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Real World Nonlinear Mechanical Applications


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Until recently, most finite element analysis (FEA) applications undertaken by design engineers were limited to linear analysis which provides an acceptable approximation of real-life characteristics for most problems. However, occasionally more challenging problems arise that call for a nonlinear approach.
In this webinar, you will hear about real-world nonlinear applications and case studies associated with Comsol’s and MSC Software’s customers.
Viewers of this webinar will learn:
– How nonlinearities in engineering systems arise from several sources including:
– Material properties including multi-physics behavior
– Geometry variations that involve large deformations and strains
– Boundary conditions that could be continuously changing affecting the response

Published in: Technology, Business
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Real World Nonlinear Mechanical Applications

  1. 1. Real World Nonlinear Mechanical Applications
  2. 2. Before We Start This webinar will be available afterwards at & email Q&A at the end of the presentation Hashtag for this webinar: #DWwebinar
  3. 3. Moderator Presenters Laura Carrabine David Kan Srinivas Reddy Design World COMSOL MSC Software
  4. 4. Real World Nonlinear Mechanical Applications Srinivas Reddy February 29, 2012
  5. 5. Product Development Challenges Can I build it? Can I test it? Is it durable? Will it perform to spec? Is it crashworthy? Will it fail? Is it safe? Why did it fail?
  6. 6. CAE to Improve Product Performance Sports equipment Brake disk Shearing/Tearing Seal analysis Bolt Loading Pipe impact
  7. 7. CAE to Optimize Manufacturing Processes Superplastic Forming Riveting Glass Forming Forming Cutting Extrusion
  8. 8. Nature is Nonlinear F Load Linear Behavior Nonlinear Behavior F u u Displacement s Stress Linear Behavior Nonlinear Behavior F F Yield Pt. Strain e
  9. 9. Sources of Nonlinearities • Materials o Metals, plastics, elastomers, powder metals, shape memory • Deformation o Buckling, folding • Boundary conditions and loads o Contact, loads changing with deformation • Multi-physics o Temperature effects, electromagnetics
  10. 10. Challenges of Nonlinear Analysis • Material modeling • Large deformation, distortions and rotations • Contact • Performance • Robustness
  11. 11. Material Modeling • • • • • • • • • • Metals Plastics Rubbers Shape memory alloys Composites Glass Concrete Powder materials Other non-metallic materials Customizable behavior Aluminum Can Pull Tab Plastic Bottle Composite Materials Rubber Tire with Metal Rims
  12. 12. Material Failure • Metals o Ductile damage • Elastomers o Material weakening • Composites Crack Propagation Fatigue crack growth o Delamination • Crack propagation • Concrete o Brittle failure, crushing Gear failure Delamination
  13. 13. Extreme Deformations • Element formulations • Appropriate stress/strain measures • Automatic local remeshing o Mesh refining in high stress/strain regions • Automatic global remeshing o Recreate a new mesh for the entire part
  14. 14. Contact • General large sliding contact with friction • Intuitive and easy set up • Automatic contact detection • Remeshing • Multi-physics
  15. 15. Performance • Efficient solvers • Parallel processing o Excellent scaling o Shared and distributed memory ~75k Degrees of Freedom • Domain decomposition method o Linear scaling o Benefit from networked desktop systems o Solver large models • Better use of hardware o GPU MPI MPI MPI
  16. 16. Case Study: Column Shifter Boot • • • • Business: Automotive supplier Challenge: Accelerate the boot development to satisfy the requirements of OEMs by evaluating more design variants in less time Solution: Design variants are studied with Marc to predict the tear areas. For some design variants the analysis results are verified with tests Value: A boot design that meets the OEMs requirement was found in less time at less cost 17
  17. 17. Case Study • Business: Leading producer of aluminum for engineered products • Challenge: Avoiding tensile & compressive instability in formed parts • Solution: Iterative Blank Design using Inverse Method with Marc • Value: Accurate & efficient prediction of proper designs for forming operation in less time 18
  18. 18. Summary • Nonlinear analysis challenges o o o o Materials, Large deformations and distortions Contact and boundary conditions Coupling • Technologies o o o o o Materials models, Contact modeling ease Physics simulation Automatic remeshing Performance
  19. 19. Nonlinear Mechanics in COMSOL A Multiphysics Perspective David Kan COMSOL, Inc. February 29, 2012
  20. 20. The Multiphysics Approach
  21. 21. Structural Mechanics Branch
  22. 22. Sources of Mechanical Nonlinearity Geometry Materials s st Contact e
  23. 23. Geometric Nonlinearity Small displacement theory Green-Lagrange strains
  24. 24. Nonlinear Constitutive Laws s s e Hyperelastic constitutive law • • Rubber Biological tissues e Elasto-plastic constitutive law • • • Metals Plastics Soils and concrete in compression
  25. 25. Hyperelastic Materials Hyperelastic constitutive laws are defined by the strain energy density, Ws • • • Neo-Hookean Mooney-Rivlin Murnaghan s e
  26. 26. Elasto-plastic Materials Elasto-plastic materials are defined by two mechanical behaviors: elastic and plastic Nonlinear constitutive laws are defined above the yield stress In the plastic regime, there are irreversible strains s sy el e
  27. 27. Contact Destination Source How about Multiphysics?
  28. 28. The Metelli Experience Hyperelastic material law Nonlinear geometry Contact everywhere Multiphysics
  29. 29. Multiphysics and Mechanics • Creep • Predefined couplings o o o o o Piezoelectric effects Acoustic-Structure Interaction Thermal-Electric-Structural Interaction Fluid-Structure Interaction Thermal-Structural Interaction • General couplings
  30. 30. Thank You!
  31. 31. Questions? COMSOL Design World Laura Carrabine Phone: 440.234.4531 Twitter: @wtwh_laurac David Kan Phone: 310.441.4800 Twitter: @COMSOL_Inc MSC Software Srinivas Reddy Phone: 847.776.6740
  32. 32. Thank You  This webinar will be available at & email  Tweet with hashtag #DWwebinar  Connect with  Twitter: @DesignWorld  Facebook:  LinkedIn: Design World Group  YouTube:  Discuss this on