Chapter 24: Friction Between Belt and Pulley 24 Friction Between Belt and Pulley Summary Introduction 439

440 440 440 Requested Solutions Analytical Solution FEM Solutions Modeling Tip Input File(s) Video 446 441 444 446

CHAPTER 24 439 Friction Between Belt and Pulley

Summary Title Contact features Chapter 24: Friction Between Belt and Pulley (Slightly) c hanging contact area Curved contact surfaces Deformable-deformable and deformabl e-rigid contact Friction between deformable bodies Material properties Pulley o ter radius = 0.55 Pulley inner radius = 0.25 Out of plane pulley thickness = 0.3 In plane belt thickness = 0.05 Out of plane belt thickness = 0.2 Initial angle spanned = /2 rad 13 10 Geometry 3-D (units: mm) R r2 r1 y z x F t E pulley = 1.0 10 Pa E belt = 1.0 10 Pa pulley = belt = 0.3

Linear elastic material Analysis type Boundary conditions Quasi-static analysis An 180o section of the pulley is modeled, which is clamped along the inner radiu s using glued contact conditions. On both ends of the belt, load-controlled rigid bodies are defined and connected to the belt using glued contact conditions. The f orces F and R are external and reaction forces on the control nodes. On the load ed control node we have u x = u y = 0 , while on the other control node u x = u y = u z = 0 . Point load F y = 1.0 105 N 3-D 20-node hexahedral solid elements Di fferent coefficients of friction between belt and pulley: = 0.05 , = 0.15 and = 0.25 Applied loads Element type Contact properties FE results Reaction force for each value of the friction coefficient

440 MD Demonstration Problems CHAPTER 24 Introduction A belt is positioned around a pulley such that a 90o section of the pulley is co ntacted. One end of the belt is fixed; the other end is loaded by a tensile forc e with magnitude F = 1.0 105 . It is assumed that the material behavior for both the belt and the pulley is linear elastic. Although this problem can be solved b y a 2-D approximation, a full 3-D model is chosen here in order to show the char acteristic behavior of 3-D parabolic hexahedral elements in a contact analysis i nvolving friction. An analytical solution for the case with Coulomb friction is known. Requested Solutions Analyses will be carried out for three different values of the friction coeffici ent: = 0.05 , = 0.15 , and = 0.25 . With a constant value of the applied load, t he reaction force will decrease for increasing values of the friction coefficien t. This reaction force is the primary requested quantity, as this can be easily compared with an analytical solution. Analytical Solution Assuming Coulomb friction between the belt and the pulley, the principle of rope friction according to the EulerEytelwein formula provides a relation between th e magnitude F of the applied force, the magnitude R of the reaction force, the a ngle spanned by the belt and the friction coefficient between the belt and the p ulley: F R = ------ e With F = 1.0 105 and = , the theoretical value of the magnitude of the reaction f orce R is listed in Table 24-1 for -2 various values of the friction coefficient . Table 24-1 Reaction Force for Vario us Values of the Friction Coefficient (Theory) Reaction Force R 9.2447x104 7.900 8x104 6.7523x104 Friction Coefficient 0.05 0.15 0.25

CHAPTER 24 441 Friction Between Belt and Pulley FEM Solutions Numerical solutions have been obtained with MD Nastrans SOL 400 for the element m esh shown in Figure 24-1 using 3-D 20-node hexahedral elements. Assuming that th e deformations of the pulley are small and localized around the contact area, on ly an 180o section has been modeled. In total, there are five contact bodies: tw o deformable and three rigid. The rigid bodies will be used to easily apply the boundary conditions (single point constraints and forces). load controlled rigid body fixed rigid body; glued contact load controlled rigid body Figure 24-1 Element Mesh applied in MD Nastran Simulation The first deformable body consists of all elements of the belt, where the second deformable body consists of all elements of the pulley. The body number IDs of t he belt and the pulley are 1 and 2, respectively. These deformable contact bodie s are identified as 3-D bodies referring to the BSURF IDs 1 and 2: BCBODY BSURF 1 1 8 16 24 32 40 48 56 64 72 2 2 82 90 98 106 114 122 130 3D 1 9 1 7 25 33 41 49 57 65 73 3D 75 83 91 99 107 115 123 131 DEFORM 2 10 18 26 34 42 50 58 66 74 DEFORM 76 84 92 100 108 116 124 132 1 3 11 19 27 35 43 51 59 67 2 77 8 5 93 101 109 117 125 133 4 12 20 28 36 44 52 60 68 78 86 94 102 110 118 126 134 5 13 21 29 37 45 53 61 69 79 87 95 103 111 119 127 6 14 22 30 38 46 54 62 70 80 88 96 104 112 120 128 7 15 23 31 39 47 55 63 71 81 89 97 105 113 121 129 BCBODY BSURF

