Workshop 5B

Localized Yielding

Workbench-Mechanical
Structural Nonlinearities

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-1 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Goal
Introduce Metal Plasticity to the Workshop 4A
problem and compare its effect on results
(contact pressure and preload) Tip

Insulator
Model Description
2D Axisymmetric model of injection molding
machine nozzle tip assembly
Materials:
Tool Steel for Housing (760Mpa Yield Strength)
Copper alloy for Tip (280Mpa Yield Strength)
Titanium for Insulator

Housing

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-2 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Model Description (contd)

Contact Pairs:
A. Frictionless contact at
Housing to Nozzle tip face
seal
B. Bonded contact at Nozzle tip
To insulator
C. Bonded contact at threaded
connection between Housing
and Nozzle tip (thread details
not modeled)

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-3 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Model Description (contd)

Thermal Boundaries:
A. Hot manifold @ 220C
B. Cold manifold plate @50C
C. Nozzle tip band heater @ 80 Watts

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-4 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Model Description (contd)

Structural Boundaries
A. Frictionless Support @
Nozzle Housing Flange
B. Frictionless Support @
Insulator

melt
Structural Loads channel
1st loadstep reconciles wall
interference fit between
housing and tip face seal
2nd loadstep reads in
temperatures from steady
state thermal run
3rd loadstep applies pressure
to melt channel wall.

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2009 ANSYS, Inc. All rights reserved. WS5B-5 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Steps to Follow:
If you already have Workbench open from a previous run, start a new
analysis with Utility Menu>File>New

Browse for and open W5B-Offset.wbpj project file.

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2009 ANSYS, Inc. All rights reserved. WS5B-6 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

The Project Schematic should look like the picture below.

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2009 ANSYS, Inc. All rights reserved. WS5B-7 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Highlight the Engineering Data Cell and

double click to open
Verify the predefined material properties
Verify that the units are in Metric
(Tonne,mm,) system.
If not, fix this by clicking on
Utility Menu>Units>Metric(Tonne, mm,..)

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2009 ANSYS, Inc. All rights reserved. WS5B-8 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Highlight the Copper NL and Stainless Steel NL materials to

confirm that the plasticity models have been defined with
Bilinear Isotropic laws as show below.

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2009 ANSYS, Inc. All rights reserved. WS5B-9 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Return to the project schematic page

Double click (or RMB=>Edit) on the Thermal Model Cell to open

Mechanical Session

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2009 ANSYS, Inc. All rights reserved. WS5B-10 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Highlight the Housing and Nozzle Tip components

In the Details Window, turn Nonlinear Effects ON to include the plasticity
effects

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2009 ANSYS, Inc. All rights reserved. WS5B-11 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Execute a SOLVE
The convergence now takes over 20 iterations, up from just 9 (WS4A)
when all materials were considered linear elastic.

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-12 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Post process the contact pressure

Notice the dramatic difference in pressure distribution at the seal face as
well as the peak value when compared with same results published in
workshop 4A

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2009 ANSYS, Inc. All rights reserved. WS5B-13 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Post process the preload at the frictionless contact resulting from the
interference fit as before. Compare the preload with workshop 4A.
Note, the change in preload is not nearly as dramatic as that of the contact
pressure. Why?

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2009 ANSYS, Inc. All rights reserved. WS5B-14 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Highlight the Solution Branch

RMB>Insert>Strain>Equivalent Plastic Strain
Note: Yielding is concentrated locally at the melt channel wall. Material
remains elastic across most of the seal face. Hence, preload does not
change very much.

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2009 ANSYS, Inc. All rights reserved. WS5B-15 Inventory #002660
Workbench Mechanical Structural Nonlinearities
Workshop 5B: Localized Yielding Workshop Supplement

Post process equivalent stress and compare to results published at

end of workshop 4A.

ANSYS, Inc. Proprietary April 30, 2009

2009 ANSYS, Inc. All rights reserved. WS5B-16 Inventory #002660