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Ansys Contact usages: tips and tricks
Let us talk about convergence
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Ansys Contact usages: tips and tricks
One reason for convergence difficulties could be the following:Suggestion
• FE Model is not modeled correctly in a physical sense1) If you use a point load to do a plastic analysis, you will never get the converged solution.
Because of the singularity at the node, on which the concentrated force is applied, the stress is infinite. The local singularity can destroy the whole system convergence behavior. The same thing holds for the contact analysis. If you simplify the geometry or use a too coarse mesh (with the consequence that the contact region is just a point contacta too coarse mesh (with the consequence that the contact region is just a point contact instead of an area contact) you most likely will end up with some problems in convergence.
point load σ Geometry Mesh
εε
l ti l i t t l i
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plastic analysis contact analysis
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:• FE Model is not modeled correctly in a numerical sense
2) A possible rigid body motion is quite often the reason which causes divergence in a contact analysis This could be the result of the following: We always believe that if we
g g
contact analysis. This could be the result of the following: We always believe, that if we model the gap size as zero from geometry, it should also be zero in the FE model. But due to the mathematical approximation and discretization, it does not have necessarily to be zero anymore. Exactly, this can kill the convergence. If possible, use KEYOPT(5) to close
the gap. You can also use KEYOPT(9)=1 to ignore 1% penetration, if it is modeled.
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KEYOPT(5)=1KEYOPT(5)=0
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:• Numerically bad conditioned FE Model
4) ANSYS uses the penalty method as a basis to solve the contact problem and the convergence behavior largely depends on the penalty stiffness itself. A semi-default value
g g
convergence behavior largely depends on the penalty stiffness itself. A semi default valuefor the penalty stiffness is used, which usually works fine for a bulky model, but might not be suitable for a bending dominated problem or a sliding problem. A sign for bad conditioning is that the convergence curve runs parallel to the the convergence norm. Choosing a smaller
l f FKN l k th bl i t If th l i i tvalue for FKN always makes the problem easier to converge. If the analysis is not converging, because of the too much penetration, turn off the Lagrange multiplier.The result is usually not as bad as you would believe.
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FKN=1 FKN=0.01
Ansys Contact usages: tips and tricks
Suggestion
One reason for convergence difficulties could be the following:• Numerically bad conditioned FE Model
One reason for convergence difficulties could be the following:
FKN=.1 FKN=0.0001
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FKN=0.0001FKN=.1
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• Load step is too large Error in element formulation or element is turned inside out 5) If it is a large deflection problem, you usually need more substeps. 5 to 10 substeps are
good if the rotations are not too large (<180 degrees) If it is a small deflection problem you
g g
good if the rotations are not too large (<180 degrees). If it is a small deflection problem, you should reduce FKN, because FKN*d produces a large force, which can destroy the element.
NLGEO,ONNSUB,1,1,1 NLGEO,ON
S
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
NSUB,10,100,1
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• Quads instead of triads Error in element formulation or element is turned inside out 6) If some elements are locally distorted you might get an error in the element formulation or
the element is even turned inside out Try to use a coarser mesh in this region to avoid
g g
the element is even turned inside out. Try to use a coarser mesh in this region to avoid those problems. You can also use NCNV,0 to continue the analysis and ignore those local problems if they do not effect the global equilibrium. In general, try to use triangular, tetrahedral or hexahedral elements (linear). Do not use quadratic hexahedral elements.
Error in element formulation
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Linear quads Mid-side triads
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• The parts have no unique minimum potential energy position.7) If the max. DOF increment is not getting smaller and the force convergence norm keeps
almost constant probably some parts in the model are oscillating Here introducing a small
g g
almost constant, probably some parts in the model are oscillating. Here, introducing a small friction coefficient is usually better than using a weak spring, not knowing exactly where to place it. Friction can be applied to all contact elements (try MU=0.01 or 0.1)
MU=0.1MU=0
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• Unreasonable defined contact pair8) Sometimes it is also important to think about possible contact configurations: Which surface
or point will be in contact with which surface ??? The way to define the contact or target canor point will be in contact with which surface ??? The way to define the contact or target can influence the convergence behavior as shown below.
Target
Contact
g
Contact
Target
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Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• Unreasonable defined plastic material11) It is not always a good idea to define the tangential stiffness to be zero using a plastic
material law If the yield stress is reached all over the whole cross section there is no
g g
material law. If the yield stress is reached all over the whole cross section, there is no material resistance anymore to carry the load. There will be a plastic hinge and so the solution will never converge. In this case, input the correct tangential stiffness.
