workshop-meshing-proces and different types).pdf

ANSYS Workbench - Meshing
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Courtesy of AEG Electric Tools GmbH
Courtesy of Parametric Technology Corporation
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Multibody Meshing
Multibody Meshing
- The order of the meshing process can be controlled manually > Direct
- The order of the meshing process can be controlled manually > Direct
M hi
Meshing
More flexibility in defining the mesh method
- More flexibility in defining the mesh method
Direct Meshing allows for more combinations of how to
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handle the common interface between bodies
handle the common interface between bodies
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Multibody Meshing
Multibody Meshing
State management: The part/body tree will indicate which bodies are
State management: The part/body tree will indicate which bodies are
h d / d t b h d
meshed / need to be remeshed:
State icons indicate status of bodies.
State icons indicate status of bodies.
When mesh controls are added you will
When mesh controls are added you will
notice that the state changes even
notice that the state changes, even
th h th h i i ibl
though the mesh remains visible.
B d h b t d
Body meshes can be generated or
l d b d l l
cleared at body level.
Generate mesh at mesh level will
generate the mesh for all unmeshed
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bodies
bodies
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A t t d hi Di t hi
Automated meshing: Direct meshing:
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Mesh methods and order
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On inspection o ld like more
– Mesh methods and order – On inspection, would like more
defined automatically mesh in some spots:
defined automatically
G d t ti h
mesh in some spots:
– Good starting mesh
Add th d i fl ti
Add method, inflation or
i i t l d
sizing control and upon
Generate Mesh, only this
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body is re-meshed
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Automated meshing Direct meshing
Automated meshing Direct meshing
Layer of tet
Layer of tet
mesh
mesh
With Direct Meshing:
required as
With Direct Meshing:
Mesh thin sweep first
q
topology
Mesh thin sweep first,
then mesh rest of model with
topology
h
then mesh rest of model with
A t t d hi
changes Automated meshing
Direct meshing complements the
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automated meshing
automated meshing
Thin Sweep Mesh Method can handle this, but the
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order the mesh is generated in is critical
order the mesh is generated in is critical
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Similarly if only part of the geometry changes:
Similarly if only part of the geometry changes:
– Only affected bodies need to be
Only affected bodies need to be
d t d/ h d
updated/remeshed
Geometry Refresh –only 1 body is out of date
y y y
Face Delete in DM
Generate mesh only 1 body is meshed
Generate mesh –only 1 body is meshed
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M th d i t bilit b t
Method interoperability between:
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Volume meshing:
– Volume meshing:
• Patch Conforming Tet
Patch Conforming Tet
P t h I d d t T t
• Patch Independent Tet
• Sweep
Sweep
Thi S
• Thin Sweep
• MultiZone
MultiZone
H d i t
• Hex dominant
– Shell meshing:
– Shell meshing:
• Default
• Uniform
• Uniform
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Instance Meshing
Instance Meshing
Information which parts are copies is
Information which parts are copies is
t f d f DM t M h i l
transfered from DM to Mechanical
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Instance Meshing
Instance Meshing
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Instance Meshing
Instance Meshing
During the meshing process only 3 parts are meshed, the rest are copies
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Instance Meshing
Instance Meshing
-For Multi-Body Part Instance Meshing‘ is only allowed for Share
-For Multi-Body Part ‚Instance Meshing is only allowed for Share
T l ti I i t‘ d N ‘
Topology option ‚Imprint‘ und ‚None‘.
All identical parts can be found with the selection option Extend to
-All identical parts can be found with the selection-option ‚Extend to
Instance‘. It didn‘t depend on which part of the identical parts is
s a ce d d depe d o c pa o e de ca pa s s
selected
selected.
-The meshing options can be expanded to all identical parts with the
-The meshing options can be expanded to all identical parts with the
l ti ti E t d t I t ‘
selection-option ‚Extend to Instance‘.
Checking the identical mesh can easily be done inside the
-Checking the identical mesh can easily be done inside the
worksheet.
