IhESJS This is to certify that the thesis entitled CALCULATED STRUCTURAL RESPONSE USING A "REDUCED" FINITE ELEMENT MODEL presented by Mark Norman Pickelmann has been accepted towards fulfillment of the requirements for MASTER DEW degree in JIECHANIQAL ENGINEERING _ A \ Major professor 5/! 7/8 2/ 0-7639 MS U is an Affirmative Action/Equal Opportunity Institution MSU LIBRARIES m RETURNING MATERIALS: Place in book drop to remove this checkout from your record. FINES will be charged if book is returned after the date stamped below. CALCULATED STRUCTURAL RESPONSE USING A "REDUCED“ FINITE ELEMENT MODEL BY Mark Norman Pickeleann A THESIS Submitted to Michigan State University in partial fulfilleent of the requireeents for the degree of MASTER OF SCIENCE Department of Mechanical Engineering 1982 ABSTRACT CALCULATED STRUCTURAL RESPONSE USING A “REDUCED” FINITE ELEMENT MODEL .J BY Mark Norman Pickelmann The use of finite element models for engineering design has grown rapidly in the past few years. These models are useful tools for predicting the behavior of systems long before the system is actually constructed. The resulting models, however, are often quite large, requiring hours of computer time to use. This thesis demonstrates that a finite element model can be reduced for the purpose of calculating structural response. This reduction is done systematically so that the model is transformed into a set of first order ordinary differential equations. These equations are solved and used to calculate frequency responses. This reduction offers considerable time and cost savings over computing the response directly from the finite element model. CALCULATED STRUCTURAL RESPONSE USING A “REDUCED” FINITE ELEMENT MODEL Submitted by: Mark N. Pickelmann M.S. Candidate Approved by: James E. Bernard Associate Professor Thesis Advisor Q4 flfiflz/e fl tefi‘fi‘flfifltiztm" Engineering ii 5/x'7/527. Date "~/ 7 ~82/ Date 5-47-52 Date To my loving wife Kristi iii AKNONLEDGEMENTS I would like to thank Dr. James E. Bernard, my major professor, for his help, friendship, and advice over the last two years. Also, I wish to thank Dr. Clark Radcliffe for all of his help on the Oldsmobile project and for letting me use his computer to print my thesis. Many thanks to Don Hine, of Oldsmobile, for all his help on the project. Finally, I would especially like to thank my mom and dad, Mary and Russell Pickelmann, for having me in the first place. iv CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER TABLE OF CONTENTS Flat-RES COCO-CC.ICIICCCCCIOIOICICOO-IOICCOOCI 1 VOU-FNN APPENDIX A INTRDMTIN 0....-ICC-OOICOIIIIIIOIOII SMTLRK mm .COCIIOOOIOOOUIOICCIIC UNCOUPLING OF MODAL EQUATIONS ......... FORCING FUNCTION ...................... fiSWSE Ckalm COCO-ICOIOIl-CIOCI OLDSMOBILE PROJECT .................... CONCLUSIONS NOMENCLATURE LISTmmRMES III-I....-I-...IIII-I...........-. vi 15 22 26 8 44 LIST OF FIGURES FIGURE 1 - FREQUENCY RESPONSE OF A UNDAMPED SYSTEM .. 11 FIGURE 2 - FREQUENCY RESPONSE OF A DAMPED SYSTEM .... 12 FIGURE 3 - FFT OF AN INPUT FORCE .................... 36 FIGURE 4 ‘ CALCULATED FREQUENCY RESPONSE ............ 37 vi CHAPTER 1 INTRODUCTION The use of finite element models for engineering design has grown rapidly in the past few years. These models are useful tools for predicting the behavior of systems long before the system is actually constructed. For complex structures, the finite element model can become quite large, requiring a large computer for the calculations. Even with the computing power of large computers the finite element models require a great deal of computing time. However, for the purpose of calculating the frequency response of a structure in a specified frequency range, the finite element model can often be reduced so that the calculation can be done on a PAGE 1 CHAPTER 1 minicomputer. This thesis is concerned with the process of reducing a large model to a smaller one for the purpose of such a frequency response calculation. Chapter 2 explains the formulation of a large finite element model, and its transformation into a modal model. The modal representation has a coupled differential equation and associated mode shape for each degree of freedom in the original finite element model. Chapter 3 presents the rational for the