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Metal Forming In LS-PrePost 4.0
LSPP Metal Forming Development Team Oct. 30, 2012
1
Table of Contents
SECTION WORKSHOPS
LS-PrePost Overview -
General/Nodes/Element/Tool and blank meshing/Tool mesh check
Workshops 1~4
eZ-Setup for Metal Forming - Overview -
eZ-Setup Workshops Workshops 5~7
Post-Processing Workshop 8 (NUMISHEET’02 fender outer)
Command File and Macros -
Configuration File -
eZ-Setup from IGES (optional) Workshop 9 (NUMISHEET’08 B-pillar)
2
LS-PrePost Overview
3
About LS-PrePost
LS-PrePost is an advanced pre and post-processor designed specifically for LS-DYNA
LS-PrePost is developed for Windows and Linux
LS-PrePost is FREE!
Core Functionality
• Full support of LS-DYNA keyword files
• Full support of LS-DYNA results files
• Robust handling of geometry data (new CAD engine in 3.0)
• Pre-processing (meshing, model clean-up, entity creation)
• Post-processing (animation, fringe plotting, curve plotting)
4
Online Resources
Latest version and training materials (metal forming): http://ftp.lstc.com/anonymous/outgoing/lsprepost/4.0/metalforming/
Official Website http://www.lstc.com/lspp
User Group http://groups.google.com/group/ls-prepost
5
Mouse and Keyboard
Dynamic Model Operation
• Rotate: Shift + Left-click
• Translate: Shift + Middle-click
• Zoom: Shift + Right-click/Scroll-wheel
(Using Ctrl instead of Shift for edge mode)
Graphics Selection
• Pick (single): Left Click
• Area (rectangle): Left-click + Drag
• Poly (polygon): Left-click at corners / Right-click to finish
List Selection
• Multi-Select: Left-click + Drag / Ctrl + Left-click
Mouse over controls for status bar help comments
6
GUI Layout
7
Menus File management & preferences
Command Line Input (left) / Output (right)
Bottom Toolbar Model rendering controls
Right Toolbar Access to pre and post-processing tools
Graphics Viewport
include: dynain file
command session file (.cfile)
LSPP database file
LS-DYNA results file (d3plot)
Input/Output
8
Misc. Menu
9
10
View Menu
text below icon
Geometry Menu Reference Geometry – Access tools for creating and editing
reference geometry (Axis, Plane, Coordinate System, and Point)
Curve – Access tools for creating and editing curves (Point, Line, Circle, Circular Arc, Ellipse, Elliptical Arc, BSpline Curve, Helix, Composite Curve, Break Curve, Merge Curve, Bridge Edge, Smooth Curve, Middle Curve, Morphing Curve, Fillet Curve)
Surface – Access tools for creating and editing surfaces (Plane, Cylinder, Cone, Sphere, Torus, Fill Plane, Extrude, Revolve, Sweep, Loft, N-Side Surface, Patch Surface, Bridge Two Faces, Combine Faces, Fit From Points/Mesh, Middle Surface, Surface Morphing)
Solid – Access tools for creating and editing solids (Box, Cylinder, Cone, Sphere, Torus, Extrude, Revolve, Sweep, Loft, Fillet, Chamfer, Draft, Thicken, Wedge, Boolean)
Geometry Tools – Access other geometry tools (Delete Face, Extend Curve, Extend Face, Intersection, Offset, Project, Replace Face, Stitch Faces, Trim Transform, Copy Entity, Management, Heal, Topology Simplify, Measure)
11
Same menu system with ICONs is at right
FEM Menu Element and Mesh – Access mesh creation tools (Shape Mesher,
Auto Mesher, Solid Mesher, Block Mesher, N-Line Mesher, Tetrahedral Mesher, Blank Mesher, Element Generation, Node Editing, Element, Editing, Mass Trimming, Spot Welding, SPH Generation)
Model and Part – Access model and part tools (Assembly and Select Part, Keyword Manager, Create Entity, Display Entity, Reference Check, Renumber, Section Plane, Model Selection, Subsystem Manager, Group, View, Part Color, Appearance, Annotation, Split Window, Explode, Lighting Setup)
Element Tools – Access element tools (Identify, Find, Blank, Move or Copy, Offset, Transform, Normals, Detach, Measure, Morph, Smooth, Part Trim, Part Travel)
Post – Access post-processing tools (Fringe Component, Fringe Range, History, XY Plot, ASCII, Binary Output, Follow, Trace, State, Particle, Circle Grid, Chain Model, FLD, Output, Setting, Vector)
Favorites – Customizable toolbar (see Setting → Toolbar Manager)
12
Same menu system with ICONs is at right
Application Menu
13
Setting Menu Current Subsystem ID – Set current subsystem ID
Current Working Directory – Set current working directory
