w03 break forming mar101

WS3-1MAR101, Workshop 3, September 2008Copyright 2008 MSC.Software Corporation

WORKSHOP 3BREAK FORMING


● Model Description

● A flat sheet is formed into an angled bracket by punching it through a hole in a rigid table. The cylindrical punch drives the sheet (workpiece) to a total stroke of 0.3 inch. The punch then returns to its original position. This exercise makes use of simple, straightforward movements of rigid bodies.


● Objective● Illustrate setting up of a multi-step analysis and the use of rigid

surfaces charged with shaping a malleable workpiece.

● Required● break_forming.igs


● Suggested Exercise Steps1. Import the geometry from an IGES file.2. Mesh the workpiece.3. Create the material properties.4. Apply boundary conditions, and contact bodies.5. Create two Loadcases.6. Create and submit the analysis job.7. Post-process results.


a

In this document:[Enter] means clicking the key on the keyboard (“carriage return”).RETURN refers to MSC Marc Mentat’s button with such a label (below).

Open a new database named bracket:

a. Open the FILES menu.b. Click SAVE AS.c. Enter SELECTION:

<work_directory>\bracket

d. Click OK. e. Click RETURN.

Step 1. Files: Save As

b

c

d

e


Step 2. Files: Import / Iges

In this document:[Enter] means clicking the key on the keyboard (“carriage return”).RETURN refers to MSC Marc Mentat’s button with such a label (below).

Import the IGES file:a. Open the FILES menu.b. Click INTERFACES IMPORT.c. Click IGES.d. Select break_forming.igs.e. Click OK.f. Click MAIN.

a

bf

e

d

c


When selecting list entities, pressing the right mouse button (with the cursor anywhere inside the viewport) is equivalent to clicking on Mentat’s END LIST (#).

Create mesh for the model:a. Click MESH GENERATION. b. Click CONVERT.c. Click DIVISIONS, d. Enter the number of convert

divisions in U and V : 80 6 [Enter].

e. Click SURFACES TO ELEMENTS.

f. Select surface 1 as shown in the picture and right-click to end list.

g. Click RETURN.

Step 3. Mesh Generation: Convert / Surfaces to Elements

a

b

g

f

e

d

c


Step 4. Mesh Generation: Sweep / All

Remove duplicate nodes:a. Click SWEEP.b. Click ALL.c. Click RETURN.d. Click

RENUMBER.e. Click ALL.f. Click MAIN.

a

e

b

c

d

f


Create the material properties:a. Click MATERIAL

PROPERTIES twice.b. Click TABLES.c. Click NEW.d. Click 1 INDEP. VARIABLE.

b

Step 5. Material Properties: New / Tables / Plastic_Strain

a

c

d


e. Click Table TYPE.f. Click eq_plastic_strain.

Step 5. Material Properties: New / Tables / Plastic_Strain (Cont.)

e

f


g. Click DATA POINTS:ADD and then enter the data from the table below:

h. Click FIT.i. Click RETURN.

Strain Stress

0 50000

0.1 63000

0.2 69000

0.3 74000

0.5 83000

0.8 94000

1.0 100000

Step 5. Material Properties: New / Tables / Plastic_Strain (Cont.)

g

h

h

i


a. Click NEW.b. Click NAME.c. Enter material name : steel

[Enter].d. Click ISOTROPIC.e. Click YOUNG’S

MODULUS. f. Enter value for

‘youngs_modulus’ : 3e7 [Enter].

g. Similarly, input ‘poissons_ratio’ : 0.3 [Enter], ‘mass density’ : 0.00074 [Enter].

h. Select ELASTIC-PLASTIC.

Step 6. Material Properties: New / Isotropic

ab

d e

fg

h

c


i. Click INITIAL YIELD STRESS.j. Enter value for ‘yield_stress’ : 1

[Enter].k. Click TABLE (PLASTIC STRAIN).l. Select table1.m. Click OK on both the sub forms.

Step 6. Material Properties: New / Isotropic (Cont.)

m

i

j

l

k


Step 6. Material Properties: New / Isotropic (Cont.)

n. Click ELEMENTS ADD.o. Click ALL EXIST.p. Click TABLES.

n

o

p


Create the Punch position history:a. Click NEW.b. Make sure it is 1 INDEP.

VAR.c. Click TYPE.d. Click time.e. Click DATA POINTS: ADDf. Enter tabular data point :

0, 0 [Enter]0.5, -0.3 [Enter]1, 0 [Enter].

g. Click FIT.h. Click MAIN.

Step 7. Create Punch Position History Table

a

g

e

cd

b

f

h


Create the Symmetry Boundary Condition:

a. Click BOUNDARY CONDITIONS.

b. Click NEW.c. Click NAME.d. Enter boundary condition name :

symmetry_x [Enter]e. Click MECHANICAL.f. Click FIXED DISPLACEMENT.g. Select DISPLACEMENT X.h. Click OK.

Step 8. Boundary Conditions: New/Mechanical/Fixed Displacement

a

b

g

fe

d

c

h


Step 8. Boundary Conditions: New/Mechanical/Fixed Displacement (Cont.)

i. Click NODES ADD.j. Select all the nodes on the x=0 line.k. Click END LIST (#).l. Click RETURN.

ij

k

l


Create a loading for the gravity:a. Click NEW.b. Click NAME.c. Enter boundary condition

name : gravity [Enter].d. Click MECHANICAL.e. Click GRAVITY LOAD.f. Select ACCELERATION Y.g. Enter value for y: -386.4

[Enter].h. Click OK.

