Internship
On
Finite element simulation using Abaqus
Undergone
at
National Institute of Technology, Trichy
Under the guidance of
Dr. N. Siva Shanmugam
Assistant Professor
Department of Mechanical Engineering
National Institute of Technology
Trichy
Contents
Introduction to ABAQUS
Problem Statements
Material Properties
Tensile Test
Erichsen Cupping Test
Three point Bend Test
Conclusion
Introduction to ABAQUS
ABAQUS/Standard : It works on Implicit procedures, solving a coupled system of
equations at each increment by forming global stiffness matrix. It is most suitable
for static problems.
ABAQUS/Explicit : It is preferred for dynamic problems where time play an
important role.
ABAQUS/CAE : It is interactive graphical user interface environment includes both
ABAQUS/standard and ABAQUS/Explicit
Introduction to ABAQUS
Abaqus analysis generally consists of below three steps:
• Pre-Processing
• Simulation
• Post-Processing
Unit System in ABAQUS
Problem statements
Tensile Test
Erichsen Cupping Test
Three point Bending Test
Material Properties
All the three tests are conducted on the titanium welded
specimens. The material properties of the both parent
metal and weld bead metal are given below.
Properties of Ti-6Al-4V Specimen
Material Section Young’s modulus (GPa) Density (g/cc) Yield stress
(MPa)
Ti-6Al-4V Parent metal 120 4.47 943
Ti-6Al-4V (Filler) Weld metal 200 4.47 880
In ABAQUS the True stress vs True strain material data is
required for defining the material models.
Material Properties
True stress vs True strain
1400
1200
1000
Stress (MPa)
800
Parent material
Weld material
600
400
200
0
0 0.05 0.1 0.15 0.2 0.25
Strain (MPa)
Tensile Test
Specimen is prepared according to ASTM E8/E8M
(Standard test method for testing metallic materials)
All dimensions are in mm
Tensile Test
Model is prepared with four node linear Tetrahedron
elements(C3D4).
Total number of nodes: 4549
Total number of elements: 16799
One end of the specimen is fixed in all directions
(U1=U2=U3=UR1=UR2=UR3=0) while the other end is
allowed to move in longitudinal direction only.
The free end is applied with a displacement of 15 mm in
longitudinal direction.
Tensile Test
Results and Discussion
• Necking is observed at the parent metal section as the
stress value reaches 1070 MPa
• The contour plots for variation of stress and
Displacement across the model are shown below.
Tensile Test
• Displacement magnitude contour plot across the full model
Tensile Test
Force vs Displacement
50000
45000
40000
35000
30000
25000
Force
combine ( 'Disp vs Time','RF vs Time' )
20000
15000
10000
5000
0
0 71 41 15 .9 68 42 17 92 67 43 19 94 69 44 .2 95 .7 45 .2 96
0 . 1 . 2 . 2 3 . 4. 5. 5. 6. 7 . 8. 8. 9. 10 . 1 1 1 1 . 1 2 13 . 14 1 4 .
Displacement
Erichsen Cupping Test
It is used to evaluate the formability of the material
The test consist of a sheet metal placed between blank
holder and die and pressing the test piece into the die by
means of a penetrator having a spherical head, until the
end point is reached.
Rupture commence when a crack appears through the full
thickness of the test piece.
Generally, rupture is accompanied by drop in the force and
this is considered as the end point of the test. The depth of
the penetration is noted.
Erichsen Cupping Test
The rectangular specimen is prepared of size 70x70x2 mm.
The punch has the diameter of 25mm and the die has
30mm and 40 mm as internal and external radius
respectively.
Blank is modelled with 3D deformable shell where as the
punch and die are modelled as rigid.
Surface to surface frictional contact property is defined
with frictional co-efficient of 0.15.
Punch is constrained in such a way that it is allowed to
move in vertical direction only.
Erichsen Cupping Test
The rigid die is completely constrained in all directions
For simulation displacement of 6 mm is given to the punch
in vertical direction.
Results and Discussion:
At the step time of 0.068 sec the maximum displacement
of 5.1 mm is reached. At the same time stress value reaches
the maximum value represents the commencement of
rupture.
Erichsen Cupping Test
Deformed shape at the step time 0.608sec
Erichsen Cupping Test
Vonmises stress vs Punch displacement
1400
1200
1000
Stress(Mpa)
800
At node
600 3281
400
200
0
0 1 2 3 4 5 6 7
Displacement(mm)
Three point Bending Test
The test is used for brittle materials to evaluate the flexural
strength and flexural modulus.
For ductile materials it is used to determine the bending
ability of the material without any rupture.
The specimen is loaded in the fashion of simply supported
beam and bent to the maximum possible angle without any
rupture.
In this work the spring back action of titanium specimen is
simulated.
Three point Bending Test
The weld specimen of rectangular section with 25.6 mm
width and 200 mm length and thickness of 2 mm is
modelled as 3D deformable body with hexahedral type
elements(C3D8R).
The two supports of 10mm radius and actuator with 10
mm nose radius are modelled with the same C3D8R
elements
Three point Bending Test
The final assembled test set up is shown below
Three point Bending Test
The distance between the supports is maintained at
100mm
The surface to surface contact formulation is given with
frictional co-efficient of 0.15.
The simulation involves both loading and discharge steps.
The actuator is allowed to move in vertically downward
direction with a distance of 27.8 mm during the loading
step and is taken back during discharge step.
Three point Bending Test
Results and Discussion:
• Due to maximum displacement given during the
loading step, the specimen undergoes maximum
bending angle of 39°.
• At the end of the discharge step it is found that the
titanium specimen undergoes a spring back angle of
22° which proves the good elastic strength of titanium.
Three point Bending Test
Conclusion
Tensile test results show that the specimen yields at the
parent metal section rather than the welded section of the
specimen, this proves the strength of welded joint.
According to Erichsen cupping test, crack is supposed to
appear at the peak load followed by drop in the load. So
the maximum stress induced of 1278.9MPa corresponding
to displacement of 5.1mm was found.
Three point bending test results prove the good spring back
ability of titanium welded joint.