR
(Newton-Raphson).
We expect the
Maximum
displacement to be
less than 30 mm so we
input this and set
Maximum number of
arc steps to 100.\
Click OK.
Click OK.

58 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

21 Set Result Response.

Right-click the Result
Options icon and choose
Define/Edit…

In the settings for the Result Options,

make sure For all Solution steps is
selected and then from the screen
select the same vertex where the load
is applied.

Click green check mark to set result

options.

22 Run analysis.
Then run by right-clicking
the study name and
choosing Run
Takes less than 5 minutes to
run.

Objective 59
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

23 View Displacement Plot.

24 Animating the displacement.

Animate the plot by either
selecting from the
COSMOSWorks Result Tools
toolbar

60 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Click the play button to animate.

25 Plot response graph.

Define a Result Options plot by right-
clicking icon.

Objective 61
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

Choose URES for X-axis value and mm

as the length unit.

Observe the
snap-back
buckling
phenomenon in
the graph.
Buckling
occurs at a
Load Factor of
about 13.15 (or
3300 N).

26 Save and close the part.

62 Objective
COSMOSWorks Non-Linear Training Manual Lesson 2
Cylindrical Shell

Q&A In this analysis, we

■ chose __________________________Control method.
■ chose this control method over _____________ and
___________control methods because, here we have both
______________ and ______________buckling.
■ would have chosen Displacement Control if we had ONLY
__________ buckling and Force control if we had
ONLY___________________.
■ expect the model (to return to its original shape / not to return to its
original shape) when the displacement is released.

Q&A 63
Lesson 2 COSMOSWorks Non-Linear Training Manual
Cylindrical Shell

64 Q&A
COSMOSWorks Nonlinear Training Manual

Geometric Nonlinear Analysis

65
 COSMOSWorks Nonlinear Training Manual

66
COSMOSWorks Nonlinear Training Manual

Introduction The overall stiffness of a structure depends on the stiffness contribution

of each of its finite elements.

During the load application:

■ The structure is displaced from its original position.
■ The nodal coordinates change.
■ The elements deform and change their spatial orientations.

These changes, if large enough, contribute to what is called

geometrically nonlinear factors which can no longer be ignored.
Small ■ The displacement–induced deformations are small.
Displacement ■ The change in the spatial orientation (rotation) is small.
Analysis
Therefore, the change in element stiffness contribution to the overall
structural stiffness can be ignored.
Large ■ The displacement–induced deformations can be finite.
Displacement ■ The spatial orientation change may no longer be infinitesimal.
Analysis
Therefore, the change in element stiffness contribution to the overall
structural stiffness cannot be ignored.
In order to consider the finite change in the geometry of structures in
the analysis, auxiliary stress and strain measures are incorporated.
Different approaches have been used:
■ Total Lagrangian (T.L.) formulation
■ Updated Lagrangian (U.L.) formulation
■ Partially Updated Lagrangian (P.U.L.) formulation
Total Lagrangian ■ All static and kinematic quantities for configuration t + Dt are
(T.L.) formulation referred to the initial configuration t = 0.

Introduction 67
 COSMOSWorks Nonlinear Training Manual

■ Strain measure: Green – Lagrange strain tensor, (symmetric)

■ Stress measure: 2nd Piola – Kirchhoff stress tensor, (symmetric)
■ These stress and strain measures are conjugate.
■ 2nd Piola – Kirchhoff stress tensor is invariant under rigid body
motion.
Updated ■ All static and kinematic quantities for configuration t + Dt are
Lagrangian (U.L.) referred to configuration t.
formulation ■ Strain measure: Almansi strain tensor, (symmetric)
■ Stress measure: Cauchy stress tensor, (symmetric)
■ These stress and strain measures are conjugate.
■ Cauchy stress tensor is not invariant under rigid body motion.
Partially Updated ■ A system of co-rotational axes is attached to the element.
Lagrangian ■ The element orientation is updated at the end of each step.
(P.U.L.) ■ Strain measure: Engineering strain.
formulation ■ Stress measure: Cauchy stress.
■ These stress and strain measures are not conjugate.

Tip (T.L.) and (U.L.) formulations are generally used with:

■ Continuum elements (PLANE2D, TRIANG, SOLID, TETS*)
* Elements supported in COSMOSWorks

(T.L.) formulation is used for:

■ Rubber – like and foam materials.

(P.U.L.) formulation is used with:

■ Skeletal elements (TRUSSES, BEAMS, & IMPIPE)
■ Shell elements (SHELL3/4*)
* Elements supported in COSMOSWorks

Finite Strain ■ Large localized deformations such that strains are not infinitesimal.
Analysis ■ Change in element spatial orientation can be finite.
■ Global structural stiffness changes due to the change in:
a. Element shape
b. Element spatial orientation
■ It is imperative that, the appropriate constitutive relations for
material behavior description experiencing finite strains, is used.

68 Finite Strain Analysis

COSMOSWorks Nonlinear Training Manual

Example: Deformation of rubber – like materials

Large ■ Induced strains are small.

Deflection ■ Change in element spatial orientation can be finite.
Analysis ■ Global structural stiffness changes due to the change in Element
Spatial Orientation.
■ Constitutive relations for material behavior under small strain
conditions are incorporated.

Large Deflection Analysis 69

 COSMOSWorks Nonlinear Training Manual

Example: Cantilever beam with end moment.

Example: Snap – through/snap – back buckling analysis.

Stress Stress stiffening and P – delta effects are inherently included in

stiffening and geometrically nonlinear analysis.
P-delta effects
References K. J. Bathe - Finite Element Procedures in Engineering Analysis
Prentice-Hall, 1982
M. A. Biot - Mechanics of Incremental Deformation Wiley, N.Y., 1965
L. E. Malvern - Introduction to the Mechanics of a Continuous Medium
Prentice-Hall, 1969

70 Stress stiffening and P-delta effects

COSMOSWorks Nonlinear Training Manual

J. T. Oden - Finite Element of Nonlinear Continua McGraw-Hill, 1972

G. A. Wempner - Mechanics of Solids with Applications to Thin Bodies
McGraw-Hill, 1973
W. Wunderlich - Incremental Formulations for Geometrically
Nonlinear Problems ... in Formulations and Computational Algorithms
in Finite Element Analysis U.S.- Germany Symposium on Finite
Element Method edited by K. Bathe, J. Oden and W. Wunderlich, MIT,
1976
O. C. Zienkiewicz and R. L.Taylor - The Finite Element Method,
Fourth Edition, Vol. 2, 1991

References 71
 COSMOSWorks Nonlinear Training Manual

72 References
COSMOSWorks Nonlinear Training Manual

Introduction

Introduction 73
 COSMOSWorks Nonlinear Training Manual

74 Introduction
COSMOSWorks Non-Linear Training Manual

Lesson 3
Trampoline

Upon successful completion of this lesson, you will be able to

Retrieve the model
Define a linear static study - apply material, loads and restraints, and
mesh
Run static analysis and visualize static analysis results
Define a nonlinear study
Define pseudo-time curves for loading.
Copy material, loads and restraints and mesh from the static analysis
study.
Define additional boundary conditions appropriate to analysis of
membranes
Edit the loading in order to follow the time curve.
Define nonlinear analysis time stepping and control appropriate to
membrane analysis.
Run nonlinear analysis and visualize the stress and displacement
results.

75
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

76
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

Objective The circular nylon trampoline shown below has a diameter of 226
inches and it is 0.01 inches thick. A uniform pressure of 0.01 psi
(approximately 0.3 inches of water) is applied to it. The outer periphery
edge is immovable.

1 Open Assembly
Click File, Open to open
the assembly file
Trampoline.sldprt
from the Lesson 3
folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Define study.
Define a study
named Linear, select
Analysis type as
Static and Mesh
type as Shell mesh
using mid-
surfaces.

4 Apply Restraint.
Apply restraint by right-
clicking Load/Restraint
and selecting Restraints.

Objective 77
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

Select the outer edge of the model and

set the Restraint type as Immovable
(No translation).

Outer circular
Edge.

Note It helps to visualize settings by showing preview.

78 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

5 Apply Rotational Restraint.

Since the membrane is too thin to
support bending loads, we need to
restrain all the rotational degrees-of-
freedom to prevent large rotational
displacements.
Restrain the entire shell face in the three
rotational directions

Objective 79
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

6 Apply pressure.
We will apply the 0.3 in of water on the
trampoline by applying a uniform
pressure of 0.01 psi on the shell face.

80 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

7 Create mesh and run analysis.

Create the mesh using a 5 in element
size, and select to Run the analysis
after meshing.

After the model meshes and

finishes solving, click on OK in
the dialog box that indicates
that the Static Analysis is
Completed.

8 Hiding Restraint symbols.

Before viewing the calculated
results, right-click the Load/
Restraint icon and select
Hide All from the context
sensitive menu.

Objective 81
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

9 Changing displacement plot settings.

Open the Displacement results folder by
clicking on the + sign next to it and
double-click on the Displacement
plot. Note that the default Deformed
shape is scaled by a value much less
than 1. To view the actual deformed
shape we need to define the deformed
shape to a scale factor of 1. Do this by
right-clicking the Plot1 icon under the
Displacement results folder and
choosing Edit Definition … from the
context sensitive menu. In the second
dialog, click on the radio button for
Defined and type in a value of 1.

10 Review displacement plot.

The resulting plot is
shown.
The deformation looks
unrealistic. In this
particular structure, the
length to thickness ratio
is very large; another
way of saying this is that
it is a very thin structure.
Such a thin structure
supports out-of-plane
loads thorough its
membrane (or in-plane)
stresses. Membrane analysis requires a large deformation analysis and
thus needs to be analyzed as a nonlinear problem.

Note For reference, thicker structures (thickness ratios of 10 to 100)

generally tend to support out-of-plane loads through bending stresses,
whereas thick, chunky structures support these loads by shear stresses.

82 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

11 Define nonlinear study.

Define a new study
named Nonlinear,
choose the analysis
type as Nonlinear,
and set the Mesh
type as Shell using
mid-surfaces.

