Explicit Drop Test and

Submodeling with ANSYS LS-DYNA

Chris Cowan
Ozen Engineering, Inc.
1210 E. Arques Ave, Suite 207
Sunnyvale, CA 94085
[email protected]
1 © 2011 ANSYS, Inc. September 2, 2011
 Ozen Engineering Inc.
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2 © 2011 ANSYS, Inc. September 2, 2011

 Contents & Abstract
1. Introduction
A consumer electronics drop-test case
2. Description of Problem study is presented to demonstrate a
3. Geometry & Meshing methodology to rapidly obtain high-
accuracy results from an explicit
4. Explicit Dynamics analysis using submodeling.
Modeling Global/local models of a mobile
5. LS-DYNA Submodeling electronic device with a BGA package
are prepared within the Workbench
environment (for LS-DYNA export),
then solved and post-processed with
LS-DYNA.

3 © 2011 ANSYS, Inc. September 2, 2011

 Introduction
• The purpose of this presentation is to provide the
audience with:
– Basic workflow in performing an explicit analysis with ANSYS
LS-DYNA for Workbench
– Background and tips on explicit modeling features
– Detailed information on submodeling with LS-DYNA
• Content is targeted towards engineers who are
already familiar with ANSYS implicit structural analysis,
and looking to implement advanced explicit structural
analysis.

4 © 2011 ANSYS, Inc. September 2, 2011

 ANSYS LS-DYNA
• Explicit Dynamics is a solution method used to simulate short-duration
highly-nonlinear structural events.
– Examples: Drop impact, metal forming, car crash, explosions
– Features: Erosion, ALE, automatic contact, failure
• ANSYS LS-DYNA for Workbench leverages convenience and advanced
capabilities of ANSYS Workbench to prepare analyses for LS-DYNA.
– A majority of the engineering effort associated with explicit dynamics is devoted
to geometry preparation and meshing.
– Access to full range of Workbench features including DesignModeler, FE
Modeler, parameterization, bi-directional CAD, coupled physics
• The LS-DYNA solver offers submodeling – a powerful and relatively new
capability for the explicit solver.
– A majority of non-engineering time with explicit dynamics is typically devoted to
solution processing.
– Submodeling compresses the processing requirements to obtain detailed results
at specific locations within the assembly.

5 © 2011 ANSYS, Inc. September 2, 2011

 Description of Problem
• A mobile device experiences
failure in electronic components
caused by drop impact.
• Simulate to assess damage to
solder joints in the BGA package.
– Follow-up to evaluate design
revisions

• Need accurate results quickly!

– ANSYS LS-DYNA for Workbench with
submodeling

• Submodeling technique is
employed
– First solve global model for the
entire mobile device assembly
– Second solve local model for the BGA
package on PCB

6 © 2011 ANSYS, Inc. September 2, 2011

 Simulation Workflow
1. Geometry: Import CAD and
prepare for analysis using ANSYS
DesignModeler.
2. Meshing: Discretize for explicit
using ANSYS Meshing.
3. Setup: Prepare the analysis using
ANSYS Explicit for LS-DYNA.
– Materials
– Contacts & Connections
– Solution settings
– Command Objects
4. Solve & Results: Obtain the
solution using LS-DYNA solver and
review results using LS-PrePost (or
/POST1).

7 © 2011 ANSYS, Inc. September 2, 2011

 Geometry Preparation
• Geometry modifications are not
required, but offer a high ROI for
solution accuracy & time.
• Slice to enable sweep meshing
– Ribs are separated from the case,
and interact via contact.
• Slice to enable top-quality elements
– Important in thin components and
critical regions (silicon, foam
adhesive)
• Group multi-body parts to reduce
contact requirements.

8 © 2011 ANSYS, Inc. September 2, 2011

 Geometry – Local vs. Global
• Local & global features are
included in the geometry, and
suppressed in DesignModeler
as required.
• The global model substitutes a
volume-averaged hybrid Densely meshed local model.
BGA/underfill region with
equivalent properties.
• Note that the submodel
includes part of the case and
target because of contact
interactions.
Coarsely meshed global model.

9 © 2011 ANSYS, Inc. September 2, 2011

 Meshing – General Considerations
• Smallest element typically controls the
solution timestep
– Based on time for a shockwave to cross
through the element.

• Preferred meshing methods:

– Swept hex (more efficient/accurate)
– Patch independent low/high order tet
(quick, easy, no hourglassing)
– Multizone hex (flexibility)
l l
– Avoid hex-dominant (poorly shaped and t  
pyramids) c E
– Avoid patch-dependant tet (poorly shaped) 
Where:
l is element characteristic dimension
c is the material speed of sound
E is Young’s Modulus
ρ is the material density

10 © 2011 ANSYS, Inc. September 2, 2011

 Meshing
• Uniform mesh sizing is desirable
in regions of interest
– Enlarged mesh size in non-critical
parts (battery).

• Swept hex mesh on thin parts

(case): Method -> Sweep ->
Automatic Thin -> All Quad -> #
Divisions
• “All Quad” setting enables fully-
integrated hex formulation (in
case of hourglassing). No prisms.
• Mass Scaling should be
considered during the
meshing/solution process.
– Identify mesh features that can be
improved to reduce mass scaling
effects.