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Share Topology
Share Topology
 Share Topology Feature
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C
Check Multi Body parts inside DM
I i t tti f t t
Imprint setting for contact
B fit d A li ti
Benefit and Application
Speedup Geometry checks
Speedup Geometry checks
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Share Topology combined with ‘Match Control’
Share Topology combined with Match Control
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Share Topology combined with Edge Coloring
Edge color based on number of faces shared
Edge color based on number of faces shared
Free – 0 face - Blue
Blue
Single – 1 face – Red
Red
Single – 1 face – Red
Red
Double – 2 faces – Black
Triple 3 faces Pink
Pink
Triple – 3 faces – Pink
Pink
Multiple – 4 faces – Yellow
Yellow
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Thi k t l f ifi d t
Thickness control for specific edge types
View options to control display of specific types
View options to control display of specific types
Display only
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Single edges
Single edges
Thick Triple
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Pi h l l l
Pinch – local manual
Clean small faces or close gaps
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Tolerance
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Pi h l l l
Pinch – local manual
Master right side Master left side
Master right side Master left side
Pi h i l ibl i id P t M lti B d P t!
Pinch is only possible inside one Part or a Multi-Body-Part!
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Pi h l b l t ti
Pinch – global automatic
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V11 Mesh V12 Mesh
V11 Mesh
120k Elements 100k Elements
120k Elements 100k Elements
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M h ti
Mesh connection
F h t d l (M lti b d t ) ti b
For sheet models (Multi-body parts), connections can be
( y p ),
defined as “Mesh connections”
defined as Mesh connections
– Options include similar options as other connections
– Options include similar options as other connections
– “Mesh connections” will be created at mesh time
Mesh connections will be created at mesh time
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Mesh connection
Mesh connection
After meshing user can check the mesh connectivity
After meshing, user can check the mesh connectivity
Automatic connections are created
– Automatic connections are created
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Mesh connection
Mesh connection
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Mesh connection
Mesh connection
M hi ld f il i Sh T l O ti A t ti “ I i t“
Meshing could fail using Share Topology Option „Automatic“, „Imprint“
and „Edge Joint“ in combination with „Mesh connections“.
and „Edge Joint in combination with „Mesh connections .
M h C ti b t d d d /f
Mesh Connection between edges and edge/face
Mesh Connection combined with Share Topology ‚None‘
Mesh Connection combined with Share Topology ‚None
Edge Joint
Edge Joint
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Vi t l Ed S lit
Virtual Edge Splits
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Vi t l Ed S lit
Virtual Edge Splits
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Advanced Size Function
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Local mesh sizes must be set
via mesh controls as no
via mesh controls as no
localized refinement due to
curvature or proximity will
curvature or proximity will
occur
Gradation between the sizes
Gradation between the sizes
will occur according to the
will occur according to the
specified growth rate
specified growth rate
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Use face sizing to define a local Growth
Use face sizing to define a local Growth
Rate
Rate
Global setting defines the
Global setting defines the
maximum possible local value !
maximum possible local value !
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Inflation Layer combined with Tetrahedrons
Inflation Layer combined with Tetrahedrons
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Inflation Layer combined with Sweepmethod
Inflation Layer combined with Sweepmethod
Manual Source
Manual Source
Definition of the Inflation-
Boundary
Boundary
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Optimal meshing options for Local Stresses
Optimal meshing options for Local Stresses
Local Face Sizing and
G th R t
Local Face Sizing Growth Rate
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Local Face Si ing Gro th
Local Face Sizing, Growth
Inflation Layer
Rate and Inflation Layer
Inflation Layer
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Multizone
Multizone
Automatic geometry decomposition
Multizone meshing
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With the swept method this part would
Multizone meshing
With the swept method, this part would
h t b li d i t 5 b di t t
Benefits and Applications have to be sliced into 5 bodies to get a
Benefits and Applications
pure hex mesh
Automated Hex mesh for semi p
Automated Hex-mesh for semi
l t
complex parts
R d ti f d l i
Reduction of model size
Limitations:
Limitations:
Sweeping through more
Sweeping through more
th 3 l l (4 t t l l l )
than 3 levels (4 total levels)
not supported
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With Multizone it can
With Multizone, it can
be meshed directly!
be meshed directly!