12 Apply restraints and mesh.

Ctrl-select both the
icons for Load/
Restraint and
Mesh from the above
Linear analysis
settings and holding
the mouse button
down drag-and-drop
them onto the
Nonlinear analysis
study name.

Note All the loads, Restraints and mesh that was defined earlier has been
exactly copied to the new study.
13 Review the applied pressure.
We will confirm the Pressure load on the trampoline by right-clicking
the pressure load icon and choosing Edit Definition…

Objective 83
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

All the settings are the same as for the

previous linear analysis, but for a
nonlinear analysis, we must use an
incremental pressure load. The
nonlinear solver must converge at
intermediate loads and move forward in
a pseudo-time path until it reaches the
full load.

We can preview the default linear load

path by clicking on graph and showing
the pressure load vs. a pseudo-time scale.
Ask your instructor if you do not
understand this concept.

84 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

14 Set Nonlinear study properties.

Set the properties of the
nonlinear study by right-
clicking the study name
and choosing
Properties… from the
context-sensitive menu.

Make sure:
Start time = 0
End time = 1
Automatic
(autostepping) is
activated and set the
Initial time increment
to 0.01. Set the Min
time increment to 1e-8
and Max time
increment to 0.1 with
the No. of adjustments
to 5.
Use large
displacement
formulation and
Solver is Direct
Sparse.

Objective 85
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

Click on the Advanced

Options… button.
Make sure that the
Control Method is
Force and iterative
method is NR
(Newton-Raphson).
Click on OK.

Click OK.
15 Run the analysis.
Run the analysis by right-
clicking the study name and
choosing run from the
context-sensitive menu or
clicking the Run icon on
the COSMOSWorks Main toolbar.
Analysis takes less than 5 minutes to complete.
This dialog box will appear while solving the nonlinear analysis. Let’s

86 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

examine what’s going on in the bottom portion of this dialog:

The element stiffness matrix is recalculated for each iteration and new
time step. The time value at the current step indicates at which pseudo-
time step the load curve is on. The calculation will march forward in
time until it reaches the end time. With the auto stepping option turned
on, the time step increment will be reduced for the current time step if
the calculation fails to converge at the previously attempted increment.
16 Edit displacement plot.
Edit the definition of the Displacement
Plot. Make sure the Time at the bottom
the Display dialog reads 1 sec. You can
adjust the Time by changing the Plot
Step box just above the time. Note how
the Time value changes when changing
the Plot Step. This will set what step and
corresponding time is plotted. Set the
displacement plot scale to 1 as before
in the Deformed Shape dialog.

Objective 87
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

17 Review displacement plot.

18 Probe the displacement at certain locations.

Probe the Displacement results
plot by clicking on the Probe
icon on the COSMOSWorks
Result Tools toolbar.

Click on the results plot in

the middle of the
trampoline.

88 Objective
COSMOSWorks Non-Linear Training Manual Lesson 3
Trampoline

After one or more

nodes are selected,
click on the
Response button and
the accompanied
response graph will be
generated for the
selected nodes.
Click on the X to close
the graph, and then on
the close button on the
Probe dialog.

19 Save and close the part.

Objective 89
Lesson 3 COSMOSWorks Non-Linear Training Manual
Trampoline

Q&A ■ The 2D version of a membrane is a ______________________

■ Generally when pressure loading is applied on a face and nonlinear
analysis is conducted the loading direction has to be updated
because _____________________. We do not need to do this in
linear analysis because ________________________.

90 Q&A
COSMOSWorks Nonlinear Training Manual

Material Models and

Constitutive Relations

91
 COSMOSWorks Nonlinear Training Manual

92
COSMOSWorks Nonlinear Training Manual

Introduction ■ Several mathematical material models are introduced to simulate

the complex behavior of engineering materials.
■ Models are developed based on experimental data.

The following material models are incorporated into COSMOSWorks

nonlinear modules:
■ Elastic Models
■ Elastic-plastic Models
■ Creep Models
■ Temperature – Dependent Properties
■ User-Defined models
Elastic Models Elastic material models are characterized by following the same stress
path for loading/unloading/reloading.
1 Small strain elasticity models:
■ Linear elastic
■ Nonlinear elastic
■ Wrinkling membrane
■ Linear viscoelastic

2 Finite strain elasticity models:

■ Hyperelastic models include:
■ Mooney – Rivlin
■ Ogden
■ Blatz – Ko
Linear Elastic ■ Material behavior can be:
Model Isotropic
Orthotropic
Anisotropic is available in COSMOS/M basic module
■ Current stress is a function of current strain only.
■ Stress – strain relation is linear (Generalized Hooke’s Law).
■ Material properties can be temperature – dependent.

Introduction 93
 COSMOSWorks Nonlinear Training Manual

Nonlinear Elastic ■ Material behavior is:

Model Isotropic
Current stress is a function of current strain only.
■ Stress – strain relation is nonlinear and based on a user – defined
uniaxial stress – strain curve.
■ The user – defined stress – strain curve:
Must be monotonic
Can be unsymmetric in tension and compression
Is not temperature-dependent (except for thermal expansion coeffi-
cient)
■ Applicable to proportional loading problems.

Hyperelastic ■ Material behavior is isotropic.

models ■ Current stress is a function of current strain only.
■ Stress and constitutive relations are derived from a strain energy
density function.
■ Different models are based on different forms of the strain energy
density function. Available models are:
- Mooney – Rivlin : Incompressible rubber – like materials (M-R)
- Ogden (OHE) : Incompressible rubber – like materials
- Blatz – Ko : Compressible foam – type material
■ Incompressibility is imposed (except for plane stress case) by:
- Introducing penalty function
- Using Poisson’s ratio (NUXY) such that 0.49 < NUXY < 0.5
■ Material properties are not temperature – dependent (except for
coefficient of thermal expansion)
Mooney - Rivlin ■ Displacement Formulation
Model (M - R) The modified Mooney – Rivlin strain energy density function
is:

94 Elastic Models
COSMOSWorks Nonlinear Training Manual

w = A ( I 1 – 3 ) + B ( I 2 – 3 ) + X ⎛ ---- – 1⎞ + Y ( I 3 – 1 ) + C ( I 1 – 3 ) ( I 2 – 3 )
1 2
⎝ I3 ⎠
2 2 3
+ D ( I1 – 3 ) + E ( I2 – 3 ) + F ( I 1 – 3 )

where,
I 1, I 2 andI 3 : Invariants of right Cauchy – Green deformation tensor
A, B, C, D, E, and F : Mooney - Rivlin material constants
X = 0.5A + B
( A ( 5υ – 2 ) + ( 11υ – 5 ) )
Y = -----------------------------------------------------------
2 ( 1 – 2ν )
■ Displacement – Pressure formulation:
The Mooney – Rivlin strain energy density function is expressed
as: w = W + Q
where,
W = Strain energy density function due to displacement field
1 2
= A ( J 1 – 3 ) + B ( J 2 – 3 ) + --- K ( J 3 – 1 ) + C ( J 1 – 3 ) ( J 2 – 3 )
2
2 2 3
+ D ( J 1 – 3 ) + E ( J2 – 3 ) + F ( J1 – 3 )
1
– ---
3
J1 = I1 ( I3 )
2
– ---
3
J2 = I2 ( I3 )
1
---
2
J3 = I3 ( I3 )
I 1, I 2, I 3 = Invariants of right Cauchy - Green deformation tensor
J 1, J 2, J 3 = Reduced invariants
Q = The additional strain energy density function due to displace-
ment and pressure field
1 2
= – ------- ( p – p̃ )
2K
where,
p = The hydrostatic pressure as computed directly from displace-
ment
p̃ = The hydrostatic pressure as computed from the separately
interpolated pressure vaiables
ˆ
= gi p i

Elastic Models 95
 COSMOSWorks Nonlinear Training Manual

For constant field, p̃ = pˆ1

For linear field, p̃ = pˆ1 + pˆ2 r + pˆ3 s + pˆ4 t
E
K = bulk modulus = -----------------------
3 ( 1 – 2ν )
E = 6(A + B )
where,
constants A and B are defined such that:
( A + B) > 0
- Constants A and B are determined from experimental data using,
at least, two pairs of strains and stresses.
For more information about how to determine the values of A and
B, refer to the reference by Kao and Razgunas cited at the end of
this chapter.
A 2 – term M – R model can fit the experimental data for a strain
range of up to 150%. (Test cases include simple tension, pure shear,
and equibiaxial extension)
In absence of experimental information, given the Young’s modulus
(E), the A and B coefficients may be roughly assumed as:
A = 0.8E
B = 0.2E
- Terms C through F can be used to expand the model to strains as
large as 600%.
Ogden Model (OHE) ■ Displacement Formulation
The modified Ogden strain energy density function is expressed
as:
α α α
⎛ ( λ1 ) + ( λ 2 ) + ( λ 3 ) – 3 ⎞
k k k
N 1 2
W = µ k ⎜ ------------------------------------------------------------------- – ln ( J )⎟ + ------- G ( J )
k = 1 ⎝ αk ⎠ 2α
where,
α k, µ k = Material constants
λ i = Prinipal stretches
J = Ratio of the deformed volume to undeformed volume.
2
G( J) = J – 1
1 N ( 1 + 4ν )
--4- = --- µ α ----------------------- where, ν - Poisson ratio
α 3 k = 1 k k 2 ( 1 – 2ν )
N = Number of terms in the function
■ Displacement - Pressure formulation:
w = W+Q
where,

96 Elastic Models
COSMOSWorks Nonlinear Training Manual

αn αn αn
N ⎧ µk ------
2
------
2
------
2 ⎫ 1 2
w = ⎨α
-----
- ( L 1 ) + ( L 2 ) + ( L 3 ) – 3 ⎬ + --- K ( J 3 – 1 )
k = 1⎩ k ⎭ 2
where,
L 1, L 2, L 3 = Reduced principal values of right Cauchy - Green
deformation tensor.
1
2 – ---
3
Li = λ ( I3 )
i
G 1 N
K i = ---------------, G = --- α µ
1 – 2ν 2k = 1 k k
Q = As defined previously for the Mooney - Rivlin model

- A 3 – term modified Ogden model is widely used.

