warning message using *MAT_PIECEWISE_LINEAR_PLASTICITY

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PJOST

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Apr 15, 2021, 10:00:04 AM4/15/21
to LS-DYNA2
Hello all.  I work as a CAE engineer for a plastics supplier in Auburn Hills, Michigan.
We create MAT24 cards for our various plastics and provide those to our customers so they can run their own simulations.  but we also do some of the CAE evaluations internally.
We create our material cards using software from 4a engineering GmbH.  this is a reverse engineering software which takes results from 3 pt bend testing at various strain rates so we can characterize high speed material properties for our various thermoplastics we develop.

I have been seeing warning messages for some simple beam impact models I've been running.  here is an example:
 *** Warning 40042 (SOL+42)
     Part ID = 1 plasticity algorithm did not converge for MAT24
     time = 3.8381E-03, ncycle = 42646

Any ideas?
Below is an example material input that apparently caused the problem.  Any advice greatly appreciate, thank you.  
Paul Opferman 
*MAT_PIECEWISE_LINEAR_PLASTICITY
$#     mid        ro         e        pr      sigy      etan      fail      tdel
         1  1.47e-09  4455.587       .45                              
$#       c         p      lcss      lcsr        vp
     0.000     0.000   1000000         0        1.
$#    eps1      eps2      eps3      eps4      eps5      eps6      eps7      eps8
     0.000     0.000     0.000     0.000     0.000     0.000     0.000     0.000
$#     es1       es2       es3       es4       es5       es6       es7       es8
     0.000     0.000     0.000     0.000     0.000     0.000     0.000     0.000
*DEFINE_TABLE
$#    tbid
   1000000
$#             value      lcid
   -9.21034037197618   1000001
   -6.90775527898214   1000002
   -4.60517018598809   1000003
   -2.30258509299405   1000004
                  0.   1000005
    2.30258509299405   1000006
    4.60517018598809   1000007
    6.90775527898214   1000008
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000001         0         1         1         0         0
$#                a1                  o1
                   0            36.48204
             .011429    49.9122997957396
             .022857    51.9522441715612
             .034286     52.777382708247
             .045714    53.2238242935045
             .057143    53.5036539629073
             .068571    53.6954456052316
                 .08    53.8351199692761
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000002         0         1         1         0         0
$#                a1                  o1
                   0    43.8266674628552
             .011429    59.9607304156844
             .022857    62.4113599254886
             .034286    63.4026167811391
             .045714    63.9389367593713
             .057143    64.2751022223542
             .068571    64.5055056902058
                 .08    64.6732995390713
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000003         0         1         1         0         0
$#                a1                  o1
                   0    51.1712949257104
             .011429    70.0091610356292
             .022857     72.870475679416
             .034286    74.0278508540312
             .045714    74.6540492252382
             .057143    75.0465504818011
             .068571      75.31556577518
                 .08    75.5114791088665
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000004         0         1         1         0         0
$#                a1                  o1
                   0    58.5159223885656
             .011429     80.057591655574
             .022857    83.3295914333434
             .034286    84.6530849269232
             .045714    85.3691616911051
             .057143    85.8179987412479
             .068571    86.1256258601542
                 .08    86.3496586786617
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000005         0         1         1         0         0
$#                a1                  o1
                   0    65.8605498514209
             .011429    90.1060222755189
             .022857    93.7887071872707
             .034286    95.2783189998153
             .045714    96.0842741569719
             .057143    96.5894470006948
             .068571    96.9356859451284
                 .08    97.1878382484569
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000006         0         1         1         0         0
$#                a1                  o1
                   0    73.2051773142761
             .011429    100.154452895464
             .022857    104.247822941198
             .034286    105.903553072707
             .045714    106.799386622839
             .057143    107.360895260142
             .068571    107.745746030103
                 .08    108.026017818252
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000007         0         1         1         0         0
$#                a1                  o1
                   0    80.5498047771313
             .011429    110.202883515409
             .022857    114.706938695126
             .034286    116.528787145599
             .045714    117.514499088706
             .057143    118.132343519589
             .068571    118.555806115077
                 .08    118.864197388047
*DEFINE_CURVE
$#    lcid      sidr       sfa       sfo      offa      offo    dattyp
   1000008         0         1         1         0         0
$#                a1                  o1
                   0    87.8944322399865
             .011429    120.251314135353
             .022857    125.166054449053
             .034286    127.154021218491
             .045714    128.229611554573
             .057143    128.903791779035
             .068571    129.365866200051
                 .08    129.702376957842

