ANSYS continued problem with running simulations using user-defined subroutines

- February 28, 2024 at 11:54 pm
  
  mer153
  Subscriber
  
  Hello,
  I am currently facing an issue with using USERMAT in ANSYS 2024 and would greatly appreciate any assistance in resolving it.
  Previously, I successfully utilized ANSYS 2022 on my laptop to define a user-defined material model for ANSYS through its USERMAT subroutine. This enabled me to conduct simulations and validate results against analytical solutions seamlessly. However, upon transitioning to our lab workstation for larger-scale simulations, I encountered difficulties. Despite my efforts, I consistently received the following error message from ANSYS Mechanical:
  
  *** ERROR ***                           CP =       1.094   TIME= 18:27:03
  The L-2 norm of the residual force overflowed. This may be caused by
  PRED,ON or birth/dead elements. Please use PRED,OFF and try again.
  
  Seeking a resolution, I had the opportunity to engage in a virtual meeting with an ANSYS expert through my supervisor's connections. Despite their dedicated efforts, we couldn't find any solution. As a workaround, I attempted to conduct simulations on alternative lab PCs, which fortunately did not exhibit the same issue.
  After that, I continued using ANSYS 2022 until recently, when I encountered a new challenge where the application started crashing without saving results upon clicking the solution tab post-simulation. Despite searching the entire ANSYS forum, I couldn't find any solution for this problem. So, I decided to upgrade to ANSYS 2024.
  While the upgrade resolved the crashing issue, I now encounter the same problem with running simulations that implement USERMAT. This time all lab PCs have that "L-2 norm error" issue. The solution panel does not display the number of equations.
  Any assistance in resolving this predicament would be immensely appreciated.
  Best Regards,
- February 29, 2024 at 12:43 pm
  
  Avnish Pandey
  Ansys Employee
  
  Hi,
  
  Try checking these links if they help you. It seems like some stabilization or convergence issue to me.
  /forum/forums/topic/i-get-different-results-when-running-the-same-model-on-different-computers/
  https://ansyshelp.ansys.com/account/secured?returnurl=/Views/Secured/corp/v232/en/ans_str/Hlp_G_STR8_13.html
  https://ansyshelp.ansys.com/account/secured?returnurl=/Views/Secured/corp/v232/en/ans_str/Hlp_G_STRUNST.html
  
  Regards,
  - February 29, 2024 at 12:50 pm
    
    mer153
    Subscriber
    
    Thank you for your response.
    The evidence below shows that this issue has nothing to do with the problem setup:
    
    1- The simulations runs without any issue on ANSYS 2022.
    2- I had the same issue with running the simulations using ANSYS 2022 on a specific machine but not on all of them. The problem characteristic I am considering here is that this L-2 norm error appears in the simulation log right before displaying the number of equations. As I wrote in my previous post, when one of your professional colleagues investigated the issue himself, he was completely confused about why ANSYS does not print the number of equations in the output log.
    
    As your colleague mentioned previously, this raises concerns regarding the machine-dependence of the problem.
- March 1, 2024 at 5:35 pm
  
  mer153
  Subscriber
  
  I am copying the solution log here to provide more information about the discussed issue. As you can see here the error appears right before when the solver is supposed to display the number of equations. The simulation consists of a simple cube that is constrained by inserting a fixed support on one of its surfaces and then stretched uniaxially by applying a force to another surface. Using a displacement boundary condition, the surface that has a force applied to it, can only move in the direction of the force vector (all other DOFs are restrained).
  
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  SINGLE PROCESS WITH 8 THREADS REQUESTED
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  INPUT FILE NAME = C:\Users\MRA\Documents\Project\CFGenerator\Anisotropic\_ProjectScratch\Scr1FD1\dummy.dat
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  TITLE=
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  PARAMETER _WB_USERFILES_DIR(1) = C:\Users\MRA\Documents\Project\CFGenerator\Anisotropic\anisotropic_samples_files\user_files\
  — Data in consistent MKS units. See Solving Units in the help system for more
  
  MKS UNITS SPECIFIED FOR INTERNAL
  LENGTH (l) = METER (M)
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  TIME (t) = SECOND (SEC)
  TEMPERATURE (T) = CELSIUS (C)
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  INPUT UNITS ARE ALSO SET TO MKS
  
  *** MAPDL – ENGINEERING ANALYSIS SYSTEM RELEASE 2024 R1 24.1 ***
  Ansys Mechanical Enterprise Academic Research
  00601254 VERSION=WINDOWS x64 12:29:48 MAR 01, 2024 CP= 0.062
  
  anisotropic_samples–Transient (AE5)
  