- Up to 4 – terms (N=4) can be specified.
- A 3 – term OHE model can describe deformation of rubber mate
rial for strains up to 600%.

■ Mooney – Rivlin (M – R) and Ogden (OHE) Models

The two-term Ogden function is equivalent to the two-term M – R
strain function by noting that:
α 1 = 2 and α 2 = – 2
µ 1 = 2 *MOONEY_A and µ 2 = – 2 *MOONEY_B

■ M – R model may have higher computational efficiency than OHE.

■ In order to obtain constants beyond the first two – terms from
experimental data, curve fitting or an optimization program is
required (supported in COSMOSM).
V
■ Element output includes the ratio ------
V0
V = the volume of the deformed element
V 0 = the initial volume of the element
Blatz - Ko Model ■ The Blatz - Ko strain energy density function can be expressed as:
1 I
w = --- G ⎛ ---2- + 2 I 3 – 5⎞
2 ⎝ I3 ⎠

where,
E
G = Shear modulus under infinitesimal deformations = --------------------
2(1 + ν)
E = Youngs’s modulus of elasticity
ν = Poisson’s ratio = 0.25

Elastic Models 97
 COSMOSWorks Nonlinear Training Manual

I k = Invariants of C = I k ( C )
˜ ˜
C = Cauchy - Green deformation tensor = 2E + I
˜ ˜ ˜
E = Lagrangian strain tensor
˜
I = Identity matrix
˜
■ Only one material constant G is needed since ν is assumed equal to
0.25.
E
G = -------
2.5
General Notes ■ The total Lagrangian formulation is used.
■ The NR (Newton – Raphson) iterative method is recommended.
■ If the structure is subjected to pressure loading, use the
displacement – dependent loading option.
■ Loads should be applied in small increments at the beginning of the
solution. Rapid increase in loading will often result in either
negative diagonal terms in the stiffness or divergence during
equilibrium iterations.
■ Using higher order elements provide higher numerical stability.
Elasto - Plastic ■ Elasto – plastic material models are characterized by their path
Models dependency.
■ Different stress path for loading/unloading/reloading and inelastic
deformations are encountered.
- Small strain elasto-plastic models:
- von Mises
- Drucker – Prager
- Finite strain elasto-plastic models:
- von Mises

Background ■ In elasto – plasticity using the flow theory approach, three

properties, in addition to the elastic stress – strain relations, are
needed.
- Yield Criterion:
Specifies the state of multiaxial stress corresponding to the onset of
the plastic flow.

98 Elasto - Plastic Models

COSMOSWorks Nonlinear Training Manual

- Hardening Rule
Specifies how the yield criterion is modified during plastic flow.
- Flow Rule:
Specifies the relationship between the plastic strain increments, the
current stress, and the stress increments after yielding.
■ Yield Surface
- A yield criterion can geometrically be represented by a surface in
the principal stress space ( σ 1, σ 2, σ 3 )
- Different yield criteria have different yield surface representa-
tions.

■ Isotropic Hardening

Elasto - Plastic Models 99

 COSMOSWorks Nonlinear Training Manual

- The initial yield surface expands uniformly in the stress space

without distortion and translation during the plastic flow maintain-
ing the same shape, center, and orientation.

■ Kinematic Hardening
- The loading surface (subsequent yield surface) translates as a rigid
body in the stress space during the plastic flow maintaining the size,
shape, and orientation of the initial yield surface.
- The hardening rule can be used to account for the Bauschinger
effect.

■ Anisotropic (Mixed) Hardening: (not yet

available)
- The loading surface surface experiences translation and uniform
expansion in the stress space, but it still keeps its original shape.
■ Associated Flow Rule:

100 Elasto - Plastic Models

COSMOSWorks Nonlinear Training Manual

- The plastic strain increment vector is developed in the direction of

the normal to the current loading surface. This is the most widely –
used flow rule.

■ Non - associated Flow Rule:

- The plastic strain increment vector is developed in the direction of
the normal to the plastic potential surface.
- Very little experimental information on the plastic potentials for
engineering materials is known.

Elasto - Plastic Models 101

 COSMOSWorks Nonlinear Training Manual

Small Strain - Material behavior is isotropic.

ELASTO – PLASTIC - Stress – strain relation is nonlinear.
Models - Strain is a function of the current stress and previous stress history
(path dependent).

■ Von Mises Model (primarily to describe

behavior of metals)
The yield criterion can be written in either of the following forms:
1 1 2
- Isotropic Hardening: F = --- S ij Sij – --- σ y = 0
2 3
where, S ij = the deviatoric stress tensor
σ y = the yield stress from uniaxial tests
1 0 0 1 2
- Kinematic Hardening: F = --- ( S ij – S ij ) ( S ij – S ij ) – --- σ y 0 = 0
2 3
0
where, S ij = the deviatoric stress tensor representing the center
of the yield surface
0
σ y = the initial yield stress from uniaxial tests
- Both bilinear and multi-linear curve description are available.
- The bilinear model can be temperature- dependent for some
elements.
- For the multi-linear curve model, the following should be
noted:
- The curve must be monotonic
- Symmetric behavior in tension and compression is
assumed (only the tension part of the curve should be
input).
- The first point on the curve defines the initial yield stress
and strain.
- The model is not temperature – dependent.
■ Drucker - Prager Elastic - Perfectly
Plastic Model

102 Elasto - Plastic Models

COSMOSWorks Nonlinear Training Manual

- the yield criterion can be written in the

form: F = 3ασ m + σ – k = 0
where,
α and k = Material constants
σ kk
σ m = Mean stress = --------
3
1---
= effective stress = S S
2 ij ij
σ and k = Function of two material parameters, φ and c obtained
from triaxial experiments.
where,
φ = Angle of internal friction
c = Material cohesion strength

- Drucker – Prager model can be used to simulate the behavior of

granular soil materials such as sand and gravel.
- For soil mechanics problems, gravitational acceleration can have
significant effect. Therefore, its effect should be included.
- Material parameters φ and c must be bounded in the following
ranges:
90 ≥ φ ≥ 0 (degrees)
c ≥ 0 (force/unit area)
General Notes ■ An associated flow rule assumption is made.
■ Problems with large displacements can be handled, provided that
the small strains assumption is still valid.
■ The use of MNR (Modified Newton – Raphson) iterative method
generally is not recommended.

■ Huber – von Mises Model

- Large strain plasticity is assumed when the large displacement
option with updated Lagrangian formulation is considered for cer-
tain element groups.
- Because the elasticity in the current case is modeled in hypoelastic
form, thus it is restricted to small elastic strains but allowed for
arbitrary large plastic strains.
- A logarithmic strain measure is defined as: ε = ln [ U ]
˜ ˜
where, U is the right stretch tensor
˜
- The large strain plasticity formulation is applied to von Mises
yield criterion with an associated flow rule and the isotropic or
kinematic hardening (bilinear or multi-linear).

Elasto - Plastic Models 103

 COSMOSWorks Nonlinear Training Manual

- Temperature-dependency of material properties is supported by

bilinear hardening only.
- The Cauchy stresses, logarithmic strains, and current thickness
(shell elements only) are available in the output.
Linear Elastic Elastic materials having the capacity to dissipate the mechanical energy
Viscoelastic due to viscous effects are characterized as viscoelastic materials.
model For the multiaxial stress state, the constitutive relation may be defined
t t
d d
as: σ ( t ) =
˜
∫ 2G ( t – τ ) d τ e˜ dτ + I˜ ∫ K ( t – τ ) d τφ˜ dτ
0 0

where, e = deviatoric strains

˜
φ = volumetric strain
˜
G ( t – τ ) = shear relaxation function
K ( t – τ ) = bulk relaxation function
- Relaxation function is represented by a Generalized Maxwell Model
–⎝ ⎛ ---------
t -⎞
⎛ NG ττ i G ⎞
⎠
expressed as: G ( t ) = G 0 1 – gi ⎜ 1 – e ⎟
i = 1 ⎝ ⎠

–⎝ ⎛ ---------
t ⎞
-
⎛NK ττ i K ⎞
⎠
K( t ) = K0 1 – ki ⎜ 1 – e ⎟
i = 1 ⎝ ⎠
where,
G 0 = instantaenous shear modulus

K 0 = instantaenous bulk modulus

104 Linear Elastic Viscoelastic model

COSMOSWorks Nonlinear Training Manual

G K
= i-th shear and bulk moduli and associated times g i, k i, τ i and τ i

- Temperature effect on the material behavior is introduced through the

time – temperature correspondence principle: Gα ( t, T ) = Gα ( γ t, T 0 )
where,
γ t = the reduced time

γ = the shift function

- The WLF (Williams – Landel – Ferry) equation is used to
⎛ C1 T ⎞
approximate the function: ln γ = ⎜ ----------------⎟ ln ( 10 ) ;T = T – T 0
⎝ C 2 + T⎠

where,
T 0 = the reference temperature which is usually picked as the Glass
transition temperature
C 1 and C 2 = material dependent constants

Note ■ For TRUSS elements, only uniaxial stress state is considered.

Relaxation functions are reduced to the extension part. The
extension and relaxation moduli are input through K1, TAUK1, …..
.
■ The parameters G1, TAUG2 are not required.
■ For BEAM elements, Note (1) is applied to the extension direction;
G1, TAUG1, ….. , are needed only when the torsional degree of
freedom is considered.
Creep ■ Creep is a time – dependent strain produced under a state of
constant stress.
■ Creep is observed in engineering material:

Creep 105
 COSMOSWorks Nonlinear Training Manual

Metals at elevated temperatures

High polymer plastics
Concrete
■ Creep involves larger time scale than structural dynamics, thus its
effect can be neglected in dynamic analysis.
■ Creep curve is a graph between strain versus time.
■ Three different regimes may be considered:
Primary
Secondary
Tertiary
■ Usually the primary and secondary regimes are of interest.