Plastic strain Stress strain curve with
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
tangential slope zero
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
• Unreasonable defined plastic material
g g
Plastic strainPlastic strainStress strain curve with tangential slope 10000
Contact region
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Stress distribution
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:• Instable solution
13) Some time, the solution could be instable, if the static analysis type is used, e.g if the contact region changes abruptly In this case you can use more load steps strategy to get
One reason for convergence difficulties could be the following:
contact region changes abruptly. In this case, you can use more load steps strategy to get rid of the instable solution.
Instable point Next solutionFE model
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Instable point Next solutionFE model
Ansys Contact usages: tips and tricks
SuggestionOne reason for convergence difficulties could be the following:
TIP• Instable solution TIP
Load step-1 ends shortly Load step-2 starts shortlyFE model
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Load step 1, ends shortly before the snap through
Load step 2, starts shortly after the snap through.
FE model
Ansys Contact usages: tips and tricks
Suggestion/prep7et,1,182,2et 2 169
lsel,s,,,5nsll,s,1
/solunlgeom on
TIPet,2,169et,3,171,,1,,1mp,ex,1,2e5mp,mu,1,.1mp,prxy,1,.3
type,2esurflsel,s,,,2,3nsll,s,1type,3
nlgeom,onnsub,100,100,1outres,all,allnsel,s,loc,y,0d,all,alll l 6 1
In order to model the contact region r,1,,,.001,,,-2r,2,,,.001,,,-2rect,0,1,0,3wpof,1,3wprot,-20
type,3esurflsel,s,,,2nsll,s,1type,2real 2
lsel,s,,,6,,,1d,all,uxd,all,uy,-.5allssolv
greasonably, you should define two contact pairs, one for load step-1 and another for load step-2, and use the node detection option(KEYOPT(4)=1 as shown below p ,
rect,-.2,3,0,.2esize,.2amesh,1esize,.1ames all
real,2esurflsel,s,,,5,8,3nsll,s,1type,3
/COM Load step-2lsel,s,,,6,,,1d,all,uxd,all,uy,-1alls
option(KEYOPT(4)=1, as shown below.
ames,all esurfallsnsub,10,10,1solv
Status-1
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Contact-1 Target-1Target-2 Contact-2
Status-2
Ansys Contact usages: tips and tricks
SuggestionGood mesh will generally make problem easier to converge.• The fine mesh and similar are always good the contact simulation:
GeometryGeometry Contact regionContact region
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Contact meshContact mesh
Ansys Contact usages: tips and tricks
How can I make the problem converge?• Trust yourself: I’m able to make it converge!Trust yourself: I m able to make it converge!• Consider the problem as idealized real world problem:
20% M h i ti 20% E i ti20%- Mechanics expertise, 20%- Engineer expertise 30%- FEA expertise, 30%- Software expertise
• Use the magic KEYOPTIONS
KEYOPT(5) 1 T li i t th i id b d tiKEYOPT(5)=1: To eliminate the rigid body motion
KEYOPT(9)=1: To eliminate the geometric noiseKEYOPT(9)=1: To eliminate the geometric noise
KEYOPT(10)=2: To make ANSYS think
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
( )
Ansys Contact usages: tips and tricks
Table of Contents
1. Introduction2. MPC connection for SOLID-SOLID, SHELL-SHELL ,3. MPC connection for SOLID-SHELL4. MPC connection SOLID-BEAM and SHELL-BEAM5. MPC connection between the FE model and loading point
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Ansys Contact usages: tips and tricks
1. Introduction, What is MPC?
• MPC means: Multipoint Constraint PC )( ijCCL
≠+∑• MPC means: Multipoint Constraint PC
)1()( )3()1( LROTZSinUY •=+4
)(01
ijCuCu jj
ji ≠=+∑=
)2()1()2()(
)1()()3()2(
)()(
LROTZSinUYLROTZSinUY
+•=−
•=+
L
L
31
LL2
Beam
)(20)2()1(
)3()2()1( ROTZSinLUYUY •−−=
+
MPC
LL
SolidMPC
For small rotation:)(20 )3()2()1( ROTZLUYUY •−−=
)1(UY )3(ROTZ
LROTZUYUYCE 2,,3,1,,2,1,,1,0,2, −−
)(20 ROTZLUYUY
)2(UY
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Ansys Contact usages: tips and tricks
1. Introduction, What do you need MPC?
• To connect the dissimilar mesh:– If the geometries are not topologically connected, you can mesh the geometry
independently and connect the FE model via MPC.
