ANSYS Explicit Dynamics 120 Workshop 02

Workshop 2
Simulate the Crushing

of an Empty Soda Can
ANSYS Explicit Dynamics
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.
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Workshop 2. Simulate the Crushing of an Empty Soda Can
Workshop Goal and Procedure
Training Manual
Goal:
Crush an aluminum beverage can and allow it to springback
Procedure:
Create an Explicit Dynamics (ANSYS) Analysis System Project
Select the units system and define the material properties
Import, modify, and mesh the soda can geometry
Define analysis settings, boundary conditions, and external loads
Initiate the solution (AUTODYN - STR) and review the results

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Step 1 Create the Project Schematic
Training Manual
Start ANSYS Workbench and follow the sequenced steps using the
abbreviations shown below:
DC = Double Click with Left Mouse Button

SC = Single Click with Left Mouse Button
RMB = Right Mouse Button Selection
D&D = Drag and Drop = Hold Left Mouse Button down on item while
dragging it to new location and then release it (i.e., Copy or Move)
1. Create an ANSYS Explicit Dynamics Analysis System Project
DC

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Step 2 Specify the Project Units
Training Manual
2.a Select MKS for the Project Units

from the Units List provided
2.b Request that Native Applications
in Workbench have their values be
Displayed in the Project Units
2.c Check those unit systems to
Suppress from appearing in the
Units List
Note:
Engineering
Data is native in
Workbench, but
Mechanical is
NOT at this time
(but will be in
the future).
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Step 3 Define Engineering Data Material

DC
Training Manual
3.a Edit the Engineering Data cell to add a

material to the default library.
3.b Select the last slot under Engineering
Data to define a new material model.
Note: An existing material

model in the Explicit
Materials library could
have been selected, but
there are restrictions on
element types that can
be used with certain
material models, which
will be discussed later.
3.c Enter material

model name:
My_Aluminum
SC

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Step 3 Define Engineering Data Material ...

3.d Make sure the new
material is active in
order to define its
properties
Training Manual
SC
3.e Add the following Physical Properties to
the material definition:
DC
DC
Density
Isotropic Elasticity
Bilinear Isotropic Hardening
DC

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Training Manual
3.f Enter the following values:

Density = 2710 kg m^-3
Youngs Modulus = 7e10 Pa
Poissons Ratio = 0.30
Yield Strength = 2.9e8 Pa
Tangent Modulus = 0.0 Pa
Since the material is sufficiently

defined, the blue question
marks and yellow fields are no
longer present in the data table.
Note: The resulting stress-strain
curve is elastic perfectly
plastic. No strain hardening can
develop.
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3.g Return to the Project Schematic
3.h Save the Project by selecting the

Save As ... icon and Browse to the
directory indicated by your instructor.
Use the name empty_soda_can for
the Project name.

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Training Manual
Note: Saving the

Project saves all of
the important files.
The Project may
also be Archived, in
which all of the
supporting files are
compressed and
saved in one file.
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Step 4 Import and Modify the Geometry
Training Manual
4.a Import the geometry by the procedure shown.

Do NOT Double Click on the Geometry cell ...
RMB
4.b Browse to the DesignModeler

11.0 SP1 geometry file named:
soda_can_filled_110.agdb
SC
4.c Workbench has now identified

the geometry file (note green
checkmark in Geometry cell). It
is now OK to Double Click on
Geometry, as the new default
action is to Edit the geometry.
Default actions are shown in
bold type after RMB selects.

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RMB
SC
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Step 4 Import and Modify the Geometry ...

4.d Suppress the solid Soda
and the surface body Hole.
Training Manual
4.e Generate the changes in the

geometry. Although additional
modifications could be made,
but none are needed.
4.f Save the entire

Project via the DM
Save icon.
RMB
SC

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Step 5 Edit the Model in Mechanical
Training Manual
5.a Edit the model in Workbench Mechanical.
RMB
Since Edit is the default action, double-clicking on

the Model cell is also acceptable here.
SC
5.b Select the MKS Units system
Recall that Mechanical is not native in Workbench, so

the Units here may not match the Project Units
Note: Although the unit system used for data entry

and post-processing is the MKS system, the actual
unit system used by the AUTODYN solver is the
mm-mg-ms system, because it provides higher
accuracy. This will be shown later when the
Analysis Settings are discussed.
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Step 5 Edit the Model in Mechanical ...
Training Manual
5.c Define the Aluminum Can properties:
Stiffness Behavior = Flexible

Thickness = 0.00025 meters
Material Assignment = My_Aluminum
5.d Define the Punch and Die properties:
Stiffness Behavior = Rigid

Material Assignment = Structural Steel
Rigid Steel Punch

(moved downwards)
Flexible Aluminum
Soda Can (crushed)
Rigid Steel Die (fixed)
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Step 5 Edit the Model in Mechanical ...
Training Manual
5.e Review the Contact specifications
Keep contact
definition defaults
Note: There is no Save

icon in Mechanical
5.f Save the Project

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Step 6 Set Sizing Controls and Mesh Model
Training Manual
6.a Select the Mesh branch

6.b Specify the Mesh Details:
Physics Preference = Explicit

Element Size = 0.010 meters
6.c Choose the Edge selection filter
6.d Orient the model to select the 8 edges

that define the can circumferences (with
the Left Mouse Button). Use the Ctrl key
for multiple selections, as needed.
RMB (anywhere)
SC

SC
6.e With the 8 edges still highlighted,

Insert (RMB anywhere on graphics
screen) an Edge Sizing
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Step 6 Set Sizing Controls and Mesh Model ...
Training Manual
6.f Specify the Edge Sizing Details:
Type = Number of Divisions

Number of Divisions = 36
Behavior = Hard
6.g Generate the Mesh (RMB on either

Mesh branch or Edge Sizing branch)
RMB
SC
Mesh view
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Step 7 Define the Analysis Settings
Training Manual
7.a Specify the Analysis Settings:
SC
End Time = 6.0e-4 seconds

Automatic Mass Scaling = Yes
Minimum CFL Time Step = 1.0e-7 sec
7.b Set the Solve Units = mm, mg, ms

Note:
The mm, mg, ms unit system is the
most accurate in most simulations, so
it is the only one currently available.
Although more solver unit systems
will be available in the future, any unit
system in the drop-down list may be
used to enter data and/or display the
results.
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Step 7 Define the Analysis Settings ...
Training Manual
7.c Keep the remaining defaults

Note:
There are multiple ways to
control the erosion of an
element. In this case, the
element will only fail when
the geometric strain reaches
150%.
7.d Use the default number of
data sets to save during the
solution. Depending on the
analysis, this number may
need to be increased, but
that requires additional disk
space, so be judicious here.

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Step 8 Apply BCs and External Loads
Training Manual
RMB SC
8.a Fix the Steel Die (base):
SC

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Select the Body filter

Insert a Fixed Support
under Explicit Dynamics
Select the steel die
Apply the selection
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Step 8 Apply BCs and External Loads ...
Training Manual
RMB
SC
SC
8.b Displace the Steel Punch

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Insert a Displacement
under Explicit Dynamics
Select the steel die
Apply the selection
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Step 8 Apply BCs and External Loads ...
Training Manual
8.c Specify the vertical (Y) displacement

to be a Tabular load and set both the X
and Z displacements to be zero.
8.d Ramp the Y displacement as follows:
Time = 0.0 sec Y = 0.0 meters
Time = 5e-4 sec Y = -0.060 meters
Time = 6e-4 sec Y = -0.030 meters
Note: The punch speed and abrupt change in direction are unrealistic,
but sufficient for demonstration purposes. Normally, the movement
would be prescribed according to a SINE wave function.
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Step 9 Insert Result Items to Postprocess
Training Manual
9.a Insert a Total

Deformation plot
request under the
Solution branch.
RMB
SC
SC
SC
9.b Insert an Equivalent
(von-Mises) Stress
plot request under
the Solution branch.
The rigid bodies (i.e.,
the punch and die)
will not show stress.
RMB
SC

SC
SC
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Step 9 Insert Result Items to Postprocess ...
Training Manual
9.c Insert an Equivalent Plastic Strain

plot request under the Solution
branch.
RMB
9.d Save the

Project again.
SC
SC
SC
Note:
Even though a single time point (at the end of the run) is specified,
the complete set of results can be viewed, including animations.
Recall that the default output controls (20 equally spaced time
points) was retained under the Analysis Settings branch.

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Step 10 Run the AUTODYN Simulation

SC
Training Manual
10.a Select Solver Output under Solution

Information and Solve the simulation.
The Solver Output shows the run statistics, including the estimated
clock time to completion. Any errors or warnings are also noted.
Termination due to wrapup time reached is expected here.
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Step 10 Run the AUTODYN Simulation ...
Training Manual
10.b Select Energy Summary under Solution

Information to review the global statistics.
Note the abrupt changes in kinetic energy
due to the unrealistic loading scenario ...
TIME = 5.0e-4 seconds occurs

around 3200 cycles into run
Constant velocity after
starting from rest

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Step 11 Review the Results
Training Manual
11.a Select Total Deformation and Show the Elements under True
Scale. The maximum deformation (-0.060 m) exceeds the punch
value due to the momentum involved (i.e., an excessive punch
speed was used to reduce the required computer run time).
SC

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Step 11 Review the Results ...
Training Manual
11.b Animate the results by setting the controls as shown below and
then pressing the Animation button. For transient dynamics, the
default Distributed mode is inadequate, as it linearly interpolates
between saved results. The Result Sets mode is optimal, as it
uses the actual saved data. To review a static result, just click on
the desired Time or Value from the Tabular Data and use the RMB
to pick Retrieve This Result. The given state will then be shown.
Pick these 2 first

Then pick this
Pick this to
save the
animation
To retrieve a given result ...