■ Elastic creep analysis is available in NSTAR. Two creep laws based

on the “Equation of State” approach are implemented.
■ Each law defines an expression for the uniaxial creep strain in
terms of the uniaxial stress and time.
■ Classical Power Law (Bailey – Norton
CT
– ⎛ ------⎞
c ( C1 ) ( C2 ) ⎝ T ⎠
law): ε = C 0 e t e , C 1 > 1 and 0 < C 2 ≤ 1
where,
C 1 to C 2 = Creep constants
t = Real time (not pseudo)
σ = Total uniaxial stress at time t
T = Absolute temperature in degree Kelvin
C T = A material constant defining the creep temp-depend.
■ Both laws only represent the primary and secondary creep regimes.
■ To extend the uniaxial creep laws to simulate the multi-axial creep
behavior, the following assumptions are made:
- The uniaxial creep law remains valid if the uniaxial creep strain
and stress are replaced by the effective strain and stress.

106 Creep
COSMOSWorks Nonlinear Training Manual

- Creep strains are incompressible

- The material is isotropic
■ For variable stress problems, strain hardening formulation is
adopted.
■ ORNL (Oak Ridge National Laboratory) auxiliary strain hardening
rules are used to extend creep behavior for stress reversal
conditions.
References K.J. Bathe - Finite Element Procedures in Engineering Analysis,
Prentice-Hall, 1982.
P.J. Blatz and W.L. Ko - Application of Finite Elastic Theory to the
Deformation of Rubbery Materials Transactions of the Society of
Rheology, Vol. 6, 1962, pp. 223-251.
R.M. Christensen - Theory of Viscoelasticity, Second edition, 1982.
M. Fujikake, O. Kojima and S. Fukushima - Analysis of Fabric Tension
Structures Computer & Structures, Vol. 32, pp. 537-547, 1989.
R. Hill - The Mathematical Theory of Plasticity, Oxford University
Press, London, 1950.

References 107
 COSMOSWorks Nonlinear Training Manual

108 References
COSMOSWorks Non-Linear Training Manual

Lesson 4
Paperclip

109
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

110
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

Objective A paperclip made of AISI 1020 steel is fixed at its inner bend and a
load of 0.2 lb is applied to its outer bend. We will use a force control
method to first apply the full load and then unload it to find its resulting
permanent set.

1 Open Assembly
Click File, Open to open
the assembly file
Paperclip.sldprt
from the Lesson 4
folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Define study.
Define a study named Linear, select
Analysis type as Static and Mesh type
as Solid.

Objective 111
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

4 Insert Restraint.
Insert a restraint by clicking on the
Restraints icon in the Loads
toolbar.

Insert a fixed
condition on
the three
faces shown.

5 Apply Force,
Apply a force by
clicking on the
Force icon in the
COSMOSWorks
Loads toolbar.

112 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

Select the face shown.

Then click in the Direction box and

choose the Top plane. Apply a force
of 0.2 lb in the Normal to the selected
plane direction.

Objective 113
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

6 Run Analysis.
Run the linear
static analysis by
clicking on the
Run icon in the
COSMOSWorks
Main toolbar.
COSMOSWorks
will
automatically
mesh the solid
with the default mesh size and then immediately solve the analysis after
meshing.
After the model meshes and
finishes solving, click on OK in
the dialog box that indicates
that the Static Analysis is
Completed.

7 Hiding Restraint symbols.

Before viewing the calculated
results, right-click the Load/
Restraint icon and select Hide
All from the context sensitive menu.
8 View Stress Results.
Open the Stress folder by clicking on the + button and then double
click the Plot1 icon to show the von Mises stress plot in the

114 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

graphics window.

Note The maximum von Mises stress has gone beyond the yield strength of
the material, indicated by the Red arrow next to the legend. The
maximum von Mises stress is roughly 80200 psi.
9 View Displacement Results.
Open the Displacement folder by clicking on the + button and then
double-click the Plot1 icon to show the Resultant Displacement plot

Objective 115
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

in the graphics window.

Note The maximum displacement is roughly 0.565 in.

10 Define Nonlinear study.
Define a study named Permanent Set,
select Analysis type as Nonlinear and
Mesh type as Solid.

116 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

11 Edit Material.
Edit the material
properties of the
paperclip by right-
clicking on the
component icon and
choosing Apply/Edit Material…
Select Custom Defined from the Select material source dialog in the
upper left corner of the window. Choose Plasticity – von Mises from
the nonlinear Material Type. Make sure Units are in English (IPS).
Set the Tangent modulus (ETAN) value to 2900755, roughly 10% of
the linear Elasticity modulus. This value is an approximation for the
bilinear stress-strain curve.

Click OK.

Objective 117
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

12 Copy load/Restraints from linear study to nonlinear study.

Ctrl+select the Load/
Restraint and Mesh
icons from the Linear
analysis, and holding down
the left mouse button, drag-
and-drop these onto the
Permanent Set
nonlinear analysis icon. Drag
This is a quick way to and
define the boundary Drop
conditions for the new
analysis by reusing the
settings of a previous
analysis.

13 Define loading and unloading force.

We will now define the loading
and unloading of the force by
choosing Edit Definition…
from the context-sensitive
Force menu.

Select the Curve radio button in the

Variation of time dialog and then click
the button that reads Edit…

118 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

Rename the Time curve: Load-

Unload 2 secs. Double-click in
the row that reads (1, 1) and a
new row will be created under
it. Type 2 in the X column for
seconds and 0 in the Y column
for the scaling value. Then click
on the button View to see the
actual curve data plotted.

The curve data is

shown.
Close the Time curve
plot by clicking the X
in the upper-right
corner of the window.

Click on OK to accept the Time curve and then click the green check to
apply the updated Force definition.
14 Set properties of nonlinear analysis.
Set the properties for the
nonlinear analysis by right-
clicking the Permanent
Set study name and
choosing Properties…
from the context-sensitive
menu.

Objective 119
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

Make these settings:

Start time: 0
End time: 2.
Initial time increment:
0.01, Min: 1e-8, Max:
0.1 & No. of
adjustments keep at 5.
Under the Geometry
nonlinearity options,
make sure Use large
displacement
formulation is selected
and also select Use
large strain
formulation (for
plasticity material
models only), Solver
is Direct Sparse. Click
on Advanced Options,
verify that Force
control and NR
iterative method are set and accept all the other default settings.
Click OK.
15 Run the analysis.

120 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

Note This analysis takes a long time to run (approximately 1 hour).

This nonlinear analysis has to incrementally load and then unload the
applied force. It will continue calculating until 2 secs has been reached,
at which time the load is no longer applied to the paperclip.
STOP the analysis now! Click on the red X in the upper right-hand
corner of the window.
16 Loading saved results.
Unzip the contents of
the “paperclip-
Permanent Set-
CWR.zip” archive file to
the directory named
“work” under the COSMOSWorks Applications installation folder,
which by default is: “C:\Program Files\COSMOS
Applications\work”.
Save and close the solid model paperclip.SLDPRT, and then
reopen the file again to refresh the data connection.

Note It is important that your nonlinear analysis study name is

“Permanent Set,” otherwise this procedure will not be
successful. If needed, you can change the second part of the CWR
filename to your study name, e.g. paperclip-your study name.CWR
The CWR file contains the entire dataset for COSMOSWorks analyses.
It is important that if you want to archive your nonlinear analysis, that
you also archive this CWR file along with your SolidWorks assembly
and part files.

Objective 121
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

17 Creating Stress Plot.

Create a Stress plot by clicking
on the Stress icon in the
COSMOSWorks Result
Tools toolbar.

Set the Plot Step to 79 for 1 sec, which

corresponds to the full applied load step
based on the load curve that we defined
earlier. Make sure that the Automatic
Deformed Shape scale is 1, otherwise
set the Defined scale to 1.
Click on the green arrow to accept.

122 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

18 Viewing Stress Result.

Note that the maximum von Mises Stress is much lower than the
roughly 80200 psi calculated for the Linear stress results. This is
because of the bilinear stress-strain curve is less steep after yielding
occurs.

19 Create Displacement Plot.

Create a Displacement plot by
clicking on the Displacement
icon in the COSMOSWorks
Result Tools toolbar.

Objective 123
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

Again set the Plot Step to 79 for 1 sec.

20 View Displacement Results.

Note that the maximum Resultant Displacement is much greater than
the roughly 0.56 in calculated for the Linear stress results. This is
because the part is undergoing large plastic strain, which will

124 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

ultimately lead to a permanent set.

21 Show Displacement plot.

Right-click and show the Displacement
Plot1.

Objective 125
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

If it is not showing Plot Step number

138 at 2 seconds, when there is no longer
any load applied, or not at a deformed
shape scale of 1 (shown by the
annotations for the plot in the upper left
corner of the graphics window) then
make the change by editing its definition.

This is the permanent set for the paperclip after its entire loading and
unloading cycle.

126 Objective
COSMOSWorks Non-Linear Training Manual Lesson 4
Paperclip

22 Probe Displacement Plot.

Select a node
near the top
of the
paperclip and
then click on
the Response
button.

The
response
plot is
shown.

23 Save and close the part.

Objective 127
Lesson 4 COSMOSWorks Non-Linear Training Manual
Paperclip

128 Objective
COSMOSWorks Non-Linear Training Manual

Lesson 5
Crankarm

Upon successful completion of this lesson, you will be able to:

Retrieve the model
Define a nonlinear static study - apply material restraints, and mesh
Define multiple pseudo-time curves for loading.
Apply loads on different faces, with each load following a different
time curve.
Study the different effects of Isotropic and Kinematic hardening
Run nonlinear analysis and visualize the stress and displacement
results.

129
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

130
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

Objective The crank arm shown below is made of alloy steel. A cyclic bearing
load of 2300 lbf is applied on it. This cyclic load is simulated by
alternately applying the 2300 lbf on the two faces shown. The
displacement response of the system is studied for both isotropic and
kinematic hardening rules.