Geometry Dissimilar meshConnected via MPC
Stress distribution
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Connected via MPC
Ansys Contact usages: tips and tricks
• To connect the different element types:
1. Introduction, What do you need MPC? y
– If the different element types are used on the connection region, because of the different DOFs, the connectivity is not consistent. The consistence can be achieved in the FE model via MPC.
Geometry Solids and Shells Connected via MPC
Deformation
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Connected via MPC
Ansys Contact usages: tips and tricks
• To apply the remote load:
1. Introduction, What do you need MPC?
pp y– If the loading point is not connected to the FE model, the connection can be
achieved in the FE model via MPC.
Loading point and FE model Connected via MPC
Stress distributions
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Ansys Contact usages: tips and tricks
1. Introduction, Why the existing contact algorithm is not used?
• The results may depend on specified contact stiffness• The results may depend on specified contact stiffness.– The existing bonded contact algorithm using the penalty method, because of
contact stiffness(cause the ill-conditioning) and the penetration, it might influence the accuracy of the resultinfluence the accuracy of the result.
• Multiple iterations are required to adjust penetration in order to satisfy equilibrium even for small deformation problemssatisfy equilibrium even for small deformation problems.
– This will cause the iteration, even for linear problem.
• Occasionally spurious natural frequencies can occur in modal analysis• Occasionally spurious natural frequencies can occur in modal analysis.– This is because of the contact stiffness used.
Only translational DOFs are treated• Only translational DOFs are treated.– This will cause the accuracy problem, if the distance between the contact and
target is not zero.Sh ll/b bl t b h dl d
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– Shell/beam assembly can not be handled.
Ansys Contact usages: tips and tricks
1. Introduction, Why the existing contact algorithm is not used?
It i l it bl f ll t i• It is only suitable for small strain.– Because the existing CE method always uses the original nodal orientation.
• The RBE3 constraint can only support low order elements. – 10 nodes tetrahedron element are most commonly used element.
• It is not allowed to apply displacement constraints on the master node of RBE3
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Ansys Contact usages: tips and tricks
1. Introduction, Advantages of new MPC approach
• Build MPC equations internallyBuild MPC equations internally.– It is not necessary to define the equations by hand, the user treats the
connection as bonded contact, ANSYS will generate automatically the MPC.
• Degrees of freedom of the contact surface nodes are eliminated.– This will improve solution efficiency.
• No contact stiffness is required as an input.– The accuracy of the solution is not dependent on try-and-error anymore.
F ll d f i bl i “ li ”• For small deformation problem, it represents “true linear contact” behavior.
– No iteration is needed in solving system equations.
• For large deformation problems, the MPC equations are updated during each iteration.
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Ansys Contact usages: tips and tricks
1. Introduction, Advantages of new MPC approach
N t l t l ti l b t t ti l d f f d l b• Not only translational but rotational degrees of freedom can also be constrained.
– It will improve the solution accuracy, and makes the connection between solid-shell shell shell solid beam and shell beam more reasonableshell, shell-shell, solid-beam and shell-beam more reasonable.
• The generation of internal MPC is also very easy thanks to contact i d fi i ipair definition.– For the users, it is nothing new, if you know how to define the contact.
• It is not like MSC/Nastran (RBE3 type)
– Shape functions are taken into account automatically; no weight factor p y; gis needed.
– not only forces but also displacements can be applied.