Step 9. Boundary Conditions: New / Mechanical / Gravity Load

a

g

f

e

d

c

b

h


Step 9. Boundary Conditions: New / Mechanical / Gravity Load (Cont.)

i. Click ELEMENTS ADD.j. Click ALL EXIST.k. Click MAIN.

i

j

k


Create a deformable contact body:a. Click CONTACT.b. Click CONTACT BODIES.c. Click DEFORMABLE.d. Click OK.e. Click NAME.f. Enter contact body name :

workpiece [Enter].g. Click ELEMENTS ADD.h. Click ALL: EXIST.

Step 10. Contact: New / Contact Bodies / Deformable

a

g

f

e

d

c

b

h


a

Label curves:a. Click PLOT.b. Unselect the following:

DRAW: NODES DRAW: POINTS

c. Select CURVES: SETTINGS.

d. Select LABELS.e. Click REGEN. f. Click RETURN on both

the subforms.

Step 11. Plot: Label / Curves

b

f

e

d

cb


Step 12. Contact: New / Contact Bodies / Rigid

Create rigid body:a. Click NEW.b. Click NAME.c. Enter contact body name :

punch [Enter].d. Click RIGID.e. Click POSITION.f. Click PARAMETERS for

Position.g. Click POSITION: Yh. Enter value for ‘py’: 1 [Enter].i. Click TABLE.j. Select table2.k. Click OK on the Subforms.

ab

c

d

h

e

g

f

i

j

k


l. Click CURVES: ADD.m. Select the circular curve.n. Click END LIST (#).

Step 12. Contact: New / Contact Bodies / Rigid (Cont.)

l

n

m


o. Click NEW.p. Click NAME.q. Enter contact body name

: table [Enter].r. Click RIGID.s. Click OK.t. Click CURVES: ADD u. Pick all curves except the

circle.v. Click END LIST (#).


o

v

u

t

s

r

q

p



w. Click ID Contact.x. Click FLIP CURVES.y. Pick the following

curves:1, 3, 4, 5, 7 and click END LIST (#).

z. Click MAIN.

wx

z

y

yy


Create load cases:a. Click LOADCASES.b. Click NAME. c. Enter loadcase name : push

[Enter].d. Click MECHANICAL.e. Click STATIC.f. Click TOTAL LOADCASE

TIME.g. Enter loadcase parameter

value : 0.5 [Enter].h. Click MULTI-CRITERIA.i. Click SOLUTION CONTROL.j. Select NON-POSITIVE

DEFINITE.k. Click OK.l. Click OK.

Step 13. Loadcases: New / Mechanical / Static

a

i

h

f

ed

cb

k

j

l

g


Step 13. Loadcases: New / Mechanical / Static (Cont.)

m. Click COPY.n. Click NAME.o. Enter loadcase name :

release [Enter].p. Click MAIN.

mn

o

p


Create an analysis job:a. Click JOBS.b. Click MECHANICAL.c. Select push and release

loadcases, in that order.d. Select PLANE STRAIN.e. Click ANALYSIS OPTIONS.

a

Step 14. Jobs: New / Mechanical

d

c

b

e


Step 14. Jobs: New / Mechanical (Cont.)

f. Select LARGE STRAIN.g. Click OK.h. Click JOB RESULTS. f

g

h


Step 14. Jobs: New / Mechanical (Cont.)

i. Select (from Available Element Scalars): Equivalent Von Mises Stress, andTotal Equivalent Plastic Strain.

j. Select (from Available Element Tensors):Global Stress.

k. Click OK on all the subforms.

i

k

j


Step 15. Jobs: Run / Submit 1

a

a. Submit the analysis job:b. Click RUN.c. Click SAVE MODELd. Click SUBMIT (1).e. Click MONITOR.f. Click OK.g. Click MAIN.

b

c

d

ef


Step 16. Results: Open Default / Monitor / Def Only

a

Read Results, and postprocess:a. Click RESULTS.b. Click OPEN DEFAULT.c. Click DEF ONLY.d. Click CONTOUR BANDS.e. Click SCALAR.f. Select Total Equivalent

Plastic Strain.g. Click OK.h. Click MONITOR.

e

d

c

h

g

b

f


Step 16. Results: Open Default / Monitor / Def Only (Cont.)

i

i. Click SCAN, Select the Increment corresponding to Time = 0.5, and Click OK.


Step 16. Results: Open Default / Monitor / Def Only (Cont.)

k

k. Click LAST.


Step 17. Create a graph Punch Force Vs. Time

a

e

d

c

b

f

a. Click HISTORY PLOT.b. Click COLLECT GLOBAL DATA.c. Click NODES/VARIABLES.d. Click ADD GLOBAL CRV.e. Enter Time as X-axis variable and

Force Y punch as Y-axis variable.

f. Click FIT.g. Click MAIN.


● The Punch Force Vs. Time graph obtained from the analysis does not seem to be very smooth. This is a typical outcome when the convergence tolerance is too large.

● Re-analyze the model with a tighter convergence tolerance, and draw a new Punch Force Vs. Time graph. Use Relative Residual Force of 0.01 (Default = 0.1).

● Hints: Modify both the load cases using the following steps, and re-submit the job:LOADCASES: Select the load case

STATICCONVERGENCE TOLERENCE

RELATIVE FORCE TOLERENCE: 0.01OKOK

Step 18. Re-analyze the model with more accuracy


When you are done working with this modela. Click on

b. then click on

c. and finally click on

w03 break forming mar101

Documents

software corporation

software corporation

b mar101

msc marc mentats button

material properties

f mar101

mesh generation

keyboard carriage return