1 Open Assembly
Click File, Open
to open the
assembly file
Crankarm.sl
dprt from the
Lesson 5
folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Create study.
Define a study named
Isotropic, select
Analysis type as
Nonlinear and Mesh
type as Solid mesh.

Objective 131
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

4 Apply Restraints.
Apply restraint by right-click Load/
Restraint and selecting Restraints... or
choosing the Restraints icon from the
COSMOSWorks Loads toolbar.

Select the outer edge of the model and

set the Restraint type as fixed.

Note It helps to visualize settings by showing preview.

132 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

5 Apply material.
Apply the following
custom-defined
properties for the part.
This represents a
bilinear material
model.

Note The hardening factor of 0 represents isotropic hardening. It may be

necessary to define a small positive value, say 1e-6, instead of 0 for the
isotropic hardening value.

Objective 133
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

6 Apply force.
Apply a 2300 lb of force in the given
direction that is associated with a time
Curve input as shown below.

134 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

Force input graph

Preview of the force

Objective 135
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

7 Apply force.
Apply a 2300 lb of force in the opposite direction
that is associated with a different time curve input
as given below.

Force input graph.

136 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

Force property manager input

Objective 137
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

8 Set Nonlinear analysis properties.

Set the Nonlinear
Analysis option are set
by right-clicking the
Isotropic study and
choosing Properties.
Click the Advanced
Options button.

Check the solution

method and make sure
that the Control
Method is Force and
iterative method is NR
(Newton-Raphson).
Click on OK.

Click OK.

138 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

9 Set response options.

Under the Isotropic study, Result
Options menu, choose Define/Edit. Choose the
vertex (see picture) at the upper quadrant of the
circle near the top of the crankarm.

Ask for the response to be saved for all

solution steps.

Objective 139
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

10 Create Mesh.
Create the mesh using a 0.2 in element
size, and select to Run the analysis
after meshing.

Make sure you select draft quality mesh

in the mesh options.

11 Review analysis dialog box.

This dialog box will appear while solving the nonlinear analysis. Let’s

140 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

examine what’s going on in the bottom portion of this dialog:

The element stiffness matrix is recalculated for each iteration and new
time step. The time value at the current step indicates at which pseudo-
time step the load curve is on. The calculation will march forward in
time until it reaches the end time. With the auto stepping option turned
on, the time step increment will be reduced for the current time step if
the calculation fails to converge at the previously attempted increment.
After the solution is completed,
click on OK in the dialog box.

12 Hiding Restraint symbols.

Before viewing the calculated
results, right-click the Load/
Restraint icon and select
Hide All from the context
sensitive menu.

Objective 141
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

13 Edit displacement plot.

Open the Displacement results folder by
clicking on the + sign next to it and
double-click on the Displacement
plot. Note that the default deformed
shape is scaled by a value that you can
change, e.g. 1. Plot the displacement
results with a scale of 1 (to-scale).
Choose the last time step. This shows
the plastic set after loading, unloading,
reverse-loading and unloading.

142 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

14 View results

Objective 143
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

Create the response for the pre-defined

vertex as below by right-clicking on the
Response option.

144 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

15 Define a new study.

Define a new study by
right clicking on the
Isotropic study
and choosing Copy.
Then go on
CRANKARM icon on
the first line, right
click and choose
Paste. This will
duplicate the previous
study under a new
name (Kinematic).

16 Change material properties.

Open the material
property definition
dialog box and change
the hardening factor
to 1, representing
kinematic hardening.
Also change the name
to Kinematic.

17 Run the analysis.

Run the analysis by right-clicking the study name and choosing Run
from the context-sensitive menu or clicking the Run icon on the
COSMOSWorks Main toolbar.
Analysis takes a couple of minutes to complete.

Objective 145
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

18 Check response.
Create the response for the pre-defined
vertex as below by right-clicking on the
Response option.

19 Save and close part.

146 Objective
COSMOSWorks Non-Linear Training Manual Lesson 5
Crankarm

Q&A ■ __________________hardening rule led to a greater plastic yield.

■ Real world behavior is simulated
by___________________________
■ If the large strain plasticity option is used, the plasticity tolerance
can be set to a maximum of ______________________
■ The plasticity strain tolerance is set under the (Study > Properties)/
(Edit/Define Material).
■ If the large strain plasticity model is used and a material curve is
loaded, the material curve should be stress vs.
_______________strain while if the small strain plasticity model is
used, the material curve should be stress vs.
________________strain.
■ If a bilinear material curve is used, only the following material
properties need to be defined for both small and large strain
plasticities _____________________________
■ The material properties used in isotropic and kinematic hardening
are similar/dissimilar.

Q&A 147
Lesson 5 COSMOSWorks Non-Linear Training Manual
Crankarm

148 Q&A
COSMOSWorks Non-Linear Training Manual

Lesson 6
Rubber Diaphragm

Upon successful completion of this lesson, you will be able to:

Mooney-Rivlin material model.
Retrieve the model
Define a nonlinear static study
Define hyperelastic material constants.
Define pseudo-time curve for displacement control.
Apply loads and restraints, and mesh
Define the nonlinear analysis properties for displacement control.
Run nonlinear analysis and visualize the results.

149
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

150
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

Objective A full 360 degree model of the rubber diaphragm is shown at left. This
model is 5 inches in diameter and 0.1 inches thick. In this analysis, only
a quarter model (at right) with symmetric boundary conditions is used.
The loading is a normal pressure, but we want to limit the maximum
displacement to 1.6 inches. We use the displacement control method to
solve this problem and thus find the load to achieve this displacement.

1 Open Assembly
Click File, Open to open
the assembly file
Rubber.sldprt from
the Lesson 6 folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Change SolidWorks configuration.
Pull down Feature
manager window, select
Configuration Manager.
Select Quarter Model
configuration. After
selection, drag Feature
Manager back up.

Note COSMOSWorks associates analysis studies with SolidWorks

configurations.

Objective 151
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

4 Create study.
Name it Nonlinear.
Analysis type:
Nonlinear
Mesh type: Shell
mesh using
surfaces

5 Define shell surfaces.

Right-click the Shell icon and
choose Define by Selected
Surfaces…

Select the quarter section of the

diaphragm and set the shell type
to Thick and input a thickness
of 0.1 in.

6 Apply Restraint.
Insert a restraint by right-clicking
the Load/Restraint icon or
clicking on the Restraints icon in
the Loads toolbar.

Fix the outer edge of the quarter

section.

152 Objective
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

7 Apply first symmetry restraint.

Apply another restraint to the one edge
of the split line that lies perpendicular to
the z-axis.

Use the Front plane as a

reference geometry so that you
can apply the correct normal
translation and other rotations
for a symmetry boundary
constraint.

Objective 153
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

8 Apply second symmetry constraint.

Now do the same thing to the other edge
of the split line that lies perpendicular to
the x-axis.

Use the Right plane as a reference

geometry so that you can apply
the correct normal translation and
other rotations for a symmetry
boundary constraint.

154 Objective
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

9 Rename restraints.
Rename all of the Restraints by slow
double-clicking on the icons so that they
reflect their settings. This is useful when
you come back to an analysis after having
archived it.

10 Apply Pressure.
Apply a Pressure restraint by right-
clicking the Load/Restraint
folder icon and choosing Pressure.

Select the face of the quarter

section and set a pressure of 20
psi.

Objective 155
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

Preview the load curve for the pressure

to verify that a load factor of 1
corresponds to 20 psi.

View graph.

11 Hide all restraints.

Hide All of the Loads and Restraints
so that they are just visually not
shown although they are still
applied.
To totally remove a boundary
condition from the analysis, you can either Delete it or Suppress it
from the context-sensitive menu.
12 Create Response plots.
Right-click Result Options
and choose Define/Edit…

Make sure that the selection to

save results for all solution
steps is chosen, and then click
on the vertex in the middle of the
diaphragm as the point to obtain
the response plot.

156 Objective
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

13 Set Nonlinear properties.

In the Nonlinear Properties, make sure that:
Start time = 0
End time = 1
Automatic
(autostepping) is
selected.
Initial time increment
= 0.01
Min = 1e-008
Max = 0.1
No. of adjustments =
5.
Click on Advanced
Options...

For the Control

Method choose
Displacement, and
make sure that the
Iterative Method is NR
(Newton-Raphson).
Select the vertex in the
middle of the
diaphragm as the
reference point to
control the analysis.
Set the displacement
component to UY: Y
Translation and the
units to inches.
Click on Edit…

Objective 157
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

In the Time Curve settings,

set the curve data to have two
rows with this data: (0, 0) and
(1, -1.6).

14 Apply material.
Choose to Apply/Edit Material…
from the Shell icon context
sensitive menu.

For the Select material source

dialog, change the setting from
Use SolidWorks material to
Custom defined.
Choose HyperElastic – Mooney
Rivlin for the Material Properties
Model Type, set the Units to
English (IPS), and rename the
material as M-R Rubber.
Set the Poisson’s ratio to 0.499 and the material constants Mooney_A
and Mooney_B to 175 and 10 psi, respectively.

Note The Mooney-Rivlin material properties selected for this rubber was
obtained by using the existing Modulus of Elasticity, EX, from the
Linear properties and using this assumption:
Mooney_A = 0.75 * (EX/6)
Mooney_B = 0.25 * (EX/6).

158 Objective
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

15 Run the analysis.

Choose to run the
analysis.
The program will
automatically
mesh the surface
with the default
mesh size and run
the solution
immediately after
meshing.
16 Plot displacement.

17 Create Response plot.

Create a Response plot by right-clicking
the folder icon and choose Define…

Objective 159
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

Set the variable to URES: Resultant

displacement and the Units to inches.

The response plot is given.

Note The maximum load factor is approximately 1.26 indicating that the
pressure required to displace the middle of the diaphragm 1.6 inches is
25.2 psi.
18 Save and close part.

