Solidworks Simulation Training Chapter 3

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1 Ι © Dassault Systèmes Ι Confidential Information Ι SolidWorks Simulation Training SolidWorks 2012

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This covers all the explanation to the exercises of chapter 3 of the Solidworks SImulation Manual

Transcript of Solidworks Simulation Training Chapter 3

Title of PPT

SolidWorks Simulation TrainingSolidWorks 2012

# Dassault Systmes Confidential Information 1PrerequisitesCourse Design PhilosophyUsing this bookA note about filesConventions used in this bookClass Introductions

About this course# Dassault Systmes Confidential Information 2Simulation PremiumSimulation ProfessionalDesign Validation ProductsFrequency/Buckling

Thermal

SolidWorks PremiumStatic

SolidWorksMotion

Drop Test

Fatigue

Nonlinear

Optimization

PressureVessel

Composites

AdvancedDynamics

# Dassault Systmes Confidential Information 3What is Finite Element Analysis?

Example: Brick road from home to mailbox measure the distance of a curved path using yard stickCurved path is approximated by straight segmentsMeasure using a yard stick

# Dassault Systmes Confidential Information 4The length of a curved path is measured using a Yard-stick. The curved path is broken into straight segments and lengths of each of the straight segments is measure by a yard stick. These lengths are added together to get the final length of the curved path.

Building the FEA ModelCAD Model Stress Results# Dassault Systmes Confidential Information 5Defeaturing: suppressing or removing geometry features deemed insignificant for analysis (external fillets, rounds, logos, and so on).Idealization: More aggressive exercise that may depart from solid CAD geometry (representing thin walls with surfaces).Clean-up: Sometimes required because the meshable geometry must satisfy much higher quality requirements than those commonly followed in Solid Modeling. We can use CAD quality-control tools to check for sliver faces or multiple entities that the CAD model could tolerate, but would make meshing difficult or impossible.Preprocessing -> Solution -> PostprocessingRepresent how the given model is attached to the rest of the worldFixed on a Surface or Edge or PointAllow Sliding or Rotation

Fixtures used to reduce the size of the problem to a component level or subassembly levelBuilding the FEA Model - Fixtures

# Dassault Systmes Confidential Information 6Loads applied to exterior surfaces of the modelForces on Surfaces or Edge or PointsTorque, MomentPressure

Loads acting on entire modelGravity, Centrifugal forceThermal loads

Building the FEA Model - Loads

# Dassault Systmes Confidential Information 7All rigid body DOFs must be removed from the model for successfull analysis no objects flying in space.FEA for structural analysis

Example of a fittingSplit the fitting into small tetrahedral pieces and approximate the deformation on each piece

# Dassault Systmes Confidential Information FEA for structural analysis

Example of a bracketSplit the surfaces of bracket into small triangular pieces and approximate the deformation on each piece

# Dassault Systmes Confidential Information FEA for structural analysisExample of a frame structureSplit the members of frame into small straight pieces and approximate the deformation on each piece

# Dassault Systmes Confidential Information MESH Approximate representation of the CAD geometry using Tetrahedra or TrianglesELEMENTS Tetrahedra or Triangles in the MeshNODES - Points at which different elements are jointed together; nodes are the locations where values of unknowns (usually displacements) are to be approximated Mesh, Nodes, Elements,

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Stresses at a point are defined by 6 quantities 3 normal stress and 3 shear stresses depend on orientation of coordinate system

Von Mises Equivalent Stress =

VON is independent of coordinate system

Principal Stresses 3 normal stresses specified in a special coordinate system for which shear stresses are zero

Factor of Safety =

Using Stress Results to Validate Design

# Dassault Systmes Confidential Information 123D state of stress -> in general 6 independent components of stress. How will the material fail? What will be the failure mode (shear, normal etc.)? Will the material fail?Von Mises gives us one number that is typically compared to the uniaxial tensile strength of the material.Response is proportional to the applied loads If you double the load, deformation also gets doubledIf you remove the load, model has no deformation

Material is linearly elastic The part returns to its original shape if the loads are removed (no permanent deformation)

Loads are staticLoads are applied slowly and gradually. Rapidly-applied loads cause additional displacements, strains, and stresses

