RADIOSS Interfaces & Study of Effect of Notches Challenge

OBJECTIVE:-

Generating the mesh for bumper assembly the target element size is 6. Run the simulation in given cases

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.

Plot RWALL forces, contact forces, internal energy and Create TH/PART for all parts and compare results for all cases.

BUMPER MESHING:-

1.First import the Select→Import Model→Select File→Import as shown below.

2.Click on the import the model is visible in the graphical area as shown below.

3.Next to clean the geometry by using Quick edit as shown below.

4.Next go to the main menu bar select →2D→Automesh as shown below.

5.The element size is given is 6 and click on the mesh as shown below.

6.Repeating the 4&5 steps complete the bumper meshing as shown below.

CASE1:-Run the crash tube model as it is.

1.First import the file Select→Import→Import solver→Import as shown below.

2.Click on the import the model will be seen in the graphical area as shown below.

3.Next create the TH/PART go to tab bar click on output blocks create a new one and assign all components as shown below.

4.Next go to the main menu bar Select→Analysis→Radioss as shown below.

5.Click on Radioss lets start the simulation automatically as shown below.

the simulation is completed.

6.Next check the energy error and mass error it is acceptable range is not.

7.Go to simulation files open the 0001.rad file in note pad the values is visible as shown below.

8.The energy error is -3.8% and the mass error is 0.000 the both are acceptable ranges.

9.Next changing the Client selector to hyper view and select animation h3d file click on apply as shown below.

10.Clicking apply the animation will be applied in the graphical area as shown below.

See the above animation the elements are buckling, the von Mises stress is high at the end of the simulation.

11.Next plot the graphs by changing the client selector into hypergraph 2D and select the T01 file to plot the graphs.

→Rigid wall force.

→Contact energy.

→Internal Energy.

CASE 2:-Change the Inacti=6 and run.

1.Import the radioss file in hypermesh.

2.Next go to the menu bar Select→View→Browser→Hypermesh→Solver as shown below.

3.Then open the solver Select Inter→Type7→Self contact→Inacti is 6 as shown below.

4.Next go to the main menu bar Select→Analysis→Radioss as shown below.

the radioss job is completed.

5.Next check the energy error and mass error is an acceptable range or not.

The energy error is -3.8% and the mass error is 0.000. Both errors are in an acceptable range.

5.Next change the client selector hypermesh to hyper view.

6.Select the animation h3d file in simulation flies click on apply and see the graphical area changed as shown below.

The elements are buckling in the above animation. See the animation in case 1 and case 2 there is no changes.

7.Next plot the graphs change the client selector hyper view to hypergraph 2D select T01 file plot the graphs as shown below.

→Rigid wall force.

→Contact energy.

→Internal Energy.

CASE 3:-Create the type 11 contact and run.

1.Create the new contact Solver→Inter→Create→Type11 as shown below.

2.Next click on the type11 assign the given values as shown below.

3.Next run the simulation as shown below.

4.Next check the energy error and mass error is in acceptable range or not.

5.Open the 0001.out file in note pad the values are visible.

6.In the above figure shows the energy error is -4.0% and mass error is 0.000 those values are in an acceptable range.

7.Client selector change hyper mesh to hyper view and select h3d file see the animation in the graphical area as shown below.

In the simulation developed von mises at the end of the simulation, it develops high.

8.Next client selector change hyper view to hypergraph 2D select the T01 files and plot the required graphs as shown below.

→Rigid wall force.

→Contact energy.

→Internal Energy.

CASE4:-Remove both notches and remove boundary condition on rigid body node then run.

1.First remove the notches in hypermesh by using F7 to select the align nodes rem, moving the notches as shown below.

BEFORE.

AFTER.

2.Next run the simulation as shown below.

The radios job is completed.

3.Check the energy error and mass error.

Both values are in the acceptable range.

4.Next go to hyper view see the animation below.

The contact forces are developed at the end of the simulation as seen in the above animation.

5.Next plot the required graphs as shown below.

→Rigid wall force.

→Contact energy.

→Internal Energy.

CASE5:-Create a new notch in the middle, select the whole section and run.

1.Creating the new notch in the middle in hypermesh as shown below.

2.Next run the simulation as shown below.

The radioss job is completed.

3. Check the energy error and mass error as shown below.

The energy error is -3.4% and the mass error is 0.000 it is in an acceptable range.

4.Next go to hyper view see the animation below.

In the above animation, elements are buckling and the contact forces developed at the end of the simulation lightly.

5.Next change the hypergraph 2D plot the required graphs as shown below.

→Rigid wall force.

→Contact energy.

→Internal Energy.

CASE6:-Create a new notch with nodes only from opposing 2 faces and run.

1.Create a new notch on the opposing 2 faces as shown below.

2.Next run the simulation as shown below.

The radios job is completed.

3.Next check the energy error and mass error.

The energy error is -3.6% and the mass error is 0.000 both are in an acceptable range.

4.Next select hyper view see the animation as shown below.

See the above animation first notches elements buckling the contact forces developed at the end of the simulation.

5.Next go to hypergraph 2D plot the required graphs as shown below.

→Rigid wall force.

→Contact energy.

→Internal Energy.

Comparison of all cases:-

1.The first 3 cases depend upon contact type so I am taking 3 cases as shown below.

Case No.	ContactType	Number of Cycles	Elapsed Time(Sec)	Max.Energy Error (%)	Max.Mass Error(%)	Max.Von Misses	Rigid Wall Force(KN)	Contact Energy (Kg mm2/ms2)	Internal Energy (Kg mm2/ms2)
case 1	Type7	83529	204.55	-3.8	0.000	7.358E-01	1350	2025	40000
case2	Type7	83529	197.37	-3.8	0.000	7.358E-01	1350	2025	40000
case3	Type11	83336	224.16	-4.0	0.000	7.488E-01	1400	2000	40250

2.By comparing case1 and case2 the elapsed time is changed all parameters are constant and in case 3 except for the number of cycles all parameters are increased. The number of cycles will be decreased by changing the Inacti=6.

3.The other cases depends upon the notches as shown below.

Case No.	Changes	Number of Cycles	Elapsed Time(Sec)	Max.Energy Error (%)	Max.Mass Error(%)	Max. Contact Force	Rigid Wall Force(KN)	Contact Energy (Kg mm2/ms2)	Internal Energy (Kg mm2/ms2)
case 4	Remove both notches and remove boundary condition on rigid body node then run.	79544	60.13	-3.2	0.000	6.633E+01	1200	1650	40000
case 5	Create a new notch in the middle, select the whole section and run.	85254	195.32	-3.4	0.000	1.686E+02	1280	1800	40000
case 6	Create a new notch with nodes only from opposing 2 faces and run.	81756	187.92	-3.6	0.000	7.820E+01	1500	2000	40000

4.Comparing case 4, case 5 and case6. In case6 Except for mass error, all parameters are increased.

RESULT:-

Thus, I am completing all cases with given changes complete the simulation, Plot the required graphs and comparing all cases by using hyper works.