Modeling Seals With ANSYS Mechanical - Seminar Presentation

ANSYS Webinar
Sealing Applications
Siddharth Shah
Presented by Pierre THIEFFRY
Product Managers
Ansys, Inc.
2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

Agenda
Seals and ANSYS tools ~ 40 min

Siddharth Shah
Q& A ~ 15 min

Seals
Gaskets
O-rings Body seal
Boot seal Bushing

Seals
Automotive (Gaskets, Hoses, compressor valves etc.)

Aerospace (Remember the failed O-ring on the Space Shuttle ??)
Biomedical
Electronics, Packaging
Sports (Equipment safety, Shoes, Helmets)
determining the viability of a new material,

defining the correct geometry shape
or minimizing stress to maximize life expectancy
ANSYS has the tools to help you design a better product in less
time!

Observations about Elastomers
Elastomers - also know as Hyperelastic materials exhibit the

following
They can be molded into complex shapes
They can undergo large deformations - up to 500% strain
The load-displacement or the stress-strain relationship is highly
nonlinear
Elastomers are nearly or fully incompressible i.e. they undergo
very little volumetric change under stress
They exhibit high energy absorption under cyclically varying
load and hence have excellent damping properties
They are highly dependent on Temperature, operating
Frequency and Time (duration of use)

Hyperelastic Material Models in ANSYS
Mooney-Rivlin
Polynomial
Ogden
Hyperelastic
Arruda-Boyce
Gent
Yeoh
Ogden (Foam)
Foam
Blatz-Ko
Anisotropic
Hyperelasticity
+
Beyond ANSYS Material Models
USERMAT - User Programmed

Material Option
Modular interface
Supports all 180 series of
elements
General purpose
Allows users to define
custom material models
Easy to incorporate third
party/proprietary constitutive
laws

Which Material Model ?
Many material models available
The choice will depend on:

Type of elastomer
Loading conditions (% Strain)
Material test data available
In general, the best material model is the one that

produces the closest curve fit of stress vs. strain test
data
In the most challenging applications, there might be
only one function that is appropriate.
Often two or more functions will produce same
response.
Material Characterization
Collected data may need to be adjusted to account for

effects such as hysteresis and stress-softening behavior.
A typical engineering stress-strain curve for a rubber
sample under cyclic loading is shown on the right. 1.8
1.6
Note that hysteresis is present. Stress- 1.4
softening effects (such as Mullins effect) are 1.2
also present. 1
0.8
A stabilized curve needs to be chosen: 0.6
1) Loading or unloading path

0.4
2) Initial or Nth repetition
0.2
This curve would then be shifted to the origin (zero
stress for zero strain) and used for curve-fitting -0.5
0
0 0.5 1 1.5 2 2.5
procedures.
Mullins effect material model to be available

soon

Curve Fitting
ANSYS supports curve fitting for

Hyperelastic materials
Creep materials
Viscoelastic materials
Temperature dependency is
supported for all three behaviors.

General Material Guidelines
Neo-Hookean model is most simple and a good way to start.
Two-term Mooney-Rivlin is one of the most widely used models, although not
suitable to capture the stiffening effect. General M-R models (i.e., Polynomial)
are an extension of this for larger strains
3-term Yeoh model provides good fit for large stretch values, though maybe
not so for low strain.
Arruda-Boyce and Gent models can be thought of as extensions of Yeoh,

where the constants have physical meaning. Good for small + large stretch
Ogden is based on principal stretches, usually provide much better curve

fitting. Usually a little more computationally intensive because of this.
For compressible polyurethane foam-type rubbers, Blatz-Ko is suitable. Other

highly compressible elastomeric foams require Hyperfoam model.