Assumptions in Linear, Static Analyses

Small deformationLarge deformation# Dassault Systmes Confidential Information 13Lets look a little closer at a couple of these assumptions.A linear system displays a response that is directly proportional to the applied loads. So the displacement and stress at a load of 100 psi is exactly 2 times larger than the displacement and stress at 50 psi. This comes from the fact that the stress is considered to be directly proportional to the strain (a linear material) and that the displacements are small compared to the part.Second, the elastic material assumption means there is no plastic deformation and the part returns to its original shape if the load is removed. A situation like bending sheet metal (where the amount of plastic deformation determines the final bent shape) cannot be analyzed with an elastic material.Finally, the static load assumption means that the loads are applied slowly enough for the inertial effects to be insignificant. Fast loads, like with a drop test or striking a nail with a hammer, cause load amplification due to the speed of application.Material?Steel 1040Physical Working Condition?Pressure or forceBolted or WeldedModeling in SolidWorks SimulationTRAININGIs my Design OK (Results)Factor of SafetyStressCheck list for SolidWorks Simulation

# Dassault Systmes Confidential Information Lesson 1The Analysis Process

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Introduction to the Simulation interfacePerform linear static analysis Static studyMaterial propertiesRestraintsLoadsMeshRunInfluence of mesh density on displacement and stress resultsPost-processingLesson 1 Topics

# Dassault Systmes Confidential Information 16SolidWorks Simulation interface

Study treeStudy tabsToolbarSimulation AdvisorCommandManager tab

Analysis library# Dassault Systmes Confidential Information Loads and restraints

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von Mises Stresses in coarse studyLesson 1: Results

# Dassault Systmes Confidential Information 19Because the FEM mesh is not symmetric. It is not possible to obtain exactly symmetrical results.Lesson 1: Resultsvon Mises Stresses in default study

# Dassault Systmes Confidential Information 20Because the FEM mesh is not symmetric. It is not possible to obtain exactly symmetrical results.Only quarter of the model > symmetric boundary conditions.

Lesson 1: Resultsvon Mises Stresses in fine study# Dassault Systmes Confidential Information 21Because the FEM mesh is not symmetric. It is not possible to obtain exactly symmetrical results.Only quarter of the model > symmetric boundary conditions.Finer mesh More accurate results More computational timeLesson 1: ResultsSummary of results convergence study

# Dassault Systmes Confidential Information 22More elements will give more accurate simulation of the analytical results.Comparison with analytical

Which result is correct???

Lesson 1 Results

# Dassault Systmes Confidential Information Answer: Neither result produces the correct solution. Each approach has assumptions that limit the validity of the approach. Only the real test in the real conditions provides the correct result.23Exercise 1: Bracket

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Exercise 2: Compressive Spring Stiffness

# Dassault Systmes Confidential Information Exercise 3: Container Handle

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Lesson 1: Questions# Dassault Systmes Confidential Information Lesson 2Mesh Controls, Stress Concentrations and Boundary Conditions

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no fillet configurationUsing SolidWorks ConfigurationsUse of mesh controls, automatic transition FEA Convergence issuesDifferent boundary conditionsLesson 2: Topics

fillet configuration# Dassault Systmes Confidential Information 29Loads and restraints

# Dassault Systmes Confidential Information Lesson 2: ResultsNo fillet configuration

# Dassault Systmes Confidential Information 311- When increasing the number of elements, will the stresses converge? 2- Why?Lesson 2: ResultsStress Results mesh1, mesh2 and mesh3

# Dassault Systmes Confidential Information 32Stresses will not converge due to the sharp corner in the model.No Mesh ControlLesson 2: ResultsFillet, Mesh ControlMesh Control

# Dassault Systmes Confidential Information 33Higher element count close to the entities with higher curvatureFixed edge produces unrealistic stresses at the support location.Lesson 2: ResultsWelded boundary condition

# Dassault Systmes Confidential Information 34Can greatly simplify the modelCan also affect resultsKnow your assumptions

Lesson 2: Boundary Conditions

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Exercise 4: C-bracket

No filletFilleted edge# Dassault Systmes Confidential Information

Exercise 4Stress concentrationsFixed hole# Dassault Systmes Confidential Information Exercise 5: Bone Wrench

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Exercise 6: Foundation Bracket

