ContactLogic Abaqus

Contact Logic and Diagnostics Tools
Lecture 4
L4.2
Overview
Newton Method
The Contact Algorithm

Contact Iterations
Contact Diagnostics (Visual)

Contact Diagnostics (Text)
Understanding the logic that Abaqus uses to solve contact problems is
helpful for:
Understanding output
Troubleshooting convergence problems

Tools are available in Abaqus/CAE to visualize contact output.
This greatly simplifies the troubleshooting process.
Modeling Contact with Abaqus/Standard
Newton Method
L4.4
Newton Method
The Newton method is an iterative method used to solve nonlinear
problems.
Given:
Desired load P
Ability to evaluate f(u) and K(u)

Find:
us, such that f(us) = P
L4.5
Newton Method
The Newton method, however, is not guaranteed to converge.
Example in which Newton iterations diverge:

Load
Goal: find this point
P
Diverging!
Applied load
Displacement
Starting point
Load applied in 1 increment
Increase the likelihood of convergence by decreasing load increment.
Use multiple load increments to achieve desired total load.

Load
Load
P
P1
Displacement
Displacement
Half load in 1st increment
Remaining load in 2nd incr.
L4.6
Newton Method
Abaqus automatically adjusts the load increment size.
Goal: Find converged solution robustly and efficiently with respect to the
number of iterations.
Basic idea: Track convergence rate in order to determine when to
increase or decrease load increment size.
User suggests increment size; Abaqus tries to optimize it.
Slow convergence
or divergence
Reduce
increment size
Convergence in few
iterations
Increase
increment size
L4.7
Newton Method
Contact causes kinks in the load vs. displacement curve.
There is a slope discontinuity upon change in contact status.

As a result, contact changes interrupt overall convergence rate tracking.
Undeformed shape
3. Compress tip
2. Contact
rigid surface
1. Bend beam
P
Deformed shape
(Mises stress contours)
Challenging for
Newton method!
L4.8
Newton Method
Severe discontinuity iterations (SDIs)
An SDI is an iteration during which contact constraints change state
(open/closed, stick/slip)
Idea is to filter out contact effects from convergence rate tracking
The logic to adjust the increment size treats SDIs separately
Separate counts for
SDIs and non-SDIs
Status (.sta) file

for the previous
example (beam
contact)
1st attempt did not

convergereduce Dt
2nd attempt at first

incr. converges
Increase Dt due to
fast convergence
DP = (Dt/T) Pfinal
Converged incr. with

contact activated
Total step
time=1.0
Trend toward larger

Dt after contact is
established
L4.10

Hard contact pressure vs. overclosure:
Contact
pressure
Hard contact
Compliant
Non-compliant
Penetration
distance
Gap distance
Penetration for
open contacts
Tensile stress for
closed contacts
Default behavior: SDIs do not block convergence

Convert SDI: small penetrations/tensile stresses trigger contact status
changes (& SDIs) but do not necessarily block convergence
Without Convert SDI

Contact status changes (SDIs) block convergence
L4.11

Schematic of behavior within an increment (default behavior)
Begin
increment
Identify initially
active contact
constraints
Newton
iterations
Yes
No
(Reduce increment
size and try again)
Identify changes
3
in contact
constraint status
Form and
solve system
of equations
Determine if
tending toward
convergence
No
Check if
solution has
converged
(At least one

convergence criterion
is not satisfied)
End
increment
Yes
(Within
convergence
tolerances)
L4.12

Default contact algorithm (refer to flowchart on previous page):
1
Determine the initial contact state at each point (closed or open).

For first increment of a step, based on initial model state; otherwise,
based on solution extrapolation (if any)
Calculate the stiffness, imposing contact constraints accordingly. Form

the system of equations and pass through the equation solver.
Are contact pressures and clearances consistent with the assumed

contact state?
Contact status changes (open/closed or stick/slip) often cause
significant changes to the system of equations
Iterations with contact status changes are flagged as severe
discontinuity iterations (SDIs)
L4.13

4
Has convergence been achieved?
By default, Abaqus quantifies the contact incompatibilities

associated with SDIs. These incompatibilities must be sufficiently
small to achieve convergence with respect to the contact state.
Also have to ensure that the force residuals and solution corrections
are sufficiently small to achieve equilibrium.
If the contact state and equilibrium conditions satisfy their respective
convergence criteria, the increment is complete.
5
If convergence is not achieved, is it likely to be achieved?

