ANSYS Mechanical在焊接仿真中的应用详细解析
焊接作为现代制造业必不可少的工艺，在材料加工领域一直占有重要地位。焊接是一个涉及到电弧物理、传热、冶金和力学等各学科的复杂过程，其涉及到的传热过程、金属的融化和凝固、冷却时的相变、焊接应力和变形等是企业制造部门和设计人员关心的重点问题。焊接过程中产生的焊接应力和变形，不仅影响焊接结构的制造过程，而且还影响焊接结构的使用性能。这些缺陷的产生主要是焊接时不合理的热过程引起的。由于高能量的集中的瞬时热输入，在焊接过程中和焊后将产生相当大的残余应力和变形，影响结构的加工精度和尺寸的稳定性。因此对于焊接温度场合应力场的定量分析、预测有重要意义。
传统的焊接温度场和应力测试依赖于设计人员的经验或基于统计基础的半经验公式，但此类方法带有明显的局限性，对于新工艺无法做到前瞻性的预测，从而导致实验成本急剧增加，因此针对焊接采用数值模拟的方式体现出了巨大优势。
ANSYS作为世界知名的通用结构分析软件，提供了完整的分析功能，完备的材料本构关系，为焊接仿真提供了技术保障。文中以ANSYS为平台，阐述了焊接温度场仿真和热变形、应力仿真的基本理论和仿真流程，为企业设计人员提供了一定的参考。
2 焊接数值模拟理论基础
焊接问题中的温度场和应力变形等最终可以归结为求解微分方程组，对于该类方程求解的方式通常为两大类：解析法和数值法。由于只有在做了大量简化假设，并且问题较为简单的情况下，才可能用解析法得到方程解，因此对于焊接问题的模拟通常采用数值方法。在焊接分析中，常用的数值方法包括：差分法、有限元法、数值积分法、蒙特卡洛法。
差分法：差分法通过把微分方程转换为差分方程来进行求解。对于规则的几何特性和均匀的材料特性问题，编程简单，收敛性好。但该方法往往仅局限于规则的差分网格（正方形、矩形、三角形等），同时差分法只考虑节点的作用，而不考虑节点间单元的贡献，常常用来进行焊接热传导、氢扩散等问题的研究。
有限元法：有限元法是将连续体转化为由有限个单元组成的离散化模型，通过位移函数对离散模型求解数值解。该方法灵活性强，适用范围广，因此广泛地应用于焊接热传导、焊接热弹塑性应力、变形和焊接结构的断裂分析等领域。
数值积分法：该方法采用辛普生法则等方式对很难求得原函数的问题进行积分求解，通过该方法避免了求解复杂的原函数问题，同时使用较少的点即可获得较高的精度。
蒙特卡洛法：该方法基于随机模拟技术，对随机过程的问题进行原封不动的数值模拟。
焊接模拟通常基于以上几种理论对焊接热传导、热弹塑性应力等问题进行模拟，而合理的选择热源函数和计算焊后应力等问题则需要设计人员选择合适的数学模型。
2.1 焊接数值模拟常用热源模型
焊接热过程是影响焊接质量和生产率的主要因素之一，因此焊接热过程的准确模拟，是准确进行焊接应力变形分析的前提。早期对于焊接热过程的解析，前人做了大量的理论研究工作，提出了多种热源分布模型：
集中热源：Rosenthai-Rykalin公式
该方法作为典型的解析方法，认为热源集中于一点，此方式仅对于研究区域远离热源时较为适用，同时此方法无法描述热源的分布规律，对于熔合区和热影响区影响较大。
平面分布热源：高斯分布热源、双椭圆分布热源
高斯分布热源
高斯热源分布假设焊接热源具有对称分布的特点，在低速焊接时，效果良好，焊接速度较高时，热源不再对称分布，误差较大。此方法适合于电弧挺度较弱及电弧对熔池冲击较小的情况。
高斯分布虽然给出了热源分布，但没有考虑焊枪移动对热源分布的影响。实际上，由于焊缝加热和冷却的速度不同，因此电弧前方的加热区域比后方的加热区域小。
双椭圆分布热源
体积分布热源：半椭球分布热源、双椭球分布热源
半椭球分布热源
对于熔化极气体保护电弧焊或高能束流焊，焊接热源的热流密度不光作用在工件表面上，也沿工件厚度方向作用。此时，应该将焊接热源作为体积分布热源。为了考虑电弧热流沿工件厚度方向的分布，可以用椭球体模式来描述
实际上，由于电弧沿焊接方向运动，电弧热流是不对称分布的。由于焊接速度的影响，电弧前方的加热区域要比电弧后方的小；加热区域不是关于电弧中心线对称的单个的半椭球体，而是双半椭球体，并且电弧前、后的半椭球体形状也不相同
双椭球分布热源
2.2 焊接变形模拟常用方法
由焊接产生的动态应力应变过程及其随后出现的残余应力和残余变形，是导致焊接裂纹和接头强度与性能下降的重要因素，因此针对焊接变形与残余应力的计算发展出了以下几种理论：
解析法：一维残余塑变解析法
该方法以焊接变形理论为基础，确定焊接接头收缩的纵向塑变与焊接工艺参数、焊接条件的关系，需要大量经验积累，此方法对规则等截面的梁型结构，较为适用
固有应变法：固有应变可以看成是残余应力的产生源
焊接时的固有应变包括包括塑性应变、温度应变和相变应变。焊接构件经过一次焊接热循环后，温度应变为零，固有应变就是塑性应变和相变应变残余量之和。焊接时，固有应变存在于焊缝及其附近，因此了解固有应变的分布规律就能仅用一次弹性有限元计算来预测残余应力大小及结构变形，但此方法同样着重与焊后结构的变形，属于近似方法，没有考虑整个焊接传热过程
热弹塑性有限元法：记录焊接传热过程，描述动态过程的应力和变形
热弹塑性有限元法首先进行焊接热过程分析，得到焊接结构瞬态温度场，再以此为结果，进行焊接应力和变形计算。由于该计算为非线性计算过程，因此计算量大，一般用来研究焊接接头的力学行为，而不用来进行大型复杂结构的整体研究
3 焊接仿真案例
3.1 基于ANSYS Workbench平台的焊接仿真
针对如下部件采用激光焊，以ANSYS Workbench为平台，模拟该模型的温度场变化和应力场变化情况。
ANSYS Workbench作为统一的多场分析平台，支持数据协同，因此在Workbench中建立该焊接分析的项目，如下图所示。
在本例中，仅以说明焊接仿真流程为例，因此材料假定为线弹性结构钢，在EngineerData中输入材料参数如下：
ANSYS Workbench以ANSYS Meshing为基础对模型进行网格划分，对于此模型中的两个焊接件和焊缝均以六面体方式进行划分，除此之外，软件还提供了大量的size funcon、局部控制等功能，针对不同特征的几何模型进行高质量的网格划分。
以Workbench平台以基础对焊接过程进行瞬态热分析需要用到基于ANSYS Workbench开发的Moving_Heat_Flux插件。该插件嵌入在Workbench界面中，提供了以平面高斯热源法为基础的移动热源分布方式，在该插件中用户可以指定焊枪移动速度、焊接电流、功率，焊接时间等参数。除此之外，进行传热过程分析，还需要输入瞬态热分析所需的其他边界条件如Convecon等。此案例中输入的焊接相关参数如下所示：
针对此类大规模仿真问题，建议使用HPC高性能计算，可以充分发挥计算机硬件性能，大幅度提高求解效率。最终针对该参数下的焊接瞬态热分析结果如下：
基于瞬态热分析之上，可以进行焊后应力分析。通过前述建立的ANSYS Workbench的耦合分析流程，通过import load方式将热分析温度场传递给结构场进行应力分析。
同时根据实际工况对该构件施加约束，进行应力分析，最终得到某一时刻应力云图如下所示：
3.2 基于ANSYS经典界面的焊接仿真
如前所述，在以Workbench为平台进行焊接仿真时存在诸多限制，例如无法选择其他形式的热源模型，因此用户可以基于ANSYS经典版进行焊接仿真。基于ANSYS经典版进行焊接仿真时，可以以命令流的方式进行，将焊接参数以参数方式读入，对于优化焊接分析，十分方便。
本例中，焊接温度场模拟采用焊板尺寸为200mmX200mmX6mm，试件材料为Q235A，材料参数如下表所示。为保证焊透，两块钢板开45&坡口。焊接方式采用电弧焊，焊接参数为：焊接电流180A，电弧电压20V，焊接速度4.8mm/s，焊接热输入0.75kJ/mm，焊接效率&=0.825，结构与空气的换热系数为15W/（m^2*℃）。
在ANSYS经典版中建立该构件的几何模型，采用solid70，建立好的模型如下图所示：
通过MP命令建立完整的材料参数表，如下图所示：
通过esize等命令，对该模型进行局部网格控制，生成六面体网格，并达到较高的网格质量。有限元模型如下：
本例中同样采用高斯热源方式进行模拟，相关焊接工艺以参数方式表达，为后期优化提供基础，典型的命令流如下：
对该模型底部施加固定约束，根据APDL中设定的求解参数进行迭代计算，迭代曲线如图所示：
经过求解计算后可以得到该焊接件的温度场分布云图，如下图提出的某时刻温度场分布云图：
通过以上介绍，以ANSYS软件为基础可以方便的进行焊接过程的温度场和应力场仿真，目前在Workbench中仅支持以插件的形式进行焊接仿真，并且只能考虑平面高斯热源的热源分布方式，如需考虑其他方式的热源方式，需要以ANSYS经典版为基础进行APDL编程，除此之外，用户还可以采用生死单元的方式进行焊接仿真，需要注意的是，生死单元的方式即通过控制单元生死的方式来模拟焊缝填充过程，采用该方式可以模拟较为复杂的热输入情况，由于热源分布与生死单元是两种不同的计算方式，因此不能叠加使用。
