Contact

Contact Analysis
Analysis in
in ANSYS
ANSYS

Mechanics Group
ANSYS, Inc.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Topics

• Capabilities Overview
• Lagrange versus Penalty Contact
• MPC Applications
• Contact Analysis using ANSYS Workbench

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 Capabilities Overview

• Rigid­flex
– Bodies of vastly different stiffness
– Steel against rubber seals

• Flex­flex
– Bodies of comparable stiffness
– Metal contacting metal

• Self contact
– Body folds over itself
– Column buckling

• Large sliding with friction for all

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 Variety of algorithms

ANSYS offers a series of CONTA178 CONTA175 CONTA171­

CONTA174
contact elements with
Type Node­Node Node­ Surface­
consistent specifications Surface Surface
Sliding Small Large Large

High order No No Yes

Pure Yes Yes Yes

Penalty Traditional Penalty based method
Robust library of Augmented Yes Yes Yes
algorithms to meet Lagrange Min Penetration with Robust Convergence
Pure Yes Yes Yes
every contact Nearly Zero Penetration
Lagrange
challenge MPC Yes Yes
Assembly Contact and Constraints
–ANSYS has them all!default
calculations for minimal user Contact Semi­ Semi/fully Semi/fully
stiffness automatic automatic automatic
intervention
Thermal Yes Yes
Multiphysics Capabilities Electric Yes Yes
Magnetic Yes Yes

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Ease of Use

Contact Manager: Offers many powerful and user friendly tools…

Launch Contact Wizard Control
Show Element Normals
­to create a new pair Context
Flip Element Normals ­translucency
Review/Edit Contact Pair Properties
to clarify plot
­element keyopts and real constants Switch Contact/Targets
Plot Elements Select Results for
List Elements Post Processing
and results

Delete Select Element type to view or list: Run CNCHECK command: List/Select
Contact Pair ­Contact or Target or both Detail//Post/Adjust/Reset Pairs

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 Higher order

• ANSYS Surface­to­Surface
Contact has better geometry
representation
– True curved surface
representation (non­faceted) in 8­Nodes
higher order Hex

– Contact analysis with higher

order elements is significantly
more accurate

10­nodes
Tets

20­Nodes
Hex

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 MPC Assembly Contact

shell­solid MPC constraint

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 MPC Assembly Contact

Parts are connected

Boundary conditions via MPC
Remote force via MPC

Hex dominant mesh

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 MPC Assembly

•Binder Clip Assembly

•Pure Lagrange Multiplier Method is
utilized for normal contact at
location between clip and spring to
take advantage of robust zero
penetration feature
•MPC bonded contact pair is
utilized at clip/spring interface

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 Multiphysics Applications

– Thermal­Structural
• Stresses induced by thermal
expansions in an assembly
• Frictionally induced Heating
• Metal Forming (Sequential only)
– Thermal­Electric­Structural
• Electric conduction with Joule Thermal Assembly
heating and structural expansion
– Simulation of resistance welding or
similar processes
• Micro­electro Mechanical Systems
(MEMs devices)
Thermal­Electric contact
pairs across resistance spot
welding assembly
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 Multiphysics Applications

– Structural­Electric
• Electrostatic analysis
• Piezoelectric Magnetic contact
pair across gap
– Transducers Sensor
Pipe
– Magnetic
• Magnetic Flux analysis
• Static and Transient Magnetic
B­field contours

Pipeline Sensor
(Electromagnetic)

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 Robustness of Contact

• ANSYS offers a rich library of contact

features
– 26 real constants, 3 material properties, 50
element keyopt settings
– model numerous special effects
– overcome difficult convergence situations
• User friendly with a focus on robustness
– Advanced contact algorithms
– Adaptive contact stiffness schemes
– Automated, intelligent choice of default settings
– Little user intervention

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Robustness of Contact

• The contact stiffness is the most important parameter

affecting both accuracy and convergence behavior
• We have implemented an adaptive scheme:
– Reasonable default for the normal contact stiffness in the
very first iteration.
– If bisections occur in the beginning of the analysis the default
stiffness will be reduced by a factor of 0.2 for each bisection.
– The normal contact stiffness is updated at each iteration
based on the current mean stress of the underlying elements
and the allowable penetration.
– The tangential contact stiffness is updated during each
iteration based on:
µp
ε T= lcrit Allowable Max. elastic slip = 0.01* l
lcrit
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 Robustness of Contact

Contact stiffness gradually raises to

establish the initial contact and
reduce the chartering.
­ Small stiffness, if contact is open
­ The larger the penetration, the
higher the stiffness

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 Robustness of Contact

60 iterations 32 iterations

FKN=1: KEY(10)=0 Divergence

42 iterations FKN=0.01, KEY(10)=0 FKN=0.01,

KEY(10)=1

Using defaults
is our goal !

FKN=1: KEY(10)=2
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 Robustness of Contact

Bending stress

Using defaults
is our goal !
ANSYS80: ANSYS81:
KEYO(10)=1 KEYO(10)=2
KFN = 1 KFN = 1
156 Iterations 83 Iterations

ANSYS80: ANSYS81:
KEYO(10)=1 KEYO(10)=1
KFN = 0.0001 KFN = 0.0001
25 Iterations 15 Iterations

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 Robustness of Contact

Iteration
Pure Lagrange 675

Augmented Lagrangian
Keyo(10)=2, FKN = 0.5 1028

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 Robustness of Contact

• Executing CNCHECK, ADJUST to bring

assemblies into contact
– Physically move contact nodes to targets to close the
gap or reduce penetration.
– Applicable to problems where other initial adjustment
options cause undesirable residual forces if large
rotation appears at contact surface.
Before CNCHECK After CNCHECK
open gap gap is closed

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 Robustness of Contact
1 0.0000

Frequencies
2 0.0000
Reaction force
3 0.0000
FX = 0.4234448E­01 GAP
4 0.33021E­02
FY = ­0.9639680E­03
5 0.39932E­02
FZ = ­0.1933389E­01
6 0.63336E­02
MX = 0.9152497E­04
7 186.83 81: MPC
MY = ­2033.720 No adjustment
8 322.63
MZ = ­0.4560663E­03
9 505.61
1 0.0000
2 0.0000 FX = 0.5690360E­01
3 0.0000 FY = ­0.1863415E­03
4 0.31505E­02 FZ = ­0.3476209E­01
5 0.44871E­02 MX = 0.1647255E­03
6 0.64525E­02 MY = ­2033.722
7 188.31 MZ = ­0.4195581E­03 81: MPC with
8 324.94 CNCH,ADJU

© 2004 ANSYS, Inc.

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 Robustness of Contact
80: MPC without
Adjustment
FX = 0.1092029
Reaction force at fix end FY = ­0.1135057E­02
FZ = 0.1444514E­01
MX = 1.311696
Rev.80 MPC is built between contact & target surface
Rev.81 uses CEINTF Logic: MPC between contact surface MY = ­1749.186
wrong
and underlying elements of the target surface MZ = ­2.819364
81: MPC with 81: Penalty with 81: MPC without 81: Penalty without
Adjustment Adjustment Adjustment Adjustment
FX = 0.5690360E­01 FX = 0.4440884E­01 FX = 0.4234448E­01 FX = 0.2764014E­01
FY = ­0.1863415E­03 FY = ­0.6834833E­03 FY = ­0.9639680E­03 FY = ­0.5543082E­02
FZ = ­0.3476209E­01 FZ = 0.3651396E­01 FZ = ­0.1933389E­01 FZ = 0.4484582E­01
MX = 0.1647255E­03 MX = 0.1917886E­02 MX = 0.9152497E­04 MX = ­1.402200
MY = ­2033.722 MY = ­2033.599 MY = ­2033.720 MY = ­1216.365
MZ = ­0.4195581E­03 MZ = ­0.1567494E­02 MZ = ­0.4560663E­03 MZ = ­12.31326

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Robustness of Contact

Free body frequencies

Rev.80 MPC is built between contact & target surface.
Rev.81 uses CEINTF Logic for MPC contact.

81: MPC with 81: Penalty with 81: MPC without 81: Penalty without 80: MPC without
Adjustment Adjustment Adjustment Adjustment Adjustment
1 0.0000 1 0.0000 1 0.0000 1 0.0000 1 0.0000
2 0.0000 2 0.82242E­03 2 0.0000 2 0.35709E­03 2 0.15729E­02
3 0.0000 3 0.32439E­02 3 0.0000 3 0.37133E­02 3 0.37388E­02
4 0.31505E­02 4 0.21737 4 0.33021E­02 4 32.650 4 8.8276
5 0.44871E­02 5 0.23349 5 0.39932E­02 5 48.024 5 14.405
6 0.64525E­02 6 0.74425 6 0.63336E­02 6 250.89
wrong 6 47.379
7 188.31 7 188.31 7 186.83 7 336.43 7 190.34
8 324.94 8 324.94 8 322.63 8 394.80 8 324.56
9 513.96 9 513.92 9 505.61 9 599.23 9 507.71
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 Robustness of Contact

Tips for bonded contacts :

(1) Always issue CNCH,ADJU to close the
gap/penetration which produces most
accurate solutions.
(2) If certain pairs can not be adjusted use MPC
logic.
(3) Penalty method for solving bonded contact
with gap will be improved in the future.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Robustness of Contact

MPC bonded contact fails in Rev.80.

It works in Rev.81 thanks to an over­ Solid­solid constraint
constraint checking & elimination logic.

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 Robustness of Contact

Shell­solid constraint

MPC bonded contact fails in Rev.80.