Евгений Калентьев

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Apr 15, 2021, 10:47:39 AM4/15/21
to LS-DYNA2
Dear Paul.
Just a guess.
The LCSS parameter sets a table in which the strain rate is matched with a curve that determines the dependence of the effective stress on the effective plastic deformation.
 In this regard, the question is, why do you have negative strain rates in this table?

Sincerly,
Eugene Kalentev

четверг, 15 апреля 2021 г. в 18:00:04 UTC+4, pghg...@gmail.com:

l...@schwer.net

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Apr 15, 2021, 11:11:23 AM4/15/21
to PJOST, LS-DYNA2

My guess this Warning is caused by your use of the parameter VP=1 Viscoplastic formulation in your MAT024 definition. The Viscoplastic algorithm requires an iterative scheme to return the trial stress to the shear yield surface.

 

When the effective plastic strain increments are large the iteration scheme can fail to meet the internally set tolerance.

 

Try reducing the time step size via TSSFAC on *CONTROL_TIMESTEP, perhaps TSSFAC=0.8                              --len

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James M. Kennedy

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Apr 15, 2021, 12:24:14 PM4/15/21
to PJOST, LS-DYNA2

Dear Paul,

 

Are you using a double precision executable?

 

------------------------------------

 

Some notes I found:

 

Evidently, MAT_024 does not rediscretize the S-S curve when LCSS is a

curve while it does rediscretize the curves when LCSS is a table.

 

As I understand, LS-DYNA uses the re-discretized curves in the strain 
direction [when LCSS is a table]. This means that the original intervals 
are retained in the strain-rate direction but not in the strain direction.

 

------------------------------------

 

*CONTROL_ACCURACY

 

Purpose: Define control parameters that can improve the accuracy of the

calculation.

 

EXACC Explicit accuracy parameter:

EQ.0.0: Off (default)

GT.0.0: On (see Remark 5)

 

5. EXACC. The EXACC option is developed to improve the numerical accuracy

for an explicit analysis. Currently, nodal coordinates are computed and

stored in double precision in all versions. In most cases, this is suffic-

iently accurate and EXACC is recommended to be off. However, in some cases,

particularly when initial coordinates are large and displacements are small,

EXACC can increase the accuracy of computations. To use this option, the

EXACC parameter should be set to a positive value which is a characteristic

element length for the mesh. For example, if the typical edge length in a

model is 5.0 mm and the length units are millimeters, then set EXACC = 5.0.

 

------------------------------------

 

See discussion on pages 22 and 23 in the following:

 

Question: Plasticity Algorithm Warning Messages

 

https://www.dynalook.com/fea-newsletters/fea-newsletters-2006/fea-newsletter-april-2006.pdf

 

------------------------------------

 

Sincerely,

James M. Kennedy

KBS2 Inc.

April 15, 2021

 

From: ls-d...@googlegroups.com [mailto:ls-d...@googlegroups.com] On Behalf Of PJOST
Sent: Thursday, April 15, 2021 9:00 AM
To: LS-DYNA2 <ls-d...@googlegroups.com>
Subject: [LS-DYNA2] warning message using *MAT_PIECEWISE_LINEAR_PLASTICITY

 

Hello all.  I work as a CAE engineer for a plastics supplier in Auburn Hills, Michigan.

