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OBJECTIVE: The objective of this model is to compare the results and effect of applying different contact interface types to a crush tube model. TASK : Create the mesh for bumper assembly,mesh size should be 6mm. Run the crash tube model as it is. Change the Inacti=6 and run. Create…
Leslie Enos
updated on 28 Sep 2020
OBJECTIVE: The objective of this model is to compare the results and effect of applying different contact interface types to a crush tube model.
TASK :
These 6 cases are going to be investigated and compared with each other.
INTRODUCTION
Interfaces & Contact Modelling
Interfaces are defined to model how parts interact when they come into contact with each other. The method used is the penalty method.
Penalty method threats the behaviour between slave and master as springs that generate resistive forces as a function of penetration.imagine a surface with a gap which the slave node must penetrate. When the slave is approaching the master, springs are created and this springs can be linear or non linear.
Below are some of interface types in hypercrush
PROCEDURE
CASES |
DESCRIPTION |
1 |
Run the crash tube model as it is. |
2 |
Change the Inacti=6 and run. |
3 |
Create the type 11 contact and run. |
4 |
Remove both notches and remove boundary condition on rigid body node then run. |
5 |
Create a new notch in the middle ,select the whole section and run. |
6 |
Create a new notch with nodes only from opposing 2 faces and run. |
TYPE 7
Interface TYPE7 is a multi-usage impact interface, modeling contact between a master surface and a group of slave nodes. It is also possible to consider heat transfer and heat friction.
Parameters which control type 7 card
Gapmin | Minimum gap for impact activation |
Recommended properties for tpe ( 7&11)
Gapmin | >0.5mm : Half of the thinnest part is mostly used |
PROPERTY CARD
There are two property card set with a material thickness difference of 3mm and 2mm. The remaining properties are the same and are listed below.
MATERIAL CARD
CASE_1
Total number cycle |
83691 |
Energy error |
-3.8% |
Mass error |
0.000 |
Time of simulation |
01:56 |
Von_Misses Stress
Internal Energy
Rigid wall forces
Total Energy, Hourglass,Contact and Kinetic Energy
CASE_2
Setting contact interface card to type 7 and setting inacti value to 6
Total number cycle |
83691 |
Energy error |
-3.8% |
Mass error |
0.000 |
Time of simulation |
01:58 |
Von-misses stress
Rigid wall forces
Total Energy, Internal, Hourglass,Contact and Kinetic Energy
CASE_3
Create the type 11 contact and run with Type_7
Total number cycle |
81644 |
Energy error |
-3.5% |
Mass error |
0.000 |
Time of simulation |
02:08 |
Von-misses stress
Rigid wall forces
Total Energy,Internal, Hourglass,Contact and Kinetic Energy
CASE_4
Combine Type_7 & Type_11 with removed notches and removed boundary condition on rigid body node then run.
Total number cycle |
73521 |
Energy error |
-2.3% |
Mass error |
0.000 |
Time of simulation |
01:50 |
Von-misses stress
Rigid wall forces
Total Energy,Internal, Hourglass,Contact and Kinetic Energy
CASE_5
Combine Type_7 & Type_11 and create a new notch in the middle.
Total number cycle |
81023 |
Energy error |
-2.7 |
Mass error |
0.000 |
Time of simulation |
02:20 |
Von-misses stress
Rigid wall forces
Total Energy,Internal, Hourglass,Contact and Kinetic Energy
CASE_6
Combine Type_7 & Type_11 and create a new notch with nodes only from opposing 2 faces and run.
Total number cycle |
82600 |
Energy error |
-2.8 |
Mass error |
0.00 |
Time of simulation |
02:16 |
Von-misses stress
Rigid wall forces
Total Energy,Internal, Hourglass,Contact and Kinetic Energy
RESULTS AND CONCLUSION
CASE TIME CYCLES MASS ERROR ENERGY ERROR COMMENTS
1 | 1.56 | 83691 | 0 | -3.8 | The mass error remained constant throughout. |
2 | 2:29 | 83600 | 0 | -3.8 | |
3 | 3:00 | 81976 | 0 | -4.1 | The energy error decreased the most with the |
4 | 2:08 | 73615 | 0 | -2.7 | notch removed. The notches increases the |
5 | 2:45 | 78837 | 0 | -3.1 | energy error. |
6 | 2:57 | 81887 | 0 | -3.1 | |
Cases Von Misses stress Comments
1 | 0.6964Gpa | It can be seen that notches |
2 | 0.6964Gpa | have higher stresses,and the |
3 | 0.6737Gpa | notches after case_3 have |
4 | 0.6545Gpa | low stresses.The effrct of notches is |
5 | 0.6509Gpa | evident here.Removing the notches |
6 | 0.6668Gpa | reduces the stress. |
RIGID WALL FORCES
CASES | RIGID WALL FORCES |
1 | 1350J |
2 | 1350J |
3 | 1350J |
4 | 1150J |
5 | 1300J |
6 | 1200J |
it can be seen that the forces on the wall was the same for first three cases , but reduced the most in case 4 without the notches. It increased back after adding the notch in the middle and at the sides. This means that less force is resisted from wall in case 4 due to low stiffness without the notch and if the notches placements are controlled lower Forces are developed compared with the early cases.
CONTACT ENERGY
CASES | CONTACT ENERGY |
1 | 2020J |
2 | 2020J |
3 | 2125J |
4 | 1375J |
5 | 1770J |
6 | 1625J |
it can be seen that the contact energy the same for first two cases , but reduced the most in case 4 without the notches. It increased back after adding the notch in the middle and at the sides. This means that less contact energy is present in case 4 due to low stiffness without the notch and if the notches placements are controlled lower contact energy are developed compared with the early cases. The contact energy reduced a bit in case 3 after adding the type 11.That means edges crossing are controlled to capture the phhysics correctly.
Contact energy is proportional to the rigid wall forces.
INTERNAL ENERGY
CASES | INTERNAL ENERGY | TIME |
1 | 42.5KJ | 26ms |
2 | 42.5KJ | 26ms |
3 | 42.5KJ | 26ms |
4 | 42.9KJ | 28ms |
5 | 42.5KJ | 28ms |
6 | 42.5KJ | 28ms |
it can be seen that the internal energy was roughly the same for all cases , but the time at which maximumis reach varies. It took a longer time to reach maximum for the cases 4 and after. Depending on the location of the notches, the maximum internal energy is reached faster or slower.
For all simulations the hourglass remain constant at zero due to physical stabilization which is set in the property card, kinetic and total energy all remained the same for all simulations.
CONCLUSION
No difference was seen in case1 and 2 because the was no initial penetration in the model (inact=6)
The notches affect the simulation in many ways. They are first to collapse during compression. Also the position of the notches controlls the variation of contact, internal and rigid wall forces.The presence of notches increases the stress and the energies.
For all simulations the hourglass remain constant at zero due to physical stabilization which is set in the property card, kinetic and total energy all remained the same for all simulations.
Depending on the location of the notches, the maximum internal energy is reached faster or slower.
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