It works in Rev.81 thanks to an over­
Shell­shell constraint constraint checking & elimination logic.
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Robustness of Contact

Tips for overconstraint elimination logic:

(1) No Guarantee
(1) Certain overconstraints may not be detected.
(2) Certain good constrains may be eliminated.
(2) Local solutions near overconstraint points
may not be very accurate. Use your
engineering judgment to verify it.
(3) Global solutions should be accepted.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Diagnostic Tools

• Visualization and adjustment tools for initial

contact status
– CNCHECK, DETAIL: evaluate Contact Pair
specifications
– CNCHECK, ADJUST: move contact nodes to
target to close gap or reduce penetration
– CNCHECK, POST: view contact initial status
before solving
– CNCHECK, RESET: reset contact default settings

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Diagnostic Tools
•CNCHECK command is available for reviewing contact pair
specifications
•The output file will echo all information including the initial contact
status and gap specifications.

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 Diagnostic Tools

• NLHIST command will enable users to

monitor contact related diagnostic
results of interest in real time during
solution, providing valuable
information for troubleshooting contact
related convergence problems.

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 Diagnostic Tools

• NLHIST command

Result Trackers
• Available for each
contact pair
• Converged
solution data
• Various types

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 Diagnostic Tools

• Troubleshoot unconverged solutions with NLDIAG

– Visualize the Newton­Raphson residual
– Visualize the elements causing bisections and pivots.
– Identify when and how contact occurs.
– Determine the regions where contact is unstable and then
focus on the specific settings of those particular pairs instead
of having to deal with all of them.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Diagnostic Tools

• When troubleshooting contact problems, notes,

warnings, errors in the output file often provide valuable
feedback:
– Warning: Min. contact depth 5.376d­6 is too small which may
cause accuracy problem, you may scale the length unit in the
model.
– Warning: Max. contact stiffness 1.21d16 is too big which may
cause accuracy problem, you may scale the force unit in the
model.
– Warning: The initial penetration/gap is relatively large. Using
bonded/no separation option may cause an accuracy issue. You
may use the CNCHECK,ADJUST command to move the
contact nodes towards the target surface.
– Warning: The closed gap/penetration may be too large.
Increase pinball if it is a true closed gap/penetration. Decrease
pinball if it is a false one.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Diagnostic Tools

– Warning: Convergence has been achieved inspite of large

penetration. If this message is repeated frequently, we
recommend either increasing penalty stiffness(FKN), or enlarge
penetration tolerance(FTOLN).
– Warning: Overconstraint may occur for Lagrange multiplier or
MPC based contact algorithm.
• BC/CP/CE has been applied on certain contact nodes (e.g. 101).
• Certain contact elements (e.g. 104 & 195) overlap with other.
• Self contact Definition (e.g. real constant set 6).
• Certain nodes (e.g.10) appear in both sides of contact and target
surface.
• Certain nodes (e.g.101) appear in different contact pairs.
– Overconstraints are indicated by the presence of zero pivot
warnings and solution fails
• Warning: at least 1 number of ZERO PIVOT is in Eqn. Matrix
system.
• Error: There are 3 small equation solver pivot terms.
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Penalty
Penalty vs.
vs. Lagrange
Lagrange

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Pure penalty method

Penalty means that any violation of the contact condition will be punished by
increasing the total virtual work:

δΨ = ∫ σ T δε dV + ∫ (ε N g N δg N + ε T gT δgT )dA
V Γ

Augmented Lagrange method: ∫ [(λ

Γ
N + ε N g N )δg N + (λT + ε T g T )δg T ]dA

The equation can also be written in FE form:

( K + ε G T G )u = F
This is the equation used in FEA for the pure penalty method where ε is the contact
stiffness

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 Pure penalty method
F ( K + ε G T G )u = F
The contact spring will deflect an amount ∆,
such that equilibrium is satisfied:
∆ ε∆=F
where ε is the contact stiffness.

ê Some finite amount of penetration, ∆ > 0, is required mathematically to maintain

equilibrium. However, physical contacting bodies do not interpenetrate (∆ = 0).
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.
−
K = K + ε GT G
é There is no additional DOF. ( K + ε G T G )u = F
N
é There is no overconstraining problem

é Iterative solvers are applicable – large models are doable!

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Pure penalty method
ê Some finite amount of penetration, ∆ > 0, is required mathematically to maintain
equilibrium. However, physical contacting bodies do not interpenetrate (∆ = 0).
§ ∆ is the Result from FKN and the equilibrium analysis. Pressure= ∆ *ε => Stress
§ 100­times Difference in FKN leads to 100­times Difference in ∆
Ø but leads to only about 1% Difference in Contact pressure and the related stress.
FKN=1e4 FKN=1

Difference in d:
0.281e­3/ 0.284e­7
=1e4
PENE PENE

Difference in stress:
(3525­3501)/ 3525
=0.7%

Stress Stress
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 Pure penalty method

ê Some finite amount of penetration, ∆ > 0, is required mathematically to maintain

equilibrium. However, physical contacting bodies do not interpenetrate (∆ = 0).

Tip:
As long as the penetration does not leads to the change of the contact
region,
The penetration will not influence the contact pressure and Stress
underneath the contact element
Caution:
For pre­tension problem, use large FKN>1, Because the small penetration
will strongly influence the pre­tension force.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.
If the contact stiffness is too large, it will cause convergence difficulties.
The model can oscillate, with contacting surfaces bouncing off of each other.

F F
FContact

Iteration n Iteration n+1 Iteration n+2

FKN=1
FKN=0.01

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 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.

This problem is almost solved since 7.1, with

automatic contact stiffness adjustment.
KEYOPT(10)=1 or 2

205 100 130

iterations iterations iterations

KEYOPT(10)=0 KEYOPT(10)=1 KEYOPT(10)=2

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.

For bending dominant problem, you should still use

the 0.01 for the starting FKN and combine with
KEYOPT(10)=1 or 2

60 32
iterations iterations

FKN=1: KEY(10)=0 Divergence

FKN=0.01, KEY(10)=0 FKN=0.01, KEY(10)=1

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 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.
Hertz Contact problem – nonlinear material (BISO)
PENE PRES KN 1 KN2 KN3 KN4 ITER. SEQV Conv.
Default 0.00552 2426 112329 112329 112329 112329 144 1037 ok
P+L
Key10=1 0.0038 2482 57459­ 526681­ 626150 649175 96 1024 ok
P+L 517133 592516

Key10=2 0.008 2376 122329­ 84247­ 84247­ 84247­ 124 1045 ok

P+L 379110 122329 122329 122329

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 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.

ITER. Conv. Large deflection problem:

Default 248 ok
P+L
Key10=1 52 ok
P+L
Key10=2 69 ok
P+L

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 Pure penalty method
ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.
/prep7
/solu
et,1,185,,1
nlgeo,on
et,2,173,,1
solcon,on
et,3,170
csys
keyopt,2,10,1
asel,s,,,1
mp,ex,1,2e5
nsla,s,1
mp,nuxy,1,0.3
D,all,all
tb,biso,1
alls
tbdata,1,200,1000
dl,8,5,ux,15
r,2,5,,.1
*do,i,1,90,3
block,­1,1,­1,1,0,90
nsel,s,loc,y,1
esiz,,3
sf,all,pres,0
lesi,2,,,2
nsel,r,loc,z,i­2,i
lesi,9,,,90
sf,all,pres,100+i
vmes,all
alls
n,10000,­3,­6,0
nsub,3,100,1
n,10001,20,­6,0
solv
type,3
*enddo
real,2
tshasp,cylindl
Pure Lagrange: Augmented Lagrange: e,10000,10001
asel,s,,,3
6320 Iterations 4877 Iterations nsla,s,1
2190 Sec. 1375 Sec. type,2
esurface
/solu
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 Pure penalty method
/prep7 asel,s,,,3,4
et,1,181 nsla,s,1
et,2,170 type,2
et,3,173 real,2
Rigid keyop,3,10,1 esurf
et,4,184,1 asel,s,,,7,8
mp,ex,1,2e5 nsla,s,1
tb,biso,1 type,3
tbdata,1,200,10000 real,2
r,1,3 esurf
r,2,,,0.1,,,­5 allsel
cylin,0,10,0,200,0,360 type,4
vgen,2,1,1,,,20 lmes,5,8
lsel,s,loc,z,0 lmes,15,18
lesi,all,,,6 /solu
alls nlgeo,on
esiz,4 nsel,s,loc,z,0
amap,3,5,2,3,7 d,all,all
amap,4,5,2,3,7 alls
amap,7,13,10,11,15 dk,6,all
amap,8,13,10,11,15 dk,6,rotz,4*3.14
dk,16,all
dk,16,rotz,4*3.14
nsub,100,10000,20
cnvt,f,,0.01,
outres,all,­30
solve

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure penalty method

ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.

Tip:
Always use KEYOPT(10)=1,2
For bending problem use FKN=0.01 and KEYOPT(10)=1,2
For bulky problem use FKN=1 and KEYOPT(10)=1,2
Caution:
For pre­tension problem, use large FKN>1. Because the small penetration
will strongly influence the pre­tension force.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure penalty method

ê The condition of the stiffness matrix crucially depends on the contact stiffness itself.

Penalty:
FKN=10
Pretension load=2000 N Bolt working load=2012 N
External load 1000 N FKN=1 Lagrange:
Bolt working load=2012 N Bolt working load=2012 N
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Pure penalty method
é There is no additional DOF.