Abaqus evaluates trends, such as the number of contact status
changes in successive iterations, to determine whether or not to
continue iterating or cut back the increment size.
If convergence is likely, update the contact constraints based on 3

and the stiffness, and re-solve the system of equations; otherwise,
try again with a smaller increment size.
L4.14

The default limit on total SDIs per
increment is 50.
In principle not necessary to
limit the number of severe
discontinuity iterations.
Sophisticated criteria determine
whether iteration should be
continued or terminated.
The default limit for the

maximum number of severe
discontinuity iterations is 50,
which in practice should always
be more than the actual number
of iterations in an increment.
Contact Iterations
L4.16
Contact Iterations
Contact iterations can be used instead of regular severe discontinuity
iterations to speed up computations.
Regular severe discontinuity iterations involve costly assembly and
factorization of the global stiffness matrix.
With contact iterations, the displacement correction is obtained by
changing only the global right-hand side of the matrix equation.
When the number of contact elements changing status from
open to closed and vice versa is small, this approach is more
effective.
Abaqus determines automatically whether contact iterations are
more efficient than regular SDIs.
Contact iterations can be especially effective for the solution of large
linear elastic frictionless contact problems that require many severe
discontinuity iterations.
L4.17
Contact Iterations
Schematic of behavior within an increment with contact iterations
Begin
increment
3a
Identify initially
active contact
constraints
Newton
iterations
Yes
No
(Reduce increment
size and try again)
Identify changes
3
in contact
constraint status
Form and
solve system
of equations
Determine if
tending toward
convergence
No
Check if
solution has
converged
(At least one

convergence criterion
is not satisfied)
End
increment
Yes
(Within
convergence
tolerances)
L4.18
Contact Iterations
Contact algorithm with contact iterations:
3a
Are contact pressures and clearances consistent with the assumed

contact state?
When the number of contact elements changing status from open to
closed and vice versa is small, "contact iterations" are an effective
alternative to regular SDIs
Perform "nested" iterations without re-assembling and re-factoring
the global stiffness matrix
Stiffness changes due only to contact state changes; effect

introduced through RHS of the matrix equation
Continue until no changes in contact state or number of contact
iterations is exhausted
L4.19
Contact Iterations
Range of effectiveness
Most effective
Linear elastic geometrically linear small-sliding

contact problems.
Materially nonlinear geometrically linear smallsliding contact problems.

Linear elastic geometrically nonlinear finite-sliding
contact problems.
Materially nonlinear geometrically nonlinear finitesliding contact problems.
Less effective
L4.20
Contact Iterations
Usage:
*SOLUTION TECHNIQUE,
TYPE=CONTACT ITERATIONS
correction_factor, n_max
where
correction_factor = factor on
the upper limit of the number of

contact status changes to solve,
for the contact iteration to be
effective; and
n_max = maximum number of
contact iterations per trial
L4.21
Contact Iterations
Example: engine bulkhead with
1.4 M dofs
Many bodies, connected by
contact pairs and *TIE
Contact iteration improves the
solution time
Linear elastic
(NLGEOM=NO)
Frictionless, small-sliding
contact
Time to factorize is
greater than to obtain the
right-hand side solutions
Without
contact
iterations
With
contact
iterations
Wallclock time (min.)
177
97
# SDIs
10
# Contact iterations
L4.22
Contact Iterations
Example: engine block with 2.6 M dofs
Only nonlinearities are elastic-plastic

gasket and small-sliding contact
Contact to be resolved in many areas
(gasket, bolts, rings, etc.)
Also run with linear gasket behavior
NLGEOM=NO
Gasket behavior
# Contact
iterations
# Equilibrium
iterations
Wallclock time speedup
factor with contact iterations
Elasticplastic
Linear
1.47
5.20
Plastic strain
in gasket
L4.23
Contact Iterations
Limitations:
can be used only with the static solution procedure;

require the use of the direct sparse solver;
cannot be used with coupled analyses with the separated solution

technique;
cannot be used with sparse format matrix input and assemblage; and
the following features cannot use contact iterations:
contact with friction

points that are permitted to violate contact conditions
points that are released from contact by overconstraint checks

debond contact
L4.25

Contact diagnostics example using Abaqus/CAE
Reference: Example Problem 1.3.4, Deep drawing of a cylindrical cup
L4.26

Visual diagnostics are available in the Visualization module of
Abaqus/CAE.
Step 3, Increment 6: 5 iterations (3

involve SDIs)
L4.27
Constrained nodes want

to open: incompatible
contact state
Toggle on to see the locations

in the model where the contact
state is changing.
L4.28
Slave nodes that slip; stick/slip

messages cause SDIs only if
Lagrange friction is used or if
slip reversal occurs.
L4.29
Contact incompatibilities are

quantified: max force
error for constrained nodes
The contact force error is

larger than the time-average
force (=3137; will see this
shortly) contact
incompatibility too large
L4.30
Contact incompatibilities are

quantified: max penetration
error for unconstrained nodes
The maximum penetration error is

much smaller than the
displacement correction (=1.68e-5)
L4.31
Not only is the contact incompatibility

too large, but force equilibrium has not
been achieved either.
The force residual is larger

than the time-average force,
as is the estimated contact
force error (seen previously)
L4.32

