A fully coupled thermal-electrical-structural analysis:
is performed when coupling between the displacement, temperature, and electrical potential
fields makes it necessary to obtain solutions for all three fields simultaneously;
requires the existence of elements with displacement, temperature, and electrical
potential degrees of freedom in the model;
allows for transient or steady-state thermal solutions, static displacement solutions, and
steady-state electrical solutions;
can include thermal interactions such as gap radiation, gap conductance, and gap heat
generation between surfaces (see Thermal Contact Properties);
cannot include cavity radiation effects but may include radiation boundary conditions (see
Thermal Loads);
takes into account temperature dependence of material properties only for the properties
that are assigned to elements with temperature degrees of freedom;
Coupling between the temperature and electrical degrees of freedom arises from
temperature-dependent electrical conductivity and internal heat generation (Joule heating),
which is a function of the electrical current density. The thermal part of the problem can
include heat conduction and heat storage (About Thermal Properties). Forced
convection caused by fluid flowing through the mesh is not considered.
Coupling between the temperature and displacement degrees of freedom arises from
temperature-dependent material properties, thermal expansion, and internal heat generation,
which is a function of inelastic deformation of the material. In addition, contact
conditions exist in some problems where the heat conducted between surfaces may depend
strongly on the separation of the surfaces and/or the pressure transmitted across the
surfaces as well as friction (see About Mechanical Contact Properties and Thermal Contact Properties).
Coupling between the electrical and displacement degrees of freedom arises in problems
where electricity flows between contact surfaces. The electrical conduction may depend
strongly on the separation of the surfaces and/or the pressure transmitted across the
surfaces (see Electrical Contact Properties).
An example of a simulation that requires a fully coupled thermal-electrical-structural
analysis is resistance spot welding. In a typical spot welding process two or more thin
metal sheets are pinched between two electrodes. A large current is passed between the
electrodes, which melts the metal between the electrodes and forms a weld. The integrity of
the weld depends on many parameters including the electrical conductance between the sheets
(which can be a function of contact pressure and temperature).
Fully Coupled Solution Scheme
The coupled thermal-electrical-structural analysis in Abaqus uses an exact implementation of Newton’s method and involves a nonsymmetric Jacobian
matrix, as illustrated in the following matrix representation of the coupled equations:
where , , and are the respective corrections to the displacement, electric potential,
and temperature; are submatrices of the fully coupled Jacobian matrix; and , , and are the mechanical, electrical, and thermal residuals, respectively.
Solving this system requires the use of the unsymmetric matrix storage and solution
scheme. In addition, the mechanical, thermal, and electrical conduction equations must be
solved simultaneously. The method provides quadratic convergence when the solution
estimate is within the radius of convergence of the algorithm.
Steady-State Analysis
Steady-state analysis provides the steady-state solution directly. Steady-state thermal
analysis means that the internal energy term (the specific heat term) in the governing
heat transfer equation is omitted. A static displacement solution is assumed. Only direct
current is considered in the electrical problem, and it is assumed that the system has
negligible capacitance. Electrical transient effects are so rapid that they can be
neglected.
Assigning a “Time” Scale to the Analysis
In steady-state cases you should assign an arbitrary “time” scale to the step: you
specify a “time” period and “time” incrementation parameters. This time scale is
convenient for changing loads and boundary conditions through the step and for obtaining
solutions to highly nonlinear (but steady-state) cases; however, for the latter purpose,
transient analysis often provides a natural way of coping with the nonlinearity.
Accounting for Frictional Slip Heat Generation
Frictional slip heat generation is normally neglected in the steady-state case.
However, it can still be accounted for if user subroutine FRIC provides the incremental
frictional dissipation through the variable SFD. If
frictional heat generation is present, the heat flux into the two contact surfaces
depends on the slip rate of the surfaces. The “time” scale in this case cannot be
described as arbitrary, and a transient analysis should be performed.
Transient Analysis
Alternatively, you can perform a transient coupled thermal-electrical-structural
analysis. As in steady-state analysis, electrical transient effects are neglected and a
static displacement solution is assumed. You can control the time incrementation in a
transient analysis directly, or Abaqus/Standard can control it automatically. Automatic time incrementation is generally preferred.
Automatic Incrementation Controlled by a Maximum Allowable Temperature
Change
The time increments can be selected automatically based on a user-prescribed maximum
allowable nodal temperature change in an increment, . Abaqus/Standard restricts the time increments to ensure that this value is not exceeded at any node
(except nodes with boundary conditions) during any increment of the analysis (see Time Integration Accuracy in Transient Problems).
Fixed Incrementation
If you do not specify , fixed time increments equal to the user-specified initial time
increment, , will be used throughout the analysis, except when the explicit creep
integration scheme is used. In this case Abaqus/Standard might decrease the time increment if the stability limit is exceeded.