é There is no overconstraining problem

é Iterative solvers are applicable – large models are doable!

Tip:
Always use Penalty if:
• Symmetric contact or self­contact is used.
• Multiple parts share the same contact zone
• 3D large model(> 300.000 DOFs), use PCG solver.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method
• Any violation of the contact condition will be furnished with a Lagrange multiplier.

δΨ = ∫ σ T δε dV + ∫ (λ N δg N + λ Tδg T )dA
V Γ
Contact constraint condition:
gN ≥ 0 Ensure no penetration
λN ≤ 0 Ensure compressive contact force/pressure
g N λN = 0 No contact λ N = 0, gap is non zero
Contact g N = 0, contact force is non zero

The equation is linear, in case of linear elastic and Node­to­Node contact. Otherwise,
the equation is nonlinear and an iterative method is used to solve the equation. Usually
the Newton­Method is used.

For linear elastic problems: K G u F

T =
G 0 λ g0

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 Pure Lagrange multipliers method
N+G

K G u F
T =
G 0 λ g0
ê Lagrange multipliers are additional DOFs à the FE model is getting large.

ê Zero main diagonals in system matrix àNo iterative solver is applicable.

ê For symmetric contact or additional CP/CE, and boundary conditions, the equation
system might be over­constrained
ê Sensitive to chattering of the variation of contact status
é No need to define contact stiffness

é Accuracy ­ constraint is satisfied exactly, there are no matrix conditioning problems

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method
ê Lagrange multipliers are additional DOFs à the FE model is getting large.

Tip:
Always use Lagrange multiplier method if:
• The model is 2D.
• 3D nonlinear material problem with < 100.000 Dofs

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 Pure Lagrange multipliers method

ê Zero main diagonals in system matrix àNo iterative solver is applicable.

Tip:
never use Lagrange multiplier method if:
• The model has > 500.000 DOFs.

For 700.000 DOFs nonlinear contact model,

Penalty+PCG is 2 times faster than
Lagrange+Sparse!

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method
ê For symmetric contact or additional CP/CE, and boundary conditions, the equation
system is over­constrained
Tip:
If the Lagrange multiplier method is used:
• Always use asymmetric contact.
• Do not use CP/CE in on contact surfaces
• Do not define the multiple contacts, which share the common
interfaces.
Contact pair­1 Single contact pair

Contact pair­1

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 Pure Lagrange multipliers method
• Typical problem for Lagrange Multiplier Contact Formulation

Contact Target

Contact
Contact
Contact Target

Target
Target
Contact with mid­side nodes Lagrange Multiplier
Asymmetric
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 Pure Lagrange multipliers method
• In most cases, Lagrange still works with symmetric contact

Penalty and Lagrange

symmetric

self­contact
self­contact

self­contact
self­contact
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 Pure Lagrange multipliers method

Penetration Pressure Penetration Pressure

Iterations: 487 Iterations: 92

CPU: 200 CPU: 50

Penalty symmetric Lagrange symmetric

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 Pure Lagrange multipliers method
ê Sensitive to chattering of the variation of contact status
Tip:
Use Penalty is chattering occurs or
Chattering Control Parameters:
FTOLN and TNOP R1=R2­Delta

F R1 R2

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 Pure Lagrange multipliers method
Use Penalty is chattering occurs
DELT=0.1 lsel,s,,,1 /solu
/prep7 nsll,s,1 Nsel,s,loc,x,0
et,1,183 Real,2 D,all,ux
et,2,169 type,3 lsel,s,,,5
et,3,172,,4,,2 esurf nsll,s,1
mp,ex,1,2e5 lsel,s,,,7 d,all,all
pcir,190,200­DELT,­90,90 nsll,s,1 lsel,s,,,3
wpof,0,­delt type,2 nsll,s,1
pcir,200,210,­90,90 Esurf *get,nn,node,,count
Penalty wpof,0,delt f,all,fy,200/nn
esiz,5 alls
FKN=1 Esha,2 Solv
ames,all

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 Pure Lagrange multipliers method
é No need to define contact stiffness

é Accuracy ­ constraint is satisfied exactly, there are no matrix conditioning problems

Sy Pene Sy Pene Sy Pene

Pure Lagrange Pure Penalty(FKN=1) Pure Penalty(FKN=1e4)

Iter=13 Iter=8 Iter=39

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 Pure Lagrange multipliers method
é No need to define contact stiffness

é Accuracy ­ constraint is satisfied exactly, there are no matrix conditioning problems

Sy Pene Sy Pene Sy Pene

Pure Lagrange Pure Penalty(FKN=1e4) Augmented Lagrange

FKN=1, TOL=­3e­7
Iter=13 Iter=39 Iter=1327
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 Pure Lagrange multipliers method
example­1
Element: Plane183
Material: Neo­
Neo­Hookean
Hookean
Contact: Pure Lagrange
Load: Displacement

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 Pure Lagrange multipliers method
/prep7 wpcs,­
wpcs,­1 1 lsel,s,,,1,4 /solu
/solu
et,1,183 rect,­
rect,­16,
16,­­6,
6,­­100, 80 lsel,a,,,9,12
100,­­80 nlgeo,on Tip:
et,2,169 rect,­
rect,­6,
6,­­5,
5,­­100, 80 lsel,a,,,17,20
100,­­80 acel,,9810
et,3,172,,3,,2 rect,­
rect,­5,5,
5,5,­­100, 80 lsel,a,,,25,28
100,­­80 asel,s,,,1,9,1,1
tb,
tb,hyper,1,,,neo
hyper,1,,,neo asel,s,,,10,31,1,1 lsel,a,,,33,36 cmsel,u,l1 For large sliding
tbdata,1,.3,0.001 numm,
numm,kp kp cm,l1,line cmsel,u,l2
mp,ex,2,2e5 nsll,s,1 nsll,s,1 problem,
esha,2
mp,
mp,dens,2,7.8e
dens,2,7.8e­­9 9 esiz,2 type,3 d,all,all Use Lagrange method,
r,2,,,,,,5 ames,1,28 esurf asel,s,,,29,31,1
lsel,s,,,76,108,8 nsla,s,1
the convergence
r,3,,,,,,5 esha
pcir,2,5 alls lsel,a,,,78,102,8 d,all,ux behavior is very good
agen,5,1,1,,22 mat,2 lsel,a,,,113,129,4 nsub,5,15,1 and stable
agen,2,1,1,,11,­
agen,2,1,1,,11,­30 30 ames,all lsel,a,,,135,147,4 lsel,s,,,109,,,1
agen,4,6,6,,22 lsel,s,,,74,106,8 nsll,s,1 d,all,ux
rect,­
rect,­6,
6,­­5,
5,­­80,0
80,0 lsel,a,,,80,112,8 type,2 d,all,uy,0
rect,5,6,­
rect,5,6,­30,0
30,0 lsel,a,,,115,131,4 real,3 alls
agen,9,11,11,,11 lsel,a,,,133,145,4 esurf cnvt,f,,.01
pcir,5,6,0,180 nsll,s,1 lsel,s,,,41,44 nsub,100,10000,1
agen,5,20,20,,22 type,2 lsel,a,,,49,52 solv
wpof,11,­
wpof,11,­30 30 real,2 lsel,a,,,57,60 lsel,s,,,109,,,1
pcir,5,6,180,360 mat,3 lsel,a,,,65,68 d,all,uy,­
d,all,uy,­50
50
agen,4,25,25,,22 esurf cm,l2,line nsub,100,10000,1
nsll,s,1 outres,all,all
type,3 alls
esurf solv
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 Pure Lagrange multipliers method

Lagrange: Penalty:
110 Iterations 218 Iterations
CPU: CPU:
14 Sec. 24 Sec.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method
Sliding example
/prep7
lsel,s,,,14,18,2
et,1,42,,,1
nsll,s,1
et,2,169
type,2
et,3,171,,3
real,2
mp,ex,1,2e5
mat,2
rect,1.5,2,0,5
esurf
wpof,1,2.5
lsel,s,,,7,8
pcir,1,1.5,­90,90
nsll,s,1
aovl,all
type,3
adel,3,,,1
esurf
adel,7,8,1,1
lsel,s,,,1,,,1
aadd,all
d,all,all
arsym,x,all
/solu
agen,2,2,2,,4.5,1.8,,0,,1
nlgeo,on /post26
l,16,5
nsub,30,30,30 rfor,2,141,f,y
asbl,2,21
outres,all,all rfor,3,147,f,y
adel,3,,,1
lsel,s,,,9,,,1 *rep,3,1
esiz,.2
d,all,uy,­4 add,6,2,3,4
amap,1,1,2,3,4
alls add,6,6,5
amap,4,16,5,19,18
solv plva,6

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method

Bending example Lagrange:

10 Iterations
Bending stress 2 Sec.

Penalty Key(10)=1:
54 Iterations
12 Sec.