160 Objective
COSMOSWorks Non-Linear Training Manual Lesson 6
Rubber Diaphragm

Q&A ■ In this analysis, we checked the “Update load direction with

deflection’ option because we applied _____________________
loading.
■ The above option is found under
____________________________________
■ In this model, we use __________________ control, though the
loading is through ___________________.
■ In a majority of models, in this manual, we use
__________________control, except in Exercise 2, where we use
___________________ control.
■ In displacement control, the value to which we want to limit the
displacement to is defined by the _______________ curve. But the
values should be entered ONLY in __________ units.

Q&A 161
Lesson 6 COSMOSWorks Non-Linear Training Manual
Rubber Diaphragm

162 Q&A
COSMOSWorks Non-Linear Training Manual

Lesson 7
Beam

Upon successful completion of this lesson, you will be able to:

Retrieve the model
Define a linear static study - apply material, loads and restraints and
mesh
Run static analysis and visualize static analysis results
Define a nonlinear study
Define a stress strain curve
Define pseudo-time curves for loading.
Copy loads and restraints and mesh from the static analysis study.
Edit the loading in order to follow the time curve.
Apply the stress strain curve
Run nonlinear analysis and visualize the stress and displacement
results.

163
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

164
COSMOSWorks Non-Linear Training Manual Lesson 7
Beam

Objective The rectangular beam shown below is a half-symmetric model of a 2x2

inch cross-sectional 20-inch long solid beam. The beam is made of a
material with an Elastic modulus of 1e+7 in compression and 1e+6 in
tension. A vertical force is applied on the cantilever beam.

1 Open Assembly
Click File,
Open to open
the assembly file
beam.sldprt
from the
Lesson 7
folder.

2 COSMOSWorks FeatureManager.
Click COSMOSWorks FeatureManager.
3 Use configuration.
Click on the Configuration tab.
Notice the Default and
Symmetry
configurations, which
model the full and half-
symmetric beam respectively.
COSMOSWorks studies can be
associated with a specific configuration. We will work with the
symmetry configuration in the study to be created.

Objective 165
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

4 Create Study.
Define a study
named Linear, select
Analysis type as
Static and Mesh
type as Solid mesh.

5 Define Material.
Define a Custom defined material and apply an Elastic modulus of
1e7 psi and a Poisson’s ratio of 0.3. The shear modulus is
automatically calculated based on the elastic modulus and Poisson
ratio. Note the selected unit while inputting the values.

6 Apply Restraints.
Apply restraint by right-click Load/Restraint and selecting
Restraints... or choosing the Restraints icon from the COSMOSWorks
Loads toolbar.
Select the back face of the model and set the Restraint type as fixed.

166 Objective
COSMOSWorks Non-Linear Training Manual Lesson 7
Beam

Note It helps to visualize settings by showing preview.

7 Set symmetry restraints.
Select the symmetry plane of the model
and set the Restraint type as Symmetry.
This will allow the face to slide in its
plane but prevents movement in the
perpendicular direction.

Objective 167
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

8 Apply Load
Apply a 1000 lb of force on the
horizontal lower edge at the other end.

The force
is applied
along the
vertical
edge.

9 Create Mesh.
Select the Draft quality element under Mesh and select Properties.

168 Objective
COSMOSWorks Non-Linear Training Manual Lesson 7
Beam

Create the mesh using the default

element size, and select to Run the
analysis after meshing.

After the model meshes and finishes solving, click on OK in the dialog
box that indicates that the Static Analysis is completed.
10 Hide all loads and restraints.
Before viewing the calculated results, right-click the Load/
Restraint icon and select Hide All from the context sensitive
menu.

Objective 169
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

11 Set displacement settings.

Open the Displacement results folder by
clicking on the + sign, right-click the
Plot1 icon and choose Edit
Definition.
Select the scale factor as Defined and
type in a value of 1 to see the actual
displacement.

12 View Displacement.

13 Define Nonlinear study.

Define a new study
named NL, choose
the analysis type as
Nonlinear, and set
the Mesh type as
Solid mesh.

170 Objective
COSMOSWorks Non-Linear Training Manual Lesson 7
Beam

14 Copy study.
Ctrl-select the icons for Materials,
Load/Restraint and Mesh from
the above Linear analysis settings
and holding the mouse button down
drag-and-drop them onto the NL
analysis study name. Note that all the
materials, loads, restraints and mesh
that was defined earlier has been
exactly copied to the new study.

15 Change material and load.

Open the material
property definition
dialog box, choose
Model Type as
Nonlinear Elastic and
name it the same, input
a Poisson ratio of 0.3.

Edit Stress-Strain curve and input a 3 point curve as below,

representing different Elastic modulus values in tension and

Objective 171
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

compression.

16 Set Nonlinear properties.

Set the Nonlinear Analysis option by right-clicking the NL study and
choosing Properties.
Click the Advanced
Options button to check
the solution method.

172 Objective
COSMOSWorks Non-Linear Training Manual Lesson 7
Beam

Make sure that the

Control Method is
Force and iterative
method is NR
(Newton-Raphson).
Click on OK.

Click OK.
17 Run Nonlinear analysis.
This dialog box will appear while solving the nonlinear analysis. Let’s
examine what’s going on in the bottom portion of this dialog:

The element stiffness matrix is recalculated for each iteration and new
time step. The time value at the current step indicates at which pseudo-
time step the load curve is on. The calculation will march forward in
time until it reaches the end time. With the auto stepping option turned
on, the time step increment will be reduced for the current time step if
the calculation fails to converge at the previously attempted increment.

Objective 173
Lesson 7 COSMOSWorks Non-Linear Training Manual
Beam

18 Hide all loads and restraints.

Before viewing the calculated results, right-click the Load/
Restraint icon and select Hide All from the context sensitive
menu.
19 Displacement settings.
Open the Displacement results
folder by clicking on the + sign
next to it and double-click on the
Displacement plot. Note that the
default deformed shape is scaled
by a value that you can change,
e.g. 1. Plot the displacement
results with a scale of 1 (to-
scale) for the last time step.

20 View Displacement Plot.

Discussion Comparing with the previous study, you see that the maximum
displacement at the tip is about 3.7 times higher in this nonlinear study
where the elastic modulus in tension is 1/10 of that in compression, the
same unique value specified in the first analysis for both tension and
compression.

174 Objective
COSMOSWorks Non-Linear Training Manual Lesson 7

Objective 175
Lesson 7 COSMOSWorks Non-Linear Training Manual

176 Objective
COSMOSWorks Nonlinear Training Manual

3D Contact

177
 COSMOSWorks Nonlinear Training Manual

178
COSMOSWorks Nonlinear Training Manual

Global Contact/ When COSMOSWorks analyzes 3D solid assemblies (except in

Gap Conditions Optimization studies) a new icon, named Contact/Gaps, above the
Mesh icon is always present. We use this icon to define how the
assembly components interact with each other. Let’s examine the
options available when defining component interaction. Right-click
Contact/Gaps and select Set Global Contact. The Global Contact
window appears.

The Global Contact window specifies how to treat all touching faces
in the assembly. You can override the global conditions by defining
different conditions locally for selected pairs of faces or for selected
components. The available options: Bonded, Free and Node-to-node
are explained in the following illustration and table:

Global Contact
Types
Global Contact
Description
Type
Touching faces: The default choice, this option, when selected,
Bonded causes the assembly to behave as one part.
Common nodes on the touching faces are
actually merged together. If touching faces are
left as Bonded, the only difference between a
part and an assembly is that in an assembly we
can assign different material properties to
individual components.

Global Contact/Gap Conditions 179

 COSMOSWorks Nonlinear Training Manual

Global Contact
Description
Type
Touching faces: Select this option when the assembly is a
Free series of unattached components with no
structural connection between them. As the
illustration depicts, individual components
may penetrate each other, which is a physical
impossibility, so it is not recommended to use
this option if you expect the external loads to
push components into each other. It is only
recommended to use this option to allow
components, initially touching, to move away
from each other.
Touching faces: Select this option when touching faces can
Node to node come apart, but cannot penetrate each other.
The faces have to share a common area, but
do not have to be identical. Use this option
only when sliding is negligible, otherwise it is
recommended to define a local contact set.
Whereas the previous two options, Bonded
and Free, are linear types of contact
definitions, the Node-to-node option is a
nonlinear contact type, so it requires more
computational time to solve. This option will
be explained in more detail later in this
section.

Local Contact/Gap Similar to global conditions, local Contact/Gap conditions can also be
Conditions Bonded, Free, and Node-to-node. However, Surface and Shrink fit
conditions are only available as local Contact/Gap conditions.
To define a local condition, right-click on the Contact/Gaps folder
icon and choose Define Contact Set.

180 Global Contact/Gap Conditions

COSMOSWorks Nonlinear Training Manual

Then select the contact type from the pull-down menu. Finally in the
top box select the appropriate face, edge or vertex for the source nodes
and in the bottom box choose the face to be used as the target surface

Before proceeding with the exercise, review the following table that
describes the additional local contact conditions available in
COSMOSWorks.
Additional Local
Contact Types
Local Contact
Description
Type

Touching/seprate The faces may move away from each other,

faces: Surface but preserve the physical requirement that
they may not penetrate each other. Surface
contact may be defined for a pair of faces of
different shape and there may exist an initial
gap between faces. This contact option is
similar to the Node-to-node condition, but it
is defined as a node-to-surface condition, thus
is more computationally intensive. The
advantage is that the Surface condition is not
limited to sliding faces or faces that are
initially not touching. This option will be
explained in more detail later in this section.
Interfering faces: The program creates a shrink fit condition
Shrink Fit between the selected faces. The faces may or
may not be cylindrical but should be either
partially or fully interfering.

Note Defining a contact condition is only applicable to faces of different

components. It is tempting to define a contact set for faces of the same
component, especially with a local contact set, but it is not allowed. If
you want to do this, it is recommended to split the component into more

Global Contact/Gap Conditions 181

 COSMOSWorks Nonlinear Training Manual

than one.
Contact Hierarchy Contact/Gaps follow a hierarchy, where local conditions (those created
by choosing Define Contact Set…) have a higher precedence than the
global condition. Thus defining a contact set for a pair of faces
overwrites the global condition for those faces. Define Contact by
Components is not available for nonlinear studies.