Elements Technology
Topologies Comprehensive architecture
2D Quad/Tri Accepts all material models
3D Hexahedron Elastic, hyperelastic, viscoelastic,
plastic, viscoplastic, creep, cast
3D - Tetrahedron
iron
3D - Wedge Supports many features &
3D - Pyramid infrastructure
Solid Shell Initial stress, thermal loading,
element death/birth
Stress States Formulations
Static, transient, modal, buckling
Plane Stress Displacement and restart
Plane Strain B-Bar Consistent formulation across the element
family
3D Enhanced Strain
Consistent within the family and
Axisymmetric URI+HG constitutive algorithms
Gen. Plane Strain Mixed u-P Accounts for follower pressure
effects
Analysis
Lagrange multipliers for constraints
Large Strain
Have minimum assumptions
Large Rotation
Gasket Material Model
ANSYS Gasket Material Models
Gasket Closure
Model Deflections Gasket Pressure

Eaton Example

Contact Technology
Node-Node; Node-Surface; Surface-Surface; Line-Line Contact

Small and Large Sliding
Lower and Higher order elements
Pure Penalty;Augmented Lagrange;
Pure Lagrange; MPC contact
Semi-Automatic Contact Stiffness Update
Multiphysics Contact; Rigid Contact
Friction Sliding (Small/Large Deformation)
Shell/Beam Thickness Effects

Summary of Contact Algorithms
Pure Penalty Augmented Lagrange Normal Lagrange MPC

Good convergence May require additional May require additional Good convergence
+ behavior (few equilibrium - equilibrium iterations if - equilibrium iterations if + behavior (few equilibrium
iterations) penetration is too large chattering is present iterations)
Sensitive to selection of Less sensitive to No normal contact No normal contact
- normal contact stiffness selection of normal + stiffness is required + stiffness is required
contact stiffness
Contact penetration is Contact penetration is Usually, penetration is No penetration
- present and present but controlled to + near-zero +
uncontrolled some degree
Useful for any type of Useful for any type of Useful for any type of Only bonded contact
+ + + -
contact behavior contact behavior contact behavior behavior is allowed
Either Iterative or Direct Either Iterative or Direct Only Direct Solver can Either Iterative or Direct
+ + - +
Solvers can be used Solvers can be used be used Solvers can be used
Symmetric or Symmetric or Asymmetric contact Asymmetric contact
+ asymmetric contact + asymmetric contact only only
available available
Contact detection at Contact detection at Contact detection at Contact detection at
+ +
integration points integration points nodes nodes

Pressure Penetration Loading
Modeling of fluid penetrating into the interface between two

contacting bodies
It supports:
2D/3D surface-to-surface
contact pair
Small and large sliding
contact
Rigid-flexible and
flexible-flexible contact
Path-dependent loading

Solvers
ANSYS provides a complete set of Sparse Direct and iterative solver technology
Large scale computing via parallel processing, iterative and domain-based solvers
ANSYS has the the right solver
Direct Sparse Solver for robustness and efficiency
Iterative Solvers for speed and model size
For increased speed, parallel processing with iterative and domain-
based solvers
Solver Type Solver Name
Direct Sparse
Iterative PCG
AMG
DSparse
Distributed
DPCG
Memory
DDS
Solver Tools
Convergence Enhancement Convergence and Results Tracker

Predictor/ Line Search/ Arc Length
Cutback on load stepping options
Wide choice of solvers
Automated solution control
Comprehensive troubleshooting
(CNCHECK)
Nonlinear Diagnostics
Choice of Newton-Raphson procedure
Process simulation
Transfer between explicit &
implicit
Initial Stress and Restarts
Partial solution (PSOLVE)
Birth and death of elements
Result Trackers
Valuable for knowing how

the model performs with
increasing load
Available for each contact

pair
Converged solution data
Various types

Diagnostic Tools
Troubleshoot unconverged nonlinear solutions with the

Newton Rhapson residuals capability
Enables users to visualize the Newton-Raphson residual
information for iterations leading up to no convergence
Helpful for indicating where adjustments should be made prior to
executing a restart after an unconverged solution

2-D Rezoning
Rezoning: Recreate mesh based on deformed domain and continue the
analysis
Used
In large deformation analysis when mesh is distorted (nlgeom,on)
To complete the analysis or achieve higher accuracy with better mesh quality
Features Outline
Rezoning can be done at any time and
many times
It can be done at any time of simulation as
long as the restart files exist
It can be done repeatedly if it is needed
Just repeat the steps, no new commands
Very flexible on which region to rezone
Rezone the whole deformed domain
Rezone any selected regions
Keep selected group of nodes on boundary
unchanged during rezoning
Stabilization
Instabilities in nonlinear analysis