Configuration Settings – Set configuration settings
Toolbar Manager – Customize toolbars
14
Help Menu Document – View LS-PrePost documentation
Tutorial – View LS-PrePost tutorials
Old to New – View mapping between old (v2.4) and new (v3.0) GUI
Release Notes – View release notes
Check for Update – Check server for new version of LS-PrePost
About LS-PrePost – View version info
Edge/mesh line width
Element outline
Bottom Toolbar
15
Opti Toggle Title, Legend, Min-Max, Time Stamp, Triad,
Background Color, Mesh Color, and Performance Stats on/off
HidEle Display elements with hidden lines removed
ShaEle Display elements in shaded mode with mesh lines off
VieEle Display elements in plain color mode
WirEle Display elements in wireframe mode
Feat Display elements in feature line mode (default angle=30°)
Edge Display elements in edge line mode
Grid Display each nodal point as a colored pixel
Mesh Toggle element mesh on/off
Shrink Draw elements in shrunken mode (default=0.85)
Frin Toggle Fringe/Line-contours/Iso-surfaces
Unref Toggle unreferenced nodes on/off
EdgGeo Display geometry in shaded mode with edges on
ShaGeo Display geometry in shaded mode with edges off
WirGeo Display geometry in wireframe mode
ShfCtr Toggle Off/Shift/Ctrl (for one-handed rotate/pan/zoom)
AutCen Automatically center model to fit within window
ZoIn Zoom in, click and drag to draw a box
Zout Zoom out to previous zoom position
Pcen Pick node as new center point for model rotation
Top Choose Top, Bottom, Front, Back, Right, or Left view
Angle Left-click to reverse rotation direction
Right-click to modify rotation angle
Rotate Left-click to rotate about axis shown
Right-click to switch rotation axis (X/Y/Z)
Persp Toggle Parallel/Perspective view mode
Clear Clear all picked or highlighted information
ActAll Restore all entities to be active
BacCol Toggle background color black/white (Plain background
mode only)
Anim Display animation controls or start/stop animation
SelPart Launch Assembly and Select Part interface
ResPart Restore the last removed part (Shift+R)
FEM General Selection
16
Pick Select a single entity
Area Select using a rectangular window
Poly Select using an irregular polygon
Sel1 Pick 1 entity (only 1 will be in
buffer)
Sphe Select entities within a sphere
Box Select entities within a box
Prox Select entities within proximity to
a part
Circ Select entities within a circle
Frin Select entities within a fringe plot
range
Plan Select entities within a plane
In Select entities inside Area/Poly
Out Select entities outside Area/Poly
Add Add entities to a selection set
Rm Remove entities to a selection set
ID Manually key-in entity IDs
Label Turn label on/off for new selection
3Dsurf Select outer surface (solids only)
Prop Propagate selection (pick seed)
Adap Propagate across adaptive elements
Ang Feature angle for propagation
Adjacent Select adjacent elements
Attach Select attached elements
Clear Clear selection
Save Save selection to buffer
Load Load selection from buffer
Deselect Undo last selection
Whole Select all entities in model
Visible Select all visible entities
Reverse Reverse selection
ByNode Select nodes
ByElem Select elements
ByPart Select parts
BySet Set based selection
ByEdge Edge based selection
BySegm Segment based selection
Point Select points
Curve Select Lines
Surface Select surfaces
Workshop 1 General Operations
17
18
Disable “New Rendering work”:
1 – double click this area
2 –click this area
want to see these
messages
need to remove this
message
3 – hit
keys:
ctrl l l
19
3
1
2
Directory: Workshop 1
4
Rotate model using Shift with left mouse button
5
Open keyword file and rotate model:
20 20
or Ctrl a 1
Auto Center:
21 21
1
2
3
4
5
6
7
8
Display in standard views:
22 22
12
13
14
1 2
3
4
5
6
7
8
9
10
11
Display in different modes and background colors:
23 23
Select part for display:
1
2
3 4
5
6
Shift with left click for multiple selection
7 8 9
10
24 24
Identify nodes/elements:
1
2
3
4 5
6
left click to pick nodes
7
8
9
left click to pick elements
10
left click to pick elements
7
25 25
1
2 3
4 5
6
Identify material direction for anisotropic material:
Note: axis “A “is rolling direction, see next page
8
26 26
Anisotropic material (*MAT_036):
Material axes options, see below.
