WorkBench Mechanical bending simulation

- March 10, 2020 at 5:05 pm
  
  Han-yu
  Subscriber
  
  Hi:
  
  I had some trouble during workbench mechanical simulation.
  
  I tried to push one connector from one side and make it join with another one and observed0 the maximum stress happened positions.
  
  Yet the simulation can't provide good simulation results.
  
  Seems the simulation isn't completed.
  
  Could someone help me figure out how to correct it??
- March 11, 2020 at 9:16 am
  Aniket
  Forum Moderator
  - Please check the solve.out file that is available in the project directory.
  - open it in a text editor.
  - Search for "Error".
  - Now copy-paste that error message and search on this forum.
  - If you do not find any useful posts for the said error, please post it here in replies.
  -Aniket
  
  Guidelines on the Student Community
  
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- March 12, 2020 at 7:59 am
  
  Aniket
  Forum Moderator
  
  There doesn't seem any error. only one warning as follows:
  
  The maximum friction coefficient 0.4 is defined in the model. Switch to the unsymmetric solver (NROP,UNSYM) instead if convergence difficulty is encountered
  
  Have you switched to Newton-Raphson option under Nonlinear controls in analysis settings to unsymmetric and retried?
  
  -Aniket
  
  Guidelines on the Student Community
  
  How to access ANSYS help links
- March 12, 2020 at 4:14 pm
  
  Han-yu
  Subscriber
  
  Hi:
  
  Could you show me how to switch to the unsymmetric solver and other solvers?
  
  Thank you
- March 13, 2020 at 7:11 am
  
  Aniket
  Forum Moderator
- March 13, 2020 at 5:49 pm
  
  Han-yu
  Subscriber
  
  Hi:
  
  I tried the setting you suggested but still shows error during simulation and give me a different result.
  
  The solve.out message shows as below.
  
  Could you help me take a look?
  
  Thank you
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
- March 13, 2020 at 7:18 pm
  
  Aniket
  Forum Moderator
  
  please refrain from posting the entire solve.out file for the sake of readability of the thread. you can always search for the errors in the solve.out file and paste them here.
  
  you are seeing multiple element distortion errors. As mentioned in the error:
  
  "Excessive distortion of elements is usually a symptom indicating the need for corrective action elsewhere. Try incrementing the load more slowly (increase the number of substeps or decrease the time step size). You may need to improve your mesh to obtain elements with better aspect ratios. Also consider the behavior of materials, contact pairs, and/or constraint equations. If this message appears in the first iteration of first substep, be sure to perform element shape checking."
  
  -Aniket
  
  Guidelines on the Student Community
  
  How to access ANSYS help links
- March 13, 2020 at 7:59 pm
  
  Han-yu
  Subscriber
  
  Hi:
  
  These are all five error messages I can find in the solve.out file.
  
  Please take a look at them.
  
  Thank you
  
  *** ERROR *** CP = 512.594 TIME= 13:16:07
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
  
  *** LOAD STEP 1 SUBSTEP 4 NOT COMPLETED. CUM ITER = 8
  
  *** BEGIN BISECTION NUMBER 1 NEW TIME INCREMENT= 0.10500
  
  FORCE CONVERGENCE VALUE = 0.8917E-09 CRITERION= 0.5102E-04
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  DISP CONVERGENCE VALUE = 0.3994E-10 CRITERION= 0.4500E-03 <<< CONVERGED
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.3994E-10
  
  DISP CONVERGENCE VALUE = 0.3994E-10 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.3994E-10
  
  FORCE CONVERGENCE VALUE = 0.1056E-09 CRITERION= 0.5206E-04 <<< CONVERGED
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.3445E-11
  
  DISP CONVERGENCE VALUE = 0.3445E-11 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.3445E-11
  