reduction of the modal model. Chapter 4 introduces the forcing functions so that frequency response can be calculated, and the calculation of the response from the reduced model is presented in Chapter 5. Chapter 6 presents some details of a project where structural responses were calculated by this method. A summary of the assumptions used in the analysis are reviewed in chapter 7 along with some of the advantages to this method. PAGE 2 CHAPTER 2 STRUCTURAL MODEL The goal of the analysis discussed here is to develop an analytical model of a structure which predicts the response of that structure to forces of a given frequency range. The starting point of the analysis is a finite element model of the structure, which yields equations of the form. [MJ{N} + [C3{i} + llw [DJ{i} + [K]{X} = {F} exp(i w t) Equation 1 PAGE 3 CHAPTER 2 Since our main interest is the calculation of frequency response, the forcing function has been assumed to be harmonic. However it could be any forcing function provided it can be expressed as a Fourier series. In the structural model developed here dissipative forces arise from two different sources, viscous damping and structural damping. The damping forces which are proportional to velocity are classified as viscous damping. Viscous damping occurs when molecules of a viscous fluid rub together, causing a resistive friction force that is proportional to, and opposing, the velocity of an object moving through the fluid. Damping forces which are proportional to Displacement are classified as structural damping. Structural damping may be viewed as a sliding friction mechanism between molecular layers in a material. The friction force is proportional to the deformation or displacement from some equilibrium point with an orientation opposite the relative velocity. Imagine a rod made up of a bundle of axial fibers. The siding PAGE 4 STRUCTURAL MODEL friction force between each fiber and its neighbor will increase as the rod is bent and the fibers are pinched together. This pinching phenomena occurs in most materials as the various molecular layers slide past one another [1] [2]. A complex structure such as an automobile includes several sources of dissipation. The shock absorber, whose design mission is to provide damping, is closely approximated by a viscous model. But important dissipation occurs in mounting elements such as coil springs and rubber mounts as well. Tests indicate that the dissipation of a spring is most closely approximated by a structural damping model. Tests done on rubber mounts indicate a combination of viscous and structural dissipation is needed to adequately model the dissipation. For the problems of concern here, we will assume the structure is lightly damped, resulting in small but non zero dissipation forces. Since the total dissipation is small, the natural frequencies and mode shapes of the PAGE 5 CHAPTER 2 structure can be determined from the mass and stiffness matrices. But the amplitude of the forced response of the structure depends on the damping as well. In general, the matrices in Equation 1 are not diagonal. Therefore the solution of one equation depends on the solution of others and the system of equations is said to be coupled. The size of the matrices depends on the number of elements in the finite element model and the number of degrees of freedom of each element. The structure discussed as an example is modeled by 500 elements, each with six degrees of freedom, thus Equation 1 would include 3000 coupled equations. It is desirable to simplify the model in such a way as to make the response calculation more convenient. The procedure which leads to a simplified model begins with the equations of undamped free vibration. PAGE 6 STRUCTURAL MODEL [M] {I} + [K] (x; a {0} (2) Hhere: [M] and [K] are n x n matrices Equation 2 is formulated from Equation 1 by neglecting the damping matrices and setting the force vector to zero. A solution for {X} may be found in the form {X} B {A} exp(i w t) (3) Using Equation 3 in Equation 2 results in 2 ( -w [M] + [K] ) {A} exp(i w t) I {0} (4) Rewriting Equation 4 defines the eigenvalue problem [K] {A} = X [M] {A} (5) CHAPTER 2 The solution of Equation 5 results in a set of n eigenvalues xi. If these are distinct, as is the usual case, there