All solid geometry should be free of any interferences, 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 defeature and remove this geometry in CAD. This will dramatically reduce mesh cell count and therefore solve time.
This is a jig used to bend aluminum tubing. It consists of a small and large roller, a stopper, and the aluminum pipe.
Reference project link:
Once the geometry is in the platform, create a new simulation by selecting the “+” icon next to “Simulation”. Select Static for the type of analysis. Make sure to toggle on “Nonlinear analysis”.
The standard mesh will be used, and each setting can be left alone.
We are going to add 3 refinements to the mesh. The first will be a local element sizing on the pipe. To select all the faces, toggle 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:
You can now generate the mesh.
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 going to add a bonded contact between the stopper and the pipe. To add a bonded contact, click the plus next to Contacts in the simulation tree – this is not the same as a physical contact.
After creating the bonded contact, we need to make a physical between the two rollers, and the pipe.
The SimScale platform comes with many default materials. Select steel for the small and large roller, as well as the stopper.
Select Aluminum for the pipe. 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.
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 rotated about the x-axis with a non-linear value of (pi/180)*130*t rad.
Create additional solution fields for contact pressure and signed vonMises stress.
We have also added two volume calculations. The volume calculations will allow us to graphically see the stress in the pipe over time.
The numerics can be left alone.
A few changes need to be made to the simulation control that can be seen here:
Changing the simulation interval to 1 second with a time step length of .05 seconds will give us 20 data points through the simulation. Everything else in the simulation control menu can be left alone.
You are now ready to run the simulation.
Review & Interpretation of Results: 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.
An animation of the entire simulation can also be shown:
For additional post-processing, check out this documentation page.
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