Spurious Oscillations due to Small Time Increments
In transient analysis with second-order elements there is a relationship between the
minimum usable time increment and the element size. A simple guideline is
where is the time increment, is the density, c is the specific heat,
k is the thermal conductivity, and is a typical element dimension (such as the length of a side of an
element). If time increments smaller than this value are used in a mesh of second-order
elements, spurious oscillations can appear in the solution, in particular in the
vicinity of boundaries with rapid temperature changes. These oscillations are
nonphysical and may cause problems if temperature-dependent material properties are
present. In transient analyses using first-order elements the heat capacity terms are
lumped, which eliminates such oscillations but can lead to locally inaccurate solutions
for small time increments. If smaller time increments are required, a finer mesh should
be used in regions where the temperature changes rapidly.
There is no upper limit on the time increment size (the integration procedure is
unconditionally stable) unless nonlinearities cause convergence problems.
Automatic Incrementation Controlled by the Creep Response
The accuracy of the integration of time-dependent (creep) material behavior is governed
by the user-specified accuracy tolerance parameter, . This parameter is used to prescribe the maximum strain rate change
allowed at any point during an increment, as described in Rate-Dependent Plasticity: Creep and Swelling. The accuracy
tolerance parameter can be specified together with the maximum allowable nodal
temperature change in an increment, (described above); however, specifying the accuracy tolerance
parameter activates automatic incrementation even if is not specified.
Selecting Explicit Creep Integration
Nonlinear creep problems (Rate-Dependent Plasticity: Creep and Swelling) that exhibit
no other nonlinearities can be solved efficiently by forward-difference integration of
the inelastic strains if the inelastic strain increments are smaller than the elastic
strains. This explicit method is efficient computationally because, unlike implicit
methods, iteration is not required as long as no other nonlinearities are present.
Although this method is only conditionally stable, the numerical stability limit of the
explicit operator is in many cases sufficiently large to allow the solution to be
developed in a reasonable number of time increments.
For most coupled thermal-electrical-structural analyses, however, the unconditional
stability of the backward difference operator (implicit method) is desirable. In such
cases the implicit integration scheme may be invoked automatically by Abaqus/Standard.
Explicit integration can be less expensive computationally and simplifies
implementation of user-defined creep laws in user subroutine CREEP; you can restrict Abaqus/Standard to using this method for creep problems (with or without geometric nonlinearity
included). See Rate-Dependent Plasticity: Creep and Swelling for further
details.
Excluding Creep and Viscoelastic Response
You can specify that no creep or viscoelastic response occurs during a step even if
creep or viscoelastic material properties have been defined.
Unstable Problems
Some types of analyses may develop local instabilities, such as surface wrinkling,
material instability, or local buckling. In such cases it may not be possible to obtain
a quasi-static solution, even with the aid of automatic incrementation. Abaqus/Standard offers a method of stabilizing this class of problems by applying damping throughout
the model in such a way that the viscous forces introduced are sufficiently large to
prevent instantaneous buckling or collapse but small enough not to affect the behavior
significantly while the problem is stable. The available automatic stabilization schemes
are described in detail in Automatic Stabilization of Unstable Problems.
Units
In coupled problems where two or three different fields are active, take care when
choosing the units of the problem. If the choice of units is such that the terms generated
by the equations for each field are different by many orders of magnitude, the precision
on some computers may be insufficient to resolve the numerical ill-conditioning of the
coupled equations. Therefore, choose units that avoid ill-conditioned matrices. For
example, consider using units of megapascal (MPa) instead of pascal (Pa) for the stress
equilibrium equations to reduce the disparity between the magnitudes of the stress
equilibrium equations, the heat flux continuity equations, and the conservation of charge
equations.
Initial Conditions
By default, the initial temperature of all nodes is zero. You can specify nonzero initial
temperatures. Initial stresses, field variables, etc. can also be defined; Initial Conditions describes all of
the initial conditions that are available for a fully coupled thermal-electrical-structural
analysis.
Boundary Conditions
Boundary conditions can be used to prescribe temperatures (degree of freedom 11),
displacements/rotations (degrees of freedom 1–6), or electrical potentials (degree of
freedom 9) at nodes in a fully coupled thermal-electrical-structural analysis (see Boundary Conditions).
Boundary conditions can be specified as functions of time by referring to amplitude curves
(Amplitude Curves).
Loads
The following types of thermal loads can be prescribed in a fully coupled
thermal-electrical-structural analysis, as described in Thermal Loads:
Concentrated heat fluxes.
Body fluxes and distributed surface fluxes.
Node-based film and radiation conditions.
Average-temperature radiation conditions.
Element and surface-based film and radiation conditions.
The following types of mechanical loads can be prescribed:
Concentrated nodal forces can be applied to the displacement degrees of freedom (1–6);
see Concentrated Loads.
Distributed pressure forces or body forces can be applied; see Distributed Loads.
The following types of electrical loads can be prescribed, as described in Electromagnetic Loads:
Concentrated current.
Distributed surface current densities and body current densities.