ANSYS软件通过完整的材料本构关系、求解能力，为焊接仿真提供了强有力的技术保障，因此设计人员可以以此进行焊接仿真，为电流、电压等焊接工艺参数的设置提供参考依据，从而合理优化焊接工艺。
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Ansys workbench mechanical官方教程及用法大全
ANSYS R12 New N F Features tM h i l Mechanical Capabilities? 2009 ANSYS, Inc. All rights reserved.1ANSYS, Inc. ProprietaryR12 Highlights in Mechanical Capabilities ? New Element Technology ? Advances in Contact Modeling ? Additional Material Models ? Solver Performance Enhancements ? Rigid and flexible dynamics ? Explicit dynamics? 2009 ANSYS, Inc. All rights reserved.2ANSYS, Inc. ProprietaryELEMENT TECHNOLOGY? 2009 ANSYS, Inc. All rights reserved.3ANSYS, Inc. ProprietaryCurrent-technology elementsCategory Solid Elements PLANE182, PLANE183, SOLID185, SOLID186, SOLID187, SOLID285 SOLID223, SOLID226, SOLID227 SHELL181, SHELL208, SHELL209, SHELL281 SOLSH190 BEAM188, BEAM189 LINK180 PIPE288, PIPE289 ELBOW290 USER300 REINF264,REINF265 Category Interface / gasket C h i Cohesive Target Contact Constraint/ Joints General Axisymmetric p purpose p p Special Elements INTER191 C INTER195 INTER202 - INTER205 INTER20 TARGE169, TARGE170 CONTA171 - CONTA177, PRETS179 MPC184 SOLID272, SOLID273 SURF151 C SURF156, , FOLLOW201, Discrete ElementsCoupled Physics Shell Solid-Shell Beam Link Pipe Elbow User Element Reinforcement? 2009 ANSYS, Inc. All rights reserved.4ANSYS, Inc. ProprietaryNew Element TechnologyNew 4-noded Tetra element : SOLID285fInternal DOFs4(u x , u y , u z , p)DOF: Displacements & Hydrostatic Pressure Stabilized formulation to satisfy LBB check1(u x , u y , u z ) e(u x , u y , u z , p)(u x , u y , u z , p)Stru uctura al Mec chani ics3f(u x , u y , u z , p)Benefits f Can C b be used dt to mesh h complex l geometries ti f Element is less sensitive to distortion f Vital to rezoning and nonlinear adaptivity analysis Applications ppf f2Automotive Suspension MountGood for incompressible materials Ideal for Forming and Hyperelasticity5ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.New Element TechnologyGeneral Axi-symmetric Element: 272/273fB3D elements generated based on 2D mesh Boundary conditions applied in 3D space Nonlinearities, Node to surface contactAI JLY’Z’ K X’Stru uctura al Mec chani icsf fBenefitsf f fMultiple Axis can be defined in any direction Take advantage of axi-symmetry but deformation is general in 3D 1 element in Θ (hoop) directionApplication f Detailed simulation of threaded connections f Bio-Medical: Tooth implanting3D view of shaft6ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Example: Cam-Shaft3D elements Cams meshed with SOLID272Shaft Valve Ball ValveFULL 3D : 13.7 hrs? 2009 ANSYS, Inc. All rights reserved.SOLID272:7hrsANSYS, Inc. ProprietaryNew Element Technology3D Finite-strain Element: PIPE288/289 f Linear or quadratic pipes in 3D f Thin pipe (plane stress) and Thick pipe (3D stress) option f Internal fluid and external insulation Benefits f Increased accuracy f Robust nonlinear infrastructure including stabilization f Hydrostatic, current, and wave loading Application A li ti f Slender or stout pipe like structures f Undersea piping and cabling cabling, f Chemical, Nuclear Power Industry,8ANSYS, Inc. ProprietaryPipe p 288Stru uctura al Mec chani icsPipe 289Piping Assembly? 2009 ANSYS, Inc. All rights reserved.New Element TechnologyNew Curved Pipe Element: ELBOW290 f Internal nodes for C/S deformation f C/S Deformation with Fourier series f Radial expansion, expansion ovalization & warping f Follower effects of distributed pressures Benefits f Accurate and easy to use f Supports pp layered y cross-section f Broad nonlinear material library f 3D Visualization Applications f Accurate modeling of curved pipe structures f Composite pipes, cables, nuclear piping9Stru uctura al Mec chani icsWarping & Ovalization? 