Mechanical Nonlin 13.0 WS 04A Interface Treatment

Customer Training Material
Workshop 4A Contact Interface Treatment
ANSYS Mechanical Structural Nonlinearities

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved. Release 13.0 December 2010
WS4A-1
Workshop 4A: Contact Interface Treatment

Goal
Use interface treatment tools to simulate an interference fit between surfaces.
Tip
Model Description
2D Axisymmetric model of injection molding machine nozzle l tip ti assembly bl Materials:
Steel for Housing Copper alloy for Tip Titanium for Insulator
Insulator
Housing
ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.
WS4A-2
Release 13.0 December 2010

Model Description (contd)
Contact Pairs: A. Frictionless contact at H Housing i t to N Nozzle l tip ti face f seal B. Bonded contact at Nozzle tip To insulator C. Bonded contact at threaded connection between Housing and Nozzle tip (thread details not modeled)
WS4A-3

Thermal Boundaries: A. Hot manifold @ 220C B. Cold manifold plate @50C C. Nozzle tip band heater @ 80 Watts
WS4A-4

Structural Boundaries A. Frictionless Support @ Nozzle Housing Flange B. Frictionless Support @ Insulator Structural Loads 1st loadstep reconciles interference fit between housing and tip face seal 2nd loadstep reads in temperatures p from steady y state thermal run 3rd loadstep applies pressure to melt channel wall.
melt channel wall
WS4A-5

Steps to Follow:
Restore Archive browse for file W4a_offset.wbpz
Save as
File name: WS4a-offset Save as type: Workbench Project Files (*.wbpj) ( .wbpj)
WS4A-6

The Project Schematic should look like the picture below.
Note: The engineering data, geometry, loads and boundary conditions for the thermal and structural runs have already been set up. It remains to specify the contact surface offset at the tip-housing face seal, run the solution and post process contact results. results
ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved. Release 13.0 December 2010
WS4A-7

Highlight the Engineering Data Cell and double click to open
Verify the predefined material properties Verify Verif that the units nits are in Metric (Tonne (Tonne,mm,) mm ) system. If not, fix this by clicking on Utility Menu>Units>Metric(Tonne, mm,..)
WS4A-8

Return to the project schematic page
Double click (or RMB=>Edit) on the Thermal Model Cell to open Mechanical Session
WS4A-9

Once inside the Mechanical application, verify the working unit system
Unit > Metric (mm,kg,N,s,mV,mA)
Expand E d each h folder f ld in i the th project j t tree t to t become familiar with the model set up and to confirm material assignments, boundary conditions, , and loads as described on the slides 2 thru 5. Verify the initial condition of the three predefined contact regions
Highlight the Connections Branch RMB > Insert >Contact Tool
WS4A-10

Highlight the Initial Information branch of the newly inserted Contact Tool
RMB > Generate Initial Contact Results
This should produce the following table of specifications on the initial condition of the contact regions:
WS4A-11

Note:
The two bonded contact regions are assigned two contact pairs that act equal and opposite to each other to enforce the contact. This reflects S Symmetric t i behavior. b h i The frictionless contact region has only one active pair, reflecting Asymmetric behavior. The companion frictionless pair (grayed out) is inactive. It is initially in a Near Near Open Open status with a small gap. The initial penetration at the bonded regions is essentially zero and is ignored by default.
Without making any changes to the contact specifications, execute a SOLVE
WS4A-12

The Solution converges quickly and easily in a few iterations
Highlight the Solution Information Folder and switch Solution Output to Force Convergence
WS4A-13

Highlight the Solution Branch
RMB > Insert > Contact Tool
Highlight the newly inserted Contact Tool

RMB > Insert >
Pressure Penetration Gap
WS4A-14
Highlight the Contact Tool and filter out the bonded contact pairs by clicking off the checkmark in box next to each region
RMB > Evaluate Results
WS4A-15
Using the Time line in the Graph window, post process the contact pressure for each load step
Loadstep 1
Loadstep 2
L d t 3 Loadstep
As expected, pressure at the frictionless interface is zero at LS1. It ramps up to about 50Mpa for LS2 due to thermal differential expansion. It drops back to zero as a result of melt channel pressure load at LS3.
WS4A-16
Post process the contact penetrations and gaps for each load step
Note, in particular, the max gap profile (gap =0.049176)at the end of LS3. This interface must remain closed in order to prevent leakage in operation.
WS4A-17

Return to the Connections folder, highlight the Frictionless- Housing To Nozzle tip contact region
In the Details window, Set Offset to 0.050mm
This will make a mathematical th ti l adjustment to the position of all the contact co tact detect detection o points toward the target surface, creating an interference fit
WS4A-18

Use the Contact Tool to verify that the offset has been set in Initial Information in the Contact Tool
RMB > Generate Initial Contact Results Note: The frictionless contact is now reported closed at the start with an initial penetration of 4.8943e-2. Is this correct? Recall, , prior p to defining g the 0.050 Offset, , the initial gap g p was reported as 1.0567e-3 (slide 12). 0.05 - 1.0567e-3 = 4.8943e-2 Hence, the offset has been correctly introduced
Execute the another solve
WS4A-19
Highlight the Solution Information Folder and switch Solution Output to Force Convergence
The Solution takes a few more iterations then the first run, because of the contact offset offset, but it still converges relatively easily
WS4A-20

Post process the contact pressure
Because of the initial interference, a maximum pressure concentrated at the melt channel wall of about 500Mpa is now established and maintained throughout the load history. history
WS4A-21
Note also that when you zoom in on the contact region, there appears to be a small gap where we expect an interference.
This is expected as the Offset is a like a rigid region created by a mathematical adjustment to the contact detection point locations. locations This underscores the importance of using this interface treatment tool for very small adjustments only.
Rigid region
WS4A-22

Highlight Solution
RMB>Insert>Probe>Force Reaction In Details of Force Reaction Set..
Location Method = Contact Region Contact Region = Frictionless- Housing To Nozzle tip
RMB>Evaluate Results
WS4A-23
As expected, the preload is nearly constant across the three loadsteps
WS4A-24

Post process the equivalent stress at LS2.
This peak stress is much higher then the actual yield strength of the tip material. Localized yielding is expected and will likely reduce the preload.
WS4A-25

Mechanical Nonlin 13.0 WS 04A Interface Treatment

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Customer Training Material

Workshop 4A Contact Interface Treatment

ANSYS Mechanical Structural Nonlinearities

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

Without making any changes to the contact specifications, execute a SOLVE

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment

Customer Training Material

ANSYS, Inc. Proprietary 2010 ANSYS, Inc. All rights reserved.

Release 13.0 December 2010

ANSYS Mechanical Structural Nonlinearities

Workshop 4A: Contact Interface Treatment