This paper presents a new formulation for the automatic definition and treatment of mechanical contact in explicit nonlinear finite element analysis. Automatic contact offers the benefits of significantly reduced model construction time and fewer opportunities for user error, but faces significant challenges in reliability and computational costs. This paper discusses in detail a new four-step automatic contact algorithm. Key aspects of the proposed method include automatic identification of adjacent and opposite surfaces in the global search phase, and the use of a smoothly varying surface normal which allows a consistent treatment of shell intersection and corner contact conditions without ad-hoc rules. The paper concludes with three examples which illustrate the performance of the newly proposed algorithm in the public DYNA3D code