Vector components ‘a’ for AOPT=2.0, see below
R90
With this explanation, do you know how to change the rolling direction to along global Y-axis, or, in 45 deg. direction between the X- and Y- axis? This is important for Aluminum forming.
Open in WordPad the file “tools_with_blank.k”, in directory: Workshop 1
Steel_DP500-36
Steel_DP500-36
Steel_DP500-36
27 27
Element/model blanking (for display):
1
2
3
28 28
Element/model blanking (for display):
1
2 3
4
5 3
Left click, hold and drag a box to cover some portion of the die
6
7
8
29 29
1
2
3
4
Left click to pick an element on the binder
6
Element/model blanking (for display):
7
1
6
9
7
8
30 30
Find a specific element or node:
10
3
5, uncheck
4, uncheck
2
31 31
Find a specific element or node:
Left click, hold and drag a box to zoom in; then free rotate model
6
1
2
3
4
5
32 32
Modify part transparency:
1
2
3
33 33
1
2
3
4
5
Left click to pick the top of the model to make upper transparent
6
7
Modify part transparency:
Left click to pick again to go back to normal color
8
Reset transparency
9
10
34
1
2
3
4
5
6
7 8
9
Left click to pick the part to change color
10
12
13 Change part color:
12
11
Workshop 2 Mesh editing
35
36
Open keyword file:
3
1
2
4
Directory: workshop 2
37
3
1
2
4
5
6
Merge duplicate nodes:
38
3
1
2
4
Merge duplicate nodes:
Replace nodes:
39
1
2
3
4
5
Left click, hold and drag these boxes to include nodes in each node pair whose position are to be replaced
6
7
8
40
3
4
1
2
Left click to pick the part 5
Left click to pick three nodes to form a triangle, right click for node #4.
6
Create a triangular element:
7
41
Fix free edge:
Left click, hold and drag these boxes to include nodes in each node pair whose position are to be replaced
5
1
2
4
6
7
3
42
1 2
Left click, hold and drag to zoom in this area
3
4
5
6
Left click to pick these two nodes
7
Align nodes:
43
8
Left clicks to form a polygon box, right click to finish
9
10 11
12
Align nodes:
44
1
2
3
4
5
6
Left clicks to form a polygon box, right click to finish
7
8 9
Split elements:
45
1
2
3
4
5
Left clicks on a boundary node
6
7 8
Fill a hole:
Left click to show, right click on “2 LSHELL2” to delete
9
10
46
13 14
11
12
15
Auto filling all holes:
NOTE: when using “Autofill” option, all free edges within the part will be considered as ‘holes’ and filled .
47
Save keyword file:
3
1
2
5
4
48
Open keyword file:
3
1
2
4
Directory: workshop 2
49
Pick an element here
2 1
3
4
5
6 7
Detach some elements:
50
free edge display
2
1
3
Check part separation:
toggle switch
Pick an element here
51
Change PID:
2
1
3
4
5
8
6
9
7
52
Change PID again:
2
1
3 4
5, no saving
53
Open keyword file:
3
1
2
4
Directory: workshop 2
54
1
Check part normals:
2
3
Pick on part
55 Offset result with “Advanced” option on
“offset –” is opposite of normals
1
2
3
4
7 8
Pick on part 6
Offset with Advanced option on (always recommended):
5
56
Translate (make copy into a new PID) the flat area:
10
Pick an element here
1
2
3
4
5
6
7 8
9
10
11
12
57
10
Pick these two nodes
Measure part distance (method 1):
2
4
3
5
measured distance shown here
1, show only PID 2 in display
58
Measure part distance (method 2):
Pick these two nodes
Alternatively: part separation, and others
1
2
3
4
3
measured distance shown here; double click this area to expand to a new window.
59
Pick this node as origin
Pick this part as a source
Rotated part
Rotate a tool (make copy into a new PID):
1
2
3
4
7
8 9
10 11
12
13
14
5
6
60
Make a mirror image of a tool:
Pick this node as origin
Pick this part as a source
Reflected part
1
2
3
4
5
7 8
9 10
11
6
12
13
61
Make a projection of part of a tool:
Select by ‘Polygon’ these elements, right click to finish the loop.