Note Friction cannot be modeled for nonlinear studies in COSMOSWorks.

To be able to model friction with say nonlinear material properties, for
example, you would have to do the analysis in the Geostar interface,
which is a module of the COSMOSM suite (also a part of
COSMOSWorks Advanced Professional bundle).
Contact Definition To change the Global Contact condition, right-click on the Contact/
and Meshing Gaps folder icon and choose Set Global Contact just as you had done
to set the global condition.
When you defined a local contact set, a new icon is created below the
Contact/Gaps folder; right-click this icon and select Edit
Definition to edit this local contact set.

Note Defining a local contact condition, or more generally, making any

change to the contact conditions requires remeshing.
Solving Contact COSMOSWorks uses a hybrid technique to solve contact problems.
Problems
Hybrid A brief description on the hybrid technique, a combination of both
Technique for displacement and force methods, used in solving nonlinear problems
Gap/Contact involving contact is presented.
Problems:
General
Description
Hybrid Techniques Matrix methods of structural analysis can be categorized as:
The Displacement Method
In this method, the matrix equation to be solved can be expressed as:
[K] {U} = {R} (Eq. 4-1)
where
[K] = the stiffness matrix of the structure
{U} = the vector of nodal displacements
{R} = the vector of nodal forces
The unknown quantities in this matrix equation are the nodal
displacements while the prescribed quantities are the nodal forces.

182 Hybrid Technique for Gap/Contact Problems:

COSMOSWorks Nonlinear Training Manual

The Force Method

In this method, the matrix equation to be solved can be expressed as:
[F] {R} = {U} (Eq. 4-2)
where
[F] = the flexibility matrix of the structure
{R} = the vector of nodal forces
{U} = the vector of nodal displacements
The unknown quantities in this matrix equation are the nodal forces
while the prescribed quantities are the nodal displacements.
The Hybrid Method
In this method, the displacement and the force methods are combined
to solve the matrix equation. The displacement method is used where
external forces are prescribed while the force method is utilized where
the displacements are prescribed. In dealing with nonlinearities, such as
contact, a hybrid method can be efficient.
Gap Definition A gap is defined by two nodes, for example, i and j.
The direction of the gap is defined as the line connecting node i to node
j. The gap distance is defined as the maximum allowable relative
displacement between the two nodes along the gap direction.

Gap Direction

An open gap has no effect on the response of the structure while a

closed gap, if rigid, limits the relative displacements of its two nodes
along the gap direction not to exceed the gap distance.
In order to analyze gaps, the force method can be used to calculate the
forces at the gap locations. Thus, each gap is replaced by two forces,
equal in magnitude but opposite in direction, which are applied to the

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two nodes connected by a gap.

Rewriting equation 4-2 for the gaps:
[Fg] {Rg} = {Xg} (Eq. 4-3)
where
{Rg} = Vectors of gap forces
{Xg} = Vectors of relative gap displacements
In order to define [Fg], a unit force is applied in the gap direction and
the relative displacements induced in all gaps are determined. This
process is repeated for all other gaps in order to obtain [Fg].
Now, consider a configuration where the effect of the gaps is neglected.
The following inequity implies that the ith gap is closed:
Uig = Ui2 - Ui1 > gi (closed gap) (Eq. 4-4)
where
gi = Gap distance
Ui1 = Displacement induced by the external force vector {R}
Defining,
xgi = – (Uig - gi) (Eq. 4-5)
By solving equation 4-4, the gap force vector, {Rg}, is obtained.
Applying these forces to the structure, the relative gap displacement of
the ith gap will equal xig.
Since, the external force vector {R} will produce {Ug} displacement
vector, and the gap forces {Rg} will produce - ({Ug} - gi) then, ({R} +
{Rg}) will produce {g}. Therefore, the displaced shape of the structure
will resume a position where the relative displacement for each closed
gap remains equal to its prescribed allowable distance.
It should be noted that this method of solution uses no approximation
and requires no iterations. However, iterations are used to determine
which gaps are closed at a particular time, hence, forming equation 4-3
for those gaps only.
Contact Definition A contact problem can be considered as a general case of a gap
problem for the following:
1. The direction of the normal gap force is not fixed.
2. The point of contact also may change, for example, if the gap is
originally between nodes i and j, the structure may displace such

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that point i comes in contact with another point (see Figure below).

Contact Problem
Due to these factors, unlike simple gaps, the convergence and the
accuracy of the contact problem will depend on the incremental
solution where the forces are applied gradually to enable a node to
move slowly on the surface.
In order to consider the contact between two bodies, one body is
arbitrarily declared “source”, while the other is designated as the
“target”. The region of contact between the two bodies is governed by
the overall problem geometry, applied loads, material properties, and
other relevant conditions.
In COSMOSM, the contact problem is defined in accordance with the
following procedure:
1. The region of contact of the “source” body is established by a series
of nodal points to which one-node gap elements should be assigned.
2. The region of contact on the “target” body is defined by a series of
contact surfaces.
3. The extent of contact between the two bodies is limited to areas
defined by the one-node gap elements. With the small displacement
restriction removed, each gap can come in contact with any of the
surface segments in that same group.
4. Each surface of the “target” body is assigned a positive and a
negative side based on its node connectivity as shown in Figure
below. The negative side is where the gap elements are forbidden to
enter.
5. Surfaces defined in one group must form one continuous overall

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surface.

Contact Direction

GAP Elements Node-to-node

Node-to-node (or two-node) gap elements are used in 3D contact
problems where bodies are coming in contact with each other due to the
application of external forces. The main assumption for this type of
element is that the direction of the normal contact force(s) and the
contact points are known in advance and remain unchanged throughout
the analysis. The two-node gap elements are placed between two nodes
of the contacting bodies (one node on each body) such that the
direction of the gap element, represented by the straight line joining the
initial locations of its two nodes (before deformation) (see Figure
below), coincides with the normal contact force (which is normal to the
tangent line/plane at the point of contact of the two bodies).

Node-to-Node gap element defintion

The gap element is specified to limit the relative contraction between

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two nodes, a compressive gap.

Node-to-node (two-node) gap element

Surface and shrink fit

The surface (or one-node) gap elements are used to establish the
motion of a certain node on a “source” entity (on a face, edge or vertex)
with respect to a “target” surface (defined by a number of sub-
surfaces). The main advantage of one-node gap elements over the two-
node gap elements are:
1. The user does not need to know the exact location of the point of
contact a priori. The program internally will determine that location
and apply the contact forces accordingly.
2. The direction of the contact forces is determined by the program
based on the deformed shape of the entities in contact.
3. The nodal points on the contacting entities do not need to match
each other.
4. Shrink fit problems, where a portion of the model is forced to
assume a new position, can be handled through this type of gap
elements.
If the problem under consideration has more than one set of contact
bodies, then a separate local contact set, “source” and “target” must be
defined for each potential contact bodies.

Surface (one-node) gap element

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Troubleshooting Following is a list of commonly encountered errors during the

for Gap/Contact execution of nonlinear gap/contact problems.
Problems 1. The program runs successfully, but visualizing the results shows a
surface going beyond the contact surface, which should have
stopped them. The default plot setting shows the deformed shape
with an exaggerated deformation scale, therefore try to use a scale
factor of 1.0 instead. If the gap elements still exceed the contact
surface, then the conclusion is that the gap elements are not
properly closed. The original displacement is too large that the
displaced location of the gap elements cannot be compared
correctly with respect to the contact surfaces. This case usually
occurs when one of the bodies is an unconstrained structure. This
situation can be overcome by decreasing the applied load step
through modifying the “time” curve.
2. The program completes one or more steps with some gap elements
closed, but finally stops with an error messages. These errors
basically imply difficulties in problem convergence due to:
– System stiffness has deteriorated and become singular or close to
singular due to other nonlinearities (geometric or material). If the
stiffness has extremely deteriorated, a solution continuation may
not be possible.
– The load increment is too large.
In either case, reducing the load increment is most likely to solve
the problem.
3. Contact problems which involve large-deflection analysis are likely
to require mesh refinement in the regions where contact is
expected.
References 1. Bathe, K. J., Finite Element Procedures in Engineering Analysis,
Prentice Hall, 1982.
2. Belytschko, T., and Hughes, T., (eds.) Computational Methods for
Transient Analysis, North-Holland, Amsterdam, 1983.
3. Cook, D. R., Malkus, D. S., and Plesha, M. E., “Concepts and
Applications of Finite Element Analysis,” Third edition, Wiley,
1989. Kardestuncer, H., “Finite Element Handbook,” McGraw-
Hill, 1987.
4. Kulak, R. F., “Adaptive Contact Elements for Three-Dimensional
Explicit Transient Analysis,” Comp. Meth. Appl. Mech. Eng., 72,
pp. 125-151, 1989.
5. Mazurkiewicz, M., and Ostachowicz, W., “Theory of Finite
Element Method for Elastic Contact Problems of Solid Bodies,”
Comput. Struct., Vol. 17, pp. 51-59, 1983.
6. Parisch, H., “A Consistent Tangent Stiffness Matrix for Three-
Dimensional Non-linear Contact Analysis,” Int. J. Num. Meth.
Eng.. Vol. 28, pp. 1803-1812, 1989.

188 Gap Definition

COSMOSWorks Nonlinear Training Manual

7. Zienkiewicz, O. C., and, Taylor, R. L., The Finite Element Method,

Fourth edition, Vol. 2, 1991

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190 Gap Definition

COSMOSWorks Non-Linear Training Manual

Lesson 8
3D Contact

Upon successful completion of this lesson you will be able to:

191
Lesson 8 COSMOSWorks Non-Linear Training Manual
3D Contact

192
COSMOSWorks Non-Linear Training Manual Lesson 8
3D Contact

Objective A hollow rubber tube is held horizontally by two metal stands. The
rubber tube is stretched by a force of 250 lbs at its middle. The bottoms
of the two steel stands are fixed to the ground. The objective is to find
the proper displacement of the rubber tube by defining the correct
contact condition between the parts in the assembly.