Predefined Fields
You can define initial temperature fields in fully coupled thermal-electrical-structural
analyses; other predefined temperature fields are not allowed. Instead, you should use
boundary conditions to prescribe temperature degree of freedom 11, as described earlier.
You can specify other predefined field variables in a fully coupled
thermal-electrical-structural analysis. These values affect only field-variable-dependent
material properties, if any. See Predefined Fields.
Material Options
The materials in a fully coupled thermal-electrical-structural analysis must have thermal
properties (such as conductivity), mechanical properties (such as elasticity), and
electrical properties (such as electrical conductivity) defined. See Abaqus Materials Guide for details on the material models
available in Abaqus.
You can control whether to consider or ignore the strain rate–dependence of the yield
stress and the slip rate–dependence of the friction coefficient within the step.
Inelastic Energy Dissipation as a Heat Source
You can specify an inelastic heat fraction in a fully coupled
thermal-electrical-structural analysis to provide for inelastic energy dissipation as a
heat source. The heat flux per unit volume, , that is added into the thermal energy balance is computed using the
equation
or, in the case when the nonlinear isotropic/kinematic hardening model is used, from the
following equation:
where is a user-defined factor (assumed constant), is the stress, is the backstress, and is the rate of plastic straining.
Inelastic heat fractions are typically used in the simulation of high-speed manufacturing
processes involving large amounts of inelastic strain, where the heating of the material
caused by its deformation significantly influences temperature-dependent material
properties. The generated heat is treated as a volumetric heat flux source term in the
heat balance equation.
An inelastic heat fraction can be specified for materials with plastic behavior that use
the Mises or Hill yield surface (Inelastic Behavior). It cannot be
used with the combined isotropic/kinematic hardening model. The inelastic heat fraction
can be specified for user-defined material behavior in Abaqus/Explicit and is multiplied by the inelastic energy dissipation coded in the user subroutine to
obtain the heat flux. In Abaqus/Standard the inelastic heat fraction cannot be used with user-defined material behavior; in this
case the heat flux that must be added to the thermal energy balance is computed directly
in the user subroutine.
In Abaqus/Standard an inelastic heat fraction can also be specified for hyperelastic material definitions
that include time-domain viscoelasticity (Time Domain Viscoelasticity).
The default value of the inelastic heat fraction is 0.9. If you do not include the
inelastic heat fraction behavior in the material definition, the heat generated by
inelastic deformation is not included in the analysis.
Specifying the Amount of Thermal Energy Generated due to Electrical Current
Joule's law describes the rate of electrical energy, , dissipated by current flowing through a conductor as
The amount of this energy released as internal heat within the body is , where is an energy conversion factor. You specify in the material definition. It is assumed that all the electrical energy
is converted into heat () if you do not include the Joule heat fraction in the material
description. The fraction given can include a unit conversion factor, if required.
Elements
Coupled thermal-electrical-structural elements that have displacements, temperatures, and
electrical potentials as nodal variables are available. Simultaneous temperature/electrical
potential/displacement solution requires the use of such elements; pure displacement and
temperature-displacement elements can be used in part of the model in a fully coupled
thermal-electrical-structural analysis, but pure heat transfer elements cannot be used.
The first-order coupled thermal-electrical-structural elements in Abaqus use a constant temperature over the element to calculate thermal expansion. The
second-order coupled thermal-electrical-structural elements in Abaqus use a lower-order interpolation for temperature than for displacement (parabolic
variation of displacements and linear variation of temperature) to obtain a compatible
variation of thermal and mechanical strain.
Considerations for Steady-State Coupled Thermal-Electrical-Structural Analysis
In a steady-state coupled thermal-electrical-structural analysis the electrical energy
dissipated due to flow of electrical current at an integration point (output variable
JENER) is computed using the following
relationship:
where denotes the electrical energy dissipated due to flow of electrical
current and is the current step time. In the above relationship it is assumed that
the rate of the electrical energy dissipation, , has a constant value in the step that is equal to the value currently
computed.
The output variable JENER and the
derived output variables ELJD and
ALLJD contain the values of electrical
energies dissipated in the current step only. Similarly, the contribution from the
electrical current flow to the output variable
ALLWK includes only the external work
performed in the current step.
Input File Template
HEADING
…
** Specify the coupled thermal-electrical-structural element type
ELEMENT, TYPE=Q3D8
…
**
STEPCOUPLED TEMPERATURE-DISPLACEMENT, ELECTRICALData line to define incrementationBOUNDARYData lines to define nonzero boundary conditions on displacement,
temperature or electrical potential degrees of freedomCFLUX and/or CFILM and/or
CRADIATE and/or DFLUX and/or
DSFLUX and/or FILM and/or
SFILM and/or RADIATE and/or
SRADIATEData lines to define thermal loadsCLOAD and/or DLOAD and/or DSLOADData lines to define mechanical loadsCECURRENTData lines to define concentrated currentsDECURRENT and/or DSECURRENTData lines to define distributed current densitiesFIELDData lines to define field variable valuesEND STEP