442 MD Demonstration Problems CHAPTER 24 The first rigid body is a half cylinder described as a NURBS surface used to clamp the grids on the inner radius of the pulley. Its body s 3 and it is identified as: BCBODY 3 0 RIGID NURBS 0 0. 1. 0. 0 1 RIG-INNER -7 13 4 4 50 .176777 .324015 -.029538 .237263 .222631 0. .0306021.24812 3D 0. RIGID 0. 1 0 0. 0 ... The second and the third rigid bodies are load controlled rigid bodies. A load c ontrolled rigid body is associated with a control grid, which can be used to app ly forces and/or single point constraints. In the current analysis, two flat loa d controlled rigid bodies are used. They will be glued to both ends of the belt and their control grids will be used to prevent a rigid body motion in the basic z-direction, to apply the external force on the belt and to transfer the belt l oad to the fixed control grid. The load controlled rigid bodies are identified a s: BCBODY 4 0 RIGID NURBS 3D 0. 526 -2 -.2 -.2 3D 0. 527 -2 .55 .55 RIGID 0. 1 2 .6 .6 RIGID 0. 1 2 -.2 -.2 0. RIG-R 2 .05 .25 0. RIG-F 2 .05 .25 0 1. 2 -.2 -.2 0 1. 2 .6 .6 0. 50 .55 .55 0. 50 -.2 -.2 1 0. 50 .05 .25 1 0. 50 .05 .25 526 0. 4 ... BCBODY 5 0 RIGID NURBS 527 0. 4 ... Note that the control grids have the IDs 526 and 527. The BCTABLE option will be used to indicate: which grids are to be treated as slave nodes and which as mas ter grids in the multipoint constraints for deformable-deformable contact; the f riction coefficient between the belt and the pulley; glued contact between the p ulley and the half cylinder; glued contact between the load controlled rigid bod ies and the belt. The entries of the BCTABLE option are defined as: BCTABLE 1 SLAVE MASTERS SLAVE MASTERS SLAVE MASTERS SLAVE MASTERS 1 1 2 1 0 5 1 0 4 2 0 3 0. 0 0. 1 0. 1 0. 1 4 0. 0. 0 0. 0 0. 0 .05 0. 0. 0. 0. 0. 0. 0. 0 1 1 1 0. 0. 0. 0. and will be ID number i -.176777 0. 0. 50 0. 0.

CHAPTER 24 443 Friction Between Belt and Pulley The first SLAVE MASTERS combination indicates that the grids of deformable body 1 are treated as slave grids when contact is established with body 2. The fricti on coefficient is set to 0.05. The other SLAVE MASTERS combinations activate glu ed contact between the bodies with body ID numbers 1 and 5, 1 and 4, and 2 and 3 , respectively. The bilinear Coulomb friction model will be activated using the BCPARA option (FTYPE = 6); this option is also used to indicate that the separat ion behavior is based on stresses (IBSEP = 4), which is necessary in a contact a nalysis involving quadratic elements: BCPARA 0 NBODIES 5 IBSEP 4 FTYPE 6 In order to activate the full nonlinear formulation of the 20 node hexahedral el ements, the nonlinear property extension of the PSOLID entry is used. For the ma terials defining the belt (material ID number 1) and the pulley (material ID num ber 2), this results in: MAT1 MAT1 PSOLID PSLDN1 PSOLID PSLDN1 1 2 1 1 2 2 1.+9 1.+13 1 2 .3 .3 0 0 1. 1. The nonlinear procedure used is: NLPARM 1 1.e-4 1 1.e-4 1.e-4 FNT 10 1 25 UPW YES Here the FNT option is selected to update the stiffness matrix during every recy cle using the full Newton-Raphson iteration strategy. Convergence checking is pe rformed based on displacements, forces and work. The error tolerance is set to 1 0-4 for all criteria. Note that the MAXDIV field is set to 10 to avoid that bise ctions occur, since too many bisections may increase the overall solution time. The obtained values of the reaction forces are listed in Table 24-2, together wi th the relative error compared to the analytical solution. The numerical and ana lytical solutions turn out to be in good agreement. Table 24-2 Numerical Solutio ns and Relative Errors Reaction Force R 9.2314x104 7.9476x104 6.8448x104 Error ( %) 0.14 0.59 1.37 Friction Coefficient 0.05 0.15 0.25