Contact penetration

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 Pure Lagrange multipliers method

Metal forming example

Element: Solid45
Material: BISO
Contact: Pure Lagrange
Load: Displacement

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 Pure Lagrange multipliers method
/prep7 asel,s,,,8 /solu
/solu
et,1,185,,1 nsla,s,1 nlgeo,on Lagrange:
et,2,173,,3,,2 type,2 nsub,10,100
et,3,170 esurface outres,all,­
outres,all,­20
20
578 Iterations
mp,ex,1,2e5 n,20000,­
n,20000,­3,3,10
3,3,10 csys 337 Sec.
mp,
mp,nuxy,1,0.3
nuxy,1,0.3 n,20001,3,3,10 nsel,s,loc,x,0
tb,
tb,biso,1
biso,1 local,11,1,0,­
local,11,1,0,­6,10,0,0,
6,10,0,0,­­90
90 d,all,ux
tbdata,1,200,1000 n,30000 nsel,s,loc,z,0 Penalty Key(10)=1:
r,2,5,,,,,5 nrot,30000 d,all,all 546 Iterations
r,3,2,,,,,5 type,3 alls
cylin,0,1,0,30,0,90 real,3 d,30000,rotz,­
d,30000,rotz,­3.14*3/4
3.14*3/4 250 Sec.
lesi,1,,,4 tshape,
tshape,cylin
cylin solve
lesi,7,,,35 e,20000,20001
*rep,3,1 tshape,
tshape,pilot
pilot
vmes,all e,30000
vsym,y,all Type,2
numm,
numm,nodenode asel,s,,,3
numm,
numm,kp kp nsla,s,1
n,10000,­
n,10000,­3, 3,­­6,10
6,10 type,2
n,10001,3,­
n,10001,3,­6,10
6,10 esurface
type,3
real,2
tshasp,
tshasp,cylin
cylin
e,10000,10001

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Pure Lagrange multipliers method
/prep7 lsel,s,,,2
et,1,183,,,1 nsll,s,1 Rubber example
et,2,183,,,1,,,1 type,3 Lagrange:
et,3,169 real,3 Element: Plane183
et,4,172,,4,,2 esurf 32 Iterations
mp,ex,1,2e5 lsel,s,,,8,12,4
nsll,s,1
Material: Mooney 13 Sec.
tb,hyper,2,1,2,moon
tbdata,1,1,.2,2e­3 type,4 Contact: Pure Lagrange&
Lagrange&Friction
Friction
Mp,mu,2,0.3 esurf
rect,1,5,0,3 lsel,s,,,5 Load: Pressure
Penalty Key(10)=1:
rect,2,5,1.5,4 nsll,s,1
type,3
43 Iterations
asba,1,2
rect,2.1,5,2.5,3.5 real,4 13 Sec.
wpof,3,2 esurf
pcir,.501 lsel,s,,,13,14,1
esiz,.3 nsll,s,1
ames,1,3,2 type,4
esiz,.1 esurf
type,2 /solu
mat,2 nlgeo,on
ames,2 solcon,,,,1e­2
nsel,s,loc,y,0
d,all,uy
nsel,s,loc,y,3.5
sf,all,pres,2
alls
nsub,10,100,1
solv

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 Pure Lagrange multipliers method
/prep7 /solu
et,1,181 nlgeo,on Shell example Lagrange:
et,2,170 nsel,s,loc,x,0
et,3,173,,3,,2 d,all,all Element: Shell181 15 Iterations
keyopt,3,11,1 nsel,s,loc,x,10
mp,ex,1,2e5 nsel,r,loc,y,5 Material: elastic 8 Sec.
r,1,.5 nsel,r,loc,z,0
r,2,,,.1 f,all,fz,1000 Contact: Pure Lagrange
r,3,,,.1 alls Penalty Key(10)=1:
rect,0,10,0,5 nsub,1,1,1 Load: Force
agen,3,1,1,,,,0.5 solv
16 Iterations
esiz,1 8 Sec.
esha,2
ames,all
type,3
real,2
asel,s,,,1,,,1
esurf,,top
type,2
asel,s,,,2,,,1
esurf,,bottom
type,3
real,3
asel,s,,,2,,,1
esurf,,top
type,2
asel,s,,,3,,,1
esurf,,bottom

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 Let us talk about convergence

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 Suggestion
One reason for convergence difficulties could be the following:

• FE Model is not modeled correctly in a physical sense

1) If you use a point load to do a plastic analysis, you will never get the converged solution.
Because of the singularity at the node, on which the concentrated force is applied, the
stress is infinite. The local singularity can destroy the whole system convergence
behavior. The same thing holds for the contact analysis. If you simplify the geometry or use
a too coarse mesh (with the consequence that the contact region is just a point contact
instead of an area contact) you most likely will end up with some problems in convergence.

point load Geometry Mesh

σ

ε
plastic analysis contact analysis

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 Suggestion
One reason for convergence difficulties could be the following:
• FE Model is not modeled correctly in a numerical sense
2) A possible rigid body motion is quite often the reason which causes divergence in a
contact analysis. This could be the result of the following: We always believe, that if we
model the gap size as zero from geometry, it should also be zero in the FE model. But due
to the mathematical approximation and discretization, it does not have necessarily to be
zero anymore. Exactly, this can kill the convergence. If possible, use KEYOPT(5) to close
the gap. You can also use KEYOPT(9)=1 to ignore 1% penetration, if it is modeled.

KEYOPT(5)=0
KEYOPT(5)=1
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Suggestion
One reason for convergence difficulties could be the following:

• FE Model is not modeled correctly in a numerical sense

ω
Status

KEYOPT(5)=0 KEYOPT(5)=1
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 Suggestion
One reason for convergence difficulties could be the following:
• Numerically bad conditioned FE Model
4) ANSYS uses the penalty method as a basis to solve the contact problem and the
convergence behavior largely depends on the penalty stiffness itself. A semi­default value
for the penalty stiffness is used, which usually works fine for a bulky model, but might not be
suitable for a bending dominated problem or a sliding problem. A sign for bad conditioning is
that the convergence curve runs parallel to the the convergence norm. Choosing a smaller
value for FKN always makes the problem easier to converge. If the analysis is not
converging, because of the too much penetration, turn off the Lagrange multiplier.
The result is usually not as bad as you would believe.

FKN=1 FKN=0.01

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:

FKN=1: KEY(10)=0 Divergence

FKN=0.01, KEY(10)=0 FKN=0.01, KEY(10)=1

FKN=1: KEY(10)=1

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Numerically bad conditioned FE Model

FKN=.1 FKN=0.0001

FKN=.1 FKN=0.0001

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Numerically bad conditioned FE Model
Lagrange:
Bending stress 10 Iterations
2 Sec.

Penalty Key(10)=1:
54 Iterations
12 Sec.
Contact penetration

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
TIP

FKN=1

How can I know, whether the contact stiffness is too large which causes the
convergence difficulties ???
The typical sign for a too large value for the contact stiffness is that after several
iterations the force convergence value keeps almost constant, although the max.
DOF increment is getting smaller and smaller.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
TIP

FKN=­.1

How can I know, whether the contact stiffness is too small which causes the
convergence difficulties ???
The typical sign for a too small value for the contact stiffness is that after several
iterations the force convergence value is converging, but the max. DOF increment is
not getting smaller and the penetration is violated very often.

FKN=.01

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Load step is too large Error in element formulation or element is turned inside out
5) If it is a large deflection problem, you usually need more substeps. 5 to 10 substeps are
good if the rotations are not too large (<180 degrees). If it is a small deflection problem, you
should reduce FKN, because FKN*d produces a large force, which can destroy the element.

NLGEO,ON
NSUB,1,1,1 NLGEO,ON
NSUB,10,100,1

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Quads instead of triads à Error in element formulation or element is turned inside out
6) If some elements are locally distorted you might get an error in the element formulation or
the element is even turned inside out. Try to use a coarser mesh in this region to avoid
those problems. You can also use NCNV,0 to continue the analysis and ignore those local
problems if they do not effect the global equilibrium. In general, try to use triangular,
tetrahedral or hexahedral elements (linear). Do not use quadratic hexahedral elements.

Error in element formulation

Linear quads Mid­side triads

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 Suggestion
One reason for convergence difficulties could be the following:
• The parts have no unique minimum potential energy position.
7) If the max. DOF increment is not getting smaller and the force convergence norm keeps
almost constant, probably some parts in the model are oscillating. Here, introducing a small
friction coefficient is usually better than using a weak spring, not knowing exactly where to
place it. Friction can be applied to all contact elements (try MU=0.01 or 0.1)

MU=0 MU=0.1

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Unreasonable defined contact pair
8) Sometimes it is also important to think about possible contact configurations: Which surface
or point will be in contact with which surface ??? The way to define the contact or target can
influence the convergence behavior as shown below.

Target

Contact

Contact

Target

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 Suggestion
Some times, if you define the contact and target properly, the analysis convergences
much faster, and the result is also better.
Target

Contact

Target
F
Contact

Contact Target
Target Contact

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Unreasonable defined contact region
10) It is not always a good idea to define as less contact as possible to avoid convergence
problems. If a region is getting into contact (e.g. self contact) but no contact pair has
been defined, the elements will be necessarily distorted. This could result in a non
positive value for the Jacobin determinant of those elements resulting in an error.

Phase 1 Phase 2 Phase 3

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:

Not converged result converged result

No contact region is defined contact region is defined

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Unreasonable defined plastic material
11) It is not always a good idea to define the tangential stiffness to be zero using a plastic
material law. If the yield stress is reached all over the whole cross section, there is no
material resistance anymore to carry the load. There will be a plastic hinge and so the
solution will never converge. In this case, input the correct tangential stiffness.

Plastic strain Stress strain curve with

tangential slope zero

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 Suggestion
One reason for convergence difficulties could be the following:

• Unreasonable defined plastic material

Plastic strain
Stress strain curve with
tangential slope 10000

Contact region

Stress distribution
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Suggestion
One reason for convergence difficulties could be the following:
• Instable solution
13) Some time, the solution could be instable, if the static analysis type is used, e.g if the
contact region changes abruptly. In this case, you can use more load steps strategy to get
rid of the instable solution.