  Note – This MAPDL version was linked by Licensee
  
  ***** MAPDL ANALYSIS DEFINITION (PREP7) *****
  *********** Nodes for the whole assembly ***********
  *********** Nodes for all Remote Points ***********
  *********** Elements for Body 1 “Solid” ***********
  *********** Send User Defined Coordinate System(s) ***********
  *********** Send Element Orientation **********
  Sending Element Orientation Object: “Element Orientation”
  *********** Set Reference Temperature ***********
  *********** Send Materials ***********
  *********** Fixed Supports ***********
  ******* Constant Zero Displacement X *******
  ******* Constant Zero Displacement Z *******
  *********** Define Force Using Surface Effect Elements ***********
  
  ***** ROUTINE COMPLETED ***** CP = 0.516
  
  — Number of total nodes = 8805
  — Number of contact elements = 20
  — Number of spring elements = 0
  — Number of bearing elements = 0
  — Number of solid elements = 1200
  — Number of condensed parts = 0
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  *GET _WALLBSOL FROM ACTI ITEM=TIME WALL VALUE= 12.4966667
  ****************************************************************************
  ************************* SOLUTION ********************************
  ****************************************************************************
  
  ***** MAPDL SOLUTION ROUTINE *****
  
  PERFORM A TRANSIENT ANALYSIS
  THIS WILL BE A NEW ANALYSIS
  
  LARGE DEFORMATION ANALYSIS
  
  STEP BOUNDARY CONDITION KEY= 1
  
  PARAMETER _THICKRATIO = 0.000000000
  
  USE PRECONDITIONED CONJUGATE GRADIENT SOLVER
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  PERFORM A FULL TRANSIENT ANALYSIS
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  USE SETTINGS FOR MODERATE SPEED DYNAMIC APPLICATIONS
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  DELETE RESTART FILES OF ENDSTEP
  ****************************************************
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  20 ELEMENTS (OF 1220 DEFINED) SELECTED BY ESEL COMMAND.
  
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  103 NODES (OF 8805 DEFINED) SELECTED FROM
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  1220 ELEMENTS (OF 1220 DEFINED) SELECTED BY ESEL COMMAND.
  
  PRINTOUT RESUMED BY /GOP
  
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  USE 200 SUBSTEPS INITIALLY THIS LOAD STEP FOR ALL DEGREES OF FREEDOM
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  NONLINEAR STABILIZATION CONTROL:
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  *GET ANSINTER_ FROM ACTI ITEM=INT VALUE= 0.00000000
  
  *IF ANSINTER_ ( = 0.00000 ) NE
  0 ( = 0.00000 ) THEN
  
  *ENDIF
  
  ***** MAPDL SOLVE COMMAND *****
  
  *** WARNING *** CP = 0.641 TIME= 12:29:48
  Element shape checking is currently inactive. Issue SHPP,ON or
  SHPP,WARN to reactivate, if desired.
  
  *** NOTE *** CP = 0.750 TIME= 12:29:48
  The model data was checked and warning messages were found.
  Please review output or errors file (
  C:\Users\MRA\Documents\Project\CFGenerator\Anisotropic\_
  _ProjectScratch\Scr1FD1\file.err ) for these warning messages.
  
  *** SELECTION OF ELEMENT TECHNOLOGIES FOR APPLICABLE ELEMENTS ***
  —GIVE SUGGESTIONS ONLY—
  
  ELEMENT TYPE 1 IS SOLID186. KEYOPT(2)=0 IS SUGGESTED.
  
  *** MAPDL – ENGINEERING ANALYSIS SYSTEM RELEASE 2024 R1 24.1 ***
  Ansys Mechanical Enterprise Academic Research
  00601254 VERSION=WINDOWS x64 12:29:48 MAR 01, 2024 CP= 0.750
  
  anisotropic_samples–Transient (AE5)
  
  Note – This MAPDL version was linked by Licensee
  
  S O L U T I O N O P T I O N S
  
  PROBLEM DIMENSIONALITY. . . . . . . . . . . . .3-D
  DEGREES OF FREEDOM. . . . . . UX UY UZ
  ANALYSIS TYPE . . . . . . . . . . . . . . . . .TRANSIENT
  SOLUTION METHOD. . . . . . . . . . . . . . .FULL
  OFFSET TEMPERATURE FROM ABSOLUTE ZERO . . . . . 273.15
  NONLINEAR GEOMETRIC EFFECTS . . . . . . . . . .ON
  EQUATION SOLVER OPTION. . . . . . . . . . . . .PCG
  TOLERANCE. . . . . . . . . . . . . . . . . . 1.00000E-08
  PLASTIC MATERIAL PROPERTIES INCLUDED. . . . . .YES
  NEWTON-RAPHSON OPTION . . . . . . . . . . . . .PROGRAM CHOSEN
  GLOBALLY ASSEMBLED MATRIX . . . . . . . . . . .SYMMETRIC
  
  *** WARNING *** CP = 0.750 TIME= 12:29:48
  Material number 2 (used by element 3765) should normally have at least
  one MP or one TB type command associated with it. Output of energy by
  material may not be available.
  