2009 ANSYS, Inc. All rights reserved.ANSYS, Inc. ProprietaryNew Element Technology3D discrete Reinforcement: REINF264 f Reinforcing fibers modeled with embedded reinforcing elements f Fibers can be oriented arbitrarily f Reinforcement can account for a variety of nonlinear behavior Benefits f Explicit & accurate modeling of reinforcements f Predict stresses in reinforcements separately f Allows for “tension-only” treatment Application f Tire Ti i industry, d t Bi Biomedical di l d devices i f Aerospace, Civil engineering10ANSYS, Inc. ProprietaryStru uctura al Mec chani icsDiscrete Reinforcements? 2009 ANSYS, Inc. All rights reserved.CONTACT MODELING? 2009 ANSYS, Inc. All rights reserved.11ANSYS, Inc. ProprietaryContact element libraryTechnologySliding General friction (TB,USE) Pure Lagrange Augmented Lagrange Lagrange (Normal)/ Penalty (Tangent) MPC Contact Stiffness Lower-Order Higher-Order Higher Order Rigid-Flexible Flexible-Flexible Thermal Contact Electric/Magnetic Contact? 2009 ANSYS, Inc. All rights reserved.Node-toN d Node 178SMALL Y Y Y YNode-toS f Surface 175LARGE Y Y Y Y YSurfaceto-Surface 171-174LARGE Y Y Y Y Y AUTO Y Y Y Y Y YLine-toLi Line 176LARGE Y Y Y Y Y AUTO Y Y Y Y Y YLine-toS f Surface 177LARGE Y Y Y Y Y AUTO Y Y Y Y Y YANSYS, Inc. ProprietarySEMI-AUTO YAUTO Y Y (2D)Y YY Y Y Y12Advances in Contact ModelingFluid Pressure Penetration Support f Model fluid penetrating 2 contact surfaces f 2D/3D surface-to-surface contact pair f Small and large sliding contact f Rigid-flexible and flexible-flexible contact Usage f Pressure applied normal to contact & target elements f Can be cut off when contact is restored or contact pressure is larger than the fluid pressure Applications f Post-Leakage simulation f Sealing performance evaluation13Fluid pressure is appliedStru uctura al Mec chani icsFluid pressure is Not appliedSealsANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Advances in Contact ModelingContact Performance Enhancements f New Contact search algorithm f Smart over-constraint elimination & display f New Contact pair trimming logic f Solver files size reduced by 50% Benefits f Speed improved by 1x-200x f Computation time reduced f Less Disk I/O observed Applications f Most problems involving contacts should observe speed improvements f Problems involving bonded MPC contacts14ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsContact Speed-up ExampleBOOTSEAL 3D Elem: 11090 Nodes: 5040 Dofs: 30240 Rigid-Deformable +Self Contact 11.0 12.0 speedupBoot SealContact database Contact Search Contact Elements Other Elements Eq. Solver Total CPU Elapsed Time No. of Iterations No. of Substeps? 2009 ANSYS, Inc. All rights reserved.11.72 .64 .77 7 246 420.216 75.64 188.95 .35 8 240 431554.26 45.80 2.67 2.13 1.30 3.29 3.30 1.02 0.97ANSYS, Inc. ProprietaryContact Performance: Nonlinear Customer ModelElems:49701 Nodes:67582 Dofs: 405492CPU V110 V120Contact C t t Searching372s60 6 60.6sContact Elements1488s791sWall time167455s12141s? 2009 ANSYS, Inc. All rights reserved.16ANSYS, Inc. ProprietaryPerformance & Efficiency? New contact pair trimming logic C The CNCHECK command has new options for removing i (TRIM) or unselecting l ti (UNSE) contact t t and d target elements which are initially in far field. The new capabilities improve solution efficiency for small sliding contact or assembly contact, especially in Distributed ANSYS runs.Before trimmingAfter trimming? 2009 ANSYS, Inc. All rights reserved.17ANSYS, Inc. ProprietaryPerformance & Efficiency? New contact pair trimming logicBefore trimmingAfter trimming A benchmark test from John Deere No TRIM 2CPU 4CPU 8CPU18A benchmark test from a German user 8CPU No With TRIM TRIM Elements Wall time? 2009 ANSYS, Inc. All rights reserved.With TRIM587
