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2-way FEM-DEM coupling – Ansys Mechanical and Rocky – High plastic deformation

    • fatima.ferreira
      Subscriber

      I have to do a ring test compression simulation with granulates on it. I want to do a 2-way FEM-DEM coupling using Ansys Mechanical for the ring deformation part and Rocky for the granulates. It should be a 2-way coupling, as the inner pressure produce in the granulate is affecting the deformation of the ring, and the ring being compressed as well is affecting the granulates. The ring is going through a big plastic deformation.

      I was using version 23.2 and I wanted to use the System Coupling GUI. After seeing the tutorial “Ansys Rocky: 2-Way Structural Coupling with Mechanical”, I realized I couldn’t save the .scp file in rocky so I update it to the last version. Reading the manual, I have seen this:
      Limitations:

      The coupled walls cannot have:

      • Motion Frame

      • Translation

      • Rotation

      • Mass tab

      • Wear tab

      • Replication tab

      Seeing the potential applications in the mentioned video, most of them are restricted to elastic deformation. My question is, is the coupling between Rocky and Ansys Mechanical through the System Coupling possible when large plastic deformations are involved?

      Thanks in advance!

    • Jackson Gomes
      Ansys Employee

      Dear Fatima,

      Applications involving plastic deformations can be solved by the 2-way Rocky-Mechanical (DEM/FEA) coupling, and for large deformations, more care must be taken in the Mechanical time-step, aiming to increase the number of steps so that this large deformation has enough time to be solved by the FEA solver (avoiding problems of large deformations in short spaces of time, due to the forces coming from Rocky).

      Regards.

    • fatima.ferreira
      Subscriber

      Hi, 

      Thanks for your answer. I would like to know if there is a way to get the .scp file or a similar file containing the coupling information from Rocky from the version 23.2.

      Regards.

    • Jackson Gomes
      Ansys Employee

      In Rocky 2023 R2, there is no direct way to export a .scp file for System Coupling. That feature was introduced in later versions. For coupling setup in 2023 R2, you must launch the simulation via System Coupling, which starts Rocky in setup mode and handles communication directly.

    • fatima.ferreira
      Subscriber

      Hi,

      After almost 6 weeks of trying to do the co-simulation between Ansys Transient Mechanical and Rocky through the System Coupling GUI, and having encountered several errors and warning leading to the coupling unexpectedly to end, I got to 100% but with no good results.

      I need to simulate a ring compression test with granulates in it. The goal is to analyze the punch reaction force with the granulates, as well as the pression distribution in the granulates and the ring strains and stresses. The ring is deforming the most, I assigned a suitable flow curve to it. To reduce simulation time, my setting now is half of the ring/container depth. Simulation time is 3 seconds, initial time step is 0.001 seconds.

      ROCKY SIDE

      • I create the Rocky file in the same workbench I had the transient mechanical and geometry file.  When I import the geometry to Rocky, it is importing the 3 elements (container, punch, ring) as a one element to Rocky.
      •  I already increased the particle sized (doubled), diminish the Young’s Modulus of the particle and used coarse graining for a faster simulation.
      • In the last run, I reduced the friction coefficients between the particles and particles/boundary geometries. No adhesive contact forces.
      • I need to fill the inner part of the ring with 30 gr of the granulates. I used volumetric inlet, as it seemed to be the most suitable option as there is not inlet/outlet (the particles are just inside the ring at the beginning, see image "1"). However, as ring is deforming, the shape of the particles volume is only adapting to the new ring form in the upper part. The bottom part of the granulates volume is not “loose” and is not adapting to the form of the ring’s bottom part, like if they were sticked and gravity is not there (image "2"). I checked the gravity and is configurated in the -Z direction. 
      • I tried to do a particle inlet first for some seconds, to fill the ring with them, but when I am trying to adjust the injection time, the error “N particles had their release time delayed by X due to an overlap detection on inlet" appears. I tried changing the injection waiting period, but it has not worked.

       

      PAST ERRORS

      For some context, the most common frequent abort cause was the “Highly Distorted Elements” error, mostly affected the ring geometry. Also had a lot of overconstraint, abrupt contact status change and rigid body motion warning.  I tried to changed punch to flexible, decreased time step, improved mesh quality, adding missing constraints, adjusted remote point location, enabled stiffness relaxation, in between others.

       

      SYSTEM COUPLING COMMENTS

      • The system coupling region in Mechanical is limited to the inner part of the ring. 
      • I tried to decrease the relaxation value (Force to Mechanical), but also did not help.

       

      QUESTIONS:

      So my concrete questions for now are:

      •           Should I somehow consider a particle inlet to avoid this behavior of the granulates while the ring is deforming? Or there is other parameter that may be affecting this behavior of the granulates area?
      • I could not do a screenshot of the granulates/ring/container setup in EnSight, that`s why the images you are seeing are from Rocky. Is there a way to see the complete simulation (ring/granulates, with transparent container) in Ensight?
      • How can I see the results of the reaction force of the punch in EnSight? Or I should import the results of the coupling in Mechanical?
      •  Why are peaks appearing in the outer ring element in Rocky? As I understood, the mesh in Rocky is not necessary the same as Mechanical.

      I would appreciate your response, as the coupling is still not giving the expected results.

      Best regards.

       

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