manual pam stamp

PAM-STAMP 2G 2012 Users Guide

October 2012

GR/PAST/12/03/00/A

PAM-STAMP 2G 2012

USERS GUIDE

The documents and related know-how herein provided by ESI Group subject to contractual conditions are to remain confidential. The CLIENT shall not disclose the documentation and/or related know-how in whole or in part to any third party

without the prior written permission of ESI Group.

2012 ESI Group. All rights reserved.

PAM-STAMP 2G 2012 i USERS GUIDE 2012 ESI Group (released: Oct-12)

CONTENTS

CONTENTS

ABOUT THIS DOCUMENT 1 Attributes /Functionalities Chapters -------------------------------------------------- 1

INTRODUCTION 5 PAM-STAMP 2G Overview ------------------------------------------------------------ 5

PRODUCT START UP 15 ASCII Input ------------------------------------------------------------------------------- 15 Customization ---------------------------------------------------------------------------- 18 Files ---------------------------------------------------------------------------------------- 23 Solver Manager Configuration ------------------------------------------------------- 32 Solver Manager Start ------------------------------------------------------------------ 40 Solver Manager Activity --------------------------------------------------------------- 43 Calculation Stop ------------------------------------------------------------------------- 44

FINITE ELEMENT AND NUMERICAL MODELS 45 Algorithm ---------------------------------------------------------------------------------- 45 Time Step & Increments -------------------------------------------------------------- 59 Elements ---------------------------------------------------------------------------------- 68 Material Properties --------------------------------------------------------------------- 76 HILL 48 Material Law ------------------------------------------------------------------ 80 HILLs 90 Material Law ---------------------------------------------------------------- 84 BARLAT89 Material Law -------------------------------------------------------------- 86 BARLAT91 Material Law -------------------------------------------------------------- 87 BARLAT2000 Material Law ---------------------------------------------------------- 89 VEGTER Material Law ---------------------------------------------------------------- 92 Matfem Failure Criterion ------------------------------------------------------------ 100 SUPERPLASTIC Material Law ---------------------------------------------------- 106 Mooney-Rivlin Material Law -------------------------------------------------------- 112 Material Hardening Laws ----------------------------------------------------------- 113 Thermal Material Option ------------------------------------------------------------ 130 MetallurgIcal Material Option ------------------------------------------------------ 137 EWK Rupture Model ----------------------------------------------------------------- 148 Material File Format (.psm) -------------------------------------------------------- 155

SIMULATION CONCEPTS 175 Contact and Friction ------------------------------------------------------------------ 175 Objects & Attributes ------------------------------------------------------------------ 193 Kinematics ------------------------------------------------------------------------------ 200 Force and Pressure ------------------------------------------------------------------ 206 Fluid Cell and Aquadraw ------------------------------------------------------------ 209

USERS GUIDE ii PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group

CONTENTS

Rigid Body ------------------------------------------------------------------------------ 217 Adaptive Meshing --------------------------------------------------------------------- 223 Drawbead ------------------------------------------------------------------------------- 232 Symmetry Plane ----------------------------------------------------------------------- 258 Picking ----------------------------------------------------------------------------------- 260 Distributed Memory Process (DMP) --------------------------------------------- 265 Process Setup ------------------------------------------------------------------------- 271 Offset ------------------------------------------------------------------------------------- 285 Mesh Check and Cleanup ---------------------------------------------------------- 290 Filleting ---------------------------------------------------------------------------------- 297 Substructuring ------------------------------------------------------------------------- 301 Mapping --------------------------------------------------------------------------------- 309 Mapping Files -------------------------------------------------------------------------- 317 User-Defined Attribute --------------------------------------------------------------- 332

ANALYSIS TOOLS 335 Contours--------------------------------------------------------------------------------- 335 Forming Limit Diagram (FLD) ------------------------------------------------------ 349 Draw-In Tools -------------------------------------------------------------------------- 356 Blank Shifting -------------------------------------------------------------------------- 362 Solver Analysis Tools ---------------------------------------------------------------- 365 User Interface Analysis Tools ----------------------------------------------------- 371 Scripting --------------------------------------------------------------------------------- 383 Reporting -------------------------------------------------------------------------------- 390

SIMULATION METHODOLOGY FOR DESIGN AND STAMPING FEASIBILITY 397

Introduction ----------------------------------------------------------------------------- 397 Customization -------------------------------------------------------------------------- 399 Die Design (PAM-DIEMAKER) ---------------------------------------------------- 406 Part Preparation for Die Design (PAM-DIEMAKER) ------------------------ 411 Evaluation of the Tool Design (Pam-QuikStamp PLUS) ------------------- 421 Process Verification (Pam-Autostamp) ----------------------------------------- 441 Binder Generation for Die Design (PAM-DIEMAKER) ---------------------- 461 Run-Offs and Addendum Generation for Die Design (PAM-DIEMAKER) --------------------------------------------------------------------------- 465

Re-Engineering the Die Face (PAM-DIEMAKER) --------------------------- 479 Process Verification: Penalty Contact (Pam-autostamp) ------------------- 484 Iteration on Design and Stamping Feasibility ---------------------------------- 488

SIMULATION METHODOLOGY FOR STANDARD FORMING 497

Introduction ----------------------------------------------------------------------------- 497 Customization -------------------------------------------------------------------------- 502 Creation of the Tools ----------------------------------------------------------------- 509 Blank Meshing ------------------------------------------------------------------------- 539

PAM-STAMP 2G 2012 iii USERS GUIDE 2012 ESI Group (released: Oct-12)

CONTENTS

Creation of DRAWBEADS ---------------------------------------------------------- 547 Analysis Entities ----------------------------------------------------------------------- 549 Process Setup ------------------------------------------------------------------------- 550 Simulation and Postprocess ------------------------------------------------------- 564

SIMULATION METHODOLOGY FOR SPECIFIC PROCESSES 567

Tailored and Patchwork Blanks --------------------------------------------------- 567 Hot Forming ---------------------------------------------------------------------------- 582 Flanging --------------------------------------------------------------------------------- 617 Roll Hemming -------------------------------------------------------------------------- 623 Hemming -------------------------------------------------------------------------------- 663 Control Table --------------------------------------------------------------------------- 664 Die Compensation and Multi-op -------------------------------------------------- 670 Blank and Trimming Line Optimization ------------------------------------------ 697 Springback Measurement ---------------------------------------------------------- 716 Cosmetic Defects Analysis --------------------------------------------------------- 736 Press Force Analysis ---------------------------------------------------------------- 751 Volume Blank -------------------------------------------------------------------------- 758 Simulation with Ironing - T.T.S Element ---------------------------------------- 765 Gas Springs ---------------------------------------------------------------------------- 768 Drawslit or Lancing ------------------------------------------------------------------- 771 CRASHFORMING -------------------------------------------------------------------- 773 Stamping Inverse --------------------------------------------------------------------- 774

SIMULATION METHODOLOGY FOR TUBE 789 Introduction ----------------------------------------------------------------------------- 789 Customization -------------------------------------------------------------------------- 792 Tube Design Module (PAM-TUBEMAKER) ------------------------------------ 799 Bending Simulation Feasibility ---------------------------------------------------- 826 Tube Bending -------------------------------------------------------------------------- 834 Tube Hydroforming ------------------------------------------------------------------- 843

DELTAMESH 855 Introduction ----------------------------------------------------------------------------- 855 CAD Model Exchange from CAD Systems to DeltaMESH ---------------- 858 Meshing Access ----------------------------------------------------------------------- 898 DeltaMESH Parameters ------------------------------------------------------------ 902 Mesh Check and Repair ------------------------------------------------------------ 919 The Remeshing Action -------------------------------------------------------------- 931 The Multipatching Action ------------------------------------------------------------ 937 Other DeltaMESH Actions ---------------------------------------------------------- 942 Configuration of Meshing Parameters ------------------------------------------- 946

USERS GUIDE iv PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group

CONTENTS

PAM-STAMP 2G 2012 1 USERS GUIDE 2012 ESI Group (released: Oct-12)

ABOUT THIS DOCUMENT Attributes /Functionalities Chapters

ABOUT THIS DOCUMENT

ATTRIBUTES /FUNCTIONALITIES CHAPTERS

Here is a list of the chapters on the Users Guide describing the attributes and

functionalities available in PAM-STAMP 2G.