  >>> SOLUTION CONVERGED AFTER EQUILIBRIUM ITERATION 2
  
  *** LOAD STEP 1 SUBSTEP 4 COMPLETED. CUM ITER = 9
  
  *** TIME = 0.805000 TIME INC = 0.105000
  
  *** AUTO STEP TIME: NEXT TIME INC = 0.10500 UNCHANGED
  
  FORCE CONVERGENCE VALUE = 0.4132E-09 CRITERION= 0.5102E-04
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  DISP CONVERGENCE VALUE = 0.8678E-10 CRITERION= 0.4500E-03 <<< CONVERGED
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.8678E-10
  
  DISP CONVERGENCE VALUE = 0.8678E-10 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = 0.8678E-10
  
  FORCE CONVERGENCE VALUE = 0.4113E-10 CRITERION= 0.5206E-04 <<< CONVERGED
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.1616E-15
  
  DISP CONVERGENCE VALUE = 0.1616E-15 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.1616E-15
  
  >>> SOLUTION CONVERGED AFTER EQUILIBRIUM ITERATION 2
  
  *** LOAD STEP 1 SUBSTEP 5 COMPLETED. CUM ITER = 11
  
  *** TIME = 0.910000 TIME INC = 0.105000
  
  *** AUTO TIME STEP: NEXT TIME INC = 0.90000E-01 DECREASED (FACTOR = 0.8571)
  
  *** ERROR *** CP = 927.938 TIME= 13:203
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
  
  *** LOAD STEP 1 SUBSTEP 6 NOT COMPLETED. CUM ITER = 13
  
  *** BEGIN BISECTION NUMBER 1 NEW TIME INCREMENT= 0.31500E-01
  
  FORCE CONVERGENCE VALUE = 2.620 CRITERION= 0.5102E-04
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  DISP CONVERGENCE VALUE = 0.7714E-03 CRITERION= 0.4500E-03
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.7714E-03
  
  *** WARNING *** CP = 1005.609 TIME= 13:21:27
  
  Contact element 88391 (real ID 5) status changes abruptly from
  
  no-contact -> contact (with target element 100561).
  
  *** ERROR *** CP = 1179.500 TIME= 13:23:19
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
  
  *** LOAD STEP 1 SUBSTEP 6 NOT COMPLETED. CUM ITER = 16
  
  *** BEGIN BISECTION NUMBER 2 NEW TIME INCREMENT= 0.11025E-01
  
  FORCE CONVERGENCE VALUE = 0.2641E-10 CRITERION= 0.5102E-04
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  DISP CONVERGENCE VALUE = 0.4556E-11 CRITERION= 0.4500E-03 <<< CONVERGED
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.4556E-11
  
  DISP CONVERGENCE VALUE = 0.4556E-11 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.4556E-11
  
  FORCE CONVERGENCE VALUE = 0.1400E-09 CRITERION= 0.5206E-04 <<< CONVERGED
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.1801E-15
  
  DISP CONVERGENCE VALUE = 0.1801E-15 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.1801E-15
  
  >>> SOLUTION CONVERGED AFTER EQUILIBRIUM ITERATION 2
  
  *** LOAD STEP 1 SUBSTEP 6 COMPLETED. CUM ITER = 17
  
  *** TIME = 0.921025 TIME INC = 0.110250E-01
  
  *** AUTO STEP TIME: NEXT TIME INC = 0.11025E-01 UNCHANGED
  
  FORCE CONVERGENCE VALUE = 0.5026 CRITERION= 0.5102E-04
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  DISP CONVERGENCE VALUE = 0.3179E-03 CRITERION= 0.4500E-03 <<< CONVERGED
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.3179E-03
  
  DISP CONVERGENCE VALUE = 0.2981E-03 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.9377 SCALED MAX DOF INC = 0.2981E-03
  
  FORCE CONVERGENCE VALUE = 0.7427E-01 CRITERION= 0.1526E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.8920E-04
  
  DISP CONVERGENCE VALUE = 0.8920E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = 0.8920E-04
  
