Internship Report on
Finite Element Simulation Using ABAQUS
Under the guidance of
Dr. N. Siva shanmugam
Assistant Professor,
Department of mechanical engineering,
NIT, Trichy.
INTRODUCTION TO ABAQUS
Engineering simulation program which works on
finite element procedures.
Abaqus Solver Products:
Fig. Abaqus Solver Products
CONT…
Abaqus/Standard: It has ability to solve both linear and non-
linear problems involving the static, dynamic, thermal and
electric problems.
Abaqus/Explicit: uses an explicit dynamic finite element
formulation for solving the problems.
Abaqus/CAE: It is a complete Abaqus interactive environment
which involves both Abaqus/Standard and Abaqus/Explicit.
It has a graphical user interface
PROBLEMS
1. Tensile test simulation of welded specimen.
2. Erichsen cupping test/formability test.
3. Three point bend test of weld specimen (spring back
effect).
Tensile sample is prepared according to
‘STANDARD FOR TESTING METALLIC
MATERIALS (ASTM E8/E8M).
Dimensions used to prepare model are shown in fig.1
TENSILE TEST
Tensile specimen - ASTM Standards:
Fig .1 ASTM tensile test specimen
At the center of specimen trapezoidal section of weld
bead is created.
Weld bead has dimensions of two parallel sides as
9.2mm and 6.7mm.
Corresponding material properties are assigned to
both parent and weld sections as per table .2 shown
below
MATERIAL PROPERTIES:
Table .2 Properties of Ti-6Al-4V Specimen
Material Section Young’s modulus Density Yield stress
(GPa) (g/cc) (MPa)
Ti-6Al-4V Parent 120 4.47 943
metal
Ti-6Al-4V Weld 200 4.47 880
(Filler) metal
APPLIED LOADS AND BOUNDARY CONDITIONS
One end of the specimen is constrained in its all
degrees of freedoms applying a boundary condition
ENCASTRE. Another end of specimen is allowed to
move in longitudinal direction.
At the free end of specimen a displacement of 15mm
is given in longitudinal direction and explicit analysis
is carried out
MESHING
Specimen is meshed using C3D4: A 4-node linear
tetrahedron elements.
A mesh assembly has following details
Element Type: C3D4 Linear tetrahedral
Total number of nodes: 4549
Total number of elements: 16799
RESULTS AND DISCUSSION
As the stress in parent metal reaches the yield stress,
it starts yielding and necking is observed as ultimate
stress reaches the value of 1070MPa in parent metal
section.
Un-deformed and deformed shape of specimen are
shown.
Fig. Un-deformed shape of specimen.
Fig. Deformed shape of specimen.
Force vs Displacement
Force(N)
50000
45000
40000
35000
30000
25000
20000
15000
10000 combine ( 'Disp vs Time','RF vs
Time' )
5000
0
0 1 2 2 3 5 5
1.4 2.9 4.4 5.9 7.4 8.94 0.44 11.9 3.4 4.96
1 1 1
Displacement(mm)
Fig .7bdisplacement magnitude
ERICHSEN CUPPING TEST
Erichsen cupping test is one of the formability test,
which is used to evaluate the ability of sheet metal to
be formed into useful components.
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 the commencement of ruptures
accompanied by a drop in the force supported by the
test piece.
The drop in the force is considered as the indication
of the end of the test, at this point the depth of the
penetration of the penetrator is recorded.
The depth of penetration there by obtained is measured as
Erichsen index.
The formability test index is identified as one of the most
important formability test result that could be used by
industry for grading, selecting and sorting of
incoming sheet metals for manufacturing of various
components.
GEOMETRY AND MODEL
The rectangular blank being drawn has dimensions of
70mmx70mmx2mm.
The punch has diameter of 25mm.
The die has internal radius of 30mm, external radius
of 40mm and rounded off at the corner with the radius
of 2mm.
CONTACT INTERACTION
surface to surface contact between rigid punch and blank,
rigid die and blank (frictional co-efficient of 0.15)
RESULTS & DISCUSSION
At the punch displacement of around 5.1mm
corresponding to step time 0.068, maximum stress is
reached and then drop in stress value is observed.
The maximum stress reached is the indication of
commencement of rupture.
Deformed shape of the sheet at step time 0.068
Deformed shape of the sheet at step time 0.08
Vonmises stress vs Punch displacement
1400
1200
1000
Stress(MPa)
800
600 At node 3281
400
200
0
0 1 2 3 4 5 6 7
Displacement(mm)
Fig. Von mises stress vs displacement
THREE POINT BEND TEST
This test is used for brittle materials for evaluating flexural
strength and flexural modulus.
For ductile materials this test used only to determine whether
the material can be bent sharply without cracking and serves as
a simple acceptance test with respect to this form of ductility.
The main objective of the this test was to study the spring back
effect of a welded specimen.
GEOMETRY
The welded specimen of rectangular cross-section has
25.6mm width, 200mm length and thickness of 2mm.
Weld bead is trapezoidal section, size of parallel
sides 9.2mm&6.7mm.
ASSEMBLY AND CONTACT
INTERACTION
The distance between centers of the supports is maintained at
100mm.
The actuator is placed in contact with specimen at the center
position.
Contact between specimen and supports, specimen and
actuator are modeled with surface to surface contact
formulation by defining the contact property with the frictional
co-efficient of 0.1
LOADING
Abaqus/standard analysis is carried out in two steps
namely loading and discharge.
The actuator is allowed to move in vertically
downward direction towards test specimen through a
total distance 27.8mm during loading step.
vertically upward direction through a distance 27mm
during discharge step.
RESULTS & DISCUSSION
Due to maximum displacement given during the
loading step, the specimen undergoes maximum
bending angle of 39º.
As the actuator is taken back during unloading step
specimen is allowed to retain its elastic part of strain
due to which the titanium specimen undergoes spring
back action with an angle of 22º.
The magnitude of the spring back angle proves the
good elastic strength of the titanium material.
Specimen at its Maximum displacement
Final deformed shape of the specimen
CONCLUSION
The titanium Ti-6Al-4V alloy when welded, strength
of the alloy is more at welded section over the parent
metal. During the finite element analysis of welded
titanium specimen using Abaqus, it’s found that
material yields at the parent metal section rather than
the welded section of the specimen.
The Ericson cupping test for titanium alloy(Ti-6Al-
4V) sheet is simulated using Abaqus to check the
formability of the sheet. 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.
The finite element simulation of three point bending
test for welded titanium alloy is carried out using
Abaqus. The angle until which specimen can be
sharply bent without cracking at the tension side is
found to be 39º. Due to the good spring back property,
specimen found recovery of 22º.
END