FE model Instable point Next solution

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
One reason for convergence difficulties could be the following:
• Instable solution
TIP

FE model Load step­1, ends shortly Load step­2, starts shortly

before the snap through after the snap through.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
/prep7 lsel,s,,,5
TIP et,1,182,2 nsll,s,1
/solu
et,2,169 nlgeom,on
type,2 nsub,100,100,1
et,3,171,,1,,1 esurf
mp,ex,1,2e5 outres,all,all
lsel,s,,,2,3 nsel,s,loc,y,0
mp,mu,1,.1 nsll,s,1
In order to model the contact region mp,prxy,1,.3 d,all,all
type,3 lsel,s,,,6,,,1
r,1,,,.001,,,­2
reasonably, you should define two contact r,2,,,.001,,,­2
esurf d,all,ux
pairs, one for load step­1 and another for lsel,s,,,2 d,all,uy,­.5
rect,0,1,0,3 nsll,s,1
load step­2, and use the node detection wpof,1,3 alls
type,2 solv
wprot,­20
option(KEYOPT(4)=1, as shown below. rect,­.2,3,0,.2
real,2 /COM Load step­2
esurf lsel,s,,,6,,,1
esize,.2 lsel,s,,,5,8,3
amesh,1 d,all,ux
nsll,s,1 d,all,uy,­1
esize,.1 type,3
ames,all alls
esurf nsub,10,10,1
solv

Status­1

Contact­1 Target­1 Status­2

Target­2 Contact­2
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Suggestion
One reason for convergence difficulties could be the following:
• Rigid body motion, after the large deformation
14) For metal forming process, in the end of the simulation, if the analysis does not show the
convergence behavior, please watch the deformed configuration, if the work piece is out of
the holder, the rigid body motion occurs.

Stable instable

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
Good mesh will generally make problem easier to converge.
• The fine mesh and similar are always good the contact simulation:

Normal stress

Geometry Sphere influence Mesh

Contact Pressure

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
Good mesh will generally make problem easier to converge.
• The fine mesh and similar are always good the contact simulation:

Geometry Contact region

Contact mesh

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
Good mesh will generally make problem easier to converge.
• The fine mesh and similar are always good the contact simulation:

Normal stress

Contact pressure

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
• The fine mesh and similar are always good the contact simulation:

Geometry & Boundary condition Start mesh Contact settings

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
• The fine mesh and similar are always good the contact simulation:
Stress on contact surface
Fixed scaling
before local refinement

contact pressure
before local refinement Fixed scaling

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Suggestion
• The fine mesh and similar are always good the contact simulation:

Stress on contact surface

After local refinement

contact pressure
After local refinement

Convergence history

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 How can I make the problem converge?
• Trust yourself: I’m able to make it converge!
• Consider the problem as idealized real world problem:
20%­ Mechanics expertise, 20%­ Engineer expertise
30%­ FEA expertise, 30%­ Software expertise

• Use the magic KEYOPTIONS

KEYOPT(5)=1: To eliminate the rigid body motion

KEYOPT(9)=1: To eliminate the geometric noise

KEYOPT(10)=2: To make ANSYS think

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 MPC Applications

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Table of Contents

1. Introduction
2. MPC connection for SOLID­SOLID, SHELL­SHELL
3. MPC connection for SOLID­SHELL
4. MPC connection SOLID­BEAM and SHELL­BEAM
5. MPC connection between the FE model and loading point

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, What is MPC?
L
ui +
• MPC means: Multipoint Constraint PC ∑C u
j =1
j j = C0 ( j ≠ i)
4
+ UY (1) = Sin( ROTZ ( 3) ) • L L (1)
Beam
1 3 2
− UY ( 2 ) = Sin( ROTZ (3) ) • L L ( 2)
L L (1) + (2)
Solid 0 = UY (1) − UY ( 2 ) − 2 L • Sin( ROTZ ( 3) )
MPC
For small rotation:
(1)
UY ROTZ (3) 0 = UY (1) − UY ( 2 ) − 2 L • ( ROTZ (3)
)

( 2) CE ,2,0,1,UY ,1,2,UY ,−1,3, ROTZ ,−2 L

UY

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, What do you need MPC?
• To connect the dissimilar mesh:
– If the geometries are not topologically connected, you can mesh the geometry
independently and connect the FE model via MPC.

Geometry Dissimilar mesh Stress distribution

Connected via MPC

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, What do you need MPC?
• To connect the different element types:
– If the different element types are used on the connection region, because of
the different DOFs, the connectivity is not consistent. The consistence can be
achieved in the FE model via MPC.

Geometry Solids and Shells Deformation

Connected via MPC

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, What do you need MPC?
• To apply the remote load:
– If the loading point is not connected to the FE model, the connection can be
achieved in the FE model via MPC.

Loading point and FE model

Connected via MPC
Stress distributions

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, Why the existing contact algorithm is not used?

• The results may depend on specified contact stiffness.

– The existing bonded contact algorithm using the penalty method, because of
contact stiffness(cause the ill­conditioning) and the penetration, it might
influence the accuracy of the result.

• Multiple iterations are required to adjust penetration in order to

satisfy equilibrium even for small deformation problems.
– This will cause the iteration, even for linear problem.

• Occasionally spurious natural frequencies can occur in modal analysis.

– This is because of the contact stiffness used.

• Only translational DOFs are treated.

– This will cause the accuracy problem, if the distance between the contact and
target is not zero.
– Shell/beam assembly can not be handled.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, Why the existing contact algorithm is not used?

• It is only suitable for small strain.

– Because the existing CE method always uses the original nodal orientation.

• The RBE3 constraint can only support low order elements.

– 10 nodes tetrahedron element are most commonly used element.

• It is not allowed to apply displacement constraints on the master node

of RBE3

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, Advantages of new MPC approach
• Build MPC equations internally.
– It is not necessary to define the equations by hand, the user treats the
connection as bonded contact, ANSYS will generate automatically the MPC.

• Degrees of freedom of the contact surface nodes are eliminated.

– This will improve solution efficiency.

• No contact stiffness is required as an input.

– The accuracy of the solution is not dependent on try­and­error anymore.

• For small deformation problem, it represents “true linear contact”

behavior.
– No iteration is needed in solving system equations.

• For large deformation problems, the MPC equations are updated

during each iteration.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 1. Introduction, Advantages of new MPC approach

• Not only translational but rotational degrees of freedom can also be

constrained.
– It will improve the solution accuracy, and makes the connection between
solid­shell, shell­shell, solid­beam and shell­beam more reasonable.

• The generation of internal MPC is also very easy thanks to contact

pair definition.
– For the users, it is nothing new, if you know how to define the contact.

• It is not like MSC/Nastran (RBE3 type)

– Shape functions are taken into account automatically; no weight factor
is needed.
– not only forces but also displacements can be applied.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

2. MPC connection for SOLID­SOLID, SHELL­SHELL
Procedure:
1) Treat the connection as contact surface, use commands or Contact Wizard
to define the contact and the target.
2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC method
KEYOPT(4)=2 nodal based
KEYOPT(12)=5 or 6 Set the bonded contact key
3) Run the analysis

Caution: if the mesh between the contact and the target is

similar, the MPC method gives the same solution as the
continued mesh.
if the mesh between the contact and the target is largely
different, the stress gradient will be influenced. The
closer the mesh, the better will be the result.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

2. MPC connection for SOLID­SOLID, SHELL­SHELL
Accuracy Test
10 Closed solution Solid45 solution

1
PL3 62.5 * 20 3
δ= = =1
20 3EI 5E5

E=2e5 Nu=0 F=62.5

Displacement

Stress

Similar mesh connected via MPC Dissimilar mesh connected via

MPC
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2. MPC connection for SOLID­SOLID, SHELL­SHELL
/prep7 rect,­2,10,0,10
rect,5,15,7,11 lsel,s,,,4,10,3 !select the contact side
et,1,42 asba,1,2 nsll,s,1 !select the contact
et,2,169 !Target element rect,5,11,0,3
nodes
et,3,171 !Contact element asba,3,1
adel,all type,3 !turn on the contact type
Keyopt,3,2,2 !MPC method lfil,11,12,1 real,3 !turn on the ID
Keyopt,3,4,2 !nodal based lfil,8,6,1
Esurf !generate the contact
al,all
keyopt,3,12,5 bonded contact
rect,­10,5,­5,15
mp,ex,1,2e5 rect,­2,20,0,10 lsel,s,,,18 !select the target side
mp,prxy,1,.3 asba,2,3
lsel,a,,,21,22 !
smrt,3
ames,1 nsll,s,1 !select the target nodes
esiz,1.5 type,2 !turn on the target type
smrt,off
ames,4 Esurf !generate the target
nsel,s,loc,x,­10 alls
d,all,ux
Define the element types nsel,s,loc,y,­5 Define contact and the
and the keyoptions d,all,uy
target elements
nsel,s,loc,y,15
cp,1,uy,all
nsel,s,loc,x,10
sf,all,pres,­1
alls

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2. MPC connection for SOLID­SOLID, SHELL­SHELL

Model­1: mesh is pretty Model­2: mesh is quite Model­2: consistent

similar SMAX=1.71 different SMAX=1.71 mesh SMAX=1.71

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2. MPC connection for SOLID­SOLID, SHELL­SHELL

