Session7

Impact simulation

Hi guys, what’s going on?

We decided to look into impact simulation, which is very popular and contains critical
tips for simulation! The first step is to recognize the impact type. We have two types of
impact: high-speed impact and low-speed impact. We’ll leave the low-speed impact to
you to solve as an exercise. So, let’s do a high-speed impact simulation together.

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My dear, first and foremost, you should be aware that in the impact simulation, the
equation in simulating the engineering behavior of materials is critical! That’s because
in impact simulations with high-speed and high-strain rate (e.g., 104- 106 S-1), the
equations must be different than the ones in the static analysis. However, before
reaching the first point of yield strength, the material acts as an elastic. As an example,
we’ll look at the Johnson-Cook model in Abaqus. The stress-strain equation in this
model is as follows:
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   T − T m     

 = A + B n
 1 −  0
  1 + C ln pl
 0


  Tm − T0   
pl
 

The dependence of the equivalent stress on the equivalent strain quantities, the
equivalent plastic strain rate, and the temperature is well observed in this model, known
as Johnson-Cook 1983. The mechanical response of a material to dynamic loads and
the five constants A, B, n, C, and m are usually obtained from the results of a rod-to-
wall impact test, which was performed for the first time in 1984 by Taylor.

In Taylor’s experiment, a cylinder of the desired material, accelerated by a particular

Gas Gun, impacts with a rigid surface and deforms. The rod’s deformation is usually
concentrated at the point of the impact.

In the following section, we’ll use Abaqus to simulate the example of a rod hitting a
wall using the mentioned equations and tell you its key points.
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 Impact simulation in Abaqus

The problem is a cylindrical rod with lengths of 2.54 cm and radiuses of 0.381 cm
impacting with a rigid wall at a speed of 19000 cm/sec. As previously stated, we
implement the Johnson-Cookie model, which has parameters provided in the table
below:

parameters Units: CGS System

Density)ρ( 8.96 (gm/cm³)

Elastic modulus)E( 1.17e+12 (dy/cm²)

Yield Stress)Sy( 8.99e+8 (dy/cm²)

Poisson's ratio)ν( 0.33

A 8.963e+8 (dy/cm²)
B 2.9164e+9 (dy/cm²)
n 0.31
m 1.09
C 0.025
𝑻𝑴𝒆𝒍𝒕 1356 (°K)
𝑻𝒓𝒐𝒐𝒎 298 (°K)
Specific Heat 3.83E+6 (cm²/°C-s²) or (erg/g-°K)
Expansion 5e-5 (°K¯¹)
Inelastic Heat Fraction 1
𝜺̇ 𝟎 1(s-¹)
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 Step 1: Modeling (Part Module)

To model the cylinder in software, perform the following steps:

Part→ Create→ 3D, Deformable, Solid, Extrusion, Continue

Figure 1-1: Drawing the cylinder in the sketcher

After drawing the cylinder’s cross-section and clicking the Done button, the height of
the cylinder must be entered.
Edit Base Extrusion, Depth=2.54, OK

The figure will be as follows:

Figure 1-2: The modeled cylinder in 3D space

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 Step 2: Mechanical properties (Property module)

To define the mechanical properties, we do the following:

Module: Property→ Material→ Create;

General → Mass Density: 8.96 (gr/cm³)

Mechanical→ Elasticity→ Elastic; Young’s Modulus: 1.17e+12 (dy/cm²); Poisson’s

Ratio: 0.33

Mechanical → Plasticity→ Plastic; Hardening: Johnson-Cook

The material parameters in the Johnson-Cook model (A, B, n, m, T0, Tm) must be
defined in the Data table, as shown below.

Figure 2-1: Edit material window and specifying the Johnson-Cook parameters

In the “Suboptions” section of this menu, additional information on strain rate

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dependence ( 0 & C) is entered by the following procedure:

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 Edit Material; Suboptions→ Rate Dependent; Hardening: Johnson-cook

Figure 2-2: Specifying the Johnson-Cook rate dependent parameters

After entering the displayed details, click OK.