--

PO

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Apr 15, 2021, 2:52:46 PM4/15/21
to James M. Kennedy, LS-DYNA2
Hi James, yes I am using the double precision executable,  Version : smp d R12.0.0   Date: 06/19/2020   Revision: 14893.
I was not aware of this.  I don't completely understand what you mean but I will read the link you sent.

And thank you as well to Eugene and Len!   much appreciated!
Paul 

PO

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Apr 16, 2021, 9:48:54 AM4/16/21
to James M. Kennedy, L...@schwer.net, LS-DYNA2
I did want to mention that the model I've created (simple beam impact model) is using Type 16 solid tet elements (2mm size).  The MAT24 card we developed in the VALIMAT software (by 4a Engineering) was based on that element type. 

I've also created midplane shell element models for comparison (as well as Mat24 cards developed for that element type). Those models have none of the warning messages.


On Thu, Apr 15, 2021 at 12:24 PM James M. Kennedy <j...@kbs2.com> wrote:

James M. Kennedy

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Apr 16, 2021, 10:52:45 AM4/16/21
to PO, L...@schwer.net, LS-DYNA2

Dear Paul,

 

Did you try Len’s suggestion of reducing the time step safety factor?

 

Different element formulations use different characteristic lengths (Le) for determining its stable

time step (please see the following). Some time steps may be more conservative than others.

 

The following (Table 1) provides time step and run time characteristics of the various tetrahedron

(constant stress hexahedron included as a base comparison) for a simple cantilever beam simulation

(ls971d R5.1.1 - SMP with 2 CPUs) composed of either 360 hexahedron elements (cubic) or 1800

tetrahedron elements (5 equal tetrahedron per cubic hexahedron).

 


 

 

Table 1. Tetrahedron Elements Timing Information

Formulation

(elform)

Nodes/Type

(hex-tet)

Characteristic

Length (Le)

Time Step

(dt)

Normalized

Run Time

1

8-node hex

V/Amax

1.75e-5

  1.0

1

4-node tet

hmin

1.02e-5

  6.0

4

4-node tet

0.850 hmin

8.66e-6

14.5

10

4-node tet

hmin

1.02e-5

  2.0

13

4-node tet

hmin

1.02e-5

  2.3

16

10-node tet

0.3889 hmin

3.96e-6

27.0

17

10-node tet

V/Amax

3.40e-6

48.0

 

Sincerely,

James M. Kennedy

KBS2 INC.

April 16, 2021

PO

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Apr 16, 2021, 11:34:04 AM4/16/21
to James M. Kennedy, L...@schwer.net, LS-DYNA2
No I haven't yet.  
question - how do I find out the time step of the model?  here is a snipped of output for one of the tetra models.
This looks to me like the first solved time was just under 1e-4?  

  calculation with mass scaling for minimum dt
    added mass   =   2.1765E-08
    physical mass=   6.0970E-02
    ratio        =   3.5698E-07
       1 t 0.0000E+00 dt 9.00E-08 flush i/o buffers            04/16/21 11:24:24
       1 t 0.0000E+00 dt 9.00E-08 write d3plot file            04/16/21 11:24:24
    1112 t 9.9990E-05 dt 9.00E-08 write d3plot file            04/16/21 11:24:41
    2223 t 1.9998E-04 dt 9.00E-08 write d3plot file            04/16/21 11:24:59
    3334 t 2.9997E-04 dt 9.00E-08 write d3plot file            04/16/21 11:25:16  

here is what i've been using for my timestep settings.  I use ANSYS workbench to create my models.  

