2012 trends and lessons for best use of contact … trends and lessons for best use of contact...

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12

Trends and Lessons for Best

Use of Contact Capabilities

2012 Regional Users’ Meetings

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Outline

Evolution toward greater automation

Contact “lessons”

Feedback from support organization

Comments on ongoing development

This presentation will focus

on Abaqus/Standard

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Evolution towards greater automation

Contact definition

Contact elements

(e.g., GAPUNI):

v h

1

2

2 1 0h d n u u

Contact pairs: General contact:

Trends over time

Model all interactions

between free surfaces Many pairings

for assemblies

User-defined element for

each contact constraint

n

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Evolution towards greater automation Broadly applicable algorithms

Avoid simplifying assumptions that can cause non-physical results

Ramp down usage of “small-sliding” contact formulation

Master surface

Finite-sliding contact formulation: Small-sliding contact formulation:

Master surface

Trends over time

Flat approx.

per slave node General purpose

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Less quirky

For example, introduction of “surface-to-surface” contact formulation reduces likelihood of penetrations at master nodes

Trends over time

Penetrations may

occur at master nodes

Resists penetration

at slave nodes

Good resolution of contact

over the entire interface

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Avoid restrictions imposed by contact

C3D10 elements can be used with the surface-to-surface formulation

Trends over time

Slave:

C3D10

Master:

C3D8

Uniaxial

loading, s=5

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More robust

Supplementary edge-to-surface formulation is on by default for general contact

Trends over time

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Outline



Review of recommendations and not commonly known aspects

Feedback from support organization


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Contact modeling lessons

1. OK to use C3D10 elements at contact interfaces for general contact

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New message: The surface-to-surface contact formulation is fundamentally sound

with C3D10 elements

Recall uniaxial-compression-of-blocks example on a previous slide

C3D10 elements have some advantages

C3D10M elements remain an OK choice

C3D10 still should not underlie the slave surface for node-to-surface contact formulation

OK to use C3D10 elements

For years we encouraged C3D10M elements as an alternative to C3D10

elements at contact interfaces

To avoid limitations of traditional contact formulation with C3D10 elements

This message “got through” to users

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C3D10M vs. C3D10 Reference solution:

• Peak stress=4.3

7% error

Contact stress concentration

Variation of hole-in-plate example

Symmetry boundary

conditions

Unit

pressure

Frictionless (S-to-S) contact

C3D10

C3D10M

3.5% error

2% error 0.5% error Finer

mesh

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2. Quadratic elements (including C3D10) tend to be more sensitive to

localized effects than linear elements (including C3D10M)

• Example on previous slide

• Additional example to come

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2. Quadratic elements tend to be more sensitive to localized effects than linear elements

3. Contact pressure error indicators are available in Abaqus/Standard

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Contact pressure error indicator

CPRESSERI output variables

Recommend viewing CPRESS and CPRESSERI side-by-side (same units)

Learn to qualitatively interpret indicators through examples, experience, mesh refinement

Error indicator

Interpretation:

• Accurate prediction of peak CPRESS

• Some uncertainty in CPRESS at edge of

contact region where CPRESS is small

but with large gradient in this example

Error indicator

Interpretation:

• Peak CPRESSERI is of same order as

peak CPRESSERI

• Need finer mesh for accurate CPRESS

estimates in this example

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Contact pressure error indicator

Revisit stress concentration example with C3D10 elements

Error indicator somewhat over-predicts solution error in this example

0

0.5

1

1.5

2

2.5

3

Course Mesh Fine Mesh

Per

cen

t E

rro

r

Estimated from CPRESSERI_max/CPRESS_max

% deviation of CPRESS_max from reference solution of 4.3

0.07/4.28*100%

|4.28-4.3|/4.3*100%

Reference solution:

• Peak stress=4.3

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4. Contact pressures are often singular at corners

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Contact singularities near corners

Rigid punch example

CP

RE

SS

15,000

CP

RE

SS

ER

I

Position

5,000

Singularities in

analytical solution

0

2,000

4,000

6,000

8,000

10,000

12,000

1 2 3 4

Mesh #

CPRESS_max

CPRESSERI_max

More refined

Peak values increase

with mesh refinement

Peak values increase

with mesh refinement

(evidence of a possible

singularity)

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In practice, it may not be obvious that a stress singularity or concentration should exist

Quadratic elements tend to be more sensitive to localized effects

S-to-S, C3D10 N-to-S, C3D10M

N-to-S, C3D10M S-to-S, C3D10

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Also look at error indicators

Results shown for C3D10 elements

0

5

10

15

1 2 Mesh #

CPRESS_max

CPRESSERI_max

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5. (Show example first)

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Contact pressures

What is the cause of CPRESS noise in this example?