Other parameters, such as Expansion, Inelastic Heat Fraction and Specific Heat are
entered as follows:

Edit Material; Mechanical→ Expansion; Expansion Coefficient alpha: 5E-5

Edit Material; Thermal→ Inelastic Heat Fraction; Fraction: 1

Edit Material; Thermal→ Specific Heat; Specific Heat: 3830000→ OK

To define a section, perform the following steps:

Module: Property→ Section→ Create; Solid, Homogeneous→ Continue

When you click on the Continue button, the Edit section window appears. The Section
definition will be completed by choosing the defined material and clicking the OK
button.

To assign a section to a part, do the following:

Module: Property → Assign → section → Select the part and press Done→ Edit
Section Assignment; Section: section-1 → OK
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 Step 3: Assembly module

Do the following to create an instance:

Module: Assembly→ Instance→ Create Instance; Instance Type: Independent→ OK

Figure 3-1: Creating an instance

Step 4: Define the type of solution (Step module)

Because the temperature of the rod rises during the impact, the analysis must
include a temperature calculation; you can do this by creating the “Dynamic, Temp-
disp, Explicit” Step. Because of the short duration of the impact process, the analysis
can be assumed to be adiabatic. As a result, the effects of heat transfer (rather than heat
production) and, of course, node temperature calculation can be ignored. Moreover, in
“Dynamic, Explicit” analysis, we can use the following formula to calculate the
increased temperature of the part during the adiabatic process.

𝜼𝝈: 𝜺̇ 𝒑𝒍 = 𝝆𝒄𝜽̇
Where η is equal to the ratio of plastic work (per unit volume) converted to heat and ρ,
c, θ, are density, specific heat, and temperature, respectively. As a result, a proper
temperature approximation can be obtained in this type of analysis and in a impact
problem. It should be noted that temperature is not calculated as a degree of freedom in
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Dynamic Explicit analysis, but the above formula is used separately for Gaussian nodes
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(integration nodes).
 Module: Step→ Create Step; Name: Dynamic; Procedure type: General; Dynamic,
Explicit→ Continue

Edit Step→ Time period :7e-5; Nlgeom: on; toggle on “Include adiabatic heating

effects” option

This time equals the maximum time required for the rod to be completely stopped
following an impact.

Figure 4-1: Creating the Dynamic, Explicit step

In this problem, the output file must also include a parameter called NFORC for the
results evaluation. This is accomplished as follows:
Step Module: Field Output Manager→ Edit F-Output-1→ Edit Field Output request;
Force/Reactions→ Select “NFORC, Nodal forces due to element stresses” variable

There is no need to define the Contact and its conditions in the Interaction module in
this case.

Step 5: Boundary conditions (Load module)

The following method is used to define Gravity in the axial direction of the rod:
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 Load Module: Create Load → Category→ Mechanical; Types for Selected Step →
Gravity→ Continue; This is completed by defining the data as shown in the figure
below.

Figure 5-1: Creating the Gravity load

To define the initial impact velocity, do the following:

Load Module: Create Predefined Field→ Step: Initial; Category →Mechanical; Types
for Selected Step → Velocity→ Continue → Apply the initial speed on the entire model.

Figure 5-2: Creating the initial impact velocity

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 To define the initial temperature of the part, do the following:
Load Module: → Create Predefined Field; Step→ Initial; Category → Other; Types
for Selected Step → Temperature→ Continue…→ the entire model must be selected to
apply the initial temperature; Magnitude→ 200.

Figure 5-3: Creating the initial temperature for the model

The following boundary conditions must now be defined:

The cylinder’s bottom must be fixed in the Z direction. This constraint is equivalent to
a cylinder impacting with a rigid body with no friction. Therefore:
Load Module→ Create Boundary Condition; Step=Dynamic; Category→ Mechanical;
Types for Selected Step→ Displacement/Rotation→ Continue … →By selecting the
bottom of the cylinder (the surface that impacts with the rigid body) and then clicking
on the Done button, the Edit Boundary Condition window appears. Set U3 to 0 →OK.