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Ansys Contact usages: tips and tricks
2. MPC connection for SOLID-SOLID, SHELL-SHELL
Model-1: mesh is pretty Model-2: mesh is quite Model-2: consistent
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similar SMAX=1.71 q
different SMAX=1.71 mesh SMAX=1.71
Ansys Contact usages: tips and tricks
2. MPC connection for SOLID-SOLID, SHELL-SHELL
KEYOPT(9)=0 KEYOPT(9)=1
If you have the geometry penetration:1) Set the PINBALL to catch the contact2) Use KEYOPT(9)=1 to ignore the
Model-2: Penetration and KEYOPT(9)=1 SMAX=1.71
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) ( ) gpentration
Ansys Contact usages: tips and tricks
2. MPC connection for SOLID-SOLID, SHELL-SHELL
KEYOPT(9)=0 KEYOPT(9)=1
If you have the geometry gap:1) Set the PINBALL to catch the contact2) Use KEYOPT(9)=1 to ignore the
Model-2: Gap and KEYOPT(9)=1 SMAX=1.73
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2) Use KEYOPT(9)=1 to ignore the pentration
Ansys Contact usages: tips and tricks
2. MPC connection for SOLID-SOLID, SHELL-SHELL MPC connection for SHELL-SHELL(Edge-to-Edge)( g g )
Contact175
Target170Target170
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Ansys Contact usages: tips and tricks
2. MPC connection for SOLID--SHELL Summary: For most applications, default KEYOPT(5)=0 or 3 can be used. Many test cases show the best solution with KEYOPT(5)=2cases show the best solution with KEYOPT(5)=2.
New Virtual New Contact
New VirtualVirtual
shell elements
SHELL181
New Contact elements
CONTA175
Virtual
shell elements
MPC equations
shell edge – solid surface
FTOLN
Influence di t
MPC equations
(translation DOF only)
Virtual shell - solid surface
Shell thickness
MPC equations
(translation + Rotation DOF)
shell edge - virtual
FTOLN
Influence distance
gshell distance
KEYOPT(5)=1 KEYOPT(5)=2SHSD ID
KEYOPT(5)=0,3
3rd Approach: 1st Approach: 2nd Approach:
SHSD,ID SHSD,ID
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
ppshell-solid constraintsolid-solid constraint
ppshell-shell constraint
Ansys Contact usages: tips and tricks
P d
3. MPC connection SOLID-BEAM and SHELL-BEAM
Procedure:1) Treat the solid surface and/or shell edge as contact surface, treat the beam
node as target pilot node. No additional target is needed.2) S t th t t l t k ti2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC methodKEYOPT(12)=5 or 6 Set the bonded contact keyKEYOPT(4)=1 Force-distributed surfaceKEYOPT(4)=2 Rigid constraint surface
3) Run the analysis
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Ansys Contact usages: tips and tricks
3. MPC connection SOLID-BEAM and SHELL-BEAM/prep7et,1,45
vext,all,,,,,150acle,all
et,2,188et,3,173,,2 !KEYOPT(2)=2Keyopt,3,4,1 !KEYOPT(4)=1keyopt,3,12,5 !KEYOPT(12)=5
acle,allk,100,0,0,150k,101,0,0,300k,102,1,1,150l,100,101
et,4,170mp,ex,1,2e5mp,prxy,1,0.3SECTYPE, 1,BEAM, CTUBE
l,100,101lsel,s,,,33LATT,1,,2,,102,,1 lmes,33real,10
SECOFFSET, CENT SECDATA,10,11 pcir,10,11,0,90pcir,10,11,90,180
real,10type,4tshap,pilo !Pilot node on beame,2017 !Pilot node on beamnsel,s,loc,z,150 SOLID-BEAM
pcir,10,11,180,270pcir,10,11,270,360numm,kplesi,4,,,2
i 8
nsel,s,loc,z,150nsel,u,,,2017esel,s,type,,1type,3Esurf !Contact on solid
esiz,,8et,10,42esha,2type,10
ll
Esurf !Contact on solid/solunsel,s,loc,z,0d,all,allnsel,s,loc,z,300
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
ames,allesiz,,20type,1
, , , ,f,2018,fx,1000alls
Ansys Contact usages: tips and tricks
3. MPC connection SOLID-BEAM and SHELL-BEAMExample
Solid solution Solid-Beam via MPC
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