Elements selected
Elements projected
Pick this node as location
1
2
3
4
5
6
7
8
9
10 11
12
13
14
15
62
Scale (make copy) of a tool:
Pick PID 2 as a source
Scaled part 16
Pick this node as origin 1
2
3
4
5
6
7
8 9
10
12 11
13
14
15
16, no saving
Workshop 3
63
Mesh generation
64
65
Import IGES file:
3
1
2
Directory: Workshop 3
4
66
N-line meshing/4-line meshing:
3
1
2
4
Left click to pick four curves in the order shown
5
6
7
8
9
10
11
12
13 – no saving
67
Import IGES file:
3
1
2
Directory: Workshop 3
4
68
N-line meshing/Line sweep:
1
2
3
4
Left click to pick the square curve
5
Left click to pick this curve
6
7
8
69
1
2
3
4
5
Left click to pick this point as the center of the circle
6
7
Creating a circle:
70
1
2
3
Creating a circle:
71
12
1
2
3
4
Left click to pick this circle
Left click to pick this curve
6
Left click 7
Left click 8
9
10
11
N-line meshing/Line sweep:
5
Tool meshing
72
73
Import IGES file:
3
1
2
Directory: Workshop 3
4
74
1
2
3
4
6
Left click to pick the binder surface
7
8 9
Meshing binder:
5 - uncheck
75
1
Left click to pick the binder surface
2
3
4 5
6 7
Meshing die:
76
Left click on “2 LSHELL2” to highlight, right click to delete
1
2
3
4
6
5
7
10 11
Change meshing parameter for a finer mesh:
Left click to pick the binder surface
8
9
77
For advance feasibility
30
0.2
0.05
10
For springback
20
Compare tool meshes: 1, no
saving
Workshop 4 Blank Meshing/Tool Mesh Checking
78
79
Open keyword file:
3
1
2
4
Directory: workshop 4
Blank Meshing (method 1 – no surface required)
80
81
Pick nodes
More options
Pick these four nodes
1
2
3 4
5
7
8 9
Shape meshing/4N_shell:
6, increase if needed
Blank Meshing (method 2 – surface required)
82
83
Pick these two nodes to create a line
Pick these two nodes to create a line
Create two boundary lines:
1 2 3
4
5 6
7
84
Pick the line just created
Pick the line just created
Create a planar surface:
1
2
3
4
5
85
Pick the surface just created
Blank meshing:
1
2 3
4
6
7
8 9
5 - uncheck
86
Toggle geomtry display on/off:
Toggle geometry display on/off
1
87
Display mesh just created:
Note: do not exit LSPP – this model will be used for next step.
1
2
3
Blank Meshing (method 3 – Requires points/nodes, curves, or, surfaces)
88
89
Pick this line created as ‘Source Entity’
Right click to blank out BSpline Face 1
Line translated
1
2
5 4
7
8
9
10
11
Translate (make copy) a line:
Pick source when the box is shaded . Right click on an entity to delete
Unblank these two edges if needed 6
Toggle ‘ON’ geometry display
3
90
Pick these two lines
Mesh created
1
2
3
5
6
7
4
8 9
Meshing by two line: 10, no saving
Tool Mesh Checking
91
Summary: Check and merge duplicate nodes, tolerance 0.05mm – good for most cases; In this
workshop, 0.3mm tolerance was used. Check for Normal consistency – all tooling mesh normals 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 re-work needed for tool mesh if LSPP tool mesher is used.
92
Open keyword file:
3
1
2
4
Directory: workshop 4
3
1
2
93
Duplicate nodes check: measure distance
Pick these two nodes
4
measured distance shown: 0.234
94
Duplicate nodes check: merge duplicate nodes
1
2
3
4
5
6
set tolerance slightly bigger than the smallest distance measured
95
Tool mesh normal check:
Normal orientations: blank normal up, upper tools normal down, lower tools normal up;
1
2
3
4
pick the part, more details next page
5
s
Rotate the part to see the underside color – positive normal side shade color same as PID color
6
96
Wireframe mode for vector display;
Tool mesh normal check:
1
2 Shade mode for normal display;
97
Tool mesh normal reverse by part:
1
2
4
3 Pick any element
5 Pick again on any element
6
98
Tool mesh normal Auto Reverse – reverse a part normal based on one seed element normal
1
2
3
6
Pick any element
7
8 – pick the same element
x
9
10
4
Note: auto reverse works within one part boundary
5
99
Tool mesh free edge check:
3
1
2
Toggle this switch to turn on/off free edge display
4
5
Make sure background color is black:
100
1
2
3
4
0.05 5
6
7
Jacobian Check: check for zero or very small Jacobian, and save into a buffer for deletion
save to buffer
101
Element 30632 has all three nodes on a straight line
Jacobian Check: Contour display:
102
Jacobian Check: Identify element with ID:
1
2
3
4
Message indicate this is a triangular element
103
3
2
4
5
6 7
8
1
9
Jacobian Check: Delete bad elements from the buffer:
10
104
Save keyword file:
3
1
2
4
save the keyword in Workshop 4 as newmesh.k
eZ-Setup for Metal Forming
105
Development Objective
To provide LS-DYNA® metal forming users the best tool to set up
various simulation processes
To closely integrate up-to-date LS-DYNA metal forming features
To provide a simplified and streamlined capabilities for post-
processing of metal forming results
106
Current Capability - eZ-Setup
Guided GUI features:
Air and toggle draw, flanging;
Air draw with upper pad;
User-specifiable cushion travel;
One LS-DYNA run for typical process simulation
combination;
Gravity with pre-bending;
Binder closing and flanging simulation in implicit static;
Tipping (*CONTROL_FORMING_TIPPING);
Adaptive 2-D trimming and 3-D trimming, with element
checking/fixing;
Springback - constrained and constraints-free;
Versatile and easy draw bead definition;
Adaptive box definition;
Mesh pre-adaptive along curves for flanging simulation;
Tool kinematics simulation/checking; 107
Current Capability (Con’t) Automatic recognition of ELFORM and NIP from dynain file;
User material library.