4 additional iterations are required, two of which
are SDIs (involve contact incompatibilities).
In the final iteration, both the contact and
equilibrium checks pass and the increment
converges.
L4.34

Contact diagnostics example using the message ( .msg) file
Reference: Example Problem 1.3.4, Deep drawing of a cylindrical cup

Status (.sta) file:
SUMMARY OF JOB INFORMATION:
MONITOR NODE:
200 DOF: 2
STEP INC ATT SEVERE EQUIL TOTAL
DISCON ITERS ITERS
ITERS
1
1
1
1
1
2
2
1
1
0
1
1
3
1
1
10
0
10
3
2
1
7
1
8
3
3
1U
9
0
9
3
3
2
5
0
5
3
4
1
3
1
4
3
5
1
2
3
5
3
6
1
3
2
5
3
7
1
4
1
5
3
8
1
6
1
7
3
9
1
3
4
7
3
10
1U
4
0
4
3
10
2
7
1
8
3
11
1
3
2
5
.
.
.
TOTAL
TIME/
FREQ
1.00
2.00
2.01
2.02
2.02
2.02
2.03
2.04
2.05
2.07
2.10
2.14
2.14
2.16
2.18
STEP
TIME/LPF
INC OF
TIME/LPF
1.00
1.00
0.0100
0.0200
0.0200
0.0238
0.0294
0.0378
0.0505
0.0695
0.0979
0.141
0.141
0.157
0.181
1.000
1.000
0.01000
0.01000
0.01500
0.003750
0.005625
0.008438
0.01266
0.01898
0.02848
0.04271
0.06407
0.01602
0.02403
DOF
IF
MONITOR RIKS
0.000
0.000
-0.000600
-0.00120
-0.00120
-0.00142
-0.00176
-0.00227
-0.00303
-0.00417
-0.00588
-0.00844
-0.00844
-0.00940
-0.0108
L4.35

Message file, Step 3, Increment 6:
INCREMENT
6 STARTS. ATTEMPT NUMBER
1, TIME INCREMENT
1.266E-02
CONTACT PAIR (ASURF,BSURF) NODE 167 IS NOW SLIPPING.

CONTACT PAIR (ASURF,BSURF) NODE 171 IS NOW SLIPPING.
:
:
*PRINT, CONTACT=YES causes this detailed printout.
(Useful for troubleshooting)
Slave nodes that slip; stick/slip

messages cause SDIs only if
Lagrange friction is used or if
slip reversal occurs.
:
CONTACT PAIR (ASURF,BSURF) NODE 153 OPENS. CONTACT PRESSURE/FORCE IS -830689..
CONTACT PAIR (ASURF,BSURF) NODE 161 OPENS. CONTACT PRESSURE/FORCE IS -1.43706E+006.
CONTACT PAIR (ASURF,BSURF) NODE 165 OPENS. CONTACT PRESSURE/FORCE IS -1.03301E+006.
CONTACT PAIR (CSURF,DSURF) NODE 363 OPENS. CONTACT PRESSURE/FORCE IS -3.43767E+006.
CONTACT PAIR (ESURF,FSURF) NODE 309 IS NOW SLIPPING.
5 SEVERE DISCONTINUITIES OCCURRED DURING THIS ITERATION.
4 POINTS CHANGED FROM CLOSED TO OPEN
Due to slip reversal
1 POINTS CHANGED FROM STICKING TO SLIPPING
Incompatibilities
detected in the
assumed contact
state SDI
L4.36

Message file, Step 3, Increment 6 (cont'd):
CONVERGENCE CHECKS FOR SEVERE DISCONTINUITY ITERATION
MAX. PENETRATION ERROR -8.1463E-009 AT NODE 331 OF CONTACT PAIR (ESURF,FSURF)
Convergence checks
for contact state
MAX. CONTACT FORCE ERROR -4184.86 AT NODE 363 OF CONTACT PAIR (CSURF,DSURF)
THE ESTIMATED CONTACT FORCE ERROR IS LARGER THAN THE TIME-AVERAGED FORCE.
AVERAGE FORCE
5.350E+03
TIME AVG. FORCE
3.137E+03
LARGEST RESIDUAL FORCE
-1.200E+04
AT NODE
333
DOF
LARGEST INCREMENT OF DISP.
-7.783E-04
AT NODE
329
DOF
LARGEST CORRECTION TO DISP.
-1.684E-05
AT NODE
337
DOF
FORCE
EQUILIBRIUM NOT ACHIEVED WITHIN TOLERANCE.
AVERAGE MOMENT
ALL MOMENT
110.
TIME AVG. MOMENT
Not only is the contact incompatibility

too large, but force equilibrium has
not been achieved either
89.0
RESIDUALS ARE ZERO
LARGEST INCREMENT OF ROTATION
1.847E-33
AT NODE
100
DOF
LARGEST CORRECTION TO ROTATION
6.454E-34
AT NODE
300
DOF
THE MOMENT
Convergence checks
for equilibrium
EQUILIBRIUM EQUATIONS HAVE CONVERGED
L4.37