*CONTROL_TIMESTEP
$   dtinit    tssfac      isdo    tslimt     dt2ms      lctm     erode     ms1st
         0       0.9         0         0    -1E-07         0         1         0
$   dt2msf   dt2mslc     imscl                                            unused
         0         0         0  



l...@schwer.net

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Apr 16, 2021, 12:07:07 PM4/16/21
to PO, James M. Kennedy, LS-DYNA2

The time step in the provided snip it is  dt 9.00E-08

PO

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Apr 16, 2021, 2:53:30 PM4/16/21
to L...@schwer.net, James M. Kennedy, LS-DYNA2
ok, that's what I was thinking but wasn't sure.
I went back and changed the *CONTROL_ACCURACY parameter EXACC to 2.0 since the element edge length is 2.0mm (as suggested).  I still see the same warning messages.

regarding the VP=1 option for *MAT_PIECEWISE_LINEAR_PLASTICITY, that's what we use for the various plasticity curves at different strain rates.  One of our CAE guys uses the 4a VALIMAT reverse engineering software to fit those curves based on approximation of the 3-point bend testing that is performed on samples.  I don't have much background about how the software works; I just know that there is some effort involved.

Is it possible that element quality/aspect ratio can affect this too?  I wonder, because I could not mesh this part in ANSYS with what they call 'patch conforming' mesh....it was 'patch independent' where it only approximates some of the finer geometric features (such as blend radii)

l...@schwer.net

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Apr 16, 2021, 3:13:29 PM4/16/21
to PO, James M. Kennedy, LS-DYNA2

Your time step dt 9.00E-08 is determined by the combination of TSSFAC=0.9 and the mass scaling factor DT2MS=1E-7, i.e. (0.9)(1E-7)=9E-8

 

This FIXED time step causes effective plastic strain increments that are large and the interactive scheme in MAT024 fails to return the trial stress to the yield surface with the resulting warning message you posted  -- as I stated originally.

 

If this explanation is “Greek” to you, you need more self-study about plasticity algorithms.

 

               --len

PO

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Apr 16, 2021, 3:43:54 PM4/16/21
to L...@schwer.net, James M. Kennedy, LS-DYNA2
thanks Len. 
yes it's somewhat Greek to me - yes I need to read into it but might not help me much, I'm no PhD and don't understand the numerical workings.  i'm just a guy who learned enough about Ls-Dyna to run somewhat simple models.
would a 'non-fixed' time step alleviate this problem?

l...@schwer.net

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Apr 16, 2021, 3:57:32 PM4/16/21
to PO, James M. Kennedy, LS-DYNA2

Removing the mass scaling MIGHT help.

 

A lack of knowledge is not an excuse, but a danger to others that might use your results.

PO

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Apr 16, 2021, 4:25:31 PM4/16/21
to L...@schwer.net, James M. Kennedy, LS-DYNA2
Absolutely true Len, I will definitely research it.  I appreciate your time

James M. Kennedy

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Apr 17, 2021, 10:54:27 AM4/17/21
to L...@schwer.net, PO, LS-DYNA2

Dear Paul,

 

computational plasticity

 

Benson, D.J., "Computational Plasticity", Livermore Software Technology Corporation,

Livermore, California, March-April, 2005.

 

http://www.dynasupport.com/tutorial/computational-plasticity

 

Keller, C., and Herbrich, U., "Plastic Instability of Rate-Dependent Materials – A Theoretical

Approach in Comparison to FE-Analyses -", 11th European LS-DYNA Users Conference, Salzburg,

Austria, May, 2017.

 

https://www.dynalook.com/conferences/11th-european-ls-dyna-conference/crash-metal-failure/plastic-instability-of-rate-dependent-materials-a-theoretical-approach-in-comparison-to-fe-analyses/

 

time integration

 

https://www.dynasupport.com/tutorial/ls-dyna-users-guide/time-integration/

https://www.dynasupport.com/tutorial/ls-dyna-users-guide/time-step-size/

 

Bala, S., "Time Integration in LS-DYNA", Livermore Software Technology Corporation,

Livermore, California, April, 2007.

 

http://blog2.d3view.com/wp-content/uploads/2007/04/timeintegration_v1.pdf

 

Jensen, M.R., "Introduction to LS-DYNA - Level II (Chapter 11 - Timestep and Mass-

Scaling)", Livermore Software Technology Corporation, Livermore, California, (undated

publication).