For Pam Quikstamp plus project, the user must also refer to the Evaluation of the tool

design (Pam Quikstamp) chapter in the Simulation Methodology for design and

stamping feasibility section.

For Inverse project, the user must refer to the Stamping Inverse chapter in the

Simulation concepts section and to the Tube Inverse chapter in the Simulation

methodology for tube section.

ATTRIBUTES:

/FUNCTIONALITIES SECTION CHAPTER PAGE

Analysis

Simulation methodology for Standard Forming

Analysis entities

556

Aquadraw Simulation Concepts Fluid Cell

209

Autopositioning Simulation methodology for Standard Forming

Process setup 557

Behavior Simulation methodology for

Specific Processes

Gas Springs 777

Blank Meshing Simulation methodology for Standard Forming

Evaluation of the tool design

545

Simulation methodology for Specific Processes

Optimization 706

Boundary Condition on points

Simulation concepts Kinematics 200 Simulation methodology for Specific Processes

Springback measurement

725

USERS GUIDE 2 PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group


Cartesian kinematics Simulation concepts Kinematics 200 Contact Simulation concepts Contact and

Friction 175

Cooling Channel Simulation methodology for Specific Processes

HotForming 609

CPU Control Finite element and numerical models

Time Step & Increments

59

Damage Finite element and numerical models

EWK Rupture Model

137

Drawbead Forces Simulation concepts Drawbead 237

Drawbead definition

Simulation concepts Drawbead 237

DMP Simulation concepts DMP 266 Simulation for Specific Processes

Rollhemming 631

Dynamic Freeze Simulation concepts Kinematics 204

Simulation for Specific Processes /

Rollhemming 631

Element elimination Analysis tools / Solver analysis tools

368

Fluid Cell Simulation concepts / Fluid Cell 209

Follower force Simulation concepts / Force & Pressure

207

Simulation for Specific Processes

Rollhemming

Force Simulation concepts Force & Pressure 206 Freeze Simulation concepts Kinematics 203

Gravity Simulation methodology for Standard Forming

Process setup 557

Finite element and numerical models

Algorithms

45

Gluing Contact Simulation concepts Contact and Friction

175

Kinematic Path Simulation for Specific Processes

Rollhemming 631

Ironing Simulation for Specific Processes

Simulation with Ironing-TTS Element

774

Mapping Simulation concepts Mapping 311 Mesh

Simulation methodology for Standard Forming

process setup 557

Multi body system Simulation concepts Rigid Body 217 Simulation for Specific Processes

Rollhemming 631

Optimization Simulation for Specific Processes

Optimization 706



Path Definition

Simulation for Specific Processes

Rollhemming 631

Phase transformation Simulation for Numerical Models

Metallurgical material option

163

Picking Simulation concepts Picking 261

Press Force Analysis Simulation methodology for Specific Processes

Press Force analysis

760

Pressure Simulation concepts Force & Pressure 206 Quenching Simulation methodology for

Specific Processes

HotForming 590

Refinement Simulation concepts Adaptive meshing

264

Rigid Body Simulation concepts Rigid body 217 Robot Components Simulation for Specific

Processes

Rollhemming 631

Rotational kinematics Simulation concepts Kinematics 200

Solver Manager Product startup Solver configuration

32

Springback Simulation methodology for Specific Processes

Springback measurement

725

Substructure

Simulation concepts Substructure 303 Simulation methodology for Specific Processes

Surface defect analysis

504

Symmetry Plane

Simulation concepts Symmetry plane 259

Thermal properties Finite element and numerical models

Thermal material option

Simulation methodology for Specific Processes

Hotforming 590

Trimming Simulation methodology for Standard Forming

Process setup 557

User-Defined Simulation concepts User Defined Attribute

130

Values scaling Simulation concepts Picking 261


INTRODUCTION PAM-STAMP 2G Overview

INTRODUCTION

PAM-STAMP 2G OVERVIEW

PAM-STAMP 2G is available as a professional package. Essentially, it offers the user

access to a significant number of options by using a flexible license token approach.

Included in PAM-STAMP 2G v2012:

PAM-STAMP INVERSE: for estimation of the developed part blank shape and very early feasibility studies on part.

PAM-DIEMAKER: for the design of the die

DELTAMESH: as meshing module

PAM-QUIKSTAMP: for feasibility analysis

PAM-AUTOSTAMP: for validation and optimization of sheet metal forming processes

PamStamp 2G v2012 proposes:

the simulation of major sheet metal

forming processes, like:

Rollhemming

Hotforming

Super Plastic forming

Hydro forming

Tube forming

The Stamp Toolkit enables the customization of all

processes like Rubber pad

forming or stretch forming.

optimization and modification

functionalities, like:

Die compensation combined with surface reconstruction

with iCapp PanelShop

Blank and trim line optimization

Morphing

Filleting with Deltamesh fillet

Substructuring for local iterations



dedicated analysis tools, like

Cosmetic defect analysis

Draw-in analysis

Reporting tools

dedicated material models, like:

Corus Vegter material Model

Matfem Crach material Model

Yoshida material Model

Ito-Goya material model

Superplastic material models

Environment

Common environment

All modules proposed within PAM-

STAMP 2G share the same

environment.

Switching between modules is easy

and guided when necessary

Dedicated contexts

Dedicated contexts are proposed for an

automatic customization of the

environment based on the selected

process.



Customized environment

PamStamp 2G environment is fully

customizable by company or by user.

It can be adapted to the customer

needs, by creating his own toolbars,

process macro-commands, user-

defined contours, or by defining the

default parameters he wants to use.

PAM-INVERSE

PAM-INVERSE is a one step or inverse solver, designed to make;

Developed part blank shape estimation for costing purposes.

Very early feasibility studies on PART geometry, prior to die design

Inverse solvers are designed to run very fast, but only to give 1st impression of

component feasibility. Basic usage is to make 2 simulations to test the two extremes of

material movement free boundary and locked boundary. In this sense it can be

considered as a go / no-go gauge for component feasibility checking.



PAM-DIEMAKER

From an imported CAD geometry, PAM-DIEMAKER allows the user to design and

optimize the binder surface and die addendum in just minutes. Its rapid and iterative

parametric approach generates a realistic simulation model, allowing the user to quickly

evaluate the parts formability with QUIKSTAMP. Tipping direction, binder surface

and addendum geometry can easily be modified, allowing total control of upfront

design processes such as the number of stages and multi-parts grouping.

Highlights:

Parametric modeling

PAM-DIEMAKER can be used starting

from a CAD file of the part, with no

tooling information available: the user

constructs the die geometry from nothing

by preparing the part geometry, by

defining a binder surface and by

constructing the run-off. In many cases, a

new die design would be based on an

already existing geometry. As such, it is

much easier to just take this geometry as a

reference and make the appropriate

changes to certain zones rather than to

entirely re-construct this die.