Four additional iterations are required; the first two are SDIs (involve
contact incompatibilities).
In the final iteration both the contact and equilibrium checks pass and
the increment converges.
CONVERGENCE
CONVERGENCE
CONVERGENCE
CONVERGENCE
CHECKS
CHECKS
CHECKS
CHECKS
FOR
FOR
FOR
FOR
SEVERE DISCONTINUITY ITERATION

SEVERE DISCONTINUITY ITERATION
EQUILIBRIUM ITERATION
1
EQUILIBRIUM ITERATION
2
2 ...
3 ...
No SDIs in these
iterations
MAX. PENETRATION ERROR -1.24301E-015 AT NODE 331 OF CONTACT PAIR (ESURF,FSURF)

MAX. CONTACT FORCE ERROR -9.94745E-005 AT NODE 331 OF CONTACT PAIR (ESURF,FSURF)
THE CONTACT CONSTRAINTS HAVE CONVERGED.
AVERAGE
LARGEST
LARGEST
LARGEST
FORCE
5.244E+03
TIME AVG. FORCE
RESIDUAL FORCE
-1.98
AT NODE
135
INCREMENT OF DISP.
-7.809E-04
AT NODE
129
CORRECTION TO DISP.
1.063E-08
AT NODE
135
THE FORCE
AVERAGE MOMENT
109.
TIME AVG. MOMENT
ALL MOMENT
RESIDUALS ARE ZERO
LARGEST INCREMENT OF ROTATION
1.925E-33
AT NODE
100
LARGEST CORRECTION TO ROTATION
-6.933E-38
AT NODE
100
THE MOMENT
3.120E+03
DOF 1
DOF 2
DOF 2
88.8
DOF
DOF
6
6

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Contact Logic and Diagnostics Tools

The Contact Algorithm

Contact Diagnostics (Visual)

Troubleshooting convergence problems

Modeling Contact with Abaqus/Standard

Ability to evaluate f(u) and K(u)

us, such that f(us) = P

Modeling Contact with Abaqus/Standard

Example in which Newton iterations diverge:

Goal: find this point

Load applied in 1 increment

Increase the likelihood of convergence by decreasing load increment.

Use multiple load increments to achieve desired total load.

Half load in 1st increment

Remaining load in 2nd incr.

Modeling Contact with Abaqus/Standard

Modeling Contact with Abaqus/Standard

There is a slope discontinuity upon change in contact status.

Modeling Contact with Abaqus/Standard

Status (.sta) file

1st attempt did not

2nd attempt at first

Converged incr. with

Trend toward larger

The Contact Algorithm

The Contact Algorithm

Default behavior: SDIs do not block convergence

Without Convert SDI

Modeling Contact with Abaqus/Standard

The Contact Algorithm

(At least one

Modeling Contact with Abaqus/Standard

The Contact Algorithm

Determine the initial contact state at each point (closed or open).

Calculate the stiffness, imposing contact constraints accordingly. Form

Are contact pressures and clearances consistent with the assumed

Modeling Contact with Abaqus/Standard

The Contact Algorithm

Has convergence been achieved?

By default, Abaqus quantifies the contact incompatibilities

If convergence is not achieved, is it likely to be achieved?

If convergence is likely, update the contact constraints based on 3

Modeling Contact with Abaqus/Standard

The Contact Algorithm

The default limit for the

Modeling Contact with Abaqus/Standard

Modeling Contact with Abaqus/Standard

(At least one

Modeling Contact with Abaqus/Standard

Are contact pressures and clearances consistent with the assumed

Stiffness changes due only to contact state changes; effect

Modeling Contact with Abaqus/Standard

Linear elastic geometrically linear small-sliding

Materially nonlinear geometrically linear smallsliding contact problems.

Materially nonlinear geometrically nonlinear finitesliding contact problems.

Modeling Contact with Abaqus/Standard

the upper limit of the number of

contact iterations per trial

Modeling Contact with Abaqus/Standard

Wallclock time (min.)

Modeling Contact with Abaqus/Standard

Only nonlinearities are elastic-plastic

Modeling Contact with Abaqus/Standard