  *** WARNING *** CP = 0.859 TIME= 12:29:48
  Ansys, Inc.-supplied version of coding for USERCK has been used.
  
  *** NOTE *** CP = 0.859 TIME= 12:29:48
  The step data was checked and warning messages were found.
  Please review output or errors file (
  C:\Users\MRA\Documents\Project\CFGenerator\Anisotropic\_
  _ProjectScratch\Scr1FD1\file.err ) for these warning messages.
  
  *** NOTE *** CP = 0.859 TIME= 12:29:48
  This nonlinear analysis defaults to using the full Newton-Raphson
  solution procedure. This can be modified using the NROPT command.
  
  *** NOTE *** CP = 0.859 TIME= 12:29:48
  The conditions for direct assembly have been met. No .emat or .erot
  files will be produced.
  
  L O A D S T E P O P T I O N S
  
  LOAD STEP NUMBER. . . . . . . . . . . . . . . . 1
  TIME AT END OF THE LOAD STEP. . . . . . . . . . 200.00
  NUMBER OF SUBSTEPS. . . . . . . . . . . . . . . 200
  MAXIMUM NUMBER OF EQUILIBRIUM ITERATIONS. . . . 15
  STEP CHANGE BOUNDARY CONDITIONS . . . . . . . . YES
  STRESS-STIFFENING . . . . . . . . . . . . . . . ON
  TRANSIENT (INERTIA) EFFECTS
  STRUCTURAL DOFS. . . . . . . . . . . . . . . ON
  TRANSIENT INTEGRATION PARAMETERS
  GAMMA. . . . . . . . . . . . . . . . . . . . 0.10000
  ALPHA. . . . . . . . . . . . . . . . . . . . 0.30250
  DELTA. . . . . . . . . . . . . . . . . . . . 0.60000
  USING HHT TIME INTEGRATION
  ALPHAF . . . . . . . . . . . . . . . . . . . 0.10000
  ALPHAM . . . . . . . . . . . . . . . . . . . 0.0000
  TERMINATE ANALYSIS IF NOT CONVERGED . . . . . .YES (EXIT)
  CONVERGENCE CONTROLS. . . . . . . . . . . . . .USE DEFAULTS
  COPY INTEGRATION POINT VALUES TO NODE . . . . .YES, FOR ELEMENTS WITH
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  PRINT OUTPUT CONTROLS . . . . . . . . . . . . .NO PRINTOUT
  DATABASE OUTPUT CONTROLS
  ITEM FREQUENCY COMPONENT
  ALL NONE
  NSOL ALL
  RSOL ALL
  EANG ALL
  ETMP ALL
  VENG ALL
  STRS ALL
  BKST ALL
  EPEL ALL
  EPPL ALL
  CONT ALL
  NLDA ALL
  V ALL
  A ALL
  
  SOLUTION MONITORING INFO IS WRITTEN TO FILE= file.mntr
  MAXIMUM NUMBER OF EQUILIBRIUM ITERATIONS HAS BEEN MODIFIED
  TO BE, NEQIT = 22, BY SOLUTION CONTROL LOGIC.
  
  *** NOTE *** CP = 1.453 TIME= 12:29:49
  The PCG solver has automatically set the level of difficulty for this
  model to 2.
  
  *********** PRECISE MASS SUMMARY ***********
  
  TOTAL RIGID BODY MASS MATRIX ABOUT ORIGIN
  Translational mass | Coupled translational/rotational mass
  0.11775E-03 0.0000 0.0000 | 0.0000 0.17663E-06 -0.58875E-06
  0.0000 0.11775E-03 0.0000 | -0.17663E-06 0.0000 0.29438E-07
  0.0000 0.0000 0.11775E-03 | 0.58875E-06 -0.29438E-07 0.0000
  —————————————— | ——————————————
  | Rotational mass (inertia)
  | 0.42783E-08 -0.14719E-09 -0.44156E-10
  | -0.14719E-09 0.36306E-09 -0.88313E-09
  | -0.44156E-10 -0.88313E-09 0.39348E-08
  
  TOTAL MASS = 0.11775E-03
  The mass principal axes coincide with the global Cartesian axes
  
  CENTER OF MASS (X,Y,Z)= 0.25000E-03 0.50000E-02 0.15000E-02
  
  TOTAL INERTIA ABOUT CENTER OF MASS
  0.10696E-08 0.67761E-24 0.20231E-24
  0.67761E-24 0.90766E-10 -0.77259E-24
  0.20231E-24 -0.77259E-24 0.98370E-09
  The inertia principal axes coincide with the global Cartesian axes
  
  *** MASS SUMMARY BY ELEMENT TYPE ***
  
  TYPE MASS
  1 0.117750E-03
  
  *** ELEMENT MATRIX FORMULATION TIMES
  TYPE NUMBER ENAME TOTAL CP AVE CP
  
  1 1200 SOLID186 3.875 0.003229
  2 20 SURF154 0.000 0.000000
  Time at end of element matrix formulation CP = 2.421875.
  