will be a corresponding unique set of n eigenvectors {A}i. Since [M] and [K] are symmetric and positive definite, both the eigenvalues and eigenvectors are real. The eigenvectors are used to form two transformation matrices [U] and [U]T where the eigenvectors {A}i make up the columns of [U]. The transformation matrix [U] is used to define a modal coordinate Y {X} 8 [U] (V) (6) when the relationship from Equation 6 is substituted into Equation 1, which is then premultipled by [UJI we get [Mmlle + [CmJ{Y} + l/w [Dm]{Y} + [Km]{Y} a {Fm} (7) This coordinate transformation uncouples the mass and stiffness matrices, but in general does not uncouple STRUCTURAL MODEL the damping matrices [3]. Equation 7 is called the "modal model“. The modal model is a set of n coupled second order ordinary differential equations where n is the dimension of Equation 1. Each coordinate Yi of the modal model is associated with one natural frequency and its corresponding mode shape or eigenvector. The steps described above are usually done by the finite element programs on large computers. The output from the finite element program would be the transformation matrix [U], the diagonal modal mass matrix [Mm], the diagonal modal stiffness matrix [Km], and the damping matrices [Cm] and [Dm]. The damping matrices can be thought of as a coupling by which energy can flow from one mode to another. The damping can then be thought of as an input force. This can be seen by rewriting Equation 7 in the form [Mm] {Y} + [Km] {Y} . {Fm} - [Cm] {9} - 1/» [Dm] {9} (8) PAGE 9 CHAPTER 2 The fact that the {Fm} are harmonic dictates that the velocities {Y} are also harmonic at the same frequencies. Thus, it is convenient to think of the right hand side of Equation 8 expressed as {Fm}‘exp(iwt). [Mm] {Y} + [Km] {Y} a {Foi‘oxpti w t) (9) The solution to Equation 9 is shown in Figure 1. Of course, in order to calculate a response the damping must be included in the left hand side of Equation 8. But the introduction of this small amount of damping will limit the peak amplitude but will not drastically alter the basic chatacter of the frequency response as shown in Figure 2. Thus if the frequency of the force is near a natural frequency, the response of that mode will be large. By knowing the frequency range over which the forcing function is active, the modes which heavily participate in the response can be PAGE 10 Emma/EL“ >uzm30mmu as; H mag: Sm DHWQJ-(LJUJELUZF- 11 PAGE SmmEu2m3®mmu ca; N maze: am CHWQJfiLJLLJELLJZF— 12 PAGE STRUCTURAL MODEL identified. Those which do not participate are eliminated by dropping the associated modal coordinate from Equation 7 and the mode shape vector from the transformation matrix [U]. The number of modes has been reduced by detemining which modes fall significantly outside of the frequency range of the forcing function. A rule which is often used is to keep modes whose associated natural frequency is less than twice the maximum frequency of the force [4]. Since the number of modes which have meaningful participation in the response may be a great deal smaller than the number of degrees of freedom, the size of Equation 7 and the transformation matrix [U] can often be substantially reduced. In our previous example there were 500 elements each with six degrees of freedom resulting in 3000 equations. If, for example, only 100 of the 3000 natural frequencies are determined to meaningfully participate in the response, we can reduce the size of the matrices from 3000 x 3000 to 100 x 100 without significant loss in accuracy. PAGE 13 CHAPTER 2 At this point the problem has been substantially reduced. But the equations are still coupled in the damping matrices and thus the response calculation is not in a convenient form. needs further attention. PAGE 14 CHAPTER 3 UNCOUPLING OF MODAL EQUATIONS Chapter 2 showed that the n degree of freedom finite element model could be cast in the form of the modal model of Equation 7 and that the modal model could be reduced by eliminating the modes whose participation in the response was determined to be insignificant. The reduced modal model is then a set of k coupled second order differential equations. The fact that k<uzmsommu am so so am m mmsoHu e I s m r m i 4 * lllmw mm I u a 1 o r u SH .z.o.m 5mm N H #2302 Hum 36 PAGE 5:22 *NE CZMDBE e MES: H am so am _ _.i_ L2? 