Finite Element Wear Simulation Using Implicit Node Update
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Solution Overview
Problem
Existing computer-based systems struggle to simultaneously treat interdependencies among wear distances, contact stress, and contact slip for implicit finite element simulation, leading to inaccuracies and convergence problems.
Innovation Solution
A computer-implemented method that involves obtaining a finite element mesh, associating a wear variable with contact constraints, and performing a simulation to determine wear by iteratively calculating wear distance and updating node positions, while considering all contact constraints and using a Newton iteration scheme.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional wear modeling methods are used in finite element simulation, then the implementation is simpler, but the accuracy and robustness of wear prediction deteriorates due to inability to simultaneously treat interdependencies among wear distances, contact stress, and contact slip
Solution Approach 1:
The patent merges the treatment of wear distance, contact stress, and contact slip into a unified implicit finite element simulation framework. By simultaneously solving these interdependent variables within the same computational loop rather than treating them separately, the method achieves accurate wear prediction while maintaining a manageable implementation complexity through integrated formulation.
Solution Approach 2:
The patent implements feedback mechanisms where wear distances update contact constraints, which in turn update contact stresses and contact slips, which then feed back to update wear distances in the next iteration. This closed-loop feedback system within the implicit simulation ensures that all interdependencies are consistently treated, improving accuracy while the iterative nature provides a systematic approach to managing complexity.
2Reliability
If conventional wear modeling is used, then the code implementation requires fewer changes, but convergence problems arise due to artificial requirements and lack of simultaneous treatment of interdependencies
Solution Approach 1:
The patent creates a universal wear modeling framework that works with general contact constraints without requiring artificial classification of surfaces into primary and secondary roles. The method universally treats all contact constraints equally, allowing wear to be modeled on any surface participating in contact, which eliminates convergence problems associated with artificial requirements while keeping code modifications focused on the core wear formulation.
Solution Approach 2:
The patent changes the fundamental parameter treatment by introducing wear distances as additional unknowns in the system of equations rather than as post-processing outputs. This parameter change transforms the wear model from an explicit post-calculation to an implicit simultaneous solution, improving convergence reliability while the systematic integration into the existing finite element framework limits the extent of code modifications needed.
3Productivity
If wear is modeled without simultaneous treatment of interdependencies, then the computational cost per iteration is lower, but the overall simulation efficiency deteriorates due to convergence issues and need for smaller increment sizes
Solution Approach 1:
The patent ensures continuous updating of wear distances, contact stresses, and contact slips throughout the implicit solution process rather than calculating them sequentially with fixed values from previous steps. This continuous mutual updating maintains consistency across all parameters throughout the simulation, improving overall efficiency by eliminating the need for excessive refinement of movement increment sizes that would otherwise be required to achieve convergence.
Data Source
AI summary
Embodiments determine wear. One such embodiment obtains, in memory associated with a processor, a finite element mesh representing a first object. For a given node of the obtained mesh, a wear variable is associated and linked to contact constraints associated with the node. A simulation of contact is performed, over movement increments, between the first object and a second object to determine wear at the node. Wear distance is iteratively determined for a given increment using the mesh, the associated variable, and the constraints. A position of the node in the mesh is iteratively updated based on the determined wear distance for the given increment, until the wear distance for each of the increments is determined. The wear at the node is determined based on the determined wear distance for each of the increments. An indication of the determined wear is output.