  ALL CURRENT MAPDL DATA WRITTEN TO FILE NAME= file.rdb
  FOR POSSIBLE RESUME FROM THIS POINT
  FORCE CONVERGENCE VALUE = NaN CRITERION= NaN
  
  *** ERROR *** CP = 2.672 TIME= 12:29:49
  The L-2 norm of the residual force overflowed. This may be caused by
  PRED,ON or birth/dead elements. Please use PRED,OFF and try again.
  
  R E S T A R T I N F O R M A T I O N
  
  REASON FOR TERMINATION. . . . . . . . . .DOF LIMIT EXCEEDED
  RESTART BY RE-RUNNING THE ANALYSIS
  
  ALL CURRENT MAPDL DATA WRITTEN TO FILE NAME= file.db
  FOR POSSIBLE RESUME FROM THIS POINT
  
  NUMBER OF WARNING MESSAGES ENCOUNTERED= 3
  NUMBER OF ERROR MESSAGES ENCOUNTERED= 1
  
  ***** PROBLEM TERMINATED BY INDICATED ERROR(S) OR BY END OF INPUT DATA *****
  
  +——————— M A P D L S T A T I S T I C S ————————+
  
  Release: 2024 R1 Build: 24.1 Update: UP20231106 Platform: WINDOWS x64
  Date Run: 03/01/2024 Time: 12:29 Process ID: 17428
  Operating System: Windows 10 (Build: 19045)
  
  Processor Model: 11th Gen Intel(R) Core(TM) i9-11900H @ 2.50GHz
  
  Compiler: Intel(R) Fortran Compiler Classic Version 2021.9 (Build: 20230302)
  Intel(R) C/C++ Compiler Classic Version 2021.9 (Build: 20230302)
  Intel(R) Math Kernel Library Version 2020.0.0 Product Build 20191125
  BLAS Library supplied by Intel(R) MKL
  
  Number of machines requested : 1
  Total number of cores available : 16
  Number of physical cores available : 8
  Number of processes requested : 1
  Number of threads per process requested : 8
  Total number of cores requested : 8 (Shared Memory Parallel)
  
  GPU Acceleration: Not Requested
  
  Job Name: file
  Input File: dummy.dat
  Working Directory: C:\Users\MRA\Documents\Project\CFGenerator\Anisotropic\_ProjectScratch\Scr1FD1
  
  Total CPU time for main thread : 0.5 seconds
  Total CPU time summed for all threads : 4.9 seconds
  
  Elapsed time spent obtaining a license : 0.5 seconds
  Elapsed time spent pre-processing model (/PREP7) : 0.1 seconds
  Elapsed time spent solution – preprocessing : 0.0 seconds
  Elapsed time spent computing solution : 0.2 seconds
  Elapsed time spent solution – postprocessing : 0.0 seconds
  Elapsed time spent post-processing model (/POST1) : 0.0 seconds
  
  Equation solver used : PCG (symmetric)
  
  Sum of disk space used on all processes : 14.9 MB
  
  Sum of memory used on all processes : 60.0 MB
  Sum of memory allocated on all processes : 2112.0 MB
  Physical memory available : 64 GB
  Total amount of I/O written to disk : 0.0 GB
  Total amount of I/O read from disk : 0.0 GB
  
  +—————— E N D M A P D L S T A T I S T I C S ——————-+
  
  *—————————————————————————–*
  | |
  | RUN COMPLETED |
  | |
  |—————————————————————————–|
  | |
  | Ansys MAPDL 2024 R1 Build 24.1 UP20231106 WINDOWS x64 |
  | |
  |—————————————————————————–|
  | |
  | Database Requested(-db) 1024 MB Scratch Memory Requested 1024 MB |
  | Maximum Database Used 5 MB Maximum Scratch Memory Used 55 MB |
  | |
  |—————————————————————————–|
  | |
  | CP Time (sec) = 4.891 Time = 12:29:50 |
  | Elapsed Time (sec) = 8.000 Date = 03/01/2024 |
  | |
  *—————————————————————————–*
  
  All