Symmetry boundary conditions must be applied in two directions on the two lateral
surfaces of this cylinder quarter. The following instructions apply the symmetry
boundary condition to the plane X = 0.
Load Module→ Create Boundary Condition; Step=Dynamic; Category→ Mechanical;
Types for Selected Step→ Symmetry/ Antisymmetry/ Encastre→ Continue
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 When you select the X = 0 plane and click on the Done button below it, a window will
appear as shown (figure 5-4). The first symmetry constraint is applied after applying
the settings shown in the figure and clicking the OK button.

.
Figure 5-4: Applying the X symmetry boundary condition

The above procedure is also used to apply the symmetry boundary condition on the
plane Y=0, except that the YSYMM option (U2=UR1=UR3=0) will be selected in the
above window.

Step 6: Meshing (Mesh module)

Mesh Module: Seed Edges → selecting 4 radial edges→ Method: By Number

→Number of elements: 10;

selecting 3 length edges→→Method: By Number → Number of elements: 40;

selecting 2 curve edges→→Method: By Number → Number of elements: 14→ Done.

Mesh Module: Assign Mesh Controls → Element shape: Hex→ Technique: Structured
→OK
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 Figure 6-1: Mesh Controls edit window

Mesh Module: Assign Element Type→ Element Library: Explicit →Geometric Order:
Linear→ Family: 3D Stress→ Hex→ Hourglass Control: Enhanced→ OK

Figure 6-2: Assigning element type

Mesh Module: Mesh Part Instance→ Yes

Step 7: Solving problem (Job module)

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Now the model is ready, follow the instructions below to analyze it.
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Job Module: Create Job→ Continue…→ Edit Job → OK

 The solution operation starts through the following path:
Job Module: Job Manager→ Submit

Step 8: Monitoring the Results (Visualization module)

The results can be viewed by the path below:

Job Module: Job Manager→ Results

Visualization Module: Plot→ Contours → On Deformed Shape

Figure 8-1: Deformed shape contour plots

Note:

ALE Adaptive Mesh Method

ALE stands for Arbitrary Lagrangian-Eulerian.

This method is used to control the complexity and distortion of elements when large
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deformation or loss of material occurs. Tracing the boundaries of material and

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 examining the history of material behavior is complex in the Eulerian method because
the network of elements is fixed, and material is moving. In the Lagrangian method, the
main issue is that it produces large deformations, which cause numerical errors and in
some cases, termination of solution. (If you don’t remember Euler and Lagrange
theories, take a look at the Fluid Mechanics book, that might jog your memory!)

The ALE method overcomes the disadvantages of the Lagrangian and Euler methods
and takes benefit of their advantages. As shown in figure 8-1, the compaction of the
elements is greater at the location of the impact with the rigid obstacle than in other
areas. These compressions will be adjusted using the ALE method, and the deformation
of the elements becomes smoother and more uniform.

Active ALE in the Step module from the “Other” menu in the menu bar:
Step Module: Other menu → ALE Adaptive Mesh Domain→ Edit→ Dynamic

The “Edit ALE Adaptive Mesh Domain” window is opened by following the steps
above. We can make better use of the capabilities of this method by making the changes
in this window.

At the top of the window, the Step that affects the ALE method is determined, and if
several Steps are defined, the ALE settings can be extended for different steps.

Click ‘Use the ALE adaptive mesh domain below’ to activate ALE (see figure 8-2).

Figure 8-2: The ALE Adaptive Mesh Domain edit window

Click on to select the area that this feature affects. In this problem, we should select
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the whole model.