KEYOPT(9)=0 KEYOPT(9)=1

If you have the geometry penetration: Model­2: Penetration and

1) Set the PINBALL to catch the contact KEYOPT(9)=1 SMAX=1.71
2) Use KEYOPT(9)=1 to ignore the
pentration

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2. MPC connection for SOLID­SOLID, SHELL­SHELL

KEYOPT(9)=0 KEYOPT(9)=1

If you have the geometry gap: Model­2: Gap and KEYOPT(9)=1

1) Set the PINBALL to catch the contact SMAX=1.73
2) Use KEYOPT(9)=1 to ignore the
pentration

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
Closed solution
D = 20 d = 10 g = 1
π • 103
Mb =
32
σb = 1
σ = 1.74 • σ b = 1.74 • 1 = 1.74

Hex Tets

Stress concentration

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
Caution: for non­planer connection, set KEYOPT(9)=1 to
ignore the local penetration caused by dissimilar mesh.

d1=20 rect,0,l/2,0,d1/2
KEYOPT(9)=0 d2=10 rect,l/2,l,d1/2­(d1­d2)/4,d1/2
g=1 aadd,16,17
l=10 rect,2*l­0.5*l,2*l,0,d2/2
/prep7 vrot,16,18,,,,,2,1,180,2
et,1,95 smrt,off
et,2,170 esiz,d2/5 /solu
et,3,174,,2,,2 vsweep,4,18,28 nsel,s,loc,x,0
keyopt,3,9,1 vsweep,6,28,39 d,all,all
keyopt,3,12,5 vsweep,3 nsel,s,loc,z,0
mp,ex,1,2e5 vsweep,5 d,all,uz
mp,prxy,1,.3 asel,s,,,2,6,4 nsel,s,loc,x,l*2
rect,l/2,l,0,d1/2­(d1­d2)/4 asel,a,,,7,9,2 sfgrad,pres,0,y,0,2/d2
rect,l,2*l­0.5*l,0,d2/2 asel,a,,,13,14 sf,all,pres
aadd,all nsla,s,1 alls
adel,all type,3 eqsl,pcg,1e­7
lfil,7,10,g esurf solv
asel,s,,,20,22
KEYOPT(9)=1 al,all
asel,a,,,27,31,4
vrot,1,,,,,,2,1,180,2
smrt,1 asel,a,,,33,38,5
vsweep,1,1,8 nsla,s,1
vsweep,2,8,15 type,2
esurf

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2. MPC connection for SOLID­SOLID, SHELL­SHELL

Consistent shell mesh Dissimilar shell mesh via MPC

/PREP7 BLOCK,0,500,0,40,0,50, asel,s,,,2 /solu
et,1,181 vdel,all nsla,s,1 nsel,s,loc,x,0
et,2,170 adel,5,6 type,2 nsel,a,loc,x,500
et,3,175,,2 BLOCK,225,275,0,40,50,500, real,2 d,all,all
keyopt,3,12,5 vdel,all esurf nsel,s,loc,z,500
mp,ex,1,206000 adel,5,6 lsel,s,,,13,16 *get,nn,node,,count
mp,prxy,1,0.3 esiz,12 nsll,s,1 f,all,fx,1000/nn
r,1,2 ames,all type,3 f,all,fy,1000/nn
esurf f,all,fz,1000/nn

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2. MPC connection for SOLID­SOLID, SHELL­SHELL

1st mode 3rd mode 5th mode

1 88.370 0.033% 1 88.349 First 10

First 10 2 190.52 1.197%
Frequency from 2 192.80 Frequency from
3 668.62 0.322% 3 670.77
Modal analysis Modal analysis
4 711.48 0.208% 4 710.00
With consistent 5 1203.3 0.220%
With dissimilar
5 1200.4 shell mesh via MPC
shell mesh 6 1212.9 0.412% 6 1217.9
7 1261.5 0.254% 7 1258.3
8 1503.3 0.578% 8 1494.6
9 1628.1 0.725% 9 1616.3
10 1735.2 0.536% 10 1725.9

Consistent shell mesh Difference Dissimilar shell mesh via MPC

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
MPC connection for SOLID­SOLID(static analysis)

Displacement Displacement

Stress Stress

Consistent solid mesh Dissimilar solid mesh via MPC

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
MPC connection for SOLID­SOLID(modal analysis)
0.04%
0.09%
0.08%
0.05%
0.07%
0.05%

Consistent solid mesh Dissimilar solid mesh via MPC

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
MPC connection for SHELL­SHELL(static analysis)

Displacement Displacement

Stress
Stress

Consistent shell mesh Dissimilar shell mesh via MPC Dissimilar shell mesh via MPC
Without offset with offset

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
MPC connection for SHELL­SHELL( Modal analysis)
1 111.35 0.02% 1 111.37 0.02% 1 111.37
2 203.86 0.04% 2 203.95 0.04% 2 203.95
3 227.26 0.02% 3 227.34 0.02% 3 227.34
4 272.38 0.01% 4 272.42 0.01% 4 272.42
5 323.39 0.07% 5 323.63 0.07% 5 323.63
6 361.17 0.17% 6 361.85 0.17% 6 361.85

Consistent shell mesh Dissimilar shell mesh via MPC Dissimilar shell mesh via MPC
Without offset with offset

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
MPC connection for SHELL­SHELL(Edge­to­Edge)

Contact175

Target170

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2. MPC connection for SOLID­SOLID, SHELL­SHELL
Example Bonded contact with MPC method

Part­2

Part­ 3 to 5

Part­ 6 to 8
Part­1

Single part solution

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2. MPC connection for SOLID­­SHELL
It does not require alignment between the solid mesh and shell mesh
Procedure:
1) Treat the connection as contact, use Target170 for solid and Contact175 for shell.
2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC method
KEYOPT(12)=5 or 6 Set the bonded contact key
3) Set the target element keyoptions:
KEYOPT(5)=0 Automatic constraint type detection (default)
KEYOPT(5)=1 Solid­solid constraint (no rotational DOFs are constrained)
KEYOPT(5)=2 Shell­shell constraint (both translational and rotational
DOFs are constrained)
KEYOPT(5)=3 Shell­solid constraint (both translational and rotational
DOFs are constrained on shell edges; only translational
DOFs are constrained on solid surfaces)
4) Run the analysis

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2. MPC connection for SOLID­­SHELL
Accuracy Test 10
Closed solution
1
PL3 62.5 * 20 3
δ= = =1
20 3EI 5E5

E=2e5 Nu=0 F=62.5

Displacement

Stress

Consistent solid mesh Solid­shell connected via MPC

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2. MPC connection for SOLID­­SHELL
Shell
elements New
(thickness t ) Virtual KEYOPT(5)=1
Contact shell
Solid elements elements New Contact
elements (pre­existing) elements
SHELL181
CONTA175
MPC equations
Target elements (translation DOF only)
TARG170 Shell
Virtual shell ­ solid thickness
(on top of solid)
Original FEA mode
surface 1st Approach: solid­solid constraint

The virtual shell is generated

with SHSD,ID
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2. MPC connection for SOLID­­SHELL

/prep7 lsel,s,,,16
et,1,45 nsll,s,1
et,2,181 type,4
et,3,170 real,3
keyopt,3,5,1 !KEYOPT(5)=1 esurf
et,4,175,,2 !KEYOPT(2)=2 asel,s,,,6
keyopt,4,12,5 !KEYOPT(12)=5 nsla,s,1
mp,ex,1,2e5 type,3
mp,prxy,1,.3 esurf
r,1,1 shsd,3 !Virtual shell
block,0,10,0,10,0,10 nsel,s,loc,x,0
wpof,0,0,5 d,all,all
rect,10,20,0,10 nsel,s,loc,x,20
esiz,1.5 f,all,fz,­1000
vmes,1 alls
type,2 /SOL
ames,7 solv

Solids solution
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2. MPC connection for SOLID­­SHELL
Shell
elements New Virtual
(thickness t ) KEYOPT(5)=2
Contact shell
elements elements
Solid
elements (pre­existing)

MPC equations
Target elements (translation + Rotation
TARG170 DOF)
FTOLN
(on top of solid) shell edge ­ virtual shell
Original FEA mode Influence
2nd Approach: shell­shell constraint distance

The virtual shell is generated

with SHSD,ID
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2. MPC connection for SOLID­­SHELL

/prep7 lsel,s,,,16
et,1,45 nsll,s,1
et,2,181 type,4
et,3,170 real,3
keyopt,3,5,2 !KEYOPT(5)=2 esurf
et,4,175,,2 !KEYOPT(2)=2 asel,s,,,6
keyopt,4,12,5 !KEYOPT(12)=5 nsla,s,1
mp,ex,1,2e5 type,3
mp,prxy,1,.3 esurf
r,1,1 shsd,3 !Virtual shell
block,0,10,0,10,0,10 nsel,s,loc,x,0
wpof,0,0,5 d,all,all
rect,10,20,0,10 nsel,s,loc,x,20
esiz,1.5 f,all,fz,­1000
vmes,1 alls
type,2 /SOL
ames,7 solv

Solids solution
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2. MPC connection for SOLID­­SHELL
Shell
elements
(thickness t )
KEYOPT(5)=3
Contact elements
Solid (pre­existing)
elements

MPC equations
shell edge – solid surface
Target elements FTOLN
TARG170 Influence
(on top of solid) distance
Original FEA mode 3rd Approach: shell­solid constraint

The virtual shell is not

necessary

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2. MPC connection for SOLID­­SHELL

/prep7 lsel,s,,,16
et,1,45 nsll,s,1
et,2,181 type,4
et,3,170 real,3
keyopt,3,5,3 !KEYOPT(5)=3 esurf
et,4,175,,2 !KEYOPT(2)=2 asel,s,,,6
keyopt,4,12,5 !KEYOPT(12)=5 nsla,s,1
mp,ex,1,2e5 type,3
mp,prxy,1,.3 esurf
r,1,1 nsel,s,loc,x,0
block,0,10,0,10,0,10 d,all,all
wpof,0,0,5 nsel,s,loc,x,20
rect,10,20,0,10 f,all,fz,­1000
esiz,1.5 alls
vmes,1 /SOL
type,2 solv
ames,7

Solids solution

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2. MPC connection for SOLID­­SHELL
Summary: For most applications, default KEYOPT(5)=0 or 3 can be used. Many test
cases show the best solution with KEYOPT(5)=2.