ANSYS, Inc. ProprietaryAdvances in Contact ModelingFriction Definition Improvements f Tabular data for μ with up to 2 fields, eg. temperature, pressure, sliding velocity etc. f USERFRIC : A general API for user user-defined defined friction definitions Benefits f Account for complex friction behavior f Support friction definitions that do not follow Coulombs law of friction Applications f Wear or bearing analysis f Pipeline on a sea bed f Brake B k Squeal S l analysis l i19ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsExample: Pipeline on a Seabed? Straight Pipe on a seabed ? Qualitative comparison to a NAFEMS publication ? Similar Trends observed? 2009 ANSYS, Inc. All rights reserved.20ANSYS, Inc. ProprietaryAdvances in Contact ModelingEnergy & Momentum Conserving Contact f It imposes additional constraints on relative velocities in interface. f It satisfies momentum and energy balance for the contact/target interface. Benefits f Predict duration of contact & the rebound velocities after separation more accurately f Very little energy gain or loss Applications f High speed impact f Rigid-to-rigid contact in MBD f Dropping D i t tests t21ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsAdvances in Contact ModelingMany Misc. Contact ImprovementsfStru uctura al Mec chani icsModeling Rigid Bodies with Rigid Target Surfaces Boundary Conditions on any rigid target nodes Force distributed distrib ted s surface rface constraint” (RBE3) under large rotationfffNew shell shell-shell shell & shell-solid shell solid constraint type Benefits/Applications Significant robustness improvement Better performance for MBD analysis & CMS22ANSYS, Inc. Proprietaryf f? 2009 ANSYS, Inc. All rights reserved.SOLVER TECHNOLOGY? 2009 ANSYS, Inc. All rights reserved.23ANSYS, Inc. ProprietaryAdvances in Solver Technology2D Rezoning Enhancements f Allow to read in generic mesh from a third party mesher in rezoning f Allow user to split selected elements to refine mesh in rezoning f Automatically create transition region meshes h Benefits f Provides flexibility in remeshing f Solve problems otherwise can not be solved Application f Any large deformation analyses f Forming F i and d rubber bb sealing li simulation i l ti24ANSYS, Inc. ProprietarySealing Applications? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsAdvances in Solver TechnologyNew SNODE Solver for Modal Analysis f Splits FE matrix in to smaller pieces C SuperNodes f Solves reduced Eigen-value Eigen value problem f Transforms eigenvectors back to the original FE domain Benefits f Ideal for & 3 mil. DOFs , &500 modes f Non-iterative C i.e. will not fail to converge f Does not miss modes Applications A li ti f Beam-Shell or thin geometries f Automotive, Aerospace f High frequency response analysis, etc.2580000Stru uctura al Mec chani icsBlock Lanczos Supernode60000CPU Time e40000200000 100 00Number of ModesSingle Xeon 3.4 GHz processor ?17+ hours reduced to ~1 hour ?7 TB of I/O reduced to &300 GBANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Advances in Solver TechnologyMany Misc. Solver ImprovementsfStru uctura al Mec chani icsVT applied to Complex Eigen solver: Frequency Derivative Algorithm used DSPARSE solver supports unsymmetric matricesfBenefits/ApplicationsSolu ution time ef fSignificant improvement in solve speed Better performance for large number of contact pairs & constraints 00 00 Lanczos FDElapsedCPU? 2009 ANSYS, Inc. All rights reserved.26ANSYS, Inc. ProprietaryAdvances in Solver TechnologyDANSYS Improvements f Support HF-EMag calculations f PSTRESS, PSOLVE support f Cyclic Symmetry supportRepresentative Geometryuctura al Mec chani ics StruBenefits f More problems can take advantage of Parallel solvers 20 % f Scalability of solves improved by 10 10-20 Applications pp f Problems involving stress stiffening f Rotardynamics problems f EMAG problems27Machine Problem SizeWin x64 CCS 480K DOFCPUs Time (hr)1 2 4 836 36.7 7 22.3 14.5 8.4ANSYS, Inc. ProprietaryBolted Joints, N/L Contact, Contact Thermal loads Unsymmetric option? 