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 Select “ALE Adaptive Mesh Controls” → “Create Adaptive Mesh Controls” →
Display the “Create ALE Adaptive Mesh Controls” window → Continue… (accept all
options as default) →OK (see figure 8-3)

Figure 8-3: Creating ALE Adaptive Mesh Controls

Many parameters influence the performance of the ALE method, and some of them are
shown in this window (see figure 8-3).
Perhaps the most significant changes, especially for impact problems, concern the issues
of changing the two quantities of “Frequency” and “Remeshing sweeps per increment”
in the Edit ‘ALE Adaptive Mesh Domain’ window. Most errors in this method can
usually be controlled by changing these two parameters. In this operation (see figure 8-
2), the selected area will be remeshed by sweeping twice (“Remeshing sweeps per
increment”) every 10 increments (“Frequency”).

The first option can be reduced, while the second option can be increased to improve
the final network and correct solution errors. However, this will increase the process
time.

The ALE method is activated by clicking on the OK button. Submit the model with
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these new changes and the results will be similar to figure 8-4.
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 As shown in the figure below, the compression of the elements in the impact with the
obstacle will be mostly balanced, but the results will differ slightly.

Figure 8-4: Deformed shape contour plots with ALE method

Review of the analysis accuracy:

One of the most important steps in numerically analyzing problems is validating and
evaluating results. The magnitude of the impact applied at the impact location can be
calculated using the following formula (Momentum and impulse formula):
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impulse =  F dt =  Mv i
t

0
i =1

In the above equation, F is the force applied to the bottom of the cylinder, t is the total
time, M is the mass of a quarter of the modeled cylinder, v1 is the velocity of the cylinder
before the impact, and v2 is the velocity of the cylinder after impact (cylinder stops after
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the impact when v2 = 0).

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 t
You can calculate 0 F dt by the formula like below:

This calculated value is the theoretical value that you need to use to validate your
simulation results.
t
Now, let’s find the 0 F dt value by using the ABAQUS. First find the total force on the
bottom of the cylinder at the desired time. To do this, you can do as following:
Visualization Module: Tools→ Free Body Cut→ Create; Elements and nodes→
Continue

After selecting “Pick from viewport” in the pop-up window, you must choose all
cylinder bottom elements and click on the Done button, followed by OK (see figure 8-
5).

Figure 8-5: Free Body Cross-Section window

Then, a window similar to the previous one (figure 8-5) will appear, but it will be for
nodes this time. You must select all of the nodes on the bottom of the cylinder by
clicking on ‘Pick from viewport’ and clicking on the Done button.
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After that, the ‘Edit Free Body Cut’ (figure 8-6) window will appear. The force and
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moment on the bottom of the cylinder will be displayed at different times when the OK
 button is clicked. You can see the force and the moment at any increment you need by
doing the following:
Visualization module: Results menu→ Step/Frame…→ Apply desired increment.

Figure 8-6: Free Body Cut edit window

F can now be calculated using the total force on the bottom of the cylinder at different
times. This value was obtained as follows:

Now, the error is obtained from the following equation by comparing the value of the
theory with the value obtained above:
|−49298.67−(−45780)|
Percent error= × 100 = %7.13
−49298.67
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 Exercise: Impact analysis of an aluminum part to a rigid plate
A piece of aluminum falls on a rigid plate in this problem. This piece hits the center of
the plate in 0.02 seconds, at a speed of 500 mm/s and an angle of 15 degrees from the
horizontal axis.
The friction coefficient between the plate and the part is assumed to be 0.2. The
distribution of stress in 100 increments is the request of the problem.

The geometries of the part are shown in figure 1. Its depth is equal to 20 mm. It is worth
noting that the mechanical properties of aluminum are also shown in the table below.
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 Figure 1: The geometry of the aluminum part

Mechanical Properties
𝐸 (𝐺𝑝𝑎) = 70

𝑇𝑜𝑛
𝜌( ) = 𝟐. 𝟔 × 𝟏𝟎−𝟔
𝑚𝑚3

𝜈 = 𝟎. 𝟑𝟑

In addition, the geometry of the rigid plate (inside the plate) is shown in figure 2, and
its depth is 200mm.
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Figure 2: The geometry of the rigid plate

 You can find more information and tips about the impact on our website.
See ya!
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