New New
Virtual New Contact Virtual
elements
shell shell
elements CONTA175 elements

SHELL18
1
MPC equations
MPC equations
MPC equations
(translation DOF only)
(translation + Rotation
Shell shell edge – solid FTOLN
Virtual shell ­ solid DOF) FTOLN
thickness surface
surface Influence Influence
shell edge ­ virtual
shell distance distance

KEYOPT(5)=1 KEYOPT(5)=2 KEYOPT(5)=0,3

SHSD,ID SHSD,ID

1st Approach: 2nd Approach: 3rd Approach:

solid­solid constraint shell­shell constraint shell­solid constraint

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2. MPC connection for Solid­­SHELL
Two ways to exclude gap between contact and target:

1) if there is an intersection between the contact normal and the target surface,
you can use PSOLVE to physically extend the contact surface

contact surface contact surface

Example
Gap
/solu
target surface target surface psolve,elform
PSOLVE
fini
/solu
anty,modal
Gap before PSOLVE After PSOLVE modopt,lanb,7
mxpand,7
solv

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2. MPC connection for Shell­­SHELL
Without PSOLVE
KEYOPT(9)=1
With PSOLVE
SET FREQ SET FREQ SET FREQ
1 0.0000 1 0.0000 1 0.0000
2 0.0000 2 0.11336E­02 2 0.0000
3 0.0000 3 0.19459E­02 3 0.34178E­03
4 0.12203E­02 4 0.72671E­01 4 0.11133E­02
5 0.10909E­02 5 0.23382 5 0.11707E­02
6 0.13362E­02 6 2.7936 6 0.34944E­02
7 94.876 7 95.110 7 94.933

Modal Analysis
Consistent mesh MPC Distance=0.1
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2. MPC connection for Shell­­SHELL
2) if there is no intersection between the contact normal and the target surface,
constraint equations are still built as long as contact node and target
segments are inside the pinball region, if you use KEYOPT(5)=4

In case, that the PSOLVE can not

move the nodes, You should use
KEYOPT(5)=4,
Otherwise, there will be no
constrains generated,
independent of the PINBALL
size.

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2. MPC connection for Shell­­SHELL
KEYOPT(5) default KEYOPT(5)=4
SET FREQ SET FREQ SET FREQ
1 0.0000 1 0.0000 1 0.0000
2 0.0000 2 0.11336E­02 2 0.0000
3 0.0000 3 0.19459E­02 3 0.21223E­03
4 0.12203E­02 4 0.72671E­01 4 0.90930E­03
5 0.10909E­02 5 0.23382 5 0.12339E­02
6 0.13362E­02 6 2.7936 6 0.34500E­02
7 94.876 7 95.110 7 97.702

Modal Analysis

Consistent mesh MPC Distance=0.1

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2. MPC connection for SOLID­­SHELL

2nd Approach

Solids 3rd Approach Solid­Shell

SMX=25.3 MPC

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2. MPC connection for SOLID­­SHELL
csys
/prep7 v,26,25,23,24,13,14,15,16 cswp,11,1 alls,belo /solu
et,1,185,,2 v,30,29,31,32,26,25,23,24 kgen,2,13,14,,­25 vsym,x,all local,11,0,0,0,0,0,­60
et,2,181 a,29,31,3,4 l,9,10,10 numm,node lsel,s,,,30,65,35
et,3,170 a,6,7,32,30 kgen,2,9,9,,,,500 numm,kp sfl,all,pres,­6.4282
keyopt,3,5,3 va,18,10,6,14,17,1,5,2 l,9,11,4 asel,inve csys
et,4,175 asel,s,,,1,2 adra,25,,,,,,28 type,2 nsel,s,loc,z,1100
keyopt,4,2,2 asel,a,,,5 csys,1 ames,all nsel,a,loc,z,­580
keyopt,4,12,5 acca,all kgen,2,2,8,6,25 alls,belo,area dsym,symm,z
mp,ex,1,2e5 lsel,s,,,2,7,5 l,18,19,5 arsym,x,all nsel,s,loc,y,0
r,1,50 lsel,a,,,12 kgen,2,2,2,,,­40 numm,node dsym,symm,y
r,2,,,,,,­300 lcca,all l,2,20,3 numm,kp nsel,s,loc,x,­1,1
cylin,375,425,­80,600,40,90 lsel,s,,,4,5 adra,33,,,,,,34 alls d,all,ux
wprot,,­60 lsel,a,,,10 kgen,2,7,7,,25 asel,s,,,8,31,31­8 d,all,roty,
cylin,85,140,0,750,­90,90 lcca,all l,27,19,6 asel,a,,,1,2 d,all,rotz
vdel,all alls kgen,2,27,27,,,,500 asel,a,,,5 alls
adel,6,7,1,1 lesi,20,,,3 l,27,28,3 asel,a,,,41,43 solv
adel,11,12,1,1 lesi,9,,,5 adra,40,47,,,,,48 nsla,s,1
aovl,3,9 lesi,37,,,10 kgen,2,3,3,,25 type,3
aovl,4,10 lesi,17,,,20 l,36,18,6 real,2
adel,3,9,6,1 lesi,5,,,6 kgen,2,36,36,,,,­500 esurf
adel,6,7,1,1 lesi,42,,,10 l,36,37,3 type,4
afil,11,12,39 vmes,all adra,39,54,,,,,55 real,2
afil,13,14,30 lsel,s,,,25,62,62­25
lsel,a,,,33,47,14
lsel,a,,,54,68,14
lsel,a,,,78,87,9
nsll,s,1
esurf
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2. MPC connection for SOLID­­SHELL
Modal analysis

1 111.99 0.02% 1 112.08

2 206.05 0.04% 2 206.14
3 229.44 0.01% 3 229.42
4 273.70 0.17% 4 274.16
5 324.42 0.32% 5 325.47
6 368.72 0.38% 6 370.14

Consistent solid mesh 3rd Approach: shell­solid constraint

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2. MPC connection for SOLID­­SHELL

Shells

Solids

Boundary conditions FE­Model Results

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2. MPC connection for SOLID­­SHELL

Consistent solid mesh shell­solid MPC constraint

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2. MPC connection for SOLID­­SHELL

Original Solids DE­featured Solids

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2. MPC connection for SOLID­­SHELL

shell­solid MPC constraint

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3. MPC connection SOLID­BEAM and SHELL­BEAM

Procedure:
1) Treat the solid surface and/or shell edge as contact surface, treat the beam
node as target pilot node. No additional target is needed.
2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC method
KEYOPT(12)=5 or 6 Set the bonded contact key
KEYOPT(4)=1 Force­distributed surface
KEYOPT(4)=2 Rigid constraint surface
3) Run the analysis

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3. MPC connection SOLID­BEAM and SHELL­BEAM
/prep7 vext,all,,,,,150
et,1,45
acle,all
et,2,188
k,100,0,0,150
et,3,173,,2 !KEYOPT(2)=2
k,101,0,0,300
Keyopt,3,4,1 !KEYOPT(4)=1
k,102,1,1,150
keyopt,3,12,5 !KEYOPT(12)=5 l,100,101
et,4,170
lsel,s,,,33
mp,ex,1,2e5
LATT,1,,2,,102,,1
mp,prxy,1,0.3
lmes,33
SECTYPE, 1,BEAM, CTUBE
real,10
SECOFFSET, CENT type,4
SECDATA,10,11
tshap,pilo !Pilot node on beam
pcir,10,11,0,90
e,2017 !Pilot node on beam
pcir,10,11,90,180
pcir,10,11,180,270
nsel,s,loc,z,150 SOLID­BEAM
nsel,u,,,2017
pcir,10,11,270,360
esel,s,type,,1
numm,kp
type,3
lesi,4,,,2
Esurf !Contact on solid
esiz,,8
/solu
et,10,42 nsel,s,loc,z,0
esha,2 d,all,all
type,10
nsel,s,loc,z,300
ames,all
f,2018,fx,1000
esiz,,20
alls
type,1
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3. MPC connection SOLID­BEAM and SHELL­BEAM

KEYOPT(4)=2
Rigid constraint surface

Solid solution Solid­Beam via MPC

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3. MPC connection SOLID­BEAM and SHELL­BEAM

KEYOPT(4)=1
Force­distributed surface

Solid solution Solid­Beam via MPC

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3. MPC connection SOLID­BEAM and SHELL­BEAM
Example

