Assembly Modeling Using ANSYS

Luc Pontoire Simon Mendy

ansys-support-france@ansys.com
15/10/09
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Outline

Overview Connections CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints

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Overview
The CAE usage has completely changed over years. The CAE user used to realize calculations on simplified single parts. Today , calculations on detailed complete assemblies or subassemblies are common , thanks to the increase of computational power and code efficiency. It is now necessary to know the various possibilities of modeling interactions between these parts, in order to assess to best choice for the simulation

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Overview
Contact detection allows easy setup linking of parts. But do you do the best choice every time ?

Contact detection on motor assembly

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Overview
But do you the best choice every time ? Lets try to model a hinge. ( penalty contact ?)

1.3 hours CPU Time

Pin Base
Frictionless Ear to Base Pin to Base Bonded Ear to Pin
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Ear

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Overview
Take a deep breath There is maybe something more appropriate in this case
40 CPU Time

Pin Base
Revolute joint Ear to Base Pin to Base Fixed joint Ear to Pin
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Ear

New at R12

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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Remote point
New Remote Point Feature

Scoping mechanism for remote BCs Applied to face, edge, vertex of bodies

Promote remote BCs to a remote point Benefits

Multiple boundary conditions scoped to a point Avoid over-constraint conditions

Remote Points
New at R12

Applications

Point mass, springs, joints, remote loads, moments

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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Constraint Equations
A constraint equation (CE) defines a linear relationship between nodal degrees of freedom. If you couple two DOFs, their relationship is simply UX1 = UX2. CE is a general form of coupling and allows you to write an equation such as UX1 + 3.5*UX2 = 10.0. You can define any number of CEs in a model. Also, a CE can have any number of nodes and any combination of DOFs. Its general form is: Coef1 * DOF1 + Coef2 * DOF2 + Coef3 * DOF3 + ... = Constant

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Constraint Equations
Common applications: Connecting dissimilar meshes Connecting dissimilar element types Creating rigid regions Providing Interference fits

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Constraint Equations
Connecting dissimilar meshes If two meshed objects meet at a surface but their node patterns are not the same, you can create CEs to connect them. Easiest way to do this is with the CEINTF command (Preprocessor > Coupling/Ceqn > Adjacent Regions).
Requires nodes from one mesh (usually the finer mesh) and elements from the other mesh to be selected first. Automatically calculates all necessary coefficients and constants. For solid elements to solid elements, 2-D or 3-D.

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Constraint Equations
Connecting dissimilar element types If you need to connect element types with different DOF sets, you may need to write CEs to transfer loads from one to the other:
beams to solids or beams perpendicular to shells shells to solids etc.

The CE command (Preprocessor > Coupling/Ceqn > Constraint Eqn) is typically used for such cases.

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Constraint Equations
Creating rigid regions CEs are often used to lump together portions of the model into rigid regions. Applying the load to one node (the prime node) will transfer appropriate loads to all other nodes in the rigid region. Use the CERIG command (or Preprocessor > Coupling/Ceqn > Rigid Region).

Remark : WB doesn't CE but contact MPC to enforce rigid regions conditions (discussed later)

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Constraint Equations
Creating flexible regions CEs are often used to average flexibility of portions of the model towards a master point or node. Applying the load to one node (the prime node) will transfer appropriate loads to all other nodes in the flexible region. Use the CERIG command (or Preprocessor > Coupling/Ceqn > Rigid Region).

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Constraint Equations
New Constraint Equation Manager
Coupling

of two or more remote points

Applications
Use

New at R12.1

constraint equations to model various joint/hinges

Easy

idealization of complex boundary conditions

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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Coupling Equation
A coupled set is a group of nodes coupled in one direction (i.e, one degree of freedom). A coupled equation is way of forcing degrees of freedom of a nodal group to have the same value. If you couple nodes 1 and 2 in the UX direction, the solver will calculate UX for node 1 and simply assign the same UX value to node 2. DOF1 = DOF2 = DOF3 = DOF4 = DOF5 ... You can define any number of coupled sets in a model, but do not include the same DOF in more than one coupled set.

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Coupling Equation Common applications: Enforcing symmetry Frictionless interfaces Pin joints

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Coupling Equation
Enforcing Symmetry Coupled DOF are often used to enforce translational or rotational symmetry. This ensures that plane sections remain plane. For example:
To model one sector of a disc (cyclic symmetry), couple the node pairs on the two symmetry edges in all DOF. To model a half tooth of a comb-type model (translational symmetry), couple the nodes on one edge in the X direction.

Symmetry BC on this edge

Couple these nodes in UX DOF

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Coupling Equation
Frictionless interfaces A contact surface can be simulated using coupled DOF if all of the following are true:
The surfaces are known to remain in contact The analysis is geometrically linear (small deflections) Friction is to be neglected The node pattern is the same on both surfaces

To do this, couple each pair of coincident nodes in the normal direction.