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Multizone
Multizone
Multiple Sweep directions in one single body
Multiple Sweep directions in one single body
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Multizone
Multizone
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Multizone
Multizone
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M lti ith F h t ‘
Multizone with ‚Free mesh type‘
‚ yp
combined with Inflation
All elements
All elements
include midside
include midside
nodes per
p
default!
default!
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M lti ith F h t ‘
Multizone with ‚Free mesh type‘
‚ yp
bi d
combined
All elements
with
All elements
include midside with
Inflation
include midside
Inflation
nodes per
p
default!
default!
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M lti
Multizone
Multizone with ‚Free Mesh
Multizone with Free
‚
Type‘ – Not Allowed
Multizone with ‚Free
Mesh Type‘ Tet
Type Not Allowed
Mesh Type - Tet
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M lti I t
Multizone - Improvement
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Multiple-Internal Loops Multiple-connected Loops
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M lti
Multizone
Limitations:
Limitations:
Intersecting Loops - Doesn’t work yet
Intersecting Loops Doesn t work yet
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Thin-Sweep Meshing
Thin Sweep Meshing
Thin Sweep Mesh allows to create more than one
Thin Sweep Mesh allows to create more than one
Solid and Solid Shell elements through thickness
Solid and Solid-Shell elements through thickness.
Thin Sweep Mesh is also possible for Multi-Body-
p p y
Parts But here the number of elements through
Parts. But here the number of elements through
thickness is limited to one element!
thickness is limited to one element!
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Thin-Sweep Meshing
Thin Sweep Meshing
Sid F t b bl
Side Faces must be mappable
I i t b j t d i d
Imprints can be projected or ignored
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Thin Sweep Meshing more than 1 element through thickness
Thin-Sweep Meshing – more than 1 element through thickness
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Thin-Sweep Meshing 1 element through thickness
Thin Sweep Meshing g
Separate Parts MPC‘s
Separate Parts
will be
connected with
will be
d l t d!
connected with
MPC t t
deleted!
MPC-contact
Contact status
Contact status
2 elements through thickness
2 elements through thickness
Contact status
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Tetraeder-meshing of complex parts
Tetraeder meshing of complex parts
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T i l bl i l t
Typical problems in complex parts
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Courtesy of
AEG El t i
AEG Electric
Tools GmbH
Tools GmbH
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Mesh with global element size setting
Mesh with global element size setting
260 587 Knoten
260.587 Knoten
152 233 El t
152.233 Elemente
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Design Modeler Analysis Tool
Design Modeler - Analysis Tool
- Small Entity Search
Small Entity Search
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Appropriate setting of ‘DSMESH DEFEATUREPERCENT’ variable
Appropriate setting of DSMESH DEFEATUREPERCENT variable
All distances smaller than value (0.002)*
( )
Bounding Box (ca 180) will be ignored with
Bounding Box (ca. 180) will be ignored with
th P t h f i th d
the Patch-conforming method
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(Default=0 0005)
(Default 0.0005)
180*0 002 0 36 > 0 33
180*0.002=0.36 > 0.33
218.579 Knoten
126.820 Elemente
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N V13 b l t ‘ D f t i T l
New V13 – ‚absolute‘ Defeaturing Tolerance
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If Advanced Size Function‘ is set to
If ‚Advanced Size Function is set to
Y ‘ th d f lt D f t i T l ‘
‚Yes‘, the default ‚Defeaturing Tolerance‘
value depends on the Min Size‘ The
value depends on the ‚Min Size . The
Defeaturing Tolerance‘ should always
‚Defeaturing Tolerance should always
set to smaller value than ‚Min Size‘.
se o s a e a ue a ‚ S e
221.429 Knoten
128.643 Elemente
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Design Modeler - Geometry Repair
Design Modeler Geometry Repair
Initial
Geometry Merge Initial
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Applicable for Faces and Edges
A t t d ll
Automated or manually
B fit d A li ti
Merged faces
Geometry Defeaturing Merged faces
Geometry Defeaturing
Merged Edges
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ith d f d d
with merged faces and edges
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Fi di f th t b d l b f d t ti ll
Finding faces that can be merged can also be performed automatically.