444 MD Demonstration Problems CHAPTER 24

Modeling Tip Convergence Behavior A nonlinear analysis involving contact and friction may need several iterations to fulfil the convergence requirements. In such inherently nonlinear analyses, i t may be advantageous to increase the number of criteria needed to force a bisec tion. As discussed above, this number (MAXDIV on the NLPARM option) has been set to 10 instead of the default value 3. The tables below show the convergence beh avior with the increased value (Table 24-3) and the default value (Table 24-4). The increased value clearly reduces the overall number of Newton-Raphson iterati ons and thus the analysis wall time. When looking at Table 24-3, iteration 9 rea ches displacement, load and work errors which are within the required tolerances . The extra iterations needed are caused by the fact that some grids of the belt which are initially in contact with the pulley, separate because of tensile con tact stresses. After separation of these grids, a new solution with a smaller nu mber of contact constraints has to be found. Table 24-3 Load Factor 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Converge nce Behavior with MAXDIV=10 ( Step 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Iteration 1 2 3 4 5 9 10 11 12 13 14 Disp. Error 1.00E+00 7.76E+00 6.61E+02 2.12E+02 8.61E-02 3.12E03 2.60E-04 7.87E-06 3.92E-06 3.39E+00 4.26E-02 2.42E-03 8.19E-06 4.93E-06 Load Error 1.70E-01 3.54E-01 2.31E+01 1.80E+02 2.78E+01 1.70E-01 4.31E-03 4.09E-05 9. 30E-07 1.41E-02 2.05E-03 3.31E-02 2.26E-05 1.61E-06 Work Error 1.70E-01 1.58E+00 6.17E+02 1.30E+04 7.33E+00 4.67E-02 3.50E-03 1.34E-04 5.09E-05 4.30E+00 6.67E-0 1 3.33E-02 1.30E-04 6.57E-05

CHAPTER 24 445 Friction Between Belt and Pulley Table 24-4 Load Factor 1.0000 1.0000 1.0000 1.0000 0.5000 0.5000 0.5000 0.5000 0 .5000 0.5000 0.5000 0.5000 0.5000 0.5000 0.5000 0.5000 1.0000 1.0000 0.7500 0.62 50 0.5625 0.5312 ... ... 0.9688 0.9688 0.9688 1.0000 1.0000 1.0000 1.0000 1.0000 Convergence Behavior with MAXDIV=3 ( Step 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 ... 16 16 16 17 17 17 17 17 Iteration 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 1 1 1 1 ... ... 3 4 5 1 2 3 4 5 Disp. Error 1.00E+00 7.76E+00 6.61E+02 2.12E+02 1. 00E+00 8.06E+02 5.62E+02 8.37E+01 3.27E-02 8.88E-04 1.27E-04 2.93E-06 1.94E+00 2 .89E-02 3.25E-04 2.44E-05 5.60E-01 1.25E+02 1.25E+02 1.25E+02 1.25E+02 3.86E-01 ... ... 4.10E-03 7.84E-05 9.70E-06 3.58E-02 4.49E+00 3.37E-03 6.27E-05 7.94E-06 Load Error 1.70E-01 3.54E-01 2.31E+01 1.80E+02 9.36E-02 2.96E-01 3.36E+01 8.70E+ 01 1.91E+00 2.22E-02 2.24E-04 6.83E-06 1.02E-02 1.31E-03 7.79E-03 8.00E-06 2.26E -01 2.32E+02 2.32E+02 2.32E+02 2.32E+02 6.06E-01 ... ... 1.92E-02 4.16E-04 4.13E -06 5.91E-03 7.24E-01 1.27E-02 2.93E-04 2.83E-06 Work Error 1.70E-01 1.58E+00 6. 17E+02 1.30E+04 9.36E-02 3.12E+02 6.19E+02 1.92E+02 8.84E-02 2.19E-03 2.84E-04 8 .15E-06 2.71E-01 6.47E-02 5.95E-04 5.31E-05 1.27E-01 7.04E+03 7.04E+03 7.04E+03 7.04E+03 3.32E-01 ... ... 6.62E-03 1.37E-04 1.67E-05 2.16E-04 6.56E+00 5.40E-03 1.08E-04 1.34E-05

446 MD Demonstration Problems CHAPTER 24 Input File(s) File nug_24_1.dat nug_24_2.dat nug_24_3.dat Description Friction coefficient 0.0 5 Friction coefficient 0.15 Friction coefficient 0.25 Video Click on the image or caption below to view a streaming video of this problem; i t lasts about 25 minutes and explains how the steps are performed. Figure 24-2 Video of the steps above