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M d li
Peter Barrett
November 2012

2012 CAE Associates Inc. and ANSYS Inc. All rights reserved.

Assembly Modeling Webinar

Do you effectively manage how your assembly is tied together?

Do you take advantage of bonded, no separation and/or frictional contact?

This webinar will provide examples on:

Creating and managing your contact groups

Understanding your unconverged solution

Prevent rigid body motion

Ch ki th
the accuracy off your analyses

Interpreting your contact elements results

Manage Your Contact Groups

Rename Based on Definition

Adjust Auto Detection

Merge Selected Contact Regions

Manage Your Contact Groups

Insert Contact Tool

Generate Initial Contact Results Before Solving

Review Initial Information

Manage Your Contact Groups

Utilize the Multiple Body Views for Selection / Checking

Understanding Your Unconverged Solution

Force balance not obtained

Rigid body motion
Material Instabilities
Element formulation error
Combination of items 1-4 above

Correct the Force Unbalance

Reduce Normal Stiffness Factor

Increase the number of Substeps

General Rule more nonlinearities use more substeps

Rigid Body Motion Error Messages

DOF limit exceeded.

Negative main diagonal.
Small/Negative Pivot error.
MAX DOF INC = A very large number
*** WARNING ***
CP =
11.703 TIME= 16:15:15
Smallest negative equation solver pivot term encountered at UX DOF of
node 98. Check for an insufficiently constrained model.

Find the Rigid Body Motion

Plot the unconverged or last converged displacement solution and verify

displacement scaling

The example below is a converged solution where the rigid body motion is only
restrained by weak springs
Note the unrealistic 10e-6 displacement scaling

Correct the Rigid Body Motion

Isolate the error by

y creating
g a smaller simpler
p model KISS!

Add supports and/or use displacement controlled solution

Can use adjust to touch ANSYS option, but be careful since the geometry will
be changed

Increase pinball region

If interfaces are all in compression, one might be able to leave as bonded

Modify to standard contact one pair at a time

Adjust the parts to all start in contact

Adding a rigid region and pushing it with displacements will usually converge
better than a force loading.

Use bonded contact for debugging

Make a 2d Sector model

Delete componets or fix DOF until you get an answer

This is not recommended for parts with large gaps, but is very effective for
interference fits

Add friction


Correct the Rigid Body Motion

Or Just Use Contact Stabilization!

Stab. Fact. 0

Fact = 2

Fact = .1


Fact = 2
Fact = .1
Fact 01

Correct the Rigid Body Motion

Or Just Use Contact Stabilization!


Quantify the Accuracy of Your Analyses

Check Penetration

Check Reactions


Quantify the Accuracy of Your Analyses

Contact Stiffness =1

Contact Stiffness = 10


Interpret Results on Contact Elements

p y as Un-averaged
g Results

Use Asymmetric contact


Improve Performance in Subsequent Runs

The Force Convergence graph clearly indicates that starting with more
substeps would eliminate the 27 iterations performed before the first
bisection. Reducing the starting number of substeps might eliminate this

Force Residual vs. Iterations

Time vs. Cumulative Iteration