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Connect Edges
Connect Edges
Connect Edges
Connect Edges
Benefits and Applications
Benefits and Applications
Repair ‚dirty‘ geometry
Repair ‚dirty‘ geometry
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Close uncomplete solids
Close uncomplete solids
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 Repair dirty geometry
Repair dirty geometry
Repair small Faces, Edges
Repair small Faces, Edges
Benefit and Application
Benefit and Application
Reducing unneeded Geometry
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Allow more uniform meshing
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Before
Before
B f R i
After
Before Repair:
After 302 Surfaces, 755 edges, 456 Vertices
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After Repair:
After Repair:
195 Surfaces 607 edges 370 Vertices
195 Surfaces , 607 edges, 370 Vertices
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Courtesy of
AEG Electric
T l G bH
Tools GmbH
1661 Faces 1648 Faces
1661 Faces
before Repair‘
1648 Faces
after Repair‘
before ‚Repair after ‚Repair
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257 038 Knoten
257.038 Knoten
149 961 El t
149.961 Elemente
‘ f
Mit ‚Repair‘ ohne Defeature
‚ p
Tolerance
Tolerance
217 988 Knoten
217.988 Knoten
126 357 Elemente
126.357 Elemente
Mit Repair und Defeature
Mit Repair und Defeature
Tolerance
Tolerance
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Design Modeler – Face delete
Design Modeler Face delete
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Mechanical – Virtual Topology
Mechanical – Virtual Topology
Courtesy of
Courtesy of
AEG Electric
AEG Electric
Tools GmbH
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Large deflection thin wall structure simulation
Large deflection thin-wall structure simulation
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- Scenario-1: linear material
- Scenario-1: linear material
- Scenario-2: nonlinear material
Scenario 2: nonlinear material
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Thin-wall structure simulation
Thin wall structure simulation
Loading
T=2 mm Loading
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Scenarios M t i l
Scenarios Material
• Large deflection with linear material
Large deflection with linear material
8 nodes Solid Shell
- 8-nodes Solid-Shell
4 d Sh ll
- 4-nodes Shell
- 20-nodes Hex
- 10-nodes Tets
10 nodes Tets
• Large deflection with nonlinear material
• Large deflection with nonlinear material
- 8-nodes Solid-Shell
- 4-nodes Shell
- 20-nodes Hex
- 20-nodes Hex
10 nodes Tets
- 10-nodes Tets
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Thin wall structure simulation with linear material
Thin-wall structure simulation with linear material
• SOLSH190 Large deflection with linear material
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• SHELL181 Large deflection with linear material
• SHELL181 Large deflection with linear material
In order to get good shell mesh the following options should be used
In order to get good shell mesh, the following options should be used
1) All Quad Mesh 2) Defeaturing tolerance 3) Element size
1) All Quad Mesh, 2) Defeaturing tolerance , 3) Element size
1
1
2
2
3
3
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• SOLID187 Large deflection with linear material,
SOLID187 Large deflection with linear material,
L=200 T=2, Ratio=L/T=100, Factor=5 30 30
30
, ,
25
30 30
30
Element Size < Factor*Thickness =5*2=10 mm 25
Factor
20
20
r
17
cto
12
10
Fac
10
S *
3
5 Element Size=Factor*Thickness
3
0
50 100 500 1000 2000 3000 4000 5000