Three-levels of computing options in Forming for optimal balance of
speed and accuracy:
Advance feasibility – very fast and reliable, w/ some inertia
effect;
For formability – fast and accurate, inertia minimized;
For springback – most accurate, for springback and
compensation.
Three-levels of computing options in Flanging:
Fast – initial flangebility check, explicit dynamic;
Accurate – explicit dynamic with minimum inertia effect;
Implicit Static – no inertia effect.
Tailor-welded blanks capable
Optional selective mass scaling for all explicit computing
108
Installation & File Structure Installation: fully QA’ed metal forming version:
http://ftp.lstc.com/anonymous/outgoing/lsprepost/4.0/metalforming/
Updates/customization can be made by directly replacing these files:
109
110
Opening a DYNAIN file (forming result of sheet blank)
110
DYNAIN Project file When using a dynain file for a new simulation
always move the dynain file (renamed it to last.dynain) to the current directory,
same location as the new project file will be located
always read the last.dynain file first into LSPP for eZ-Setup
always answer ‘YES’ to skip reading stress/strain
when sending the project file to other people, include the last.dynain file
1) Always move last.dynain file into the current directory. 2) Always read in the sheet blank file first, import/offset
tooling element/node IDs. 3) Always answer YES. 4) Send project file and dynain file together. 5) Note, in output file: ‘filename.blk’ has no stress/strain.
‘filename’.dynain has stress/strain.
Metal Forming Application
Metal Forming Graphics User Interface (GUI) is designed to ease the simulation set up and inputs in LS-DYNA.
Easy Setup
General Setup
111
Keyboard shortcut: Ctrl q
111
Metal Forming → Toolbar
112
Metal Forming Pre
Metal Forming Post
112
Metal Forming → eZ Setup
Forming draw type
Air draw
Toggle draw
Support contact offset
Multiple forming processes
Gravity
Forming
Trimming
Spring Back
Flanging
Closing (implicit)
Tipping
113
Note: current version does not support the use of the same process twice.
113
Metal Forming → Die definition
Pick a part
Import a part
Mesh generation
114 114
Metal Forming → Binder definition
Pick a part
Import a part
Mesh generation
Offset from Die
Travel limitation
115 115
Metal Forming → Punch definition
Pick a part
Import a part
Mesh generation
Offset from Die
116 116
Metal Forming → Blank definition
Pick a part
Import a part
Blank mesher
Translate
Symmetry condition
Adaptive box define
Support tailor welded blank
material
thickness
117 117
Metal Forming → DrawBead definition
Draw bead generator
Import IGES curve
Draw bead project
Draw bead modify
Full lock force calculate
118 118
Metal Forming → Control option (Gravity Loading)
Blank Pre-bending
119 119
Metal Forming → Control option (Forming)
For early feasibility
For formability
For spring back
User define parameters
Allow additional pad
Kinematics simulation
120 120
Metal Forming → Control option (Trimming)
2-D or 3-D trim
Pick trim curves
Select seed location
Define trim vector
Pre-adaptive mesh along trim line
Check and fix shell after trimming
121 121
Metal Forming → Control option (Spring back)
Constrained
Inertia Relief
Pick node
Pick Location
Enter coordinate
122 122
Metal Forming → Control option (Flanging)
Pre-adaptive along curve
Contact offset
Multiple flanging steels
123 123
Metal Forming → Control option (Tipping)
Define tipping center
Translation
Rotation along an axis
124 124
Metal Forming → Job submit
File folder browse
Subdirectory (option)
Input file name
Case files for multiple processes.