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Training Manual
11.c Repeat the procedure, if

desired, for the von-Mises
equivalent stress results.
SC
Note:
No stress can develop in a
rigid body. The punch and
die are each condensed out
to a mass at their respective
centers of gravity with six
DOFs active.
Contact is based on
the exterior surface,
so a six DOF body can
have a complicated
contact surface.
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Training Manual
11.d Repeat the procedure one last time for the

equivalent plastic strain results.
SC
11.e. Hide the Punch and Die for a better view of the
results. Per the Analysis Settings, erosion does
not occur until the geometric strain is 1.50
RMB
SC
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Step 12 Review the Output Files
Training Manual
12.a Pick Files under the View menu to access the Project files
12.b Select Open Containing Folder via the RMB option
for the AUTODYN print file (admodel.prt).
RMB

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Step 12 Review the Output Files ...
Training Manual
12.c Double click on the file admodel.prt
12.d As noted earlier, the solver

units system was mm-mg-ms in
order to maximize the accuracy.
After the Simulation is done, the
results are converted back into
the current Mechanical units
system.

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Training Manual
12.e The AUTODYN print

file also contains the
Material Summary
information and run
statistics.
The Energy and
Momentum are shown
on both a material
basis and a Part basis
(shown here).

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Training Manual
12.f The Energy and Momentum Balance, Mass Scaling, and Run Times
are also included in the admodel.prt file.
12.g No mass was

added to the
model, since
the time steps
were all above
the Minimum
CFL Time Step
of 1.0e-7 sec
set in Step 7.a
under Analysis
Settings

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Training Manual
12.h Close the admodel.prt file and review the setup.log file in the same
directory (F:\exp_dyn\soda_can\empty_soda_can_files\dp0\SYS\MECH).
12.i The setup.log file contains

the information pertaining to
the transfer of data from the
Explicit Dynamics (ANSYS)
Analysis System to the
AUTODYN Cycle Zero file,
which is then run by the
AUTODYN solver.
12.j Close the file and return to
the Mechanical window (i.e.,
view the model itself again).

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Step 13 Generate a Report
Training Manual
13.a Click on the Solution branch in the Project tree and then click on
the Report Preview tab at the bottom of graphics window. ANSYS
does the rest! It will now automatically generate a report by going
through the entire tree and summarizing the model and the results.

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Step 13 Generate a Report ...
Training Manual
13.b The model properties

are summarized,
including volume, mass,
centroid, and moment of
inertia properties.
13.c Loading information is

also shown in clear table
format.

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Training Manual
13.d Even the energy plots are conveniently assembled into the report.

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Training Manual
13.e The results data is shown.

13.f Finally, SAVE the model
and exit ANSYS.

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ANSYS Explicit Dynamics 120 Workshop 02

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Workshop 2

Simulate the Crushing

ANSYS Explicit Dynamics

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Workshop Goal and Procedure

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 1 Create the Project Schematic

DC = Double Click with Left Mouse Button

1. Create an ANSYS Explicit Dynamics Analysis System Project

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 2 Specify the Project Units

2.a Select MKS for the Project Units

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 3 Define Engineering Data Material

3.a Edit the Engineering Data cell to add a

Note: An existing material

3.c Enter material

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 3 Define Engineering Data Material ...

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 3 Define Engineering Data Material ...

3.f Enter the following values:

Since the material is sufficiently

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 3 Define Engineering Data Material ...

3.h Save the Project by selecting the

ANSYS, Inc. Proprietary

Note: Saving the

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 4 Import and Modify the Geometry

4.a Import the geometry by the procedure shown.

4.b Browse to the DesignModeler

4.c Workbench has now identified

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 4 Import and Modify the Geometry ...

4.e Generate the changes in the

4.f Save the entire

ANSYS, Inc. Proprietary

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 5 Edit the Model in Mechanical

5.a Edit the model in Workbench Mechanical.

Since Edit is the default action, double-clicking on

5.b Select the MKS Units system

Recall that Mechanical is not native in Workbench, so

Note: Although the unit system used for data entry

February 27, 2009

Workshop 2. Simulate the Crushing of an Empty Soda Can

Step 5 Edit the Model in Mechanical ...