Advanced Simulation of Sealings CADFEM GmbH Rainer Rauch

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1 Advanced Simulation of Sealings CADFEM GmbH Rainer Rauch Recent developments in ANSYS V12 for the simulation of sealings Element technology Material models Contact Robust design and optimization -1-

2 New Element: 4 Node Tetrahedron: SOLID285 Motivation for 4-node tetrahedral elements Current mesh generators produce triangular and tetrahedral elements reliably Can be used to mesh very complex geometrical shapes Element is less sensitive to distortion Element is vital to rezoning and large deformation problems such as metal-forming Drawbacks with 4-node tetrahedral elements Standard displacement element is hopelessly locked by the incompressibility Mixed displacement and pressure u/p formulation improves slightly the volumetric locking, however Stability is of utmost concern of mixed u/p formulation SOLID285: Stabilized Mixed u/p Formulation Displacements Hydrostatic pressure (HDSP) Interpolation functions Linear functions for both displacements and pressures Added to satisfy LBB condition Introduced with enhanced strain method Condensed out at element level DOF: HDSP A new DOF in ANSYS Its energy-conjugate partner: DVOL volume change Convergence check for both is controlled by CNVTOL Internal ( u1, u, u, p) x y z DOFs ( u, u, u ) x y 4 ( u, u, u, p) x ) z e ( u, u, u, p) x y z y 2 z ( ux, u y, uz, p)

3 New Element Solid285 Expansion of a Thick walled cylinder under internal pressure Unstructured mesh with 10 divisions in thickness directions Compare SOLID285 (Enhanced Tetra), regular mixed u/p and pure displacement formulations Radial stress for v= Analytical solutions: inner radius =-1, outer radius =0 Internal DOFs 4 ( ux, u y, uz, p) SOLID285 Regular u/p ( u, u, u ) x y ) z e ( u, u, u, p) x y z 3 u1, ( x u y, uz, p) ( u, u, u, p) x y z 2 Poisson Ratio Theory Mixed u/p enhanced Tetra Error (%) Mixed u/p Error(%) Pure Displace ment Error (%) Accuracy Tension Bending Torsion Shear Solid186 Solid285 Robustness Tension Bending Torsion Shear Efficiency Tension Bending Torsion Shear

4 Computer xp64-2 CPUs, 3 GHz Meshing - 3 Min. Analysis - 50 min Messung: Berechnung mit Solid 285: Kraft [N] Weg [mm] Import Mesh Regenerate Geometry Parameterize Geometry

5 Linear Tets SOLID285 SOLID187-8 Recent developments in ANSYS V12 for the simulation of sealings Element technology Contact Robust design and optimization -9-

6 New Formulations: Bergström-Boyce Bergström-Boyce (TB, BB) polymer viscoelasticity for current element technologies Elements: SOLID 185, 186, 187; SOLSH190; SHELL 208, 209, 281; Features: pressure sensitive, combined with creep, Combinations: isotropic damage (Ogden- Drawback: no curve fitting available; Benefits and Applications Technologies: filled/unfilled elastomers; biocompatible devices; artificial tissues. Robustness: experimentally validated; Physicality accounted: rate-dependence; hysteresis; symmetric stress relaxation; (mild) Mullins effects. -10 New Formulations: Mullins efect Modified Ogden-Roxburgh (TB, CDM) isotropic damage model for current element technologies Elements: SOLID 185, 186, 187; SOLSH190; SHELL 208, 209, 281; Features: isotropic cyclic softening in filled polymers (Mullins effect), Combinations: almost all nearly-, or fully incompressible isotropic hyperelasticity models Drawback: no curve fitting available; not applicable for foams. Benefits and Applications Technologies: filled/unfilled elastomers; damage in biocompatible devices and artificial tissues. Robustness: validated; Physicality accounted: amplitude dependent damage softening. -11

7 Example: TB,CDM (Ogden-Roxburgh) Sealing Objective: simulation of the cyclic, highpressure response of rubber sealing; Specifics: Mullins effect and BC induced incompressibility; Material models: neo-hooke with Ogden-Roxburgh; Element technology: -PLANE182 (ESF). Steel cylinders -12 Mullins effect: amplitude dependent (tangent) stiffness reduction Normalized uniaxial stress measure 1,2 1 0,8 0,6 0,4 0,0292 0,0458 0,2 0-0,05 0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45-0,2 Uniaxial strain measure 0,2 0,2-13

8 Recent developments in ANSYS V12 for the simulation of sealings Element technology Material models Contact Robust design and optimization -14- Rigid contact in Workbench WB now supports all types of rigid contacts Solid, Shells and 2D; w,w/o midside nodes Benefits and Applications Highly efficient contact simulation together with the flexible definitions of joints and drivers -15

9 Fluid Pressure Penetration Modeling fluid pressure penetration - Fluid penetrating two contact surfaces - 2D/3D surface-to-surface contact pair - Small and large sliding contact - Rigid-flexible and flexible-flexible contact - Pressure progresses with contact status Benefits and Applications - Leakage Simulation - Easy to use with few commands - Makes complex macros obsolete -16 Recent developments in ANSYS V12 for the simulation of sealings Element technology Material models Contact Robust design and optimization -17-

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11 Workflow: Parameters and optimization geometry Overview in the project page b.c. from any physics material properties

12 Workflow: Parameters and optimization Sensitivities how big is the influence of an Input parameter on an Output parameter? Correlation matrix Which are the best parameters to control the model behaviour? Define a goal and let Design Exploration optimize your model by searching on a response surface

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