Rezoning (Mesh distorted too much)
Arc-Length (Global instability)
Stabilization (Local instability: softening, wrinkling,
under constraint)
Handle local instability for nonlinear static analyses
Adding numerical damping with dashpot at each node
How to use
STABILIZE, Key, Method, VALUE, SubStpOpt
Mainly for nonlinear analysis with

NLGEOM,ON
Can be turned on/off during each
load steps
Can be turned on/off within a
load step by restart
A Few Tips

Curve Fitting Example: Data used
To demonstrate the Curve Fitting capabilities in ANSYS,

the original data from Treloar (1944) were used. They
represent an uniaxial and biaxial tension test and a pure
shear test:

Curve Fitting Example: Data
preparation
ANSYS expects in the curve fitting procedure

engineering strain and stress quantities:
Experimental Data Treloar
4
Ing. Stress
Uniaxial Tension
3 Pure Shear
Biaxial Tension
0
0 1 2 3 4 5 6 7
Ing. Strain

Curve Fitting Example: Data import
ANSYS allows the data import in Engineering Data by

a simple copy & paste:
1. Define
the
material
model
and data
2. C&P the data in the test data sheet

Curve Fitting Example: Procedure
Go to the chosen material model sheet. For the

moment, we want to use only the uniaxial test data and
fit for different models:
2
n
E =
2
1 normalized

i =1 exp

E 2 = ( exp ) absolut
n
2
i =1
Your error norms can be either

Normalized or Absolute.
Normalized error norms (the
default regression option)
generally provide better
results than absolute error
norms, since normalized error
norms give equal weight to all
of your data point

Curve Fitting: Procedure
Results for different Mooney-Rivlin models:
2-Term 3-Term 5-Term
Material instabilities M-R M-R
9-Term It can be seen, that the 2- and 9-Term

Mooney-Rivlin leads to material
instabilities and must not be used!
Better choices are the 3- and 5-Term
models. However, they also seem to be very
stiff in a multiaxial stress state!

Results for a Yeoh 3rd order model compared to a 3-

and 5-Term Mooney Rivlin:
Yeoh 3-Term 5-Term
M-R M-R
Experimental data Compared to the Mooney-Rivlin models, it can

be seen, that the Yeoh model is much closer
to the (complete) experimental data set. This
due to the polymer-mechanical background of
the model.
Hence, do not use Mooney-Rivlin on the basis
of only uniaxial tension tests!
Results for a Yeoh 3rd order model compared to a 3- and 5-Term

Mooney Rivlin based on the complete experimental data set:
Yeoh 3-Term 5-Term
M-R M-R
Ogden 3rd order The Mooney-Rivlin models now better

approximate the test data but are still inferior
compared to the Yeoh model.
On the left, you see the result for an Ogden
model, which gives also reasonable results for
the test data!

Suggestions
Take advantage of 2-D geometry where possible
Use contact-sizing mesh control

Invests more elements where required
(e.g. sliding contact region)
Available through drag and drop
Avoid sharp corners at contact surfaces

This may be the
source for too-much
penetration

Suggestions Contd
Rigid body motion
Rigid Body Motion

Sometimes, the parts in a contact model are not uniquely constrained.
The parts are not in contact (gap) [fig. a]
The initial penetration is too high; this will lead to a very high
contact force [fig. b]
Friction force is too small compared to the external force [fig. c]
F
F F
F
<F
a b c
Suggestions Contd
How to avoid the rigid body motion

Use reasonable boundary condition,
e.g., use 2 load steps, load step 1 to move the body together and then apply
the load
Use weak springs if possible, to avoid numerical noise F
This adds stability to the solution, reduces chatter
Add a small friction to avoid the numeric instability
Use displacement loading instead of force (This imposed displacement
moves the body and as a result you will get a reaction force.)
Use artificial adjustment to close the contact
With initial gap geometric penetration artificial

penetration or close gap
Suggestions Contd...
Contact tools to check initial contact status or CNCHECK

command

Convergence (nonlinear analysis)
If solutions do not converge, you should check/try

NOTE:
the message error in element formulation just means no
error detected in solution but it does not converge. It is most
often a symptom of other difficulties. It could be any of the
following:
Deformation limit problems

Is the deformation limit met?
Is the deformation practical?
(e.g., sharp corner contacts with a surface?)
Are the material properties defined at the current strain level?