The parametric re-engineering covers

this latter methodology and allows the

user to re-construct a parametric surface

model in very short time. The re-

engineering starts from an existing die

geometry (CAD or scanned data) and re-

creates the necessary surface information

step-by-step, resulting in a 3D parametric

model of the initial tool, that can e.g. be

used to perform binder or run-off

modifications or to exchange the part

geometry.



PAM-QUIKSTAMP Plus

PAM-QUIKSTAMP allows the die designer to check and evaluate different die

geometry parameters like binder surface and die addendum, including swages and die

walls. PAM-QUIKSTAMP provides a fast formability evaluation, and represents the

optimal compromise between accuracy, time and computing resources.

Since PAM-QUIKSTAMP does not require high quality mesh for tools, it is very easy

to iterate and optimize the process.

Taking into account elasto-plastic behavior, friction, blankholder pressure, drawbead

and cutting pattern, it carries out a fast and reliable 3D evaluation within minutes and

eliminates erroneous choices at the conceptual design stage.



PAM-AUTOSTAMP

PAM-AUTOSTAMP allows the user to master virtual try-out of the stamping process

taking into account the full process with industrial conditions such as gravity, binder

development, multi-stage forming, draw, restrike, trimming, springback, flanging and

hemming. PAM-AUTOSTAMP guides the user through the final validation of forming

process, tolerances and overall quality control, helping to avoid costly and time-

consuming downstream problems. PAM-AUTOSTAMP also includes a state-of-the-art

implicit solver technology, enabling fast accurate springback predictions.

The scope of processes which could be modeled is continuously increasing, and

includes hotforming, rollhemming, double blank forming, spot-welded blanks, rubber-

pad forming, super-plastic forming and multistage tube forming processes, in addition

to the standard stamping, tube bending, tube and sheet hydroforming processes.

Problems which can be detected include conventional formability issues of splits and

wrinkles, but also subtle quality issues such as cosmetic defects, slip lines, marks, and

dimensional stability after springback.

Optimization tools help finding solutions to the detected problems. Blank or trim line

optimization are useful for designing the correct initial blank shape and right trim lines,

and Die compensation modifies automatically the die for reaching the good final shape

after springback.

Courtesy of SKODA Auto



PAM-TUBE

PAM-TUBE INVERSE

PAM-INVERSE offers a very fast simulation tool for non-critical bending operations

and for general feasibility checks as a preforming step for hydroforming. An advisor is

included that will determine if PAM-INVERSE is a suitable simulation method.

With PAM-INVERSE bending operations of any circular, conical or user-defined

profile can be simulated.

PAM-TUBEMAKER

From an imported CAD geometry, PAM-TUBEMAKER allows the user to design and

optimize the bending or hydroforming process in just minutes. Its rapid and iterative

parametric approach generates a realistic simulation model, allowing the user to quickly

evaluate the parts formability. Process and tool design can easily be modified, allowing

total control of upfront design processes such as the number of stages and multi-parts

grouping.

PAM-TUBEMAKER easily reads CAD data in IGES and VDA format. While reading

the CAD surface information, it automatically meshes the surfaces as well using state of

the art meshing technology from DeltaMESH. Next to the direct treatment of CAD

surfaces, PAM-TUBEMAKER also imports various mesh formats, such as PAM-

SYSTEM, universal (.unv) and Nastran (.nas).

On user interface level, PAM-TUBEMAKER tries to propose for the user process and

tool design parameters by following as much as possible the objective of finding a

feasible process setup. At the same time full flexibility is given, and the user has at all

points the full control on the design.



DELTAMESH

The complete integration of DeltaMESH Stamping into PAM-STAMP 2G offers full

functionality of automatic meshing within the software. With DeltaMESH meshing the

user is certain to obtain a high quality mesh allowing to rapidly start the design process.

As a good simulation result requires a good mesh, DeltaMESH will do just that: based

on the initial CAD file, the program will automatically generate a connected mesh.

Fully automatic surface mesher integrated into the PAM-STAMP 2G environment that

delivers high quality mesh results

Consecutive steps for import / joining / meshing can be handled automatically or

interactively:

o Reads IGES / VDA format

o Joins surfaces with thin surface, hole, gap or overlap tolerance

o Automatic meshing algorithms based on uniform, parametric and

progressive meshing

Optional post-meshing operation: Automatic localized re-meshing according

to some element quality criteria

DeltaMESH Fillet

DeltaMESH Fillet integrated in PAM-STAMP 2G offers full functionality of automatic

filleting. With DeltaMESH Fillet the user is certain to obtain a high quality fillet mesh

on sharp edges allowing to start the process simulation as early as possible. Basically,

good stamping simulation results require a good mesh on radii in order to accurately

represent the metal flow phenomena and related physics. This will allow the user to

control the global filleting and the local radii as well.

DeltaMESH Stamping Inverse

This integration of DeltaMESH Stamping Inverse into PAM-STAMP 2G allows

generating fully automatically a FEM quality mesh dedicated to the inverse method

solver. The generation of this patch-independent mesh, consists in importing either a

CAD model or a DeltaMESH geometrical database and joining it (topological model

creation). DeltaMESH Stamping Inverse will create zones from connected face groups

(for example, blankholder ). Thus, we obtain a mesh coarser than DeltaMESH

Stamping mesh but with finite element quality



Calculation Code

PAM-STAMP2G is a calculation code that uses the finite element method (FEM). All

the components of a calculation (metal sheet or tube, tools, ) are shown as meshes,

i.e. a discrete representation of the geometry.

For non-deformable tools, the mesh is only a representation of the geometry, and the

finite elements are only facets to be used for contact description. On the contrary, for

the blank, the tube or a deformable tool, the finite elements forming this mesh represent

small pieces of the material with a prescribed behavior.

The mechanical phenomena that occur in a blank or in a tube are faithfully reproduced

using a large number of these elements. Within reason, the finer the mesh to be

generated, the better the quality of the results, whereas the higher the number of

elements, the longer the calculation time. Note that in a simulation, a detail whose size

is smaller than that of the elements cannot be represented: the size of the elements

defines the precision of the simulation.

A finite element can be a 2-node (bar), a 3-node element (triangle), a 4-node element

(quadrangle), a 6- or 8-node volume element (hexahedron), and it is constructed from

nodes that are defined in its corners. Each node has two types of degrees of freedom:

translation and rotation. The translation degree of freedom of a node represents its

ability to move in translation along a direction, whereas a rotation degree of freedom of

a node represents its ability to rotate about an axis. A node with three degrees of

freedom in translation and three degrees of freedom in rotation can move along three

axes X, Y and Z and can rotate about these three axes.

Depending on the calculation type

(implicit or explicit) the calculation is

sub-divided into increments or time-

steps. Generally, implicit increments are

large with respect to the explicit time-

steps.

Positions, velocities, accelerations and

forces are permanently calculated at the

nodes, which are points linked to the

material. Within the elements, strains are

calculated from positions.

element

nodes

mesh

Corresponding stresses are then obtained, which result in forces on the nodes. This

calculation is repeated over all the elements for the entire duration of the calculation.

Boundary conditions are used to remove degrees of freedom (locking), while velocities

and forces further define the kinematic behavior of the finite element model.

To describe the actual deformation process, material properties and thickness must be

assigned to an element.


PRODUCT START UP ASCII Input

PRODUCT START UP

ASCII INPUT

Purpose

For all projects, the data set-up is stored in the .pre file of the project, which is a

binary file. However, the application offers the user the possibility of having ASCII

input files, enabling him to modify manually or automatically the data set-up without

opening the GUI.

Data Input File

The data set-up of a simulation is described with the attributes. The .att file is the

ASCII file that contains the multistage data set-up that means the attributes of all the

simulations that will be launched one after each other.

Writing of the file

The .att file is automatically written

when starting the simulation if the option Write the input file and start the

calculation is activated.

It is also possible to write the .att file

without running the simulation, with the

option Write input file only.

Default

By default the option Write the input file and start the calculation

is always activated.



Simulation launching

When the simulation is launched, if there are in the same project directory both the

projectname.pre and a projectname.att files, the information of the .att file is

transmitted to the solver instead of the information of the .pre file.

Data reading

If there are in the same project directory both a projectname.pre and a

projectname.att files, the information of the .att file is read instead of the

information of the .pre file. The user can so modify manually the .att file and update

then the .pre file by opening the project and saving it.

Mesh Input File

The mesh used for a simulation is contained in the .pre file. However it is possible to

write ASCII mesh input file (.mif).

Writing of the file

The .mif file can be exported using the Export mesh menu with the mesh input file

format (.mif). A name different from the project name can be given.

The Mif format is as follow:

- The .mif file contains all the mesh needed by the solver to run a calculation (nodes, elements, 3D curves, objects, and picked restart files information).

- The file is divided in sections starting by a keyword with DEF_ prefix, and ending by the start of another section or the end of the file. Each section can occur once in

the file. The section can be associated to a parameter, which is the count of entities

that are written in the section (to accelerate the loading time in allocating once the

entities).

- Within each section, several entries can be defined, with associated parameters (each parameter which is preceded by / character).

- Blank lines are authorized (i.e. lines without character or with space or tab characters).

- Comment lines can be added, if they start with a # character. They will not be read by the GUI nor the solver.

- The lines must not exceed 256 characters.

Remarks:

The difference with the other export formats management is that not only the visible entities will be exported, but all the mesh, and that picking data will be

exported also.

It is also possible to do a .mif export from a .res file.



Simulation launching

The launch of a simulation with a MIF file, is done by a command line using the .att

file instead of the .pre file.

The .att file must be modified to specify the mesh input file that the user wants to use

for the simulation:

After the section DEF_SOLVER, the following section has to be manually added:

DEF_MODEL_INPUT_FILE

FILENAME = name of the .mif file to be used

Data reading

The results of the simulation will be loaded, when the user loads any of the result files.

A .psp file is then automatically created.

Note:

It is possible to import the mesh with the .mif format via the import mesh

menu, using the options Keep identifiers and Keep thicknesses.


PRODUCT START UP Customization

CUSTOMIZATION

The software allows the user to adapt the program to his needs, by creating his own

toolbars and process macro-commands, or by easily defining the default parameters he

wants to use. All such customizations are described in this chapter.

Some of the customization data is stored in a separate configuration file (both in the

installation directory and the main users directory) and can be manually modified. This

is also further explained.

Customization stored in the users file, can be copied into the installation file if you

require specific site customization, for example to implement standards across a

company.

Toolbars

It is possible for the user to create his own

toolbars with the View / Toolbars /

Customize option. This dialog box

contains five tabs:

- Commands: All the options available for pre-processing, solver and post-processing are summarized according to their order in the Menu Bar. Individual tasks are

chosen and added to the new users toolbar from this list.

- Toolbars: Default toolbars available in the program are listed. They can be activated or not. If activated, the toolbar tasks are shown in the upper part of a

graphical window. If the user prefers to have icons of tasks coupled with text labels,

the Show text labels option has to be activated too. New toolbars can be created, the

options available in this toolbar must be chosen in the Commands list. These custom

toolbars can be modified, renamed or deleted whenever necessary.

- External tools: This allows the user to define links from within the GUI to external software tools, for example a calculator, or a spreadsheet etc.

- Keyboard: This allows the user to define shortcut keys, which can be assigned to any action, making routine work more efficient.



- Menu: It is used for the Menu Bar and a Context menus definition:

Menu Bar: It can be chosen from several menu types (Curve Editor, Macro edit, etc.) specified for each kind of users work.

Context menu: Four context menu options (2D Settings, 2D View, 3D View and FLD View) can be used. The 3D View Menu called "right-click" menu is

automatically activated. Most of the options of this "right-click" menu are also

accessible through the Menu Bar, but some of them can only be used through the

former. New items can be added from the Commands list.

- Positions: Enables reset all windows and toolbar positions.

- Options: Enables defining some menu properties like displaying screen tips on toolbars, large icons, etc.

Advanced Mode

Advanced mode currently is used to access the Stamp Tool Kit options. This function is

generally designed to be used by the site Advanced User. If Advanced user mode is not

activated, the Stamp Tool Kit options will not be available.

It is possible to activate permanently the Advanced Mode in the Customize Macro page

Licenses

It is possible to select here which options will

be available; the corresponding tokens will be

taken by the program.

If the user does not have enough tokens, a

message will be displayed in the console.

The status of the Customize tokens menu is

stored in the configuration file.

If there are not enough tokens when launching

the application with the saved license

customize configuration, a message appears

and the Customize tokens menu is opened.

Warning:

The license configuration is saved when a user saves a new configuration

in the general customize menu.



Default Parameters

The default parameters and settings

proposed by the program can be defined for

each user (user login). They are stored in the

configuration file.

The Customize / Options menu allows the

user to specify the following parameters:

- Design: Default PAM-DIEMAKER and PAM-TUBEMAKER parameters can be defined in this page. See Simulation Methodology for Design and Stamping feasability and Simulation Methodology for Tube sections for further information.

- DeltaMesh: The Import, Joining, Meshing, Inverse meshing and Remeshing default parameters are defined here. The Meshing strategy can also be created and

customized as default in this page. See Deltamesh section for further information.

- Process: Default values of AutoStamp attributes are defined in the Process page. The Default unit system is also defined here, as the Check data before starting option

(It forces an attribute check to be done prior to launching the solver, giving the user

the possibility to detect input errors without wasting solver time). Automatic Blank

meshing can be deactivated here. See Blank editor chapter for further information.

Parameters of Die compensation are defined on this page as well. Users, who want

to use Tool editor before Blank editor in general workflow can deactivate Blank

editor before Tool editor option through this page.

- Files location: This page enables the user to define the default files location, especially when using Import Export and functionalities. It is also used when

opening a Project or the Material Database. The Solver Host definition with the

location of the executable used for the simulation as the eventual equivalences

between disk names must be defined here.

- GUI Parameters: All the default Display options are saved in this page, as the Camera movement and the 2D Section display. Reporting tools setting are defined

here. The Activate undo feature allows the user to activate the undo function. By



default it is on. See User interface analysis tools chapter for further information. It is possible to define Search radius for Local Min/Max annotations here as well.

- Geometry: In this page are saved the default values used for the mesh Orientation, for the Offset functionality and for the 3D curve editor. See offset chapter for

further information.

- Contours: Each contours option is by default activated or not in this page. See Contours chapter for further information. FLD contours options and Maximum

angle on a face for Thickness of solids contour are defined on this page.

- ToolEditor: Default Tool editor values are saved in this page. See the offset chapter for further information. Default initial blank mesh size (used if automatic meshing is

not active) can be set here. See Blank editor chapter for further information. It is

possible to define Flanging tool parameters on this page as well.

- Macro: Process macro options are defined here. See Process macro chapter for further information.

Note :

Refer to the Reference manual for more detailed information on each functionality of the Custom options menu.

Customization File

All of the above customizations are actually stored in an ASCII file that can reside in

two locations. The main customization file is located within the installation directory

and ensures general customization for all users. For more personalized customization

the software also generates a customization file in the users main directory. For

Windows it is:

C:\Documents and Settings\

while on Unix this would be depending on the system that is used, e.g.:

/usr/local/

The name of the personal configuration file is defined by default as stamp2G.cfg, but

can be modified by the user. For Windows users, modifying the startup batch script that

resides in the installation directory can do this.

When starting the application, the main configuration file is read first, followed by the

personal customization file. Any settings already defined by the main customization are

overwritten by the personal customization file.

The customization files are in ASCII format, so they can be read and modified by

administrators if necessary.



Macro-Command

The software is able to automatically perform successive operations, which generally

occur during the data setup of each step of a standard simulation. These tools, thanks

to which the user does not have to perform several manipulations during the data setup,

are the macros. For standard processes, nearly the whole data setup is performed by

the process macro; therefore a full data setup can be done in a few minutes.

Further explanations about the Stamp Tool Kit are given in the Process Macro and

offset chapters of this document.


PRODUCT START UP Files

FILES

Numerous files are used by PAM-STAMP 2G. Each has a very precise function.

Herein, the generic name of the project will be designated as gn.

Data Bases

Material

- material.psm:

Material data.

ASCII files.

One file per material.

Macro from Stamp Tool Kit

- macro.ksa:

Definition of PAM-AUTOSTAMP standard forming macro.

ASCII file.

One file per process macro-command.

- Macro.ksp

Definition of PAM-QUIKSTAMP Plus macro

ASCII file.


- macro.ktf:

Definition of PAM-AUTOSTAMP tube hydroforming macro.

ASCII file.


- macro.ktb:

Definition of PAM-AUTOSTAMP tube bending macro.

ASCII file.


- macro.ksi:

Definition of PAM-INVERSE standard forming macro.

ASCII file.




- macro.kti:

Definition of PAM-INVERSE tube bending macro.

ASCII file.


Template from PAM-DIEMAKER

- profile.udt:

Definition of user-defined profile template.

ASCII file.

One file per profile.

- profile.pfl:

Definition of parameters of standard profile template.

ASCII file.

One file per profile.

Project

- gn.psp:

Data common to all modules of the project (for example alarms, section planes, active state).

Preprocessor

- gn.pre:

Setting up of the project data and mesh description of the project.

Binary file.

Multistage file.

It is used to run a simulation.

- gn.att:

Project data setup.

ASCII file.

Multistage file.

It can be used with the gn.pre file or with the gn.mif file to run the calculation.



- gn.mif:

Mesh description of the project.

ASCII file.

It can be used with the gn.att file to run the calculation.

- gn.[i].und:

Temporary undo file that contains information for undo. If n undo are possible

there are n files from gn.1.und to gn.n.und. Files are removed when closing

the project.

Binary file.

Deleted when the project is closed.

CAD Meshing Module

If the project comprises several modules, the following files correspond to the Ith

module:

- gn.I.msh:

Definition of the CAD model, the elements, nodes and groups of the module.

Binary file.

- gn.I.cmd:

Command file of DeltaMESH containing the input for meshing.

ASCII file.

- gn.Ir.dtc:

DeltaMESH data base after import. Results of CAD import.

Binary file.

- gn.Ia.dtc:

DeltaMESH data base after joining. Results of CAD joining.

Binary file.

- gn.Im.dtc:

DeltaMESH data base after meshing. Results of CAD meshing.

Binary file.

- gn.Im.fma:

Results of CAD meshing.

ASCII file.

PAM-STAMP 2G temporary file that can be imported.



- gn.I.his:

DeltaMESH Stamping messages file for all operations.

ASCII file.

Design Module (PAM-DIEMAKER and PAM-

TUBEMAKER)

If the project comprises several modules, the following files correspond to the Jth

module:

- gn.J.add:

Definition of the model used by PAM-DIEMAKER and PAM-TUBEMAKER (mesh, profiles, ).

Binary file.

- gn.J.msh:

Definition of the CAD model, the elements, nodes and groups of the module.

Binary file.

- gn.Jr.dtc:

DeltaMESH data base after import. Results of CAD import.

Binary file.

- gn.Jm.dtc:

DeltaMESH data base after meshing. Results of CAD meshing.

Binary file.

- gn.Jm.fma:

Results of CAD meshing.

ASCII file.

PAM-STAMP 2G temporary file that can be imported.

- gn.J.trm:

Definition of the model used for Die Trimming.

ASCII file.

- gn.J.ptl:

Definition of the user-defined PTL.

ASCII file.

- gn.bending:

Definition of bending data.



ASCII file.

Die Compensation

- Gn_Outifo.input:

Input file for Outifo containing the settings.

ASCII file.

- Gn_Outifo.lis:

Output file of Outifo, containing all information about the computation. Used by the GUI in Show all messages

ASCII file.

- Gn_Outifo.output:

Output file of Outifo containing the status of the computation. It can be seen in the GUI, in the Outifo console.

ASCII file.

- Gn_Outifo.history:

History file written by Outifo, containing the points of Outifo history curves (max distance, average distance .).

ASCII file.

- Gn_Outifo.results:

Contours results of Outifo.

ASCII file.

- Gn_linear.asc & Gn_linear_depla.asc:

Files used by the linear solver

ASCII file.

- Linearsolver.LOG:

Output file of linear solver

ASCII file.

Substructure

- Gn.ini:

File containing the data stored from the main simulation (Id of node, position and Id of center of gravity). There is one file per stage.

Binary file.



- Gn.S0i:

File containing the data stored from the main simulation (border node displacement). There is one file per stage.

Binary file.

- Gn_ids.bf:

File used by the subrun simulation to do correspondence between node identification of main run and node identification of subrun. There is one file per

stage.

Binary file.

Solver restart

- gn.irs:

input file to restart a calculation, contains the restart file identifier and possibly new calculation parameters

ASCII file

- gn.[i].rst:

ith RESTART file written by the solver.

Binary file.

Warning:

When the maximum number of restart files is n, and the solver wants to write the (n + 1)th restart file, it will overwrite the first restart file, then overwrite the

second, etc. Thus, the user should not just rely on the filename for identifying the

most recent file, but look also for the progression value to which they

correspond.

- gn.[i].rst_P:

DMP calculation

ith RESTART file on the node P written by the solver. All these restart files per node must be located in the same physical disk space (be careful /home can

correspond to different disk for each node of a cluster).

Binary file.



Post-Processor

- gn.[i].res:

ith state file written by the solver, contains the results of a given state.

Binary file.

- gn.end.res:

State file written by the solver at the end of the calculation.

Binary file.

- gn.0.res:

Scanner state file written by the solver on users request during the calculation.

Binary file.

Temporary file.

- gn.0[j].res:

Instant state file written by the solver on users request during the calculation.

Binary file.

Saved file.

- gn.his:

History file written by the solver, contains the points of history curves.

Binary file.

The size depends on the number of points, on the number of entities stored and

on the settings defined for history.

- gn.out:

Solver listing.

ASCII file.

- gn.err:

Solver messages. Written if the solver stops with an error message after cycle 0.

Binary file.

- gn.msg:

Solver messages.

Binary file.

- gn.qst:



Temporary status file that contains the request from the interface to the solver, for example when solver interaction is requested. File is removed after action is

performed.

ASCII file.

Deleted when the solver reads the request.

- gn.asw:

File which contains the answer of the solver to the request from the interface.

ASCII file.

- gn_M01:

Mapping result file, contains requested data for computed model at end of calculation.

ASCII file.

- gn.pda:

Post-processing data archive, contains modifications in post-processing stage with respect to main project file (created curves, modified objects etc.)

Binary file.

- gn*.rib:

input files for the renderer (master file, model definition, lights definition, scene definition)

Binary files, except that the master file gn.rib is an ASCII file.



Archiving a Project

- Pre-processor:

gn.pre.

- CAD meshing module, for each selected module:

gn.I.msh.

- Design Module, for each selected module:

gn.J.msh.

gn.J.add.

- For the post-processor:

gn.1.res.

a few intermediate view files, for PAM-AUTOSTAMP projects.

gn.end.res.

gn.his, for PAM-AUTOSTAMP projects.

gn.err.

gn.out.

gn.msg.

gn.[i].rst : The restart file used for the picking of the next project, if necessary, for PAM-AUTOSTAMP projects.

gn_M01, if available.

gn.pda.

- Data common to all modules:

gn.psp.


PRODUCT START UP Solver Manager Configuration

SOLVER MANAGER CONFIGURATION

Introduction

The solver manager is a daemon that runs on a calculation host.

Its purpose is to wait for and then process the calculation requests sent by GUIs running

on the same machine or on remote machines.

The solver manager is a single executable file delivered with the standard installation.

In the following, this executable file name is assumed to be solvermanager.exe.

Configuration Modes

The solver manager can be configured either:

- by arguments in the command line used to launch the solver manager

- by a configuration file

Configuration priority:

- the configuration file options redefine the default options.

- the command line arguments redefine the configuration file options.

Warning:

On Windows systems, if the solver manager is started as a service (see the Solver Manager start chapter), no option can be set by the command line, except

the log file path. The configuration file is then the only way to configure the

solver manager for other options.

The configuration file read by the solver manager is either :

- the file specified by the -config argument in the command line used to launch the solver manager.

or

- a file named solvermanager.exe.cfg if no file was specified in the command line. This file must be located in the same directory as the solver manager.

The presence of a configuration file is not mandatory but if it is necessary, a default

configuration file can be generated by typing the command:

solvermanager.exe -genconfig [-config ]

The name of the generated file is solvermanager.exe.cfg if no filename is

specified by the optional -config argument (.cfg is appended to the solver manager

executable file name)



Configuration File Description

This is a default configuration file:

#############################################################

## ##

## ##

## E S I S O F T W A R E ##

## ##

## ##

#############################################################

#############################################################

## ##

## ##

## SOLVER MANAGER CONFIGURATION FILE ##

## ##

## ##

#############################################################

#

##################################################

# #

# SERVER PARAMETERS #

# #

##################################################

#

# SERVER_PORT | 1201

# SERVER_PROTOCOL_VERSION | 2

# SERVER_LOG_FILE |

#

##################################################

# #

# SOLVER LAUNCHING PARAMETERS #

# #

##################################################

#

# SCRIPT_TEMPLATE |

# BATCH_COMMAND | batch



# LIBRARY_PATH | NONE

# LIBRARY_VARIABLE | DEFAULT

# MP_VARIABLE | NONE

#

##################################################

# #

# OTHER PARAMETERS #

# #

##################################################

#

# TEMP_DIRECTORY | /usr/tmp

# SAVE_LAUNCH_SCRIPT | NO

# SOURCE_PROFILE | YES

# FORCE_AUTOMOUNT | NO

# SCRIPT_CLEANUP_DELAY | 5

A '#' character at the beginning of a line means that the line is commented and therefore

ignored.

To modify an option, the user must remove the '#' character and set the option value

after the '|' character.

An option value containing space characters must appear within double quotes.

Available Options

The following items can be configured:

Usage of a template for launch script generation [New in v2.2]

configuration file line : SCRIPT_TEMPLATE |

command line argument : -script

default value : no script template

is the path of a template file containing keywords that are replaced

by the solver manager with the launch parameters received from the GUI. The filled

template is then executed by the solver manager. If no template file is specified, the

solver manager uses its own built-in template (same behavior than previous versions).

This option is available on Unix/Linux systems only.

See Defining a Template File for the Launch Script, below, for more details about

defining a template file.



Command used to launch a calculation in "batch" mode

configuration file line : BATCH_COMMAND |

command line argument : -batchcmd

default value : batch

is the name of the command used in batch mode to launch the solver.

Name of the linked library path environment variable on Unix/Linux systems

configuration file line : LIBRARY_VARIABLE |

command line argument : -libvariable

default value : DEFAULT

can be an environment variable name (LD_LIBRARY_PATH for example) or a

keyword:

DEFAULT : the environment variable name depends on the operating system:

- IRIX : LD_LIBRARY_PATH

- HPUX : SHLIB_PATH and LD_LIBRARY_PATH are both set

- SOLARIS : LD_LIBRARY_PATH

- AIX : LIBPATH and LD_LIBRARY_PATH are both set

- DIGITAL : LD_LIBRARY_PATH

Automatic setting of the linked library path environment variable on Unix/Linux systems

configuration file line : LIBRARY_PATH |

command line argument : -libpath

default value : NONE

can be a standard path (/usr/lib for example) or a keyword:

NONE : do not set the library path environment variable

SOLVER_DIRECTORY : set the library path environment variable as the solver

directory path

Automatic setting of the multi-processor environment variable

configuration file line : MP_VARIABLE |

command line argument : -mpvariable

default value : NONE

can be an environment variable name or a keyword:

NONE : do not set any environment variable



DEFAULT : set an environment variable whose name depends on the operating

system:

- IRIX : MP_SET_NUMTHREADS

- HPUX : MP_NUMBER_OF_THREADS

- SOLARIS : PARALLEL

- AIX : XLSMPOPTS='parthds...

- DIGITAL : MP_STACK_SIZE

Path and name of the solver manager log file

configuration file line : SERVER_LOG_FILE |

command line argument : -output

default value : blank (no file)

is the full name of the log file (eg: /usr/tmp/solvermanager.log)

Port number on which the solver manager listens to requests

configuration file line : SERVER_PORT |

command line argument : -port

default value : 1201

is the port number on which the solver manager listens to the requests.

Version of the communication with the GUIs protocol

configuration file line : SERVER_PROTOCOL_VERSION |

command line argument : not available by command line

default value : depends on the version of the solver manager (2 for v2.2)

is a number from 1 to n.

Note:

A GUI and a solver manager can always communicate whatever their version is (full compatibility). The user should never need to modify this option.

Path of the temporary directory

configuration file line : TEMP_DIRECTORY |

command line argument : -tmpdir

default value : /usr/tmp

is the path of the directory where the solver manager will write launch

scripts



Save the launch script generated by the solver manager

configuration file line : SAVE_LAUNCH_SCRIPT | YES / NO

command line argument : -savelaunchscript

default value : NO

When this option is enabled, the launch script generated by the solver manager in its

temporary directory is not deleted once the solver is launched but renamed to

smgr_launch_script. This allows for example to check / modify this script and

restart it in a console to track a launch problem. Note that all scripts are renamed to the

same name; it is advised to work with a copy of smgr_launch_script which will be

overwritten by subsequent launches.

Enable the sourcing of profiles files (sh and ksh environments)

configuration file line : SOURCE_PROFILE | YES / NO

command line argument : -nosourceprofile

default value : YES

When this option is disabled, the launch script generated by the solver manager will not

include execution of /etc/.profile and $HOME/.profile files. This can be useful

if these files contain instructions that make the launch fail.

Force automount before entering directories [New in v2.2]

configuration file line : FORCE_AUTOMOUNT | YES / NO

command line argument : -forceautomount

default value : NO

When this option is enabled, the solver manager calls some list directory commands

to trigger automount of some directories before trying to enter them (just entering a

directory might not trigger automount on old systems). This option should not be

activated if no problem occurs with automount.

Delay before deleting scripts [New in v2.2]

configuration file line : SCRIPT_CLEANUP_DELAY |

command line argument : -scriptcleanupdelay

default value : 5 (seconds)

This option allows defining the delay (in seconds) before the solver manager deletes a

script it has just launched.



Defining a Template File for the Launch Script

This option is available on Unix/Linux systems only.

A template file is a text file that can be located anywhere. It can contain keywords that

are replaced by the solver manager with the launch parameters received from the GUI.

To enable the usage of a template file, define its path in the solver managers

configuration file or in the solver managers command line or simply copy it in the

same directory than solvermanager.exe and name it solvermanager_script.tpl

(this is the default name for templates)

A default template file, very close to the built-in script, can be generated by the

command:

solvermanager.exe genscript [-script ]

This is an example of a template file (the keywords that will be replaced by the solver

manager are highlighted in this example):

#!/bin/sh

case $SHELL in

/bin/sh | /bin/ksh | /bin/bsh )

if [ -f /etc/profile ] ; then

$SHELL /etc/profile

fi

if [ -f $HOME/.profile ] ; then

$SHELL $HOME/.profile

fi

;;

/bin/bash )

if [ -f /etc/profile ] ; then

$SHELL /etc/profile

fi

if [ -f $HOME/.bash_profile ] ; then

$SHELL $HOME/.bash_profile

fi

;;

esac

# --- Enter work directory

cd $PAMPARAM_WORKDIR

# --- Set environment variables



PAMPARAM_VAR1_LABEL="PAMPARAM_VAR1_VALUE";export PAMPARAM_VAR1_LABEL





# --- Run the command

nohup $PAMPARAM_CMDLINE > $PAMPARAM_OUTPUT

# --- Normal termination

exit 0

Note:

If a keyword is preceded by a $ character, this $ character will also be removed by the solver manager. This allows writing a template file, based on

environment variables, that could also be directly executed from a terminal or

from another script, just by setting the environment variables corresponding to

the keywords before calling the script (for testing...)

Example:

setenv PAMPARAM_WORKDIR /usr/temp

setenv PAMPARAM_CMDLINE ls

setenv PAMPARAM_OUTPUT ls.out

./solvermanager_script.tpl

The keywords that are accepted in this version are:

- PAMPARAM_WORKDIR : work directory of the calculation

- PAMPARAM_CMDLINE : full command line that launches the solver

- PAMPARAM_OUTPUT : file where solver output must be written

- PAMPARAM_NBPROC : number of processors requested for the calculation

- PAMPARAM_RUNMODE : launch mode (0 for immediate, 1 for batch)

- PAMPARAM_USER : name of the user which sent the calculation request

- PAMPARAM_SHELL : users shell (/bin/sh, /bin/csh, ...), equivalent to

systems $SHELL


PRODUCT START UP Solver Manager Start

SOLVER MANAGER START

The solver manager is a single executable file that is launched differently according to

the host operating system.

On Unix/Linux Systems

Start the solver manager from a term window:

- logon as the root user

- type the command:

cd

where is the directory where the solver manager executable

file is located.

- type the command:

nohup solvermanager.exe [-output ] > /dev/null &

where is the full path of the solver manager log file

(/usr/tmp/solvermanager.out for example)

The output argument is optional (the user can also define the log

file path in a configuration file). If the user does define any log file path, no solver

manager messages will be stored or displayed.

Start the solver manager at boot time:

- locate in the system the script file whose purpose is to start the daemons at boot time (consult the system administrator)

- insert the following command in this file:

/solvermanager.exe [-output ] > /dev/null &

where is the full path of the solver manager executable file

directory and is the full path of the solver manager log file



file path in a configuration file). If the user does define any log file path, no solver

manager messages will be stored or displayed.



On Windows Systems

The solver manager is normally installed as a service and launched by the installation

tool. This is however the procedure to install and/or launch it manually.

Start the solver manager from a command window:

- type the command:

cd


file is located.

- type the command:

solvermanager.exe noservice -output

where is the full path of the solver manager log file



file path in a configuration file). If the user does not add it to the command line and no

log file is specified in a configuration file, the solver manager messages will be

displayed in the command window.

Warning:

If the user starts the solver manager from a command window, all the calculations launched by the solver manager will be attached to the user

account the user is logged on. Therefore, these calculations will be killed by the

system when the user closes his session.

Start the solver manager as a Windows service:

A specific user account must have been created with the log on as a service privilege.

This account is named pamservice in the following.

The pamservice account will be assigned to the solver manager service so that the

calculations launched by the solver manager are also attached to this account. This

prevents the calculations from being killed when a session is closed (assuming that the

pamservice account is reserved to calculations and that nobody logs on this account).

Note that the calculations are attached to pamservice, not to the user that requests the

calculation. This must be taken into account, particularly for network access settings.

This is the procedure to install and start the solver manager as a service:

- open a command window

- type the command:

cd




file is located.

- type the command:

solvermanager.exe service user pamservice

- enter the password of pamservice

If another solver manager service is installed and is running (whatever its version is),

this service is first stopped and removed before installing and starting the new one.

If no configuration file is present or if the log file is not specified in this configuration

file, the solver manager messages will be saved in a default log file. This default log file

is located in user profile directory and it is named solvermanager.out.

More generally, the user cannot configure the solver manager by command line

arguments if the he starts it as a service, except the log file path. If the user needs to

modify some other options, he must generate a configuration file and set the options

inside it (see the Solver Manager Configuration chapter).


PRODUCT START UP Solver Manager Activity

SOLVER MANAGER ACTIVITY

If the user has defined a log file path when starting the solver manager (in the command

line or in the configuration file), he can read in this file a processing report of all the

requests received by the solver manager.

Example of log file:

### 12/03/2003 13:57:58 : Starting the solver manager...

-> Solver manager started (Version 2.2 Protocol v2)

[ Copyright ESI GROUP 2007 ]

-> Waiting for requests on port 1201...

### 12/03/2003 13:58:45 : Request received from 'remote GUI'

-> Processing script...

+ Action requested : Start a calculation

+ User name : 'user1'

+ Executable path : '/usr/local/bin/solver.exe'

+ Command line : '/usr/local/bin/solver.exe -if "test.pre"'

+ Work directory : '/usr/projects/'

+ Output file : 'test.out'

+ Nb of processors : 1

+ Execute action immediately

-> Setting work directory : OK

-> Script template loaded : OK (solvermanager_script.tpl)

-> Writing script : OK

-> Creating output file : OK

-> Creating the process : OK

The lines beginning with ### report the solver manager start-up and termination and

the date and origin of all the requests.

The lines beginning with + describe the requests.

The lines beginning with -> report the solver manager actions and the result (success

or failure with error message) of these actions.

Moreover, version 2.0 and later of the solver manager sends a full report to the GUI so

that a clear message can be displayed in the GUI to inform the user about the success or

failure of his request (and the reason it failed if necessary).


PRODUCT START UP Calculation Stop

CALCULATION STOP

A calculation should normally be stopped by the GUI so that the process can cleanly

terminate (writing of restart files), using the solver/stop option.

The user might however need to kill the calculation process because it does not respond

anymore, he does not need a clean termination or because he does not want to use the

GUI.

On Unix/Linux systems, the user can use the system command kill provided if the he

has the right to kill the process. If the user is not logged on the calculation account (or

he is not the super user), he will have to switch to the calculation account before.

On Windows systems, the user can use the task manager provided if he has the right to

kill the process. If the solver manager is running as a service with a different account

than the one he is logged on, he will not have the right to kill the calculation because it

is attached to the service account. In this case, the solver manager executable file must

be used to send a kill request to the running solver manager. This is the procedure:

- get the process id of the calculation (get it from the task manager window)

- open a command window

- go to the solver manager executable file directory

- type the following command:

solvermanager.exe killpid [-port ]

where is the process id of the calculation and is the port

number on which the solver manager listens to requests.

Note:

port is optional. If it is not specified, the default port is used.

This procedure is not available on Unix/Linux systems.


FINITE ELEMENT AND NUMERICAL MODELS Algorithm

FINITE ELEMENT AND

NUMERICAL MODELS

ALGORITHM

Explicit, Implicit and Advanced Implicit Algorithms

Algorithms used by the solver of numerical simulation, work step-by-step in order to

find dynamic equilibrium at each step. Different types of algorithms can be used:

explicit, implicit and advanced implicit. The main differences are highlighted through

this section and a comparison table at the end of the section summarizes it all.

The principle of the explicit and the implicit time integration of a 1D system with one

degree of freedom can be represented by a linear spring system:

c

k m

f(t),x,v,a

A linear damped spring system

The equilibrium equation of the spring system is:

nnnn fxkvcam ... ,

where n means the time increment.

Explicit

In the explicit method, the nodal velocities are written down at times tn-1/2, tn+1/2 and

nodal displacements and accelerations at times tn-1, tn, tn+1. At time tn the nodal

displacement xn is known and the acceleration an is computed from the internal and

external forces. Nodal velocity vn-1/2, is known at time tn-1/2. The algorithm searches for

the nodal velocity vn+1/2 at time tn+1/2 and the nodal displacement xn+1 at time tn+1.

The application of the central difference method gives nodal velocity at time tn+1/2 and

the nodal displacement at time tn+1 (assuming that Tn is small):



)x.ktf nn(.1

ma n

in case of no damping applied.

2/)n

T1-n

T(

VV

a2

1n

2

1n

n

nT

XXV

n1n

2

1n

For complex processes (other than 1D system) m is a matrix, it is diagonal and can be

immediately calculated without any matrix inversion. Unfortunately, this method is

stable only if a small time step Tn is used (see TimeStep & Increments)

Implicit

Purpose

Stamping simulations are considered as static, using an incremental method (based on

loading or tool kinematics).

The dynamic effects are neglected, the velocity and the acceleration are set to zero.

Calculation of each increment

Within one increment, (see TimeStep & Increments) the solver automatically tries to

find the solution of a set of nonlinear equations, using linear iterations, also known as

Newton iterations, with convergence criteria.

Newton iterations:

F(u)=Fext (Fext=0 in springback case)

F(u)=F(0) + F/u(0) u u1=K-1

(0)(Fext-F(0))

u1= u1

F(u)=F(u1) + F/u(u1) u u2=K-1

(u1)(Fext-F(u1))

u2= u1+ u2

So un= u1+ u2 ++ un, the displacement convergence is reached when

|un|/Max(|ui|)



F

u

Rsolution

F(u)

1st Newton iteration

2nd Newton iteration

F

u

Rsolution

F(u)

1st Newton iteration

2nd Newton iteration

- R=Fext

- The maximum number of non-linear iterations is a parameter that is defined in the Implicit calculation page of the global objects Advanced parameters attribute.

Default value:

The Maximum number of non-linear iteration is 20 for gravity and springback by default. It is 200 for QUIKSTAMP holding or forming simulation.

Convergence criteria



Two criteria are used to check the convergence of the solution, the displacement

convergence tolerance and the energy convergence tolerance.

Displacement convergence tolerance

|un|/Max(|ui|)



MUMPS Direct and MUMPS Direct Out of Core

This is a homemade ESI direct matrix solver.

The Out of core mode uses the disk memory storage to reduce the RAM allocation.

With this method the CPU time is network dependent. The default Disk path is the

project directory but it can be customized with the ELS_OOC_PATH variable.

Default setting:

By default the MUMPS Direct solver is used for gravity and springback simulations

The PCG solver is used for QUIKSTAMP holding and forming simulations.

Options

Some divergence problems may appear, they can be solved with the options available in

PAM-STAMP:

F

u u1 u2

Fext

Line search

un=K-1

(un-1)(Fext-F(un-1))

With the line search option, the algorithm tries to find to minimize:

|F(un-1+ un)-Fext |

with: =k/N (k=1,.,N) where N is the input line search parameter

un=un-1+nun



Default setting:

Default is 10 for springback and it is imposed to 2 for QUIKSTAMP PLUS.

Fext

F

u u1 u

1 u1

This option is not available for gravity simulation.

Displacement control value (buckling risk)

In some cases, the line search method is not sufficient to solve the Newton divergence

problems. This happens usually when there is a buckling behavior during springback.

This option uses the initial stress matrix.

The input parameter is the maximum displacement in one Newton iteration. This option

is still an alpha option, to be used with some care.

Damping scale factor

The Implicit damping scale factor controls the blank average nodal displacement of one

increment. When this parameter is increased, the average displacement will be

decreased, and this is usually useful to solve some divergence problems related to

blank/die contact stability.

When the damping scale factor is increased, the total number of increments is also

increased and so is the CPU time.

Default values:

The Line Search option is active by default with a value of 2 for QUIKSTAMP PLUS holding and forming simulation and a value of 10 for springback simulation.

The Displacement control option is not active by default. If activated, the advised value is 10.

The Damping scale factor option is available for Gravity stage only. Default value is 1.



Advanced Implicit

Purpose

Advanced implicit algorithm improves current Implicit algorithm. Generally the basics

are the same as for Implicit algorithm. In this chapter the differences and improvements

will be described.

In advanced implicit calculation, the mechanical equation is solved on final

configuration of the previous increment, which is known (Update Lagrange method),

while in implicit calculation it is solved on current configuration, which is unknown

(Quasi-Euler method). Updated Lagrange is usually more stable than Quasi-Eulerian

method because it is easier to compute a tangent matrix which is fully consistent with

Residual Forces.

Calculation of each increment

In advanced implicit simulation a set of non linear equations is solved by using either

Newton-Raphson method (as in Implicit) or Arc-length method, both used to

convergence criteria on Force and Displacment.

Newton-Raphson method:

Tangent Matrix (Total Stiffness matrix) : Kt = KL + KDu + Ks

KL : Linear Stiffness Matrix

KDu : Initial displacement Matrix (Updated lag. Form.)

Ks : (Initial) Stress stiffness matrix or Geometrical stiffness matrix

n

Initial configuration

(integration volume)

Current configuration

(or integration volume)

n+

1

Final configuration of previous increment

... : 00

dES

... : 11

nd

n

Total Lagrange Updated Lagrange Quasi-Euler

Advanced Implicit Implicit

... :

ndES

n



New Options

Force convergence tolerance

|Fn|/Max(|Fi|)



is load step ratio (between 0 and 1) and d the mean value of displacement.

Objective of method is to find solution into cylinder : 2 + d

2 = L0

2 with L0 imposed

arc length defined by user

The maximum number of non-linear iterations is a parameter that is defined in an

Advanced Implicit page of the global objects Advanced Parameters attribute.

Arc-Length method is efficient when instability affects global load-displacement

response. If instability is localized and has no impact onto global response, Arc-length

is not efficient.

d

)(id

)0(d d

)0(dK )(idK

)0(int dF

)(int iF d

)1( id

L0

d

Limit Point

Post-Collapse

Objective Load



With respect to optimal accuracy and CPU performance there have been validated

values for Displacement convergence tolerance, Force convergence tolerance,

Maximum number of non-linear iterations, Maximum iterations of Line search and

Load control; For each type of process advanced implicit gravity, advanced implicit

springback and advanced implicit springback with contact (and gravity). These

parameters are set to default (optimal) values if Automatic tolerance option, Automatic

maximum number of non-linear iterations option, Auto.max.search. option of Line

search and Automatic option of Load control are checked in the Advanced implicit

page of the global objects Advanced parameters attribute.

Default values advanced implicit gravity

Displacement convergence tolerance: 0.1

Force convergence tolerance: 0.1

manual pam stamp

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