Ansys Contact usages: tips and tricks
3. MPC connection SOLID-BEAM and SHELL-BEAM/prep7et,1,181
adra,1,4,7,10,,,6real 2et,1,181
et,2,188et,3,175,,2,,2 !KEYOPT(2)=2Keyopt,3,4,2 !KEYOPT(2)=2keyopt,3,12,5 !KEYOPT(12)=5
real,2ames,5,8k,100,0,0,150k,101,0,0,300k 102 1 1 150keyopt,3,12,5 !KEYOPT(12) 5
et,4,170mp,ex,1,2e5mp,prxy,1,0.3r,2,1
k,102,1,1,150l,100,101lsel,s,,,18LATT,1,,2,,102,,2 lmes 18r,2,1
SECTYPE, 2, BEAM, CTUBE SECOFFSET, CENT SECDATA,10,11pcir,0,10.5,0,90
lmes,18real,10type,4tshap,piloe,673 SHELL-BEAMpcir,0,10.5,0,90
pcir,0,10.5,90,180pcir,0,10.5,180,270pcir,0,10.5,270,360numm,kp
e,673nsel,s,loc,z,150nsel,u,,,673esel,s,type,,1type,3numm,kp
lsel,s,,,1,10,3lesi,all,,,8esha,2esiz,,20
type,3esurf/solunsel,s,loc,z,0d,all,all
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es ,, 0k,50k,51,0,0,150l,50,51
d,all,allnsel,s,loc,z,300f,674,fx,1000alls
Ansys Contact usages: tips and tricks
P d
4. MPC connection between the FE model and loading point
Procedure:1) Treat the FE surface and/or edge as contact surface, treat the loading node
as target pilot node. No additional target is needed.2) S t th t t l t k ti2) Set the contact element keyoptions:
KEYOPT(2)=2 this will activate the MPC methodKEYOPT(12)=5 or 6 Set the bonded contact keyKEYOPT(4)=1 Force-distributed surfaceKEYOPT(4)=2 Rigid constraint surface
3) Run the analysis
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Ansys Contact usages: tips and tricks
4. MPC connection between the FE model and loading point/prep7 et,1,42et,1,42et,2,169et,3,171,,2,,11 !KEYOPT(2)=2 !KEYOPT(4)=1keyopt,3,12,5 !KEYOPT(12)=5mp,ex,1,2e5p,e , , e5mp,prxy,1,.3 rect,0,10,0,2esiz,1ames,1,n,100,5,5lsel,s,,,2nsll,s,1type,3yp ,real,3esurfallstype,2yp ,tshape,pilote,100nsel,s,loc,x,0d,all,all
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, ,allsf,100,fy,-100
Ansys Contact usages: tips and tricks
4. MPC connection between the FE model and loading point
KEYOPT(4) 1KEYOPT(4)=1Force-distributed surface
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KEYOPT(4)=2Rigid constraint surface
Ansys Contact usages: tips and tricks
4. MPC connection between the FE model and loading point
KEYOPT(4)=1Force-distributed surface
KEYOPT(4)=2Rigid constraint surface/prep7
et,1,42n,1000,0,0lsel,s,,,5,8, ,
et,2,169et,3,171,,2,,1keyopt,3,12,5 mp,ex,1,2e5
, ,,, ,nsll,s,1type,3real,3esurf
/solunsel,s,loc,x,-10d,all,all
llp, , ,mp,prxy,1,.3 rect,-10,10,-5,5pcir,3asba,1,2
allstype,2tshape,pilote,1000
allsf,1000,mz,-.7e6nlgeo,onsolv
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, ,smrt,4ames,all
,
Ansys Contact usages: tips and tricks
4. MPC connection between the FE model and loading point
Bending moment Torsion momentShear forceBending moment Torsion momentShear force
/prep7 cylin,10,20,0,100,0,90 type,3 /soluet,1,45et,2,170et,3,173,,2,,1keyopt,3,12,5
1 2
*rep,4,,,,,90,90numm,kpesiz,3vmes,all
10000 0 0 100
real,3esurfallstype,2
h il
nsel,s,loc,zd,all,allallsf,10000,mx,4.766e3
ll
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
mp,ex,1,2e5mp,prxy,1,.3
n,10000,0,0,100asel,s,,,2,20,6nsla,s,1
tshape,pilote,10000
allssolv
Ansys Contact usages: tips and tricks
4. MPC connection between the FE model and loading point
Bending moment Torsion momentShear forceg Torsion moment
/prep7 et,1,63et 2 170
cylin,10,20,0,100esiz,3
type,3real,3
/solunsel,s,loc,z
et,2,170et,3,175,,2,,1r,1,1keyopt,3,12,5 mp ex 1 2e5
ames,3,4n,10000,0,0,100lsel,s,,,9,12nsll,s,1
esurfallstype,2tshape,pilot
d,all,allallsf,10000,mx,4.766e3
ANSYS, Inc. Proprietary© 2004 ANSYS, Inc.
mp,ex,1,2e5mp,prxy,1,.3
e,10000 allssolv