  FORCE CONVERGENCE VALUE = 0.1497E-01 CRITERION= 0.2589E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  EQUIL ITER 3 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.9531E-04
  
  DISP CONVERGENCE VALUE = 0.9185E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.9638 SCALED MAX DOF INC = 0.9185E-04
  
  FORCE CONVERGENCE VALUE = 0.5587E-02 CRITERION= 0.2937E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  EQUIL ITER 4 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.1040E-04
  
  *** ERROR *** CP = 2091.031 TIME= 133:13
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
  
  *** LOAD STEP 1 SUBSTEP 8 NOT COMPLETED. CUM ITER = 27
  
  *** BEGIN BISECTION NUMBER 1 NEW TIME INCREMENT= 0.50000E-02
  
  FORCE CONVERGENCE VALUE = 0.8733 CRITERION= 0.4027E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  DISP CONVERGENCE VALUE = 0.2505E-03 CRITERION= 0.4500E-03 <<< CONVERGED
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.2505E-03
  
  DISP CONVERGENCE VALUE = 0.2339E-03 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.9339 SCALED MAX DOF INC = -0.2339E-03
  
  FORCE CONVERGENCE VALUE = 0.7942E-01 CRITERION= 0.4068E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.1469E-03
  
  DISP CONVERGENCE VALUE = 0.1053E-03 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.7169 SCALED MAX DOF INC = 0.1053E-03
  
  FORCE CONVERGENCE VALUE = 0.1934E-01 CRITERION= 0.4779E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  EQUIL ITER 3 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.5366E-04
  
  DISP CONVERGENCE VALUE = 0.5024E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.9363 SCALED MAX DOF INC = -0.5024E-04
  
  FORCE CONVERGENCE VALUE = 0.8178E-02 CRITERION= 0.5418E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  EQUIL ITER 4 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.1823E-04
  
  DISP CONVERGENCE VALUE = 0.1381E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.7575 SCALED MAX DOF INC = -0.1381E-04
  
  FORCE CONVERGENCE VALUE = 0.2027E-02 CRITERION= 0.5581E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  EQUIL ITER 5 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.2380E-04
  
  DISP CONVERGENCE VALUE = 0.1969E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.8272 SCALED MAX DOF INC = -0.1969E-04
  
  FORCE CONVERGENCE VALUE = 0.8998E-03 CRITERION= 0.5710E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  EQUIL ITER 6 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.1329E-04
  
  DISP CONVERGENCE VALUE = 0.1083E-04 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 0.8150 SCALED MAX DOF INC = -0.1083E-04
  
  FORCE CONVERGENCE VALUE = 0.2793E-03 CRITERION= 0.5833E-03 <<< CONVERGED
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  EQUIL ITER 7 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.3673E-05
  
  DISP CONVERGENCE VALUE = 0.3673E-05 CRITERION= 0.4500E-03 <<< CONVERGED
  
  LINE SEARCH PARAMETER = 1.000 SCALED MAX DOF INC = -0.3673E-05
  
  >>> SOLUTION CONVERGED AFTER EQUILIBRIUM ITERATION 7
  
  *** LOAD STEP 1 SUBSTEP 8 COMPLETED. CUM ITER = 33
  
  *** TIME = 0.937050 TIME INC = 0.500000E-02
  
  *** AUTO STEP TIME: NEXT TIME INC = 0.50000E-02 UNCHANGED
  
  FORCE CONVERGENCE VALUE = 0.5320 CRITERION= 0.7817E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr002
  
  DISP CONVERGENCE VALUE = 0.7041E-03 CRITERION= 0.4500E-03
  
  EQUIL ITER 1 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.7041E-03
  
  DISP CONVERGENCE VALUE = 0.5241E-03 CRITERION= 0.4500E-03
  
  LINE SEARCH PARAMETER = 0.7443 SCALED MAX DOF INC = 0.5241E-03
  
  FORCE CONVERGENCE VALUE = 0.2403 CRITERION= 0.8919E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr003
  