 

(please contact sup...@lstc.com)

 

conventional mass scaling

 

Mass-scaling, Bala [2006], is a term that is used for the process of scaling the element’s

mass in explicit simulations to adjust its timestep. The primary motivation is to change

(usually increase) the global compute time step which is limited by the Courant’s stability

criteria.

 

Conventional mass scaling (CMS): The mass of small or stiff elements is increased to prevent

a very small time step. Thus, artificial inertia forces are added which influence all eigen freq-

uencies including rigid body modes. This means, this additional mass must be used very

carefully so that the resulting non-physical inertia effects do not dominate the global solution.

This is the standard default method that is widely used.

 

Bala, S., "Overview of Mass-Scaling in LS-DYNA", Livermore Software Technology

Corporation, Livermore, California, October, 2006.

 

http://blog2.d3view.com/?p=106

 

Day, J., "Mass Scaling", Livermore Software Technology Corporation, Livermore, California,

November, 2010.

 

http://www.dynasupport.com/howtos/general/mass-scaling

http://ftp.lstc.com/anonymous/outgoing/jday/faq/mass_scaling

 

selective mass scaling

 

Selective mass scaling (SMS): Using selective mass scaling only the high frequencies are affected,

whereas the low frequencies (rigid body modes) are not influenced. Thereby, a lot of artificial

mass can be added to the system without adulterate the global solution. This method is very

effective, if it is applied to limited regions with very small critical time steps. SMS is invoked

with  the IMSCL command over a single part or multiple parts

 

Bala, S., "Overview of Mass-Scaling in LS-DYNA", Livermore Software Technology

Corporation, Livermore, California, October, 2006.

 

http://blog2.d3view.com/?p=106

 

Borrvall, T., "Selective Mass Scaling (SMS): Theory and Practice", 2011 Developers' Forum,

Stuttgart, Germany, October, 2011.

 

https://www.dynamore.de/en/downloads/papers/forum11/entwicklerforum-2011/borrvall.pdf

 

 

Tkachuk, A., "Variation Methods for Consistent Singular and Scaled Mass Matrices", Ph.D.

Thesis, Institut für Baustatik und Baudynamik, Universität Stuttgart, Stuttgart, Germany,

December, 2013.

 

https://www.ibb.uni-stuttgart.de/publikationen/fulltext_new/2013/tkachuk_2013.pdf

 

Sincerely,

James M. Kennedy

KBS2 Inc.

April 17, 2021

James M. Kennedy

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Apr 17, 2021, 12:51:41 PM4/17/21
to L...@schwer.net, PO, LS-DYNA2

Dear Paul,

 

Vogler, M., Kolling, S., and Haufe, A., "A Constitutive Model for Polymers with a

Piecewise Linear Yield Surface", Proceedings Applied Mathematics and Mechanics

(PAMM), Vol. 6, Issue 1, pp. 275-276, December, 2006.

 

http://onlinelibrary.wiley.com/doi/10.1002/pamm.200610118/pdf

 

Vogler, M., Kolling, S., and Haufe, A., "A Constitutive Model for Plastics with Piecewise

Linear Yield Surface and Damage", 6th German LS-DYNA Forum, Frankenthal, Germany,

October, 2007.

 

http://www.dynamore.de/en/downloads/papers/07-forum/crash/a-constitutive-model-for-plastics-with-piecewise

 

Kolling, S. and Vogler, M.., "A Constitutive Plasticity Model with Piecewise Linear Yield

Surface and Damage", Institut für Mechanik und Materialforschung, Technische Hochschule

Mittelhessen, Giessen, Germany.

 

https://www.thm.de/me/images/user/IMM-110/Papers/Festschrift_Juckenack_30-51.pdf

 

Sincerely,

James M. Kennedy

KBS2 Inc.

April 17, 2021

 

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