1 Open Assembly
Click File, Open to open
the assembly file
Contact.sldasm from
the Lesson 8 folder.

2 Changing configuration for Symmetry.

Based on the geometry, loads and restraints, we can simplify the model
by utilizing symmetry in the analysis. Pull down Feature manager
window, select ConfigurationManager.
Select the Symmetry configuration. After selection, drag Feature
Manager back up.

Objective 193
Lesson 8 COSMOSWorks Non-Linear Training Manual
3D Contact

Note COSMOSWorks associates analysis studies with SolidWorks

configurations.
3 Create Study.
Define a study
named Bonded,
select Analysis type
as Nonlinear and
Mesh type as Solid
mesh.

4 Define Material.
Select the Rubber component and
select the Apply Material to
Selected Components icon from the
COSMOSWorks Main toolbar.
Choose Custom defined for Select material source, under Material
properties select HyperElastic – Mooney Rivlin as the model type,
Units to English (IPS) and type the Name as M-R Rubber. Set these
values for the material properties:
NUXY = 0.499
MOONEY_A = 175 psi
MOONEY_B = 10 psi

Click OK.

194 Objective
COSMOSWorks Non-Linear Training Manual Lesson 8
3D Contact

5 Apply Fixed Restraint.

Insert a restraint by clicking on the
Restraints icon in the Loads toolbar.

Fix the bottom face of the

metal stand as shown.

6 Apply Symmetry Restraint.

Apply a Symmetry constraint on the
cut face as shown.

7 Apply Force.
Apply a Force by selecting the icon
from the Loads toolbar.

Objective 195
Lesson 8 COSMOSWorks Non-Linear Training Manual
3D Contact

Choose the Type as Apply

normal force, Select the Face
as shown and set the value as
125 lb (half of the full model
load).

Note We will be using a Linear load path.

8 Renaming Boundary Conditions.
Rename all of the Restraints by slow
double-clicking on the icons so that they
reflect their settings. This is useful when
you come back to an analysis after having
archived it.

9 Hide all Restraints.

When you are done, Hide All of the symbols in the graphics window by
right-clicking the Loads/Restraints icon and choosing the option
from the menu.
10 Setting Global Contact.
Note that the default
Contact/Gaps
setting is Bonded.

You can change the

setting by either
right-clicking on the
item or choosing Set
Global Contact…
icon from the
COSMOSWorks
Main toolbar.

196 Objective
COSMOSWorks Non-Linear Training Manual Lesson 8
3D Contact

11 Setting Nonlinear properties.

Set the properties of the
study by right-clicking
the study name and
choosing Properties…
Make sure that the
settings are set as
shown, with the Max
Time Increment equal
to 0.1. We will use the
default Force control
method as well as all
the other default values
in the Advanced
Options window, so we
do NOT have to click
on this button.

12 Run the analysis.

COSMOSWorks will automatically
mesh the assembly and then
immediately solve the study. It
should take less than 10 minutes to
run.

Objective 197
Lesson 8 COSMOSWorks Non-Linear Training Manual
3D Contact

13 View Displacement plot.

Show the Displacement plot with a Deformation scale of 2.

14 Zoom to area of interest in the displacement plot.

Zoom up to the area where the rubber
hole is fitted over the metal stand.
Because a bonded contact was defined,
these two parts do not separate. This
does not reflect what common sense
tells us that the rubber would stretch a
bit away from the stand where they
interface. The displacement results are
thus not acceptable; we will change the
Global Contact setting to obtain more
realistic and accurate results.
15 Create new Nonlinear study.
Since the Analysis type will be
the same for the next study, then
we can copy and paste the current
study so that the setup for the new
study is accelerated. Right-click
on the Bonded study name and
choose Copy from the context-
sensitive menu.

198 Objective
COSMOSWorks Non-Linear Training Manual Lesson 8
3D Contact

Then paste the study by

right- clicking the
Assembly icon and
choosing Paste from the
menu.

Name the new study

name “Contact”.

Click OK.
16 Change global contact condition.
Set the Global Contact for the new
study as Node to Node.

A dialog box will

indicate that remeshing
is required, click OK.

Note The Mesh icon in the analysis manager shows a red X through it to
indicate that a mesh is not defined.

Objective 199
Lesson 8 COSMOSWorks Non-Linear Training Manual
3D Contact

17 Run the Contact Analysis.

Run the Contact analysis study (a mesh will again be automatically
created). It should take less than 10 minutes to complete.
18 Show Displacement Plot.

19 Zoom to a certain location in the displacement plot.

Rotate the model and
zoom up to the same area
as before. Note the gap
between the rubber and
the metal parts. This is the
result that we expect in
reality.

200 Objective
COSMOSWorks Non-Linear Training Manual Lesson 8

20 Animate Plot.
Animate the plot by clicking the green play button from the Result
Tools toolbar.
21 Compare Results.
Compare results side-by-side by sliding the window splitter to the
middle of the graphics window. With this view, it is plain to see that
the Contact study displacement is greater than the Bonded study
results.

22 Save and close the assembly.

Objective 201
Lesson 8 COSMOSWorks Non-Linear Training Manual

202 Objective
COSMOSWorks Non-Linear Training Manual

Lesson 9
Fatigue

203
Lesson 9 COSMOSWorks Non-Linear Training Manual
Fatigue

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COSMOSWorks Non-Linear Training Manual Lesson 9
Fatigue

Objective An Aluminum Alloy 2004 pressure vessel is to undergo a evaluation

for fatigue life for one million cycles each of a pressure loading and a
thermal stress load. The pressure loading is 1000 psi, and the thermal
stress is due to a heat flux of 1500 W/m2.

1 Open Assembly
Click File, Open to open
the assembly file
Pressure
Vessel.sldasm from
the Lesson 9 folder.

2 Select Symmetry configuration.

Based on the geometry, loads and restraints, we can simplify the model
by utilizing symmetry in the analysis.
Pull down Feature manager window, select Configuration
Manager.
Select the FEA_Bolt connection configuration. After selection,

Objective 205
Lesson 9 COSMOSWorks Non-Linear Training Manual
Fatigue

drag Feature Manager back up.

3 Review COSMOSWorks Studies.

Selecting the
COSMOSWorks
Manager icon, you
will notice that three
studies are already
setup.
The Thermal study
applies 1500 W/m2
heat flux to the
inside of the pressure vessel and to the outside surfaces a convective
condition of 10W/m2K and 77 oF ambient temperature.
The Th_Stress study is performed to obtain the stresses from the
resulting temperature field.
The Pressure study has 1000 psi applied to the inside surfaces of
the vessel.
Bolted connections are used in all studies.
4 Set Mesh quality.
Make sure that a Draft quality mesh is
set in the mesh options.

206 Objective
COSMOSWorks Non-Linear Training Manual Lesson 9
Fatigue

5 Create Mesh.
Click on the
Thermal study to
make sure it is the
active study, and
click on the Mesh
icon in the
COSMOSWorks
Main toolbar.

Set the global element mesh size to

30 mm and select the button to Run
analysis after meshing.

Repeat these two steps exactly for the remaining two studies. Each
analysis should take less than 5 minutes to completely run through.
You may review the results if you wish. The stresses from these studies
will be the basis on which our Fatigue analysis will be performed.

Objective 207
Lesson 9 COSMOSWorks Non-Linear Training Manual
Fatigue

6 Create Fatigure Study.

Create a new study
and name it Fatigue.
Also select the
analysis type from
the list to be
Fatigue. No mesh
type is required for a
fatigue analysis, so it
shall be left blank.
7 Define S/N curve.
Right-click on the icon
for S-N Curve and
choose Define… from
the context sensitive
menu.

Select the button that reads Get

curve… from the S-N Curve
dialog box.

208 Objective
COSMOSWorks Non-Linear Training Manual Lesson 9
Fatigue

In the Function
Curves dialog
box that opens,
select
Aluminum
Alloy 2024 (Al-
Cu-Mg) from
the Curve
Library. It is
very important
that you also set
the Stress
Ratio (R) to 0.

Click on OK to accept.
If a window comes up asking to save the curve data, enter a name and
click on Save.
Click on OK again in the S-N Curve box.
8 Add and Event.
Right-click on Loading and choose Add Event… from the context
sensitive menu.

Type in a value of one million, 1000000,

into the No. of cycles box.
Select from the Loading Type Zero
based (LR=0).
Lastly, select Th_Stress as the Study
Association name, and make sure the
Scale value is 1.

Objective 209
Lesson 9 COSMOSWorks Non-Linear Training Manual
Fatigue

9 Define Second Event.

Define another event with all the same
settings as the previous event, but with
the exception of the Study Association
to now read Pressure.

10 Review and change Fatigue Study properties.

Right-click on the Fatigue study name, and choose Properties…
from the context sensitive menu.

In the Fatigue
properties dialog box,
make sure that the
Event Interaction is set
as Random.
Change the Computing
alternating stress to
Max absolute
principal (P1).
The S-N Curve
Interpolation should
have Log-log selected.
The Fatigue strength
reduction factor (Kf)
should be set to 1.
Click on OK to accept

210 Objective
COSMOSWorks Non-Linear Training Manual Lesson 9
Fatigue

all the settings.

11 Run the Fatigue Analysis.
Run the Fatigue
analysis by
clicking on the
Run icon in the
COSMOSWorks
Main toolbar.

12 Review Results.
Open the Results folder by clicking on the + next to the folder, and
then show Plot1 by double-clicking on it.
The resulting Damage plot is shown.

Note that the Pressure vessel has a Damage factor greater than 1, so that
it has not met its life requirement as defined (i.e. one million cycles of
both thermal stress and pressure loading). All of its life has been taken
up.
Discussion What happens if the life requirement for pressure cycles goes down by
10 times to one hundred thousand cycles (100000)? Why?

Objective 211
Lesson 9 COSMOSWorks Non-Linear Training Manual
Fatigue

13 Save and close the Assembly file.

212 Objective