Solid solution Solid­Beam via MPC

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3. MPC connection SOLID­BEAM and SHELL­BEAM
/prep7 adra,1,4,7,10,,,6
et,1,181 real,2
et,2,188 ames,5,8
et,3,175,,2,,2 !KEYOPT(2)=2 k,100,0,0,150
Keyopt,3,4,2 !KEYOPT(2)=2 k,101,0,0,300
keyopt,3,12,5 !KEYOPT(12)=5 k,102,1,1,150
et,4,170 l,100,101
mp,ex,1,2e5 lsel,s,,,18
mp,prxy,1,0.3 LATT,1,,2,,102,,2
r,2,1 lmes,18
SECTYPE, 2, BEAM, CTUBE real,10
SECOFFSET, CENT type,4
SECDATA,10,11 tshap,pilo
pcir,0,10.5,0,90 e,673 SHELL­BEAM
pcir,0,10.5,90,180 nsel,s,loc,z,150
pcir,0,10.5,180,270 nsel,u,,,673
pcir,0,10.5,270,360 esel,s,type,,1
numm,kp type,3
lsel,s,,,1,10,3 esurf
lesi,all,,,8 /solu
esha,2 nsel,s,loc,z,0
esiz,,20 d,all,all
k,50 nsel,s,loc,z,300
k,51,0,0,150 f,674,fx,1000
l,50,51 alls
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3. MPC connection SOLID­BEAM and SHELL­BEAM

KEYOPT(4)=2
Rigid constraint surface

Solid solution Shell­Beam via MPC

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3. MPC connection SOLID­BEAM and SHELL­BEAM

KEYOPT(4)=1
Force­distributed surface

Solid solution Shell­Beam via MPC

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4. MPC connection between the FE model and loading point

Procedure:
1) Treat the FE surface and/or edge as contact surface, treat the loading node
as target pilot node. No additional target is needed.
2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC method
KEYOPT(12)=5 or 6 Set the bonded contact key
KEYOPT(4)=1 Force­distributed surface
KEYOPT(4)=2 Rigid constraint surface
3) Run the analysis

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4. MPC connection between the FE model and loading point
/prep7
et,1,42
et,2,169
et,3,171,,2,,11 !KEYOPT(2)=2 !KEYOPT(4)=1
keyopt,3,12,5 !KEYOPT(12)=5
mp,ex,1,2e5
mp,prxy,1,.3
rect,0,10,0,2
esiz,1
ames,1
n,100,5,5
lsel,s,,,2
nsll,s,1
type,3
real,3
esurf
alls
type,2
tshape,pilot
e,100
nsel,s,loc,x,0
d,all,all
alls
f,100,fy,­100

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

4. MPC connection between the FE model and loading point

KEYOPT(4)=1
Force­distributed surface

KEYOPT(4)=2
Rigid constraint surface
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
4. MPC connection between the FE model and loading point

KEYOPT(4)=2 KEYOPT(4)=1
/prep7 n,1000,0,0 Rigid constraint surface
et,1,42 lsel,s,,,5,8
Force­distributed surface
et,2,169 nsll,s,1
/solu
et,3,171,,2,,1 type,3
nsel,s,loc,x,­10
keyopt,3,12,5 real,3
d,all,all
mp,ex,1,2e5 esurf
alls
mp,prxy,1,.3 alls
f,1000,mz,­.7e6
rect,­10,10,­5,5 type,2
nlgeo,on
pcir,3 tshape,pilot
solv
asba,1,2 e,1000
smrt,4
ames,all

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

4. MPC connection between the FE model and loading point

Bending moment Shear force Torsion moment

/prep7 cylin,10,20,0,100,0,90 type,3 /solu

et,1,45 *rep,4,,,,,90,90 real,3 nsel,s,loc,z
et,2,170 numm,kp esurf d,all,all
et,3,173,,2,,1 esiz,3 alls alls
keyopt,3,12,5 vmes,all type,2 f,10000,mx,4.766e3
mp,ex,1,2e5 n,10000,0,0,100 tshape,pilot alls
mp,prxy,1,.3 asel,s,,,2,20,6 e,10000 solv
nsla,s,1
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
4. MPC connection between the FE model and loading point

Bending moment Shear force Torsion moment

/prep7 cylin,10,20,0,100 type,3 /solu

et,1,63 esiz,3 real,3 nsel,s,loc,z
et,2,170 ames,3,4 esurf d,all,all
et,3,175,,2,,1 n,10000,0,0,100 alls alls
r,1,1 lsel,s,,,9,12 type,2 f,10000,mx,4.766
keyopt,3,12,5 nsll,s,1 tshape,pilot e3
mp,ex,1,2e5 e,10000 alls
mp,prxy,1,.3 solv

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

MPC applications

Parts are connected

via MPC

Boundary conditions
Remote force via MPC

Hex dominant mesh

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

MPC applications

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

MPC applications

Connection options

Four different methods to connect

t
the surface bodies with non­zero t
distance:
1) MPC t
2) Beam
3) Common nodes
4) Single body

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

MPC applications
Beam contact MPC contact

Common nodes Single solid part

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

MPC applications
Summary

0,5
0,485 0,487 0,487 0,473
0,4

Surface extension

Single solid part

0,3
Beam contact
MPC contact

0,2

+Joint
0,1

0
Connection methods
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 ANSYS Contact
Workbench
Workbench Features
Features

Tim Pawlak
Corporate Fellow
ANSYS, Inc.

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Objective and Outline

• Contact related features available in

ANSYS Workbench
– Contact objects
– Initial contact status
– Contact meshing
– Solution information
– Contact results
– Wizards

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Workbench Contact Modeling

• Automatic contact generation for a

variety of CAD geometry
• Various options for specifying contact
behavior
• Associative with geometry changes

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Folder: Details

Automatic generation
based on pair options

Disable transparency

Rename based on
geometry names

Tolerance type:
a) slider
b) numeric value

Search sphere size

indicator appears in
graphics window

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Folder: Details

Auto detection types:

Face/Face
Face/Edge
Edge/Edge
Priority for type during
auto generation

Automates construction of
connections between part,
manual effort is sometimes
Joins solid and surface bodies necessary
together by defining contact Setting the appropriate priority
relationship between improves the outcome of the
corresponding faces and automatic generation, review
edges of generated objects is good
practice

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Examples of Contact Types

Surface body face to

surface body edge

Solid body edge to

surface body edge

Surface body edge to

surface body edge

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Folder: Worksheet View

• Lists details for each contact object

• Good for verifying intentions
• Rows can be sorted by clicking column header

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Folder: Worksheet View

Columns can be sized by sliding header

divider

The RMB on the

header displays
options to add,
removed, and reset
columns

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Object Display

• Contact side is
red
• Target side is
blue

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Object Display

• Click on detail and

corresponding part
highlights
• Makes it easy to
understand definition

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Objects: Transparency

Selected contact
objects in tree will be
shown in graphics
window displayed
with corresponding
parts as more opaque
than other parts

Transparency can be
disabled, level of
opaqueness can be
adjusted in options

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Objects: Object Details

Highlight of geometry
entities by selection details

Symmetry behavior on
individual basis, including
auto asymmetry
Interface treatment
Contact stiffness
specification and update
options (very important for
good solution convergence)

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Object: RMB Options

Disable
transparency
Flip contact and
target
Rename based on
geometry

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Initial Contact Status (Beta)

Available by inserting
a contact tool in the
contact folder.

Initial information
result object displays a
table of information
about the initial state
of contact throughout
the model

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Initial Contact Status (Beta)

Lists useful
information such as:
1) Status
2) Number elements
contacting
3) Penetration and/or
gap (gap is negative)
4) Size of gaps closed

Valuable information
when setting up
contact simulations

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Meshing

Based on the sphere of Element size is synchronized

influence capability across the contact interface

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Meshing

Contact objects
can be drug and
dropped

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Solution Information

• Convergence History
• Result Trackers
• Newton Raphson Residuals

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Convergence History

Useful for
understanding the
solution progress

­ Solution output text

­ Force convergence
­ Max DOF increment
­ Line search parameter
­ Time increment
© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary
 Result Trackers

Valuable for know how the

model performs with
increasing load

• Available for each

contact pair
• Converged
solution data
• Various types

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Result Tracker Types

• Directional Deformations (x, y, z)

• Contact
– Number Contacting
– Number Sticking
– Pressure
– Penetration
– Gap
– Frictional Stress
– Sliding Distance
– Chattering
– Elastic Slip
– Normal Stiffness
– Max Tangential Stiffness
– Min Tangential Stiffness
– Resulting Pinball

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Newton Raphson Residuals

Objects appear in tree if Shows regions where

activated and solution fails convergence is having difficulty,
to converged in this case the contact below the
washer and the bracket

Details

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Tool

• Collected by a
parent object
• Automatic
transparency

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Results

• Includes:
– Frictional stress
– Pressure
– Sliding distance
– Penetration
– Gap
– Status
– Reactions

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Tool ­ Reactions

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Command Objects

ANSYS macro

• Multiple instances allowed

• Can be exported or inserted
• Parametric output back to WB

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact in 2D (Beta in 8.1)

2D surface
bodies

Options for
plane stress,
plain strain,
axisymmetry

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact in 2D (Beta in 8.1)

Large Deflection 2D Sliding Contact

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Custom Wizard

• Purpose
– Helps ensure preferred
and proven options are
used
– Highlights recommends
features

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Contact Features ANSYS Workbench

• Easy to use
• Wide variety of features
• Useful results
• Sophisticated simulation

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary

 Conclusions

• Variety of algorithms
• Higher order contact
• Self­contact
• MPC assemblies
• Multiphysics applications
• Large contact/assembly models (100M)
• Ease of use
• Robustness
• Diagnostic tools

© 2004 ANSYS, Inc. ANSYS, Inc. Proprietary