0.5 mm

# Dassault Systmes Confidential Information Exercise 6: Foundation Bracket

0.5 mm

# Dassault Systmes Confidential Information Lesson 2: Questions

# Dassault Systmes Confidential Information Lesson 3Assembly Analysis with Contact

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Assembly Analysis BasicsInterference DetectionGlobal and Local Contact/Gaps conditions

Lesson 3: Topics

# Dassault Systmes Confidential Information 43Explain why we have Free Contact type.Explain that Global conditions are valid only for parts in contact at the beginning of the analysis. If any two parts are not touching, local contact conditions have to be specified. (Do not talk about node-to-node, node-to-surface and surface-to-surface as this would clutter the point; it will be discussed later on in local contact conditions). Interference Detection

# Dassault Systmes Confidential Information Default: Bonded

Global contact conditionsNo penetrationBonded (No clearance)Allow Penetration

Component ContactUncheck Global Contact boxOverrides Global Contact

Global contact

# Dassault Systmes Confidential Information Contact/Gap Hierarchy

Global and Component contact apply only to initial touching areasGlobal contact for most common condition, component and local contact as needed

# Dassault Systmes Confidential Information 46For structural studiesNo PenetrationBondedAllow PenetrationShrink FitVirtual Wall

For thermal studiesInsulated (similar to Free in a static study)Thermal contact resistance

Friction at the local level for touching entitiesInitial gap (clearance) can be ignored or accounted for by specifying it here

Local Contact Conditions

# Dassault Systmes Confidential Information Loads and restraints, mesh

225 N225 NFixed

Global No Penetration contactLocal contact# Dassault Systmes Confidential Information Von Mises stresses - Global contact (225 N force) (You can plot stresses in exploded configuration)Lesson 3: Results

# Dassault Systmes Confidential Information 49Could we study the stresses on contact surfaces?Von Mises stresses With local contact (4500 N force)Lesson 3: Results

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Exercise 7: Two Ring Assembly

# Dassault Systmes Confidential Information Lesson 3: Questions

# Dassault Systmes Confidential Information Lesson 4Symmetrical and Free Self-Equilibrated Assemblies

# Dassault Systmes Confidential Information 53Analyze shrink-fit problemUse of symmetryReview stress results in local coordinate systemsSolver options to eliminate rigid body modes

Lesson 4: Topics

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Local Contact ConditionsContact conditions (global & local) reviewContact conditions (local only) Shrink fit1 - Program creates a shrink fit condition between selected faces.2 - The faces may or may not be cylindrical.(NOTE: Virtual wall a sliding support (roller), with friction and wall elasticity capability)

# Dassault Systmes Confidential Information 55Boundary conditions

# Dassault Systmes Confidential Information Contact and Mesh

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Lesson 4: ResultsWhy is there a jump in the hoop stress value across the interface?Would the assembly experience a similar jump in radial stresses?Hoop stress (using local cylindrical coordinates)

# Dassault Systmes Confidential Information 58Hoop stress jump is due to the fact that the inner hub is compressed and outer rim stretched. In addition to it both material have different properties (Hub is made of Plain Carbon Steel. Rim is made of Alloy Steel.)2. No. Due to the force equilibrium the radial stress will be identical in both parts (at the interface).Exercise 8: Chain Link

# Dassault Systmes Confidential Information Exercise 9: Chain Link 2

Incorrect solutionCorrect solution# Dassault Systmes Confidential Information Lesson 5Assembly Analysis with Connectors

# Dassault Systmes Confidential Information 61 Connectors Rigid Spring Pin Elastic Support Bolt Spot Weld Edge Weld Link Bearing Global and local contact conditionsLesson 5: Topics

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Connectors

Spring

Pins (three in all)# Dassault Systmes Confidential Information Boundary conditions and Mesh

225 N225 NFixed

# Dassault Systmes Confidential Information Lesson 5: Results

# Dassault Systmes Confidential Information Exercise 10 & 11

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Exercise 12: Shock AbsorberSimplify the model

1. Suppress the original helical spring from the analysis.2. Introduce Spring Connector.# Dassault Systmes Confidential Information 67The original helical spring does not need to be meshed -> reduction of the problem.Exercise 12: Shock Absorber

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Exercise 13: Spot WeldsConnector types Spot WeldsSpot WeldsSpot Welds

# Dassault Systmes Confidential Information 69The introduction of Spot Welds connectors reduces the size of the problem. Otherwise, many fine elements would have to be introduced across the welded interface and the necessary contact conditions would have to be introduced. Such detailed analysis is needed only if the stress distribution within the welds is desired.Exercise 13: Spot WeldsSpot Welds - solid models - stress resultsWe notice high stresses in the vicinity of welds. Would the subsequent mesh refinement in these regions bring more accurate stress distribution?