2009 ANSYS, Inc. All rights reserved.DANSYS: Benchmarks on Win CCSDANSYS Revised Benchmark Set SpeedupsIntel Cluster Ready, 4 nodes 3 Ghz dual cores, 16 Gb, TCP interconnect6 5 4Universal Joint 400k DOF Small DSP sparse Gas-Struct 1M DOF Thermal JCG Carrier Model 2 M DOF PCG msave,on Block Assembly y 5M DOF Large g PCG msave,on Wing Model 1M DOF Lanpcg 10 Modes Wing Model 5M DOF PCG msave,offSpe eedup3 2 1 0 1 2 4 8 12 16Number of Processors? 2009 ANSYS, Inc. All rights reserved.28ANSYS, Inc. ProprietaryLINEAR DYNAMICS? 2009 ANSYS, Inc. All rights reserved.29ANSYS, Inc. ProprietaryAdvances in Linear DynamicsRotordynamics Improvements f Gyroscopic effect for shells and 2D planar elements f Rotating damping to model hysteretic damping in material Benefits f Versatility in modeling rotating shell and 3D axi-symmetric structures. f Rotating damping model enables rotor instability predictions. Applications f Aero gas turbine engines. f Electrical motors, pumps, etc f Computer disk drives30ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsAdvances in Linear DynamicsPSD (random vibration) Enhancements f Increased # of input PSD points - no longer limited to 50. f Improved performance of mode combination in spectrum analysis. f Number of modes that can be combined increased from 1,000 to 10,000 Benefits f Usability of random vibration features. f Performance improved Applications f Structures subject to random vibration such as aircrafts aircrafts, automobiles automobiles, et al. al31ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani icsBoundary Conditions and LoadingImprovements to PSD AnalysisfBase excitation: Individual or ALL Goodness of fit for PSD data Response PSD Results availableR Response PSD result lStru uctura al Mec chani icsf fApplications f Predict Dynamic y response p of a structure f seismic loading f Loading due to Ground transport f Machine operation? 2009 ANSYS, Inc. All rights reserved.32ANSYS, Inc. ProprietaryAdvances in Linear DynamicsSpectrum Analysis Improvements f Missing Mass and Rigid response method supported f Residual vector method extended to Spectrum analysis Benefits f Accurate representation of higher frequency content on structural response. f Missing Mass method meets NRC requirements Applications f Random vibration response prediction on airborne structures, nuclear reactors, et al al.Courtesy: NASA? 2009 ANSYS, Inc. All rights reserved.Stru uctura al Mec chani ics33ANSYS, Inc. ProprietaryAdvances in Linear DynamicsHarmonic Analysis Enhanced f Cyclic Symmetry now supports Harmonic Analysis. f Variational Technology (VT cyclic) based modal cyclic solve approach Benefits f Vibration response of cyclic structures subject to harmonic excitation. excitation f VT cyclic gets 3 C 4 X speed up of modal cyclic solution. Applications f Aero gas turbine engine design, electric motor / generator design34Stru uctura al Mec chani icsModal Cyclic SymmetryElapsed (sec) Standard Win32 Linux 64
VT 533 406 ~ 5.5 ~ 3.2Ratio? 2009 ANSYS, Inc. All rights reserved.ANSYS, Inc. ProprietaryAdvances in Linear DynamicsModal Superposition Enhancements f Harmonic & Transient performance improved, Results expansion pass f Tabular load as a function of frequency f Multiple load vectors supported for Mode Sup. Harmonic & Transient Benefits f Ability to solve very large models. f Ease of applying frequency dependent loading. f Improved usability of MSUP methods in ANSYS and ANSYS WB environment. Applications f Very V large l structures, t t for f example, l in i nuclear industry, space applications etc.35Stru uctura al Mec chani icsCircuit BoardNo. of equations No. of Modes A l i Analysis No. of Threads11.0SP1 CP (hr) Elapsed (hr) ~ 14.4 ~ 12.35 PSD 212.0 ~ 4.4 ~3ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.Advances in Linear DynamicsPSOLVE Method for Brake Squeal f Linear QR damped modal analysis with PSOLVE f Improved performance of QR damp eigensolver f Contact element enhancements for sliding f i ti modeling friction d li Benefits f Significantly faster problem setup due to flexibility of contact modeling f Taking advantage of advanced contact biliti t d lb k squeal l capabilities to model brake Applications f Instability prediction in automotive and aircraft landing gear brakes36Brake Assemblyuctura al Mec chani ics StruFull New Linear Nonlinear Method CP (min) ~ 66.6 ~ 13.3ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.MATERIALS TECHNOLOGY? 