125 125
Workshop 5
A flanging process set up with multiple flanging steels moving in local directions
126
127
3
1
5 6
2
9
8
4
7, use “import offset”
10
Directory: Workshop 5
11
12
1
2
3
4
5
8
128
6
7
Define the following process:
Flanging
Blinking yellow prompting for blank definition; turns green when it is defined.
Pick blank to define, right click to return
1
2
3
7
0.7 6
4 Click this button if your
material file is in the current working directory.
129
5
Three computing options to balance speed and accuracy.
“Show” lists detailed pre-set default variables, changeable by users.
Mesh Pre-adapt option
Selective mass scaling option
Optional tool kinematics simulation
Select these curves to define mesh pre-adapt,
right click to return
1
2
5
0.9 4
3
130
Blinking yellow prompting for flanging post definition; turns
green when it is defined. Pick post to define, right click to return
1
2
3
131
Blinking yellow prompting for pad definition; turns green
when it is defined.
Pick pad to define, right click to return
Optional force on pad
1
3
2
132
Blinking yellow prompting for flanging steel definition; turns
green when it is defined.
Pick this flanging steel to define, right click to return
1
2
133
3 - details next page
Blinking yellow prompting for flanging direction definition;
turns green when it is defined.
Pick two END points of the line to define the flanging
steel moving direction
Default option: geometric points; other
options as shown
Click to add an extra flanging steel.
2
4
134 3
From
To
1
1
5
7
3
From
To
4
Repeat the process to define Flg3 and Flg4
135
Pick this flanging steel to define, right click to return
2
6
8
All green – all defined; ‘Next’ to output.
1
136
Output LS-DYNA input file – eZ-Setup complete.
1
2
3
137
Key in file name as: sim.dyn
Note: Project file is an important database file, containing complete model information and eZ-Setup information. It can be reloaded back into LSPP for changes in process or models.
138
1
2
3
Save project file (overwrite existing project file): 4
Running LS-DYNA in windows with a command file:
139
Windows Explorer
1 - Right click here
2
3
4 – rename to R6s.cmd
C:\LSDYNA\program\ls971_s_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=200M
Use: single precision for this run 6 – input following command in R6s.cmd and save
5 – right click on R6s.cmd and
select ‘Edit’
7- double click to run LS-DYNA
End of simulation Beginning of simulation
Simulation Results:
140
Processing Results
Open d3plot files from your running directory
Animate the flanging process
141
1
2 3
4 6 7
5
8 9
Processing Results
Plot thinning/thickness
Change contour range
142
1
2
4
3 4
5
6
7
8
9
Workshop 6
A process set up of gravity, draw, trimming, tipping, flanging and springback
143
144
3
1
2
6
5
11
12
Directory: Workshop 6
4
10
7
8
9
Define the following process:
1
2
3
145
Gravity Forming
Trimming Tipping Flanging
Springback
Append to the last
Click on one already “selected process” in the left box, click on the “available process”, then click on this button, it will insert the latter in front of the former.
left click to pick the die, right click to return
1
2
3
146
Left click to pick the binder, right click to return
1
2
3
147
Left click to pick the punch, right click to return
1
2
3
148
Define material/thickness
1
3
5
6
Left click to pick the blank, right click to return
2
149
4
150
Left click to pick BOTH curves to define draw beads; right click to return.
5
6
1
2
3 4
9
7
8
Input tensile strength in MPa (default is for
mild steel)
151
Picked curves automatically
projected to binder. Default lockage: 50%
1
10
next screen
Modify % lockage (next screen)
Default lockage: 50%.
152
Bead lock % modification
2 You can pick bead here directly
3
4
3 – pick here or pick directly on
the bead
5
7 6 – pick here or pick directly on
the bead
8
You can pick bead here directly
6
9, then go back to previous page
Note: Project file is an important database file, containing complete model information and eZ-Setup information. It can be reloaded back into LSPP for changes in process or models.
153
1
2
3
Save project file (overwrite existing project file):
Optional pre-bending for air draw (not for toggle draw)
1
154
Three computing levels to balance speed and accuracy.
Optional selective mass scaling – for inertia effect reduction.
Optional tool kinematics simulation.
Show/modify tool speeds, etc. (details next page)
Optional upper pad (for air draw)
1
155
156
Additional control on accuracy/speeds:
Default adaptive mesh for trimming Default element checking/fixing.