7.... 3:. J. 3.. rfii: Lg fl HL pH J... .. * H z m z m _ u , < u o a m IIIESEB H ........ 53$... 2; o L .z.d.m 3mm zzzoou wzeammem N mmzommmm 37 PAGE CHAPTER 7 CONCLUSIONS In the preceeding chapters an analysis was developed whereby a finite element model of a complex structure could be reduced to a set of uncoupled ordinary first order differential equations. These equations could then be solved and the response of the structure calculated. In the last chapter the analysis was put to use and the results compared to the measured data. The analysis is based on four assumptions, 1) the finite element model is an accurate model of the structure, 2) the damping forces which occur in the structure are small, 3) the frequency of oscillation of the forcing function are known to be in a given range, 4) PAGE 38 CONCLUSIONS modes whose natural frequencies are not near the range of the forcing frequencies do not significantly affect the response of the structure. The goal of this analysis is to facilitate the calculation of the response of a structure based on a finite element model of the structure. The analysis met this goal offering considerable cost savings over computing the response directly from the finite element model. PAGE 39 APPENDIX A WHENCLATURE PAGE 40 [H] {i} cc: ID] {i} [K] {X} {F} {A} [U] [U] [Mm] {Y} [Cm] c?) NOMENCLATURE Matrix of inertia coefficients (mass matrix) The acceleration vector Matrix of viscous damping coefficients Matrix of structural damping coefficients The frequency of oscillation The velocity vector Matrix of stiffness coefficients The displacement vector The force vector F—‘I Time The exponential function w2 is the eigenvalue and the square of the undamped natural frequency The associated eigenvector The transformation matrix of eigenvectors The transpose of the [U] matrix The diagonal modal mass matrix IUJTIM] [U] The second order modal acceleration vector The coupled modal viscous damping matrix [UJTIC] run The second order modal velocity vector PAGE 41 APPENDIX A [Dm] I The coupled modal structural damping matrix [UJTED] run [KmJ a The diagonal modal stiffness matrix [U]T[KJ [U] (V) a The second order modal coordinate vector {Fm} - The modal force vector [UJT{F} exp (i w t) {B} I A solution vector x 8 The first order eigenvalue {C} a The first order eigenvector [V] I The first order transformation matrix made up of the first order eigenvectors [V] 8 The transpose of the [V] matrix {P} - The first order transformation coordinate {P} 8 The first order transformation velocity [Mp] - The first order mass matrix [Kp] I The first order stiffness matrix {Pp} = The first order force vector [M2] = The diagonal first order modal mass matrix rvnTran [V] {I} = The first order modal velocity [K2] 8 The diagonal first order modal stiffness matrix [VJTEKpJ [V] {Z} The first order modal coordinate PAGE 42 {Fz} {D} {R} {I} I The - The - The NOMENCLATURE first order modal force vector [VJT{Fp} phase angel with respect to time amplitude of the force real part of the force imaginary part of the force PAGE 43 LIST OF REFERENCES PAGE 44 1) 2) 3) 4) 5) 6) LIST OF REFERENCES Kimball A. L. and Lovell D. E., Internal Friction in Solids, Physical Review Vol. 30 December, 1927 Bishop R. E. D., The General Theory of Hysteretic Dasping, The Aeronautical Quarterly February, 1956 pp 60 - 70. Meirovitch L., "Analytical Methods in Vibrations“, MacMillan Co. London, 1967 pp 100 - 104. Swanson Analysis Systems Inc., 'Ansys Users Manual”, Houston, Pennsylvania. Bishop R. E. D., The Treateent of Daaping Force: in Vibration Theory, Journal of the Royal Aeronautical Society, Vol. 59 November 1955 pp 738 —742. Myklestad N. O. The Concept of Coeplex Daeping, Journal of Applied Mechanics, Vol. 19 1952. PAGE 45 LIST OF REFERENCES 7) Richardson M. and Potter R., Uiscoa: 9: Structural G) 9) Danping in Nodal Analysis, 46th Shock and Vibration Symposium, October 1975. Frazer R. A., Duncan H. J. and Collar A. R., "Elementary Matrices", Cambridge University Press, New York, New York, 1957 p 289. Wylie C. Ray, "Advanced Engineering Mathematics“, McGraw - Hill Book Co., 1975 Sec. 1.6. 10) Stewart B. R., ”Introduction to Matrix Computations“, Academic Press New York, New York 1973. PAGE 46