2009 ANSYS, Inc. All rights reserved.37ANSYS, Inc. ProprietaryNew Material Models AddedRate Dependent Chaboche Plasticity ModelfStru uctura al Mec chani icsBased on Chaboche Nonlinear Kinematic Hardening model Plastic Strain Rate-dependent effects Captures cyclic hardening & softeningf fApplications/Benefitsf f fApplicable for turbine and engine design Simulation of Ratcheting and Shakedown Strain rate dependent applications: for ex ex. Impact simulationsStre ess 3.E+08 2.E+08 1.E+08 0.E+00 -1.E+08 -2.E+08 -3.E+08 -0.015 0 015 -0.010 0 010 -0.005 0 005 0.000 0 000 0.005 0 005 0.010 0 010 0.015 0 015 Displacement? 2009 ANSYS, Inc. All rights reserved.38ANSYS, Inc. ProprietaryNew Material Models AddedImproved Extended Drucker-Prager modelfStructure OceanStru uctura al Mec chani icsInclude creep effect for all options except CAP option Capture strain rate effect of a geological materialfApplications/BenefitsfAnalyze geological materials that exhibit pressure dependency such as sand soil sand, soil, ceramics etc etc.? 2009 ANSYS, Inc. All rights reserved.39ANSYS, Inc. ProprietaryNew Material Models AddedNew Bergstr?m-Boyce ModelfCombines Hyperelastic & Viscoplastic effects The model decomposes the mechanics response of material into two distinct networks: A: time-independent B: time-dependent. pStru uctura al Mec chani icsfBio -TissuesApplications/BenefitsfAccurately capture material behavior under various loading conditions Model hysteretic behavior of Elastomers under large strain deformation Simulation of Polymers, Elastomers, Plastics, Bio-tissues which are strain-rate dependent40ffKeyboardANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.New Material Models AddedNew Elastomer Damage ModelfBased on Ogden-Roxburgh model A continuum damage model for rubber like material Isotropic damage assumptionReaction Forces soften with the 2nd load cycleStru uctura al Mec chani icsffBenefits/Applicationsf f fC t Captures cyclic li softening ft i of f elastomers l t Simulation of Mullins effects Applicable to rubber like materials such as polymers, elastomers, plastics and etc.? 2009 ANSYS, Inc. All rights reserved.41ANSYS, Inc. ProprietaryNew Material Models AddedAnands Viscoplasticity ModelfStru uctura al Mec chani icsImplemented for current generation elements Unified viscoplastic constitutive model Includes an internal state variable - the deformation resistance No yield surface Highly nonlinear large deformation problems High Hi ht temperature t metal t lf forming i simulations Electronic Packaging, g g, Solder j joint simulation42ANSYS, Inc. Proprietaryf f fBenefits & Applicationsf f fMetal Forming Applications? 2009 ANSYS, Inc. All rights reserved.Fracture Mechanics ImprovedEnhancements to J-integral CalculationsfStru uctura al Mec chanicsThermal strain is automatically included in the J-Integral calculation Surface pressure load on element surfaces or edges is automatically included in the J-Integral g calculationfBenefits/ApplicationsfProvide accurate estimation of J-Integral when there are thermal strain and surface pressure on crack k faces f Structural integrity assessments Nuclear reactor safety analysis43Spot Weld Failure Analysisf f? 2009 ANSYS, Inc. All rights reserved.ANSYS, Inc. ProprietaryExample: Turbine Blade CrackAnalysisPenny CrackPRCINT prints calculated J-Integral values to Solution Information Window? 