Couple each node pair in UY Y X

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Coupling Equation : CycloSymmetry

Cyclic Symmetry A component or assembly is cyclically symmetric if it has a correspondence in form or arrangement of parts (that is, repetitive patterns) centered around an axis.
CPCYC allows modelling of cyclic symmetry

CPCYC, Lab, TOLER, KCN, DX, DY, DZ, KNONROT By specifying a cylindrical coordinate system (KCN) and a wedge spacing (DY) in degrees, ANSYS will find your wedge boundaries and couple them for you! Meshes have to match on both sides of the pattern

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Coupling Equation : CycloSymmetry

Considering the following sector with a wedge spacing of 20 around Z with solid elements
CPCYC,ALL,,1,0,20,0 ! ALL allows to couple all 3 DDL : Ur, U, Uz

EXEMPLE2

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Coupling in Workbench
New Boundary Conditions Support
Coupling

Coupling Constraint

of two or more faces coordinates for displacement control for fixed rotation

Cylindrical Directional

Applications
Use

New at R12

Fixed Rotation, Cylindrical Coordinates

coupling to model various joint/hinges rotation as an applied displacement 2D modeling, more granular control for rotations
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Apply

For

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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MPC Contact
Limitations of existing bonded or no-separation contact ( with penalty or augmented lagrangian): Results depend on specified contact stiffness. Multiple iterations are required to adjust penetration in order to satisfy equilibrium even for small deformation problems. Occasionally spurious natural frequencies can occur in modal analysis. Only translational DOFs apply Limitations of existing constraint tools (CERIG and RBE3) Only suitable for small strain. RBE3 only supports force constraints applied on the master node, not displacements RBE3 requires manual definition of weighing factors. MPC surface constraints calculate weighing factors automatically
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MPC Contact
MPC algorithm enforces compatibility at an interface using internally generated constraint equations Degrees of freedom of the contact nodes are eliminated
No normal or tangential stiffness required For small deformation problem, no iteration is needed in solving system equations For large deformation problems, the MPC equations are updated during each iteration This method only applies to bonded or no-separation behaviors Not applicable for symmetric contact pairs

MPC is not available with node-to-node contact

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MPC Contact
MPC algorithm enforces compatibility at an interface using internally generated constraint equations Degrees of freedom of the contact nodes are eliminated
No normal or tangential stiffness required For small deformation problem, no iteration is needed in solving system equations For large deformation problems, the MPC equations are updated during each iteration This method only applies to bonded or no-separation behaviors Not applicable for symmetric contact pairs

MPC is not available with node-to-node contact

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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Bolt Pretension You have an assembly with bolts You want to take in consideration the prestress of the model

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Bolt Pretension Procedure to follow: Model all the parts Mesh it Put the pretention bolt in 2 steps:
First step: preload by load or adjustment Second step: fix the pretension

Put the other loads Check the results

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Bolt Pretension How does ANSYS Apply bolt pretention? Mesh bolt part Choice of the section

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Bolt Pretension Creation of PRETS179 element:

The goal of these elements is to create the prestress on the model by penetrate the two surfaces.
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Bolt Pretension Check of the PRETS179 in our example:

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Bolt Pretension Input for the pretention

First step: load Second step: we lock

Result
We can clearly see the penetration due to the PRETS179 element

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Outline

Overview Connections Remote Point CE (Constraint Equation) CP (Coupling Equation) Contact Bolt Pretension Joints
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Joints

Spherical Revolute Cylindrical Planar

Universal

Translational Slot
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Joints
The kinematic joints give the opportunity to directly impose kinematic constraints between bodies with MPC184 element. Example of a translational Joint:
The Constrained degrees of freedom are: UY, UZ, ROTX, ROTY, ROTZ .

Definition of a translational joint

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Joints
Setup of a kinematic joint:
Creation of two pilot nodes Constraint equation between pilot node and Interfaces Creation of element MPC 184

WB automatically setup this for you

What the solver sees..

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Joints: Configure Tool

Used to define initial position of the parts Can detect locking and redundancy Help to assemble unassembled models Defined with a prescribed value of angle or translational degree of freedom
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Joints
Benefits of joints Easy to set up Easy to model Engineer joints Large deformations are supported Advanced friction definition Easy modification of bodies positions through configure tool Faster in most cases than penalty quivalents

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Springs
An elastic element ,used to store mechanical energy and regains original shape after force is removed Types: Longitudinal Torsional Inputs: pre-load stiffness damping Can be scoped to part and/or ground No geometrical representation

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Bushing Joint
Has six degrees of freedom, three translations and three rotations Inputs: Stiffness Coefficients Dampening Coefficients Equivalent to having 6 independent springs for six DOF Used to introduce flexibilities to an over-constrained mechanism

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Assembly Modeling Using ANSYS

Companion Samples

Luc Pontoire Simon Mendy

ansys-support-france@ansys.com
15/10/09

2009 ANSYS, Inc. All rights reserved.

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Companion Samples

Translational coupling

cyclo symmetry

Rigid regions versus flexible regions

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Rotor/Stator and various modeling strategies

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