11 © 2011 ANSYS, Inc. September 2, 2011

 Mass Scaling
• Mass Scaling is a powerful tool to
speed-up solutions
– Increase minimum time step by artificially
increasing density
– Applicable to poorly shaped elements
– Users discretion in evaluating validity

• Extend the D3PLOT database to

include Mass Scaling & Timestep
informaiton
– Insert an LS-DYNA Command Object
– Review graphically in LS-PrePost

• Alternate - Review MATSUM and

GLSTAT text output files
$ Include mass scaling information in the D3PLOT file
*DATABASE_EXTENT_BINARY
$

$ MSSCL
1

12 © 2011 ANSYS, Inc. September 2, 2011

 Command Objects

13 © 2011 ANSYS, Inc. September 2, 2011

 Connections
• Bonded “Contacts” account
for uniform parts that were
split during geometry
operations to facilitate
meshing.
• “Body Interactions” include
automatic generalized
contact
– Also self contact
• Separate body interaction
objects can be scoped to
components that will contact.
– Improve efficiency for large
assemblies.
– Example: Chip will never contact
the target platform.

14 © 2011 ANSYS, Inc. September 2, 2011

 Element Formulation
• Preliminary results show significant error
associated with hourglass energy.
– Hourglass modes are non-physical, zero-energy
oscillations. Result from point loading.
– Problematic for default hex elements.
– Review MATSUM & GLSTAT files to verify that
hourglass energy is small relative to internal energy

• Default methods to control hourglassing

include: viscous and stiffness damping
controls
– mesh refinement, non-point loading

• Convert hex element type $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

$ SECTION DEFINITIONS $
– Type 1 (default single-point integration hex element) $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
→ Type 2 (fully-integrated hex element) $
*SECTION_SOLID
– Not susceptible to hourglassing $ 1SECID 2ELFORM 3AET
1 13 OK, tet elements
– Increased solution time, increased accuracy *SECTION_SOLID
– Apply selectively $ 1SECID 2ELFORM 3AET
2 1 2
• Modify the LS-DYNA keyword (.K) file for each
applicable hex element type.

15 © 2011 ANSYS, Inc. September 2, 2011

 Submodeling in LS-DYNA
• ‘Component Analysis’ in LS-DYNA is analogous
to ‘submodeling’ in ANSYS
• Efficient method for simulating detailed
response of a local section within a larger
structure.
• The global model is discretized to capture
sufficiently accurate displacements at the cut
boundary.
• The local model is discretized to sufficiently
resolve results of interest.
• User can apply multiple local models
– Multiple levels of “sub-submodel”
– Multiple detailed component locations within a global
model

Reference “Introduction to LS-DYNA: Component Analysis”

16 © 2011 ANSYS, Inc. September 2, 2011

 Submodeling Boundary Conditions
• Motion from the global model drives the
local model.
– Additional loads must be specified if they are not
transmitted through the cut boundary interfaces
– e.g. gravity.

• Recommended to output cut-boundary

data at each timestep.
• Exercise engineering judgement to ensure
that changes between local/global models
do not affect motion at interfaces.
– Hybrid material → Solder Balls + Underfill
– Include contacting components

17 © 2011 ANSYS, Inc. September 2, 2011

 Submodeling Steps & Commands
$ Define GLOBAL cut boundary condition
*INTERFACE_COMPONENT_SEGMENT
• Global model $# ssid
2
– Named Selection at “cut boundary” $
$ SSID identifies segment in .K file corresponding to
– *INTERFACE_COMPONENT command $ the cut boundary named selection.
object
– Execute solution with z=DataFilename Solve global, Identify database to write (z=):

cd C:\Work\ProjectName_files\dp0\SYS-1\MECH
ls971.exe pr=DYNA i=LSDYNAexport.k z=Global_Cut_Results

$ Define LOCAL cut boundary condition

*INTERFACE_LINKING_SEGMENT
$# ssid ifid
2 1
• Local model $
$ SSID identifies segment in .K file corresponding to
– Named Selection at “cut boundary” $ the cut boundary named selection.
– *INTERFACE_LINKING command object $ IFID identifies the appropriate section of cut
$ boundary data to use (in case multiple cut
– Execute solution with l=DataFilename $ boundaries are written to the output file).

Solve global, Identify database to read (l=):

cd C:\Work\ProjectName_files\dp0\SYS-2\MECH
ls971.exe pr=DYNA i=LSDYNAexport.k l=Global_Cut_Results

18 © 2011 ANSYS, Inc. September 2, 2011

 Results
• Solve times:
– Parallel on 7 CPUs @3GHz
– Global = 15 minutes
– Local = 200 minutes

• Solder balls are predicted to fail for

this drop condition.
– Criteria: maximum plastic strain
– Solder material erosion is visible in the cut-
view animation.

19 © 2011 ANSYS, Inc. September 2, 2011

 Summary
• This presentation has demonstrated how ANSYS
products & technology can be used to characterize
drop test performance of a mobile electronic device.
• These results show that ANSYS LS-DYNA submodeling
techniques can be employed to rapidly and accurately
obtain structural solutions for detailed components
within complicated assemblies that experience short-
duration, highly-nonlinear loading.

20 © 2011 ANSYS, Inc. September 2, 2011

 Notes
• Special thanks to Stefano Mazzalai for providing
technical expertise in implementing submodeling with
LS-DYNA.

21 © 2011 ANSYS, Inc. September 2, 2011

 QUESTIONS ?
Thank you for your attention

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