2009 ANSYS, Inc. All rights reserved.44ANSYS, Inc. ProprietaryFracture Mechanics ImprovedMixed Mode Stress Intensity Factors f Based of Interaction integral approach by Gosz and Moran f Minimum input f Crack front/tip nodes f Crack plane normal or extension direction f Number of contours Benefits f Much easier to use f Improved p accuracy y observed Applications f Mixed mode stress intensity factor calculation , Safety analyses45ANSYS, Inc. ProprietaryStru uctura al Mec chani icsStress Intensity Factor calculation? 2009 ANSYS, Inc. All rights reserved.Advanced Analysis FunctionsImprovements in Initial StatefSupport Initial strains Support Plastic stress and strainStru uctura al Mec chani icsfBenefits/Applicationsf f f f fA l i of Analysis f residual id l stress/strain t / t i Analysis of Weldment with residual stress Transfer state of a 2D analysis to 3D Start in 2D and continue analysis in 3D Pre-stressed modal, Transient type analysis? 2009 ANSYS, Inc. All rights reserved.46ANSYS, Inc. ProprietaryRIGID AND FLEXIBLE BODY DYNAMICS? 2009 ANSYS, Inc. All rights reserved.47ANSYS, Inc. ProprietaryRigid DynamicsBushing Joint ? Free motion in some directions, constrained in others ? Elastic and damping forces in constrained directions Benefits ? Add flexibility at joints w/o large CPU cost ? Add realism to rigid simulations Applications ? Suspensions S i ? Pivots with compliance ? Vibration isolation48ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.R Rigid DynamicsRigid/Flexible DynamicsStops and Locks ? All Translational DOF’s ? Single rotational axis jointsR Rigid DynamicsBenefits ? Simplifies mechanism modeling ? Much requested feature ? Faster F t than th modeling d li contact t t Applications ? Travel limiters ? Non-moving impact points? 2009 ANSYS, Inc. All rights reserved.49ANSYS, Inc. ProprietaryRigid DynamicsRemote Loads ? Remote displacements ? Remote forces now supportedR Rigid DynamicsBenefits ? Much requested feature ? Allows load input w/o requiring geometry Applications ? Partial assembly modeling ? Inverse Dynamics? 2009 ANSYS, Inc. All rights reserved.50ANSYS, Inc. ProprietaryRigid DynamicsSpring Preload ? Specify free spring length ? Specify preloadR Rigid DynamicsBenefits ? More realistic modeling of spring mechanisms Applications ? Valve trains, ? Plungers, ? Solenoids? 2009 ANSYS, Inc. All rights reserved.51ANSYS, Inc. ProprietaryRigid DynamicsRedundancy Analysis and Repair ? Troubleshooting tool ? Common problem with mechanism models Benefits ? Points out over constrained joints ? Allows selective unconstraining ? Help H l prevent t problems bl going i f from Rigid to Flex pp Applications ? All but the very simplest mechanisms ? All models d l that th t will ill b be solved l di in fl flex dynamics52ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.R Rigid DynamicsFlexible DynamicsComponent Modal Synthesis ? Uses substructuring approach ? Standard command objects ? Requires R i li linear materials t i l ? Large rotation/translation Benefits ? Potentially huge time savings ? CMS for linear parts or model, flex for others Applications ? Mechanisms and machines with linear materials ? Non-contact Non contact dominated parts of assembly53Fle exible e Dynamics sRigid g Flexible Flexible Flexible Flexible Flexible Dynamics Dynamics Dynamics Dynamics Dynamics Dynamics Rigid Full Mesh CMS CMS Full Mesh Parts 7 60 ~75k ~75k ~1 mill ~1 mill Total # DOF 625 0 1015 ??? Total Iterations N/A N/A N/A 27 s 24 min N/A Time for Gen N/A N/A N/A 25 s 1 min N/A Time for Use N/A N/A N/A N/A Time for Exp 1s 60 s 217 min 52 s 25 min Too long! Total Time? 2009 ANSYS, Inc. All rights reserved.ANSYS, Inc. ProprietaryEXPLICIT DYNAMICS? 2009 ANSYS, Inc. All rights reserved.54ANSYS, Inc. ProprietaryANSYS Explicit STRNew Product at 12.0 ? Access within ANSYS Workbench ? Familiar user interface ? ANSYS AUTODYN solver Benefits ? WB native, , data sharing g with other WB applications ? Short learning curve for WB users, easiest explicit to learn ? Mature element/solver technology Applications pp ? Impact events ? Highly nonlinear events ? Very short transients ? ALL industries55ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitANSYS Explicit STRMaterials ? Solids S lid ? Rigid and flexible ? Linear/nonlinear ? Erosion ? Failure Benefits ? WB native engineering data easily accessed ? Easy to customize material to match application, or to try what-ifs Applications ? Impacts, drop tests ? Rubber, foam, steel, R bb ceramic, i f t l etc. t ? All solid material industries56ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitANSYS Explicit STRMeshing ? Solids/shells/beams ? Patch dependent and independent ? Swept meshing ? Explicit preference Benefits ? Simulation-based meshing ? Short learning curve from implicit experience i Applications ? Construction/agri equipment ? Automotive/defense? 2009 ANSYS, Inc. All rights reserved.Ex xplicit t Dynamics s57ANSYS, Inc. ProprietaryANSYS Explicit STRConnections ? Body interaction definitions ? Contact regions ? Frictionless/frictional, F i ti l /f i ti l static/dynamic t ti /d i ? Eroding contact Benefits ? Simple/automated definition ?E Ease of f use WB f famous f for ... Applications ? Impacts I t across all ll industries i d ti ? Low velocity to high velocity ? Manufacturing, Manufacturing defense industries58ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitANSYS Explicit STRConnections ? Breakable bonded contact ? Breakable spot welds ? Force F and d stress t failure f il criteria it i Benefits ? Connect dissimilar meshes ? Model conditional connections ?M Model d l connection ti f failures il Applications L i t d components t ? Laminated ? Spot weld/rivet connections ? Glue joints ? Critical in nuclear industry59ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitANSYS Explicit STRConnections ? Discrete reinforcement ? Tie line bodies to interior of solid bodies ? Use any material for solid and line Benefits ? Independent mesh for solid and volume ? Trivial to set up models A li ti Applications ? Reinforced concrete structures ? Steel reinforced rubber ? Civil, nuclear, automotive60ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitANSYS Explicit STR - Applications ? Applications C Electronics? 2009 ANSYS, Inc. All rights reserved.61ANSYS, Inc. ProprietaryANSYS Explicit STR - Applications ? Applications C Aerospace? 2009 ANSYS, Inc. All rights reserved.62ANSYS, Inc. ProprietaryANSYS Explicit STR - Applications ? Applications C Nuclear p power safety y? 2009 ANSYS, Inc. All rights reserved.63ANSYS, Inc. ProprietaryANSYS Explicit STR - Applications ? Applications C Homeland security y? 2009 ANSYS, Inc. All rights reserved.64ANSYS, Inc. ProprietaryANSYS Explicit STR - Applications ? Applications C Sporting p gg goods? 2009 ANSYS, Inc. All rights reserved.65ANSYS, Inc. ProprietaryANSYS AUTODYNTrajectory Contact ? Trajectory T j contact ? Penalty and energy conserving ? Solids/shells/beams/SPH ? Static/dynamic friction ? Option to fix initial penetrations Benefits ? P better suited to work with CAD geometry ? Efficiency improvements Applications ? Mid-high speed Impact events ? Explosive & complex FSI problems ? Defense industry standard improved66ANSYS, Inc. Proprietary? 2009 ANSYS, Inc. All rights reserved.t Dynamics s Ex xplicitR12 Summary? Continued Innovation in Element Technology ? Additional Productivity with Native Workbench Features ? Committed to Advanced Solver Performance ? New Framework for Multiphysics Simulations? 2009 ANSYS, Inc. All rights reserved.67ANSYS, Inc. ProprietaryTHANK YOU? 2009 ANSYS, Inc. All rights reserved.68ANSYS, Inc. Proprietary
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