  EQUIL ITER 2 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= -0.6893E-03
  
  DISP CONVERGENCE VALUE = 0.5487E-03 CRITERION= 0.4500E-03
  
  LINE SEARCH PARAMETER = 0.7959 SCALED MAX DOF INC = -0.5487E-03
  
  FORCE CONVERGENCE VALUE = 0.9248E-01 CRITERION= 0.9387E-03
  
  Writing NEWTON-RAPHSON residual forces to file: file.nr001
  
  EQUIL ITER 3 COMPLETED. NEW TRIANG MATRIX. MAX DOF INC= 0.1319E-02
  
  *** ERROR *** CP = 3074.062 TIME= 13:43:54
  
  Element 47329 (type = 4, SOLID187) (and maybe other elements) has
  
  become highly distorted. Excessive distortion of elements is usually
  
  a symptom indicating the need for corrective action elsewhere. Try
  
  incrementing the load more slowly (increase the number of substeps or
  
  decrease the time step size). You may need to improve your mesh to
  
  obtain elements with better aspect ratios. Also consider the behavior
  
  of materials, contact pairs, and/or constraint equations. If this
  
  message appears in the first iteration of first substep, be sure to
  
  perform element shape checking.
  
  
  
  *************************************************
  
  SUMMARY FOR CONTACT PAIR IDENTIFIED BY REAL CONSTANT SET 5
  
  Max. Penetration of -4.977825129E-03 has been detected between contact
  
  element 86809 and target element 97908.
  
  *WARNING*: The geometrical penetration may be too large. Increase
  
  pinball if it is a true geometrical penetration. Decrease pinball if
  
  it is a false one.
  
  For total 16680 contact elements, there are 508 elements are in
  
  contact.
  
  Contacting area 7.624716095E-04.
  
  4 contact points have abrupt change in contact status.
  
  Contact element 86954 has the highest number of status changes (total
  
  5) during this substep.
  
  Max. Total sliding distance 3.149999985E-02.
  
  Max. Pinball distance 5.E-03.
  
  One of the contact searching regions contains at least 442 target
  
  elements.
- March 14, 2020 at 2:20 am
  
  Aniket
  Forum Moderator
  
  please refrain from posting the entire solve.out file for the sake of readability of the thread. you can always search for the errors in the solve.out file and paste them here.
  
  you are seeing multiple element distortion errors. As mentioned in the error:
  
  "Excessive distortion of elements is usually a symptom indicating the need for corrective action elsewhere. Try incrementing the load more slowly (increase the number of substeps or decrease the time step size). You may need to improve your mesh to obtain elements with better aspect ratios. Also consider the behavior of materials, contact pairs, and/or constraint equations. If this message appears in the first iteration of first substep, be sure to perform element shape checking."
  
  -Aniket
  
  Guidelines on the Student Community
  
  How to access ANSYS help links
  
  Did you try with more substeps? with improved mesh?
- March 14, 2020 at 2:32 am
  
  Han-yu
  Subscriber
  
  Hi:
  
  I am not quite sure how to do it, could you guide me on how to do it?
  
  The first step is to make the mesh smaller?
  
  Or move two parts closer at beginning?
  
  Thank you.
- March 18, 2020 at 3:46 pm
  
  Aniket
  Forum Moderator
  
  please check mesh settings and analysis settings for these options.
  
  https://ansyshelp.ansys.com/account/Secured?returnurl=/Views/Secured/corp/v195/wb_sim/ds_Apply_Mesh_Controls_step.html
  
  https://ansyshelp.ansys.com/account/Secured?returnurl=/Views/Secured/corp/v195/wb_sim/ds_establish_analysis_settings.html
  
  -Aniket
  
  Guidelines on the Student Community
  
  How to access ANSYS help links