# Dassault Systmes Confidential Information 70No. Spot welds are a point-to-point contacts. Mathematically they introduce singularities with infinite values of stresses. Further refinement of the mesh would not bring more accurate stress distribution. Spot welds can only be used to study the global deformation of the entire body. Detailed analysis of the welds would be required.

Lesson 6Compatible/Incompatible Meshing

# Dassault Systmes Confidential Information 71Compatible solid element mesh with Bonded contactsIncompatible solid element mesh with Bonded contactsSimplified bonding for incompatible solid meshes

Lesson 6: Topics# Dassault Systmes Confidential Information 72 Bonding of touching parts is achieved by imprinting and merging the nodes.Compatible solid mesh

# Dassault Systmes Confidential Information 73 Bonding of touching parts is achieved by additional constraint equations.Incompatible solid mesh

# Dassault Systmes Confidential Information 74Incompatible solid mesh: More Accurate Bonding

Surface based contact. Results at the contact interface are uniform but solution time is longer.# Dassault Systmes Confidential Information Incompatible solid mesh: Simplified Bonding

Node based contact. Results at the contact interface may be patchy but solution time is lower.# Dassault Systmes Confidential Information Lesson 7Assembly Analysis Mesh Refinement

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Analyze larger assembly using solid elementsRemote load featureDefine multiple contact conditionsNontraditional contact and connector useAnalyze mesh quality and question the results of the simulation

Lesson 7: Topics

# Dassault Systmes Confidential Information 78Load (Direct transfer)Load/Mass (Rigid connection)Displacement (Rigid connection)Remote loads

# Dassault Systmes Confidential Information Bolt typeTight fitMaterialPre-loadBolt seriesBolt connectors

# Dassault Systmes Confidential Information Type of contact that replaces modeling a componentRigid or FlexibleVirtual wall

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Lesson 7: ResultsDraft mesh: mesh parameters and resultsMesh parameters are not ideal leading to excessive von Mises stress results

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High mesh: mesh parameters and resultsMesh parameters improved, so did the results of the simulation.(NOTE: The time required to complete the simulation increased as well.)

Lesson 7: Results# Dassault Systmes Confidential Information 83Exercise 14: Bolt Connectors

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Exercise 15: Awning

# Dassault Systmes Confidential Information Lesson 7: Questions

# Dassault Systmes Confidential Information Lesson 8Analysis of Thin Components

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Shell ElementsMid-plane and surface shell element meshingAlignment of shell meshEvaluating mesh sizesEvaluating results for shell elementsReaction forcesSolid vs. Shell meshing

Lesson 8: Topics# Dassault Systmes Confidential Information 88

55449 DOFLesson 8: ResultsSolid Elements Von Mises Stress987978 DOF (1 element per thickness) (2 element per thickness)

# Dassault Systmes Confidential Information 89Solid elements -> no bottom or top is relevant from the perspective of the FEA.Only 2 elements per thickness -> 1400% increase in the # of elements -> advantage of shell elements in capturing the through thickness behavior.

Defined by:Existing surface or sheet metal bodiesMid-plane surfacesOutside/inside faces of solid bodiesShell elements

Outside facesMid-plane surface

# Dassault Systmes Confidential Information Shell Type

Kirchoff TheoryMindlin TheoryThin shells ignore shear deformation through the thickness of the shell

# Dassault Systmes Confidential Information Misaligned shell elementsShell Element Alignment

Shell Elements - Alignment Incorrect stress result representation

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Shell Elements (midplane) Von Mises Stress Bottom (orange) Top (gray)

Lesson 8: Results

# Dassault Systmes Confidential Information 93Questions: Why are the stress results on both sides positive? A: (Von Mises stresses)Stress out the top and bottom alignment of the shell elements.Shell elements can greatly decrease the required computational time.Modeling with shell elements is more demanding than with solids.* See results of Exercise 16 Lesson 8: ResultsShell vs. Solid Elements

# Dassault Systmes Confidential Information 94Demanding: we have to pay attention to the surfaces (top, bottom) etc.Case Study: Joist Hanger

Shell elements generatedautomatically for sheet metal features

# Dassault Systmes Confidential Information Exercise 16: Bracket

# Dassault Systmes Confidential Information TopExercise 17: Shell Mesh Using Outer/Inner FacesShell Elements (surfaces) Von Mises Stress Bottom

Bottom (orange) Top (gray)

# Dassault Systmes Confidential Information 97Exercise 18: Spot Welds - Shell meshSpot Welds - shell model - stress resultsBoth solid and shell models predict similar behavior. Which one would you choose?

# Dassault Systmes Confidential Information 98Exercise 19: Edge Weld ConnectorEdge Welds - shell model weld bead sizesDesign the size of the edge weld beads.

# Dassault Systmes Confidential Information 99Exercise 20: Container Handle WeldSelf-guided exerciseDesign double sided fillet welds connecting the container handle to the square plates.

# Dassault Systmes Confidential Information 100Lesson 8: Questions

# Dassault Systmes Confidential Information Lesson 8: Questions

# Dassault Systmes Confidential Information Lesson 9 Mixed Meshing Shells & Solids

# Dassault Systmes Confidential Information 103Mixed meshingSolid-shell bondingShell offsetMesh failure diagnosticsLesson 9: Topics# Dassault Systmes Confidential Information Mixed meshingWhy Mixed Meshing?Some design assemblies may contain bulky parts suitable for solid mesh, as well as thin parts ideal for shell elements.

# Dassault Systmes Confidential Information 105Mixed meshing may greatly reduce the size of the problem.Compatibility problems in mixed solid and shell element meshingUse of mixed mesh in simulation

Solid and Shell ElementsHow many DOF does a solid element have?

How many DOF does a shell element have?

# Dassault Systmes Confidential Information 106Hinge formed at the connecting edgeMay introduce rigid body modes if not handled properlyMesh incompatible at the interfaceBond generated through multi-point constraints internally (mortar bonding)Bonding between solids and shells

Hinge# Dassault Systmes Confidential Information Mid-surfaceTop surfaceBottom surfaceRatioShell offset

By default, mesh located at mid-planeOrientation important when defining shells with different thickness# Dassault Systmes Confidential Information Incompatible meshMesh controlAuto-loopingCheck geometrySwitch mesher

Mesh failure diagnostics

# Dassault Systmes Confidential Information Lesson 9: ResultsWhy are the stresses highest at the base near the support and bonded contacts?

# Dassault Systmes Confidential Information 110Exercise 21: Mixed Mesh Analysis

# Dassault Systmes Confidential Information Lesson 9: Questions

# Dassault Systmes Confidential Information Lesson 10 Mixed Meshing Solids, Beams & Shells

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Beam elementsJointsBonding of beamsPost-processing of beam elementsLesson 10: Topics# Dassault Systmes Confidential Information 6 DOFsBeam elements

# Dassault Systmes Confidential Information joints are connected to two or more beam members. joints are connected to a single member onlyJoints

# Dassault Systmes Confidential Information Bonding of beams

Bond joints or entire beam to target entities

Beam profile imprinted on target entities Accurate results at the interface# Dassault Systmes Confidential Information Lesson 10: Results

# Dassault Systmes Confidential Information 118Stress: Axial, bending, worst-case, torsional, shearDisplacementAxial force diagramsShear & bending moment diagramsReaction forces & moments

Results for beam elements

Simply supported with uniform distributed loading# Dassault Systmes Confidential Information

Exercise 22: Beam Elements

# Dassault Systmes Confidential Information Exercise 23: Cabinet

# Dassault Systmes Confidential Information Exercise 24: Frame Rigidity

# Dassault Systmes Confidential Information Exercise 24: Frame Rigidity

# Dassault Systmes Confidential Information Lesson 11Design Study

# Dassault Systmes Confidential Information 124Lesson 11: TopicsDesign Study performing several studies for different input data (model geometry or loads)Stresses in vehicle suspension when vehicle is:Stationary and loadedMoving at constant acceleration on a smooth roadMoving on a bumpy roadMoving at a constant speed on a banking roadDifferent loads in different directionsReview different connectors and fixtures

# Dassault Systmes Confidential Information 125Design Scenario with loads input

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Lesson 11: Results (Loads input)# Dassault Systmes Confidential Information Design Scenario with geometry input

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Lesson 11: Results (Geometry input)

# Dassault Systmes Confidential Information Exercise 25: Design Scenarios

# Dassault Systmes Confidential Information Lesson 12Thermal Stress Analysis

# Dassault Systmes Confidential Information 131Static analysis with temperature loadUse of various contact conditionsTemperature dependent material propertiesSoft spring and Inertia relief options

Lesson 12: Topics

# Dassault Systmes Confidential Information 132Averaging across boundaries ONAveraging across boundaries OFFLesson 12: Results

# Dassault Systmes Confidential Information 133Axial strain at the sensor locationsLesson 12: Results

# Dassault Systmes Confidential Information 134Lesson 12: Results

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Lesson 13Adaptive Meshing

# Dassault Systmes Confidential Information 136Lesson 13: TopicsWhy and What is Adaptivity?What do FEM results depend on?1. Mesh2. Type and order of the elements used (Draft or High quality)3. Other phenomena (numerical errors, modeling errors etc.)What is our Goal? Is it just to obtain a solution?How to achieve it?Make sure our results are close to some defined accurate solution.(typical parameter is strain energy density)1. Modify and refine the mesh topology2. Modify the order of elementsh-adaptivityp-adaptivity# Dassault Systmes Confidential Information 137Simple analogy for h-adaptive and p-adaptive: How would a Designer increase the power of a Car Engine ? Option 1: Put more Cylinders in the Engine (V-6, V-8, V-10 and so on). Option 2: Make the Cylinder Larger (2 Liter, 2.6 Liter, 3.0 Liter and so on).Option 1 is like h-adaptive where we put more elements. Option 2 is like p-adaptive where we put more power into each element.

Adaptive Finite Element Analysis

h-Adaptivity, p-AdaptivityRefining the mesh (h-Adaptivity)Changing the order of elements (p-Adaptivity)

1st order(Draft Quality)2nd order(High Quality)5th order# Dassault Systmes Confidential Information 138Remind that 1st and 2nd order can be used for direct modeling, 3rd-5th can only be used with using adaptivity.h-Adaptivity and p-Adaptivity can not be combined.

Lesson 13: Resultsh-Adaptivity - results98% convergence criteria (2% accuracy) was achieved in 6 iterations

# Dassault Systmes Confidential Information 139The mesh on the top shows the original mesh topology.

Lesson 13: Resultsp-Adaptivity - results0.05% convergence criteria was/was not achieved in 4 iterations

# Dassault Systmes Confidential Information 140The mesh on the top shows the original mesh topology; mesh topology is not changing.The looping stopped after 5 steps we do not know whether the criteria of 0.05% has been met or not. Von Mises stress error can be calculated from the graph values.Note, that 0.05 convergence criteria was specified for strain energy, not stresses.SummaryMax. displacement difference:0.2%Max. Von Misses stress difference:10%Which method would you use?Lesson 13: Results

# Dassault Systmes Confidential Information 141All of them produce similar results.Displacement results are nearly the same, stress difference is acceptable give the sharp corner re-entrant.Standard solution is usually acceptable if using High quality elements.h- and p-Adaptivity should be used only if solution with tight accuracy requirements is desired. It also consumes more time.

Lesson 14Large Displacement Analysis

# Dassault Systmes Confidential Information 142Surface contactContact analysis with the large displacement optionEvaluate mesh adequacy for modeling bending stressesLimitations of the linear material model

Lesson 14: Topics

# Dassault Systmes Confidential Information 143Lesson 14: ResultsSmall displacement contact analysis Incorrect Displacements

# Dassault Systmes Confidential Information 1441/ Small displacement contact analysis assumes constant (initial) normal vectors (geometrical vectors), and uses constant (initial) stiffness matrix.2/ With the above assumption, the load is applied in one step.Lesson 14: ResultsLarge displacement contact analysis Correct Displacements

# Dassault Systmes Confidential Information 145Node to surface contact options are suitable for line and points contacting with surfaces (lines and other points).Lesson 14: Questions

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