Pick trim seed on a punch or die node/ location where trimmed part will remain
Left click to pick trim curves, right click to return
Define vector
Turns green when defined.
1 3
2 4
5
6
157 More options to define vector.
For Information Only: merge curves into a single ENCLOSED curve (loop) – requited for 3-D trimming:
1
2
Note: 2-D trimming can have multiple curves forming a ENCLOSED loop .
3
4
5 – pick curves
158
2
3
159
1
Three computing options to balance speed and accuracy.
Selective mass scaling option to reduce inertia effect (not for
implicit option)
Optional tool kinematics simulation.
160
1
Blinking yellow prompting for flanging post definition; turns
green when it is defined. Left pick post to define,
right click to return
1
2
3
161
Blinking yellow prompting for pad definition; turns green
when it is defined.
Left pick pad to define, right click to return
Optional force on pad
1
2
3
162
Blinking yellow prompting for flanging steel definition; turns
green when it is defined.
Left click to pick flanging steel to define, right click
to return
1
2
3 – follow next page
163
Default option: geometric points; other
options as shown
Pick the two END points along this line to define the flanging
steel moving direction
5
4
6 164
3
7
1
2
Constraint-free springback
165
Output LS-DYNA input file – eZ-Setup complete.
1
2
3
166
Key in file name as: sim.dyn
Note: Project file is an important database file, containing complete model information and eZ-Setup information. It can be reloaded back into LSPP for changes in process or models.
167
1
2
3
Save project file (overwrite existing project file): 4
LS-DYNA input files for running the process simulation:
Control files copied from Lspp_forming
Primary simulation file to run LS-DYNA – linking all processes together
Individual single process simulation input file – “.k” file
168
C:\LSDYNA\program\ls971_d_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=200M
Running LS-DYNA in windows with a command file:
R6d.cmd
use ‘edit’ to add the following command;
double click the file to execute the LS-DYNA solver run.
169
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
Use: double precision for this run
Processing Results
Open the following d3plot files in LSPP, in the order shown:
case5.d3plot
case10.d3plot
case15.d3plot
case20.d3plot
case25.d3plot
case30.d3plot
Select case10 (forming) as shown:
Animate punch contact
Plot thinning/thickness for forming
170
2
1
3
Processing Results
Select case15 (trimming) as shown:
Plot thinning/thickness for trimming
171
2
1
3
4
Processing Results
Select case20 (tipping) as shown:
Plot thinning/thickness for tipping
172
2
1
3
Processing Results
Select case25 (flanging) as shown:
Animate flanging action
Plot thinning/thickness for flanging
173
2
1
3
Processing Results
Select case30 (springback) as shown:
Animate springback
Plot dZ and resultant Z (next page)
174
2
1
3
Change contour range (optional)
175
Plot springback amount in Z
1
2
4
3
Forming complete – case10.d3plot
Gravity complete – case5.d3plot Trimming complete –
case15.d3plot
Tipping complete – case20.d3plot
Flanging complete – case25.d3plot
Springback complete – case30.d3plot
176
Workshop 7
TWB Forming + Springback (constrained)
177
178
3
1
2
4
Directory: Workshop 7
Hit “next” to define die, binder, punch.
179
Define process:
Pick the red piece as “blank1”
180
Use BH210.k
Define blank1:
Define “blank2”
181
Define blank2:
Use BH210.k
2
3
4
6
182
Check for and delete existing boundary conditions:
1
5
1
2
3
4
Pick on this edge of any element along the symmetry
5
6
7 183
Redefine symmetric boundary conditions:
8 9
skip “draw bead”
Select constraints before picking node/location
Always pick nodes/locations on final tool position (where the blank will be in contact)
184
Define springback constraints:
1
2
3
A
A
B
B
C
C
9
Coordinates X, Y,Z (constraints X, Y, Z)
If needed, select the defined constraints then Modify
6
6
5
4
7
8
Not much to do here
185
Define Forming control:
Output simulation input files:
Key in file name as: sim.dyn
186
Note: Project file is an important database file, containing complete model information and eZ-Setup information. It can be reloaded back into LSPP for changes in process or models.
187
1
2
3
Save project file (overwrite existing project file): 4
C:\LSDYNA\program\ls971_d_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=800M
Running LS-DYNA in windows with a command file:
R6d.cmd
use ‘edit’ to add the following command;
double click the file to execute the LS-DYNA solver run.