Convergence (cont.)
Element technologies/formulations
Is volumetric locking a possibility?
If yes, is appropriate element technology used?
Is shear locking possible?
If yes, is enhanced strain formulation used or uniform reduced
integration is used with a lower order element? (with refined
meshes)
Is material fully incompressible?
If yes, mixed u-P has to be used. Is solution of the problem
not unique? Use = 0.4995 instead of 0.5
Is mixed u-P used in the model?
If yes, is the correct solver (sparse or front) used? Is model
over-constrained?

Convergence (cont.)
Step length (Number of substeps)

Is the allowed minimum step length still too big? Check
the displacement/strain/force changes in the sub-step
Solution tools
Is problem stable? If no, try the arc-length method

Examples

Rockwell Automation
Hyper-Elastic finite element analysis capabilities within the ANSYS

program, allow engineers to rapidly evaluate and optimize complex
non-linear material and contact behavior of rubber diaphragm seals
prior to fabrication of costly proto-types and tooling.
Hyper-Elastic Contact Analysis of a Push-Button Diaphragm Seal
Jeffrey R. Annis
Rockwell Automation- Allen Bradley

Final thoughts
Test the material model before analysis

A poor material model will cause problems while running your
simulation. And you might get results which are erroneous and you
will not even know it.
Take advantage of the Advanced Nonlinearities class
offered by your local ANSYS sales office
Other Resources
ANSYS Customer Support
Customer Portal Sample Models
Ansys.net
Axel Products Datapoint Labs
Materiality
PolymerFEM.com
XANSYS.org Hyperelastic Biaxial Testing
Materials Testing, Database
ANSYS Enterprise Solution Partner
Testing and Analysis of Elastomers for Users of ANSYS

www.axelproducts.com
siddharth.shah@ansys.com
pierre.thieffry@ansys.com
Thank
You

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ANSYS Webinar

2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

Seals and ANSYS tools ~ 40 min

2008 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

O-rings Body seal

Boot seal Bushing

Automotive (Gaskets, Hoses, compressor valves etc.)

determining the viability of a new material,

2008 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

Elastomers - also know as Hyperelastic materials exhibit the

2008 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

USERMAT - User Programmed

2008 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

Many material models available

The choice will depend on:

In general, the best material model is the one that

Collected data may need to be adjusted to account for

Note that hysteresis is present. Stress- 1.4

softening effects (such as Mullins effect) are 1.2

A stabilized curve needs to be chosen: 0.6

1) Loading or unloading path

Mullins effect material model to be available

2008 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

ANSYS supports curve fitting for

2008 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

Neo-Hookean model is most simple and a good way to start.

Arruda-Boyce and Gent models can be thought of as extensions of Yeoh,

Ogden is based on principal stretches, usually provide much better curve

For compressible polyurethane foam-type rubbers, Blatz-Ko is suitable. Other

2008 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

Model Deflections Gasket Pressure

2008 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

2008 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary

Node-Node; Node-Surface; Surface-Surface; Line-Line Contact

2008 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

Pure Penalty Augmented Lagrange Normal Lagrange MPC

2008 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

Modeling of fluid penetrating into the interface between two

2008 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

Convergence Enhancement Convergence and Results Tracker

Valuable for knowing how

Available for each contact

2008 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary

Troubleshoot unconverged nonlinear solutions with the

2008 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

Instabilities in nonlinear analysis

Mainly for nonlinear analysis with

2008 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

To demonstrate the Curve Fitting capabilities in ANSYS,

2008 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

ANSYS expects in the curve fitting procedure

Experimental Data Treloar

2008 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

ANSYS allows the data import in Engineering Data by

2. C&P the data in the test data sheet

2008 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary

Go to the chosen material model sheet. For the

Your error norms can be either

2008 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary

Results for different Mooney-Rivlin models:

2-Term 3-Term 5-Term

Material instabilities M-R M-R

9-Term It can be seen, that the 2- and 9-Term

2008 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary