metal forming ezsetup in ls-prepost 4 -...
TRANSCRIPT
Metal Forming eZSetup In LS-PrePost 4.2
LSPP Metal Forming Development Team Janurary, 2015
1
Table of Contents
SECTION WORKSHOPS
LS-PrePost Input/Output
eZSetup for Metal Forming
Tool & blank mesh Workshop 1
Tooling offset & check Workshop 2
Multi-stage process simulation Workshop 3
Multi-flanging setup Workshop 4
Post-Processing Workshop 5 (NUMISHEET’02 fender outer)
Configuration run script
Practice: setting up a job from CAD IGES Workshop 6 (NUMISHEET’08 B-pillar)
2
Input/Output
command session file (.cfile)
LSPP database file
LS-DYNA results file (d3plot)
3
include: dynain file
eZSetup for Metal Forming
4
Installation & File Structure Full installation: ftp://ftp.lstc.com/outgoing/lsprepost/4.2
Material library
5
Process templates
Application Menu
6
Note:
Unit System: mm-second-tonne-Newton All tools must be in their home position eZSetup works best with LSDYNA R6.1.0 and later versions.
Metal Forming toolbar
7
Metal Forming Pre
Metal Forming Post
When you go to application/metal forming/easy setup once, two metal forming toolbars will appear.
Workshop 1 Tool / blank mesh generation
8
Open an IGES file:
3
1
2
Directory: Workshop 1
4
9
Meshing binder:
1
2
3
4
5
Left click to pick the binder surface
6
7
8
10
Meshing die:
4
Left click to pick the binder surface
1
2
5 6
7 8
11
3
12
Tool mesh result:
1
2
3
4
5
13
Import IGES file:
4
5
7
8 9
1
2
3
Left click on surface 6
10 14
Blank mesh:
Turn part1 off
Workshop 2 Tool mesh check and offset
Summary: Check and merge duplicate nodes, tolerance 0.05mm – good for most cases; Check for normal consistency – all tooling mesh normal should be consistent; Normal orientation: blank normal up, upper tools normal down, lower tools normal up; Free edge – use ElEdit to check for free edges; Small gaps mostly okay, big overlaps will
be a problem; Check zero or very small Jocabian for collapsed elements; This messes up the normal
determinations for contact. Use “model check” Least amount of work needed for tool mesh if LSPP tool mesher is used.
15
Open keyword file:
5
Directory: workshop 2
4
1
2
3
16
Duplicate nodes check and show free edges:
2
4
5
6 1
3
17
1
2
3
Pick the part. Wire frame mode: vector display in wireframe mode.
Tool mesh normal check:
4
Normal orientations: blank normal up, upper tools normal down, lower tools normal up;
18
Pick the part. Shaded mode: a color consistent with the PID color indicates normal going up; a color that is different from the PID color indicates normal going down.
Wireframe mode for vector display;
Tool mesh normal reverse by part:
1
2
4
Pick any element
5
3
19
Tool mesh normal align – reverse a part normal based on one seed element normal
6
Pick the element with the desired normal
3
1
2
7
Note: auto rev. works within one part boundary
4
20
5
1 2
3
4
6
7
Jacobian Check: check for zero or very small Jacobian, and delete failed
21
Type in 0.05 and enter
5
Element 30632 has all three nodes on a straight line
Jacobian Check: Contour display:
22
“offset +” is positive of normals
1
3
4
7
Offset with Advanced option on:
23
2
5
6
8
Workshop 3
Stage 1 : gravity, closing and drawing Stage 2 : trimming and springback Stage 3 : tipping Stage 4 : flanging and springback
24
Import blank and forming tools:
3
2
1
Directory: Workshop 3
4
25
5
Rename blank and tools:
2
1,right click
26
3, type in a name and enter
1
27
Stage 1 : gravity, closing and drawing
Insert gravity loading and closing process
2
3
2
Define tools:
3, pick part
5
1
4
8
9
6 ,pick part
10, pick part name and right
click
28
7 , enter 130 130
2
Define blank and material:
3 ,pick part
5
1
4
6
8 ,type in thickness and
friction
29
7
Click this button if your material file is in the
current working directory.
8
2
Define drawbead:
3 ,select file
6, righr click
1
4
30
5
2
Drawbead force modify:
1, enter 230 as full lock
force
3
4, modify the force % by
the table list
31
Drawbead name
Force percentage(%)
1 DBead1 50
2 DBead2 50
3 DBead3 50
4 DBead4 50
5 DBead5 50
6 DBead6 40
7 DBead7 20
8 DBead8 10
9 DBead9 10
10 DBead10 10
11 DBead11 20
12 DBead12 20
13 DBead13 20
14 DBead14 20
15 DBead15 30
16 DBead16 30
17 DBead17 30
18 DBead18 30 5
6
Stage1 process control:
6
32
7
2 4
1 3
5
2
Stage 2 : trimming and springback
1
3
4 , remove forming then add trimming
and springback process
33
Import trim curve:
3
34
2
1
3
Stage2 process control – trimming:
2 ,pick curve then right
click
1
4 ,pick a location inside
trim curve
35
Stage2 process control – springback:
2 ,pick three locations then
right click
1
36
2
3
4
1
Stage 3 : tipping
2
3 , remove forming then add tipping
process
37
Stage3 process control – tipping:
1, RY: 2; RX: -10; TZ: 8
38
2
Stage 4 : flanging and springback
1
3
4 , remove forming then add flanging and
springback process
39
Import flanging tools:
3
40
2 1
4
Import flanging direction line:
3
41
2
1
Import pre-adaptive curve:
3
42
2
1
2
Stage4 process control – flanging control:
3 ,pick the curve then right click
1
43
2
Stage4 process control – flanging post and pad:
3 ,pick part 1
44
5
4 6 ,pick part
2
Stage4 process control – flanging steels:
3 ,pick part PID 9
1
45
4
5 6 ,pick two end points
of line 6
7
2
Stage4 process control – add flanging steels:
3 ,pick part PID 10
1
46
4
Repeat step 1 to 4, define one more flanging steel and their direction.
2
Stage4 process control – springback:
1
47
Submit job: LS-dyna input deck output
2
48
3
4
1
Output folder:
49
Workshop 4
A flanging process set up with multiple flanging steels moving in local directions
50
2 1
3
Directory: Workshop 4
51
Import keywords:
4
Import iges:
3
52
2
1
3
53
Stage 1 : flanging
Remove forming then insert flanging process
4
2
1
5
1
Define blank and material:
2 ,pick part PID 1
4
3 ,type in thickness 0.7
54
8
5
6
7 9
2
3
55
Flanging control:
1
Select these curves to define mesh pre-adapt, right click to
finish the selection.
4
2
3
56
Flanging post and pad:
1 Pick part
6
Pick part
5
4
Blinking yellow prompting for flanging steel definition; turns green when it is defined.
1
57
2
Pick part
Flanging steel 1 part:
Blinking yellow prompting for flanging direction definition; turns green when it is defined.
1
58
2
Pick two END points of the line to define the flanging steel moving direction
Flanging steel 1 direction:
3
4
Add a new flanging steel.
4
59
5
Repeat the process to define Flg3 and Flg4
Add flanging steel 2 to 4 :
6
7
1
2
3
Pick part
Submit job: LS-dyna input deck output
2
60
3
4
1
Output folder:
61
Note: Project file is an important database file, containing complete model and eZSetup information. It can be reloaded back into LSPP for changes in process or models.
1
2
3
Save project file (overwrite existing project file):
62
4
End of simulation Beginning of simulation
Running LS-DYNA in windows:
Submit test.bat to execute the LS-DYNA solver run.
Simulation involving gravity, springback, static implicit must use double precision (DP) solver
All other dynamic explicit simulation (for example, draw or flanging) use SP solver
DP solver slower than SP solver
63
Workshop 5 Post-Processing
64
Animate punch contact/part breakdowns:
2 1
3
4
5
6
workshop5
65
Create a movie (wmv):
2 1
3
4
66
Use MediaPlayer to open and play the movie file.
67
Cut a section plane:
2
1
3
5
Pick a location
4
6
67
3
2
1
4 2
1
3
4 5
Save multiple cut sections in keyword format:
Read in the saved cut sections into a fresh LSPP session as keyword file, and check for the saved cuts – useful in springback measurement comparison.
move the cut planes:
68
Plot Thickness/thinning contour:
2
3
5
6
1
4
7
8
69
70
Set contour range for thickness/thinning contour:
Thickness range: Thinning range:
1
3 3
4 5
5 6
2 2
4
71
Save a JPG file for the screen display:
1
2
3
4
6
optional
72
Plot thickness distribution along a section:
1
2
3
5
Pick a location close to this node
4
6
73
Plot thinning distribution along a section:
7
8
74
Changing the thinning of a section plot in contour:
2
1
75
Identify detailed results in value:
1
2
3
4
Left click and drag over the part for live updates. 5
Display trim lines on post-processing results, follow square box A, B, C in sequence:
right click
B - Translate curves:
1
2
3
4 – red color box means current pick
5
6
8 – multiple
times
7
C - Change curve color:
1 2
3
4
A - Import IGES file: newtrim1.iges 1
76
77
Plot mean stress (pressure) contour (wrinkles):
2
3
4
1
5
6
Set contour range for mean stress:
negative tensile
positive yield 4
5
3
78
1
2
6
79
Similarly, plot In-plane major/minor strain contour:
1
2
79
Plot FLD: If use ‘File’ option, open ‘fld_true.fld’
1
2
3 4
5
8 – need to select
7
9
0.2
pick this part anywhere
6
Hit “enter” after input values 80
10
Plot In-plane major/minor strain vectors:
1
2
3
4
5
Pick location
6
81
2
Display blank and binder only
1
3
5
7
7
8
4
pick blank
6
left click on the colored lines to show exact values
9
10
10
82
11
pick binder
Blank draw-in:
The state when closing is done
83
Plot tool tonnage: Open ‘rcforc’ file in Workshop 8/Forming In MPP, the file name is ‘binout0000’
1
2
3 4
5
6
7
Note: 1 English ton=8900 Newton
83
84
Plot sheet blank mass increase:
Note: total weight of the model is used to calculate the %.
3
4
5
6
1
2
84
Configuration and run script
85
LS-PrePost configuration file location (each version has its own directory)
• Windows – C:\Users\uname\AppData\Roaming\LSTC\LS-
PrePost4.2
• Linux - $HOME/LSTC/LS-Prepost4.2
86
eZSetup parameter file and LS-Dyna run script file are under LSPP
installation folder and subfolder lspp_forming
eZSetup parameter file(lspp_parameter):
87
Solver location.
Process executable commands.
eZsetup default parameters.
LS-Dyna run script file (Windows):
88
Workshop 6 (Practice)
eZSetup From IGES Surfaces – NUMISHEET2008 B-pillar
89
NUMISHEET2008 B-pillar
90
Procedures
Import IGES files:
Numisheet08-BM03-Blank.igs
Numisheet08-BM03-Blankholder.igs
Numisheet08-BM03-Dies.igs
Numisheet08-BM03-Punch.igs
drawbeads.iges
Mesh tools: Mesh/AutoM/deviation, use these parameters
Mesh blank, element size=12mm
(Mesh/BlankM/Curve by Surface, size 12)
Check model – free edge, dup nodes, Jacobian, normals etc.;
Position tools into home position, blank thickness=1.95mm;
Measure distance first, then EleTol/Transf/translate by part;
Blank position does not need to be moved.
Activate eZSetup, air draw:
Stage1: gravity, forming, springback;
Use material Steel
/DQSK/M37_Curve_DQSK25Ksi_t069.k
91
Procedures
Draw beads definition
Select all four draw bead curves and define them as draw beads;
Check for tensile value;
Modified fore and aft draw beads to 40% lock.
In “Control-gravity”, check for gravity prebend along Y-axis. In “Control-forming”, change
nothing.
Save a project file, and output simulation file.
Run simulation using output bat file.
Try removing gravity from the process, just run the
forming with single precision solver
Post-processing results –
Open case5.d3plot (gravity). Animate gravity simulation. Can you see a slight bending
in the blank in the start of the simulation?
Open case10.d3plot (forming)
Animate punch contact;
Plot thinning contour, range 0 ~ 20%;
Do a section cut along X in the middle of the part in thinning contour; Animate in
section view; Also, plot thinning distribution along the cut section.
Plot mean stress (pressure) contour, range positive yield ~ negative tensile (MPa);
Plot FLD and FLD formability;
Check for in-plane major/minor strain vectors at the lower door corners
Check for % mass increase.
For static implicit simulations, e.g. gravity loading and springback , double precision (DP) must used.
DP solver slower than SP solver
92
Thanks
93