The following picture demonstrates what should be visible after importing the tutorial project.
If you are using your own CAD model make sure to follow these instructions:
All solid geometry should be free of any interference, intersecting surfaces, and small edges. Issues such as these should be fixed in CAD before bringing the geometry into the SimScale platform. More specific preparation details are mentioned here.
Before starting to set up the model, check the following:
Please make sure that the imported geometry consists of solid parts and not sheet/surface elements.
If the geometry has small fillets or round faces which are insignificant for the analysis, then it is recommended to remove this geometry in CAD. This will dramatically reduce mesh cell count and therefore solve time.
1.1. Create the Simulation
Hitting the ‘Create Simulation’ button leads to the following options. Choose ‘Static’ as analysis type and click on the new ‘Create Simulation‘ option to get started:
2. Assigning the Simulation Properties
Initially, make sure the ‘Non Linear analysis‘ is toggled on:
2.1. Creating Contacts
SimScale will automatically detect any touching faces within the geometry, but sometimes assignments are needed for faces that SimScale won’t automatically detect. We are adding a bonded contact between the stopper and the pipe.
Click on the ‘+‘ icon next to the Contacts in the simulation tree – this is not the same as a physical contact.
Select the ‘Bonded‘ under the Manual Contact creation.
Change the Position tolerance to ‘Off‘.
Assign the following faces:
Proceed to the Physical Contacts assignment.
Click on the ‘+’ icon next to the Physical Contacts.
Apply ‘1e-12‘ to the Penalty Coefficient.
2.2. Model & Element technology
Leave those two panels as default, and proceed to the Materials.
2.3. Define the Materials
Two different materials are used for this simulation.
The Steel is assigned to the Stopper, the Small roller, and the Large roller:
Finally we need to create Aluminium:
The pipe is modeled as aluminium. The material behavior needs to be changed to plastic, and this csv needs to be imported as the stress-strain data.
Changing the material behavior to plastic allows permanent deformation, where the elastic behavior will cause the body to rebound to its original shape:
2.4. Initial and Boundary conditions.
For this simulation, the initial conditions can be left untouched. Apply a fixed value boundary condition to the small and large roller:
A symmetry plane will be applied to the flat faces of the pipe.
Apply a rotating motion boundary condition to the small roller.
It is rotating around the x-axis, so set the Rotation axis as below.
Then click on the icon next to the Rotation angle:
For a non-linear value of (pi/180)130t rad, set the following formula.
Then confirm your definition by clicking ‘Apply‘.
2.5. Numerics and Simulation Control.
The numerics can be left in their default state. Fill in the simulation control settings as below:
2.6. Result Control
Create additional solution fields for contact pressure and signed von Mises stress
Change the Stress type to ‘Signed von Misses stress’.
Then add a ‘Contact’ the same way, and leave the panel in its’ default state:
Two volume calculations will now be added. The volume calculations will allow to graphically see the stress in the pipe over time.
Change the Field Selection to ‘Stress’.
Select the ‘Von Mises’Stress type.
The Component selection will be automatically changed to ‘Von Misses stress’.
Assign this calculation to the Pipe. Select it from the Geometry tree like before.
Repeat for a ‘Signed von Mises’ Stress type and Component selection.
The standard mesh will be used, and each setting can be left alone.
Three mesh refinements are going to be added.
The first will be a local element sizing on the pipe. To select all the faces, toggle on the face select and the box select options at the top. Hiding the other parts can make it easier to ensure only the desired parts are selected.
The slashed out eye symbol indicates the part is hidden. In this scenario, only the pipe is shown.
The second mesh refinement is another local element size that is applied on the face of the large roller that contacts the aluminum pipe.
The final mesh refinement is a local element size applied on the face of the smaller roller that is in contact with the tube:
The resulting mesh will have about 53.2k nodes and look like this:
4. Start the Simulation
Create a new run by clicking on the ‘+‘ icon next to the Simulation Runs on the simulation tree like below:
Now you can start the simulation and after about 91 minutes you can have a look at the results.
Click on the ‘Solution Fields’ under the finished run in order to be redirected to the Post Processor. Within the results tab, the scalar von Mises stress can be toggled globally.
Also, the displacement should be applied. After 1 second, the displacement of the tube is shown, with the color map of the stress.
Analyze your results with the SimScale post processor. Have a look at our post-processing guide to learn how to use the post-processor. Congratulations! You finished the tutorial!
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