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Contact pressures

Reproduce behavior in a simpler model

Rigid

Elastic

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Contact pressures Mesh refinement study

Not numerical noise; there is

a physical stress concentration

0

500

1,000

1,500

2,000

2,500

Mesh 1 Mesh 2 Mesh 3

Maximum CPRESS per Mesh

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Contact pressures Also examine error indicators

0

500

1,000

1,500

2,000

2,500

Mesh 1 Mesh 2 Mesh 3

CPRESS_max CPRESSERI_max

Decreasing with

mesh refinement

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Contact pressures A literature search may lead to a better understanding

of a stress concentration

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5. Contact pressures are often concentrated near rounded corners

• Discussed in previous slides

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6. (Show example first)

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Contact pressures (another example)

Considering a modeling change

Second-order tet elements instead of linear bricks

Easier to mesh

Significant increase in peak contact stress and

contact stress noise observed

But this is not really due to problems with second-

order elements or contact

Note that both of these CPRESS solutions are actually

quite noisy

Further diagnosis on next slides

1.00

1.21

Relative peak values of CPRESS

With first-order hex

With second-order tet

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Contact pressures

Closer view near a peak in CPRESS

Master surface (based on R3D3): Slave surface (based on C3D10):

Same

scale

Vertex of mesh for rigid body

Side view,

magnified

Solution noise shown on previous

slide is due to poor representation

of the opposing contact surface

Vertex coincides

with peak CPRESS

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Contact pressures Effects of element type choices for both bodies

Deformable

slave:

Second-order tet

First-order hex

First-order tri Second-order tri

Rigid master:

1.00

0.85 1.21

0.83

Relative peak values of CPRESS

Element type SFM3D6 made rigid

(R3D6 is not available)

Coarse mesh of linear elements

causing noise for this example

Only considering these two solutions

can lead to wrong conclusions

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6. Meshing with linear elements can result in non-physical “corners” and,

therefore, cause contact pressure noise

• Discussed in previous slides

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6. Meshing with linear elements can result in nonphysical “corners” and, therefore, cause

contact pressure noise

7. Surface geometry corrections mitigate issues with faceted surfaces

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Surface geometry corrections Corrections account for distance between initial

FE geometry and idealized geometry

Quite effective even after deformation

Conical interface example

*Surface Property Assignment,

Property=Geometric Correction

Slave

surface

Master surface

Correction

factors

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8. Contact stabilization and implicit dynamics for overcoming static

instabilities

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Pin joint example This analysis cannot even get started

Due to unconstrained rigid body modes (RBM’s) prior

to establishing contact

From status file:

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Pin joint example Initial gap around pin

Force-controlled loading is also a

factor in rigid body modes

Pin starts out “floating in space”

(except for a BC in its axial direction)

BCs restrain all RBMs for this part

except translation in direction of loading

Five initially unconstrained

rigid body modes for pin (two

translational, three rotational)

One initially unconstrained RB

mode for this part (translational)

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Pin joint example Unconstrained modes trigger “Numerical Singularity” warnings

Five associated with pin, and one associated with plate to right

Can’t distinguish between

rotational and translational RB

modes in these warning messages

From message file:

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Pin joint example With *Contact Stabilization added

Relatively new keyword interface associated with general contact

Acts only in normal direction by default (less likely to degrade accuracy)

Last converged increment has

83% of loading completed

Lingering issue??

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Pin joint example Also specify friction coefficient of 0.1 (instead of no friction)

Helps stabilize rotational mode of pin

Model % complete # incrs. # iters.

contact stabilization,

no friction 83% 12 104

contact stabilization

and friction 100% 6 32

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Implicit dynamics (another form of stabilization)

Viable for “industrial” contact models starting in Abaqus 6.9EF

Leverage inherent stabilizing effects of mass

Intuitive: due to inertia, an unsupported body with a force applied to it will not suddenly

experience an infinite displacement

f=ma

Not only reliant on static internal forces (Ku) to counter an external load

Numerical: Effective stiffness for an implicit dynamics iteration is like: K ́= K + (4/Dt2) M

Singular modes for K are often not singular for K ́ Stabilizing effect tends to increase

after a cut-back in increment size

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Implicit dynamics (another form of stabilization)

One “macro” user control parameter

Affects many detailed control settings

Moderate Dissipation Transient Fidelity

Quasi-static

APPLICATION =

Default for contact models

Default for noncontact models

Intended for quasi-static modeling

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Bouncing disc example (gravity load) “Moderate Dissipation” “Transient Fidelity” “Quasi-Static”

Kinetic Energy

Comparison

1 2

3

0

500

1000

1500

1 2 3

# Solver Passes

“Mo

der

ate

Dis

sip

atio

n”

“Tra

nsi

ent

Fid

elit

y”

“Qu

asi-

Sta

tic”

Compressed

Just before and after contact

Peak height

after rebound

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Implicit dynamics Comparison to statics

Pure static analysis is usually more efficient than quasi-static analysis with the

dynamic procedure if a model is statically stable

Quasi-static analysis with the dynamic procedure tends to more robust

Often beneficial to supplement with other stabilization methods, also

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Implicit dynamics Comparison to explicit dynamics

Cost of increments/iterations vs. number of increments/iterations

Relative overall performance is very problem dependent

Satisfaction of residual tolerances in implicit only

Effects of “mass scaling” (adjusting the density for implicit dynamics)

Increases stable time increment in Abaqus/Explicit

Increases inertia effects in both

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8. Contact stabilization and implicit dynamics for overcoming static instabilities

9. Use general contact (or similar formulation options in contact pairs)

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Robust contact search

Automated choice of slave and master roles

Distribution of nodal forces consistent with underlying element formulation Ability to satisfy “contact patch tests”

Continuity of contact forces up sliding

Individual constraint forces oppose penetration Even for corner nodes of 2nd order elements

Accurate representation of surfaces Slave surface: not just a collection of points

Master surface: not approximated as flat per slave node

Reduce discretization error

Special treatment of feature edges

Small amount of numerical softening

Contact formulation characteristics Good characteristics for accuracy, robustness, and generality

finite-sliding

surface-to-surface

geometry corrections

general contact

penalty method

finite-sliding

edge-to-surface

surface-to-surface

surface-to-surface

surface-to-surface

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Outline



Feedback from customer support


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Support feedback #1

“I see many models which contain combinations of NODE TO SURFACE and

SURFACE TO SURFACE contact with obsolete *CONTACT CONTROLS

commands thrown in. These models generally run better when I switch

everything to the latest and greatest contact definitions.”

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Support feedback #2

“The first thing we do when a contact support issue comes in is strip out the

contact definitions and replace them with general contact. Often times it

works right away, or we may have to make minor modifications from there.”

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Support feedback #3

“Implicit dynamics, general contact, and contact stabilization help

tremendously in finding solutions.”

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Support feedback #4

“Customer requests a small-sliding option within general contact”

No plans to provide this, due to:

Limited applicability of small-sliding formulation

Causes nonphysical results if used inappropriately

Judging applicability deserves careful, close attention (per pairing)

Focus development effort on general-purpose methods

Including performance enhancements, etc. to take away reasons for

using specialized methods

Existing UI aspects

Near-automated generation of contact pairs based on initial proximity

is appropriate for “small-sliding” contact pairs

General contact and contact pairs can be used together

White dots: slave nodes

White lines: linear appox.

of master surface per slave

Example

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Outline



Feedback from customer support


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Ongoing development: Robustness

Diagnostics

More feedback on modeling issues and problems encountered during a simulation

Convergence

Better convergence behavior by default

New approaches

Innovation

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Ongoing development: Performance

Many aspects

Enable larger models to run

Better parallel scaling

Faster algorithms

Remove isolated bottlenecks

Pre, analysis codes, post-processing

Reduce extra costs for general-purpose algorithm

General contact vs. contact pairs

Finite-sliding formulation vs. small-sliding formulation

0

50

100

150

0 60 120 180

Bat

ch P

re w

all t

ime

(min

ute

s)

Millions of DOF

Abaqus 6.10EF

Abaqus 6.11

Abaqus 6.12

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Ongoing development: Accuracy

Accurate representation of general curved surface

shapes

Formulation and output refinements

Supplemental formulations

E.g.: Beam-to-beam general contact in Abaqus/Standard

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Conclusions

Best practices have evolved considerably in recent years

General contact defaults are quite robust

Contact pair defaults are not quite as robust (hard to change long-standing

defaults due to pre-existing customer models)

Can often find a solution with various combinations of tricks without

following recommended “best practices”

But users typically benefit from adopting best practices

Significant ongoing investment in contact development

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2012 trends and lessons for best use of contact … trends and lessons for best use of contact...

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