188
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
Use: double precision for this run
Processing Results
Open the following d3plot files in LSPP, one after another:
case5.d3plot
case10.d3plot
Select case5 (forming) as shown:
Animate punch contact
Plot THINNING for forming
189
2
1
3
Processing Results
Select case10 (springback) as shown:
Animate springback
Plot dZ and resultant Z (next page)
190
2
1
3
Change contour range (optional)
191
Plot springback amount in Z
1
2
4
3
Future Work - eZ-Setup
Unlimited, flexible processes allows for progressive dies simulation
in one setup and one run.
Flanging with multiple CAM pads.
Sequential flanging – flanging process 2 following flanging process 1,
with auto move.
Guide pins in gravity, forming.
Multiple 2-D trimming with own Cam trim vectors.
Springback on fixture nets.
Mutli-beads support and physical bead generation based on force.
Blank size and trim line development with *CONTROL_BLANKSIZE_
DEVELOPMENT.
Unfolding with *CONTROL_FORMING_UNFLANGING.
Material property creation GUI.
Directional and pressure sensitive friction.
Springback compensation.
GUI for a one step simulation with *CONTROL_FORMING_ONESTEP.
Stoning
Post-processor for metal forming. 192
Workshop 8 Post-Processing
193
194
Animate punch contact/part breakdowns:
2 1
3
4
5
6
workshop8
195
Create a movie (AVI):
3
1
5
2
4
196 196
Cut a section plane:
2
1
3
5
Pick this node 4
6
7
197
2
1
3
4 5
3
2
1
4
Cut multiple planes:
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.
Optional:
198
Plot Thickness/thinning contour: 2
3
5
6
1
4
7
8
199
Set contour range for thickness/thinning contour:
Thickness range: Thinning range:
1
2 2
3 3
4 4
200
Save a JPG file for the screen display:
1
2
3
4
5
201
Plot thickness distribution along a section:
1
2
3
5
Pick a node close to this location
4
6
202
Plot thickness distribution along a section:
7
8
203
Changing the thickness of a section plot in contour:
2
1
204
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 1, 2, 3 in sequence:
right click
2 - Translate curves:
1
2
3
4 – red color box means current pick
5
6
8 – multiple
times
7
3 - Change curve color:
1 2
3
4
1 - Import IGES file: newtrim1.iges 1
205
206
Plot mean stress (pressure) contour (wrinkles):
2
3
4
1
5
6
207
Set contour range for mean stress:
negative tensile
positive yield 2
3
1
208
Similarly, plot In-plane major/minor strain contour:
1
2
209
Plot FLD:
1
2
3 4
5
6 –pull down and
select
7
8
If use ‘File’ option, open ‘fld_true.fld’
0.2
210
Plot In-plane major/minor strain vectors:
1
2
3
4
5
Pick location
6
211 211
Measure skid marks:
create the definition of a feature line
1
2
3
4
5
Pick on the edge of an element on the styling feature line
6
7
Select only PID 3 lower punch to display on screen
212 212
Measure skid marks:
definition of parts and curve
1
2
3
Display all parts on screen
Pick tool
4
Pick blank
5
6
7
8
213 213
Measure skid marks:
show only skid marks on display
9
214 214
Measure skid marks:
show skid amount on display
10
click on the skid lines to show skid amount on display, good for JPG capture.
215 215
Measure blank edge draw-ins (method 1):
define parts, state and show draw-in map
1
2
Pick blank
4
Pick blank
5
9
3
6
10
7
8
216 216
Measure blank edge draw-ins (method 1):
change display density of edge draw lines
1
2
click on upper arrow or double click on the blue ‘INTERVAL’ to change the density of the edge drawin lines
217 217
Measure blank edge draw-ins (method 1):
show detailed draw-in amounts on screen
1
click on the drawin lines to show draw-in amounts on screen, good for JPG capture.
218 218
Measure blank edge draw-ins (method 2):
Write closing blank meshing as a keyword file.
1
2
3
4
5
6 7 Write file as S6.k
3
219 219
1
2 3 Write file as S17.k
Measure blank edge draw-ins (method 2):
Write formed blank mesh as keyword file 4
220
Measure blank edge draw-ins (method 2):
Open new session of LSPP, and import s6.k and s17.k, use “Import Offset’ for the 2nd file.
1 2
3
221
Measure blank edge draw-ins (method 2):
Translate binder closed blank mesh down.
1
2
3
4
6
7 – pick part
8
129 5
222
Measure blank edge draw-ins (method 2):
Measure distance between edge nodes.
1
2
3 4 – pick edge nodes in pairs
223
Measure blank edge draw-ins (method 3):
Alternatively, blank edge curves can be created using d3plot files
1
2
3 6 – pick the blank
4
7