Length/Thickness Ratio
Length/Thickness Ratio
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Thi ll t t i l ti ith li t i l
Displacement Displacement Displacement Displacement
p
Dmax=7.40 mm
Displacement
Dmax=7.39 mm
p
Dmax=7.42 mm
p
Dmax=7.19 mm
Dmax 7.39 mm
Stress St
Stress
Smax=993 MPA
Stress
S 964 MPA
Stress Stress
Smax=993 MPA Smax=964 MPA Smax=1052 MPA Smax=1029 MPA
SOLID187
SOLID186
SOLSH190 SHELL181 SOLID187
SOLID186
SOLSH190 SHELL181
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8 00
8.00
993
1052 1029
7.40 7.39 7.42 7.19
993
964
1029
900
0
0
6.00
90
90
1
1
6
6
7
7
90
90
81
81
6
6
7
7
19
19
18
18
86
86
87
87
600
H19
H19
18
18
18
18
18
18
4.00
H1
H1
L1
L1
D1
D1
D1
D1
SH
SH
LL1
LL1
D1
D1
D1
D1
LS
LS
ELL
ELL
LID
LID
LID
LID
300
LS
LS
EL
EL
LID
LID
LID
LID
2.00
OL
OL
HE
HE
OL
OL
OL
OL
300
OL
OL
HE
HE
OL
OL
OL
OL
SO
SO
SH
SH
SO
SO
SO
SO
0
SO
SO
SH
SH
SO
SO
SO
SO
0.00
Total displacement
S
S
S
S
S
S
S
S
0
Stress
Total displacement
5000
90
90
1
1
6
6
Conclusion: 5093
19
19
18
18
86
86
Conclusion:
4000
H1
H1
L1
L1
D1
D1
7
7
-All 4 element give good answer
3000
LS
LS
EL
EL
LID
LID
187
187
All 4 element give good answer
SOLSH190 and SHELL181 are most efficient 3000
OL
OL
HE
HE
OL
OL
D1
D1
-SOLSH190 and SHELL181 are most efficient
SOLID187 i th t i 2000
SO
SO
SH
SH
SO
SO
LID
LID
-SOLID187 is the most expensive
S
S
S
S
S
S
OL
OL
111 66
868
1000
SO
SO
868
0
S
S
0
Elapsed time
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Thin-wall structure simulation with nonlinear material
• SOLSH190
SOLSH190
Displacement Stress Plastic strain
Displacement
D 27 96
Stress Plastic strain
E 4 48%
Dmax=27.96 mm Smax=451 MPA Emax=4.48%
Material
Material
Convergence monitor
Convergence monitor
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SOLSH190 SHELL181 SOLID186 SOLID187
Displacement Displacement Displacement Di l t
Displacement
Dmax=27.96 mm
Displacement
Dmax=26 96 mm
Displacement
Dmax=22 51 mm
Displacement
Dmax=22 27 mm
Dmax=26.96 mm Dmax=22.51 mm Dmax=22.27 mm
Stress St
Stress
Smax=451 MPA
Stress
Smax=453 MPA
Stress Stress
Smax 451 MPA Smax=453 MPA
Smax=422 MPA
Stress
Smax=402 MPA
S a 0
Plastic strain Plastic strain Plastic strain Plastic strain
Emax=4.48%
Plastic strain
Emax=4.63% Emax=2.77%
Plastic strain
Emax=2.41%
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L t’ l k t th l ti t i lt
Let’s look at the plastic strain results:
p
Plastic strain Plastic strain Plastic strain Plastic strain
Emax=4.48% Emax=4.63% Emax=2.77% Emax=2.41%
It’ ti d th t t l th t i l t th th l ti t i
It’s noticed, that not only the strain values are not the same, even the plastic strain
distributions are not the same
distributions are not the same.
SOLSH190 and SHELL181 show the same plastic strain distributions and the
SOLSH190 and SHELL181 show the same plastic strain distributions and the
l
same value.
SOLID186 and SOLID187 show the same plastic strain distributions and the
SOLID186 and SOLID187 show the same plastic strain distributions and the
same value.
same value.
- 70 -

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0.045
0 04
0.045
SOLSH190
n
0 035
0.04
SOLSH190
ain
0 03
0.035
stra
0.03
c
s
0.025
SOLID186
tic
0.02
SOLID186
ast
0.015
Pla
0.01
P
0 005
0
0.005
0
380 400 420 440 460 480 500 520
380 400 420 440 460 480 500 520
Path
Path
It i ti d th t th t b i diff t i l ti t i lt b t
It is noticed, that there are two obvious differents in plastic strain results between
SOLSH190 and SOLID186:
SOLSH190 and SOLID186:
1) In some regions SOLID186 show zero plastic strain while SOLSH190 does not
1) In some regions, SOLID186 show zero plastic strain, while SOLSH190 does not.
2) SOLSH190 h h hi h l ti t i SOLID186
2) SOLSH190 show much higher plastic strain as SOLID186.
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Conclusion: St i di t ib ti th h thi k
Conclusion:
SOLID186 and SOLID187 answers are incorrect:
Strain distribution through thickness
- SOLID186 and SOLID187 answers are incorrect:
When the stress beyond the yield stress, the strain distribution is not
linear anymore through the thickness, SOLID186 and SOLID187
y g ,
have only 2 integration points through the thickness, which is not
have only 2 integration points through the thickness, which is not
enough to model the strain distribution through the thickness
enough to model the strain distribution through the thickness.
El ti Pl ti
SHELL181 h 5 i t ti i t ( t th b ) th h th thi k f
Elastic Plastic
- SHELL181 has 5 integration points (user can set the number) through the thickness for
material nonlinearity, the answer is much more accurate.
y,
SOLID186
SHELL181 SOLID186
SHELL181
Dmax=22.51 mm
Dmax=26.96 mm
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SOLSH190:
- SOLSH190:
N b f th i t ti i t th h th thi k b d fi d ith SECTION
Number of the integration points through the thickness can be defined with SECTION
definition, in this case 5 points are used
de t o , t s case 5 po ts a e used
SOLID186
SHELL181
SOLSH190 SOLID187
SOLID186
SHELL181
SOLSH190 SOLID187
D 26 96 D 22 51
D 27 96 D 22 27
Dmax=26.96 mm Dmax=22.51 mm
Dmax=27.96 mm Dmax=22.27 mm
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27.96
26.96
25 00
451 453
422
400
25.00 422
402
0
0
22.51 22.27
20.00
90
90
81
81
6
6
7
7
300
90
90
81
81
86
86
87
87
15 00
19
19
18
18
86
86
87
87
H19
H19
L18
L18
18
18
18
18
15.00
SH
SH
LL1
LL1
D1
D1
D1
D1
200
SH
SH
LL
LL
D1
D1
D1
D1
10.00
LS
LS
EL
EL
LID
LID
LID
LID
LS
LS
EL
EL
LI
LI
LI
LI
5 00
OL
OL
HE
HE
OL
OL
OL
OL
100
OL
OL
HE
HE
OL
OL
OL
OL
5.00
SO
SO
SH
SH
SO
SO
SO
SO
0
S
S
S
S
S
S
S
S
0.00
T t l di l t
S
S
S
S
S
S
S
S
0
Stress
Total displacement
90
90
81
81
5.00
16232
15000
19
19
18
18
4.48 4.63 2.77 2.41
4 00
8420
12000
SH
SH
LL1
LL1
87
87
4.00
0
0
1
1
6
6
7
7
12000
LS
LS
EL
EL
86
86
18
18
3.00
19
19
81
81
86
86
87
87
9000
OL
OL
HE
HE
18
18
D1
D1
H1
H1
L1
L1
D18
D18
D18
D18
6000
SO
SO
SH
SH
D1
D1
LID
LID
2.00
LSH
LSH
LL
LL
LID
LID
LID
LID
1658
1226
6000
S
S
S
S
LI
LI
OL
OL
1 00
OL
OL
HE
HE
OL
OL
OL
OL
1658
3000
O
O
SO
SO
1.00
SO
SO
SH
SH
SO
SO
SO
SO
0
S
S
0.00
Pl i i
S
S
S
S
S
S
S
S
0
Elapsed time
Plastic strain
- 74 -

g
g
The most efficient ways to solve linear and nonlinear thin-wall structure are:
y
1) Use DM to get mid-surface, use all-quad-mesh with SHELL181.
1) Use DM to get mid surface, use all quad mesh with SHELL181.
2) Use sweep mesh to get SOLSH190 model
2) Use sweep mesh to get SOLSH190 model.
If the above methods can not be used a fine SOLID187 model can also achieve
If the above methods can not be used, a fine SOLID187 model can also achieve
the accurate result, but it’s a very expensive way.
, y p y
- 75 -

g
g
- 76 -

workshop-meshing-proces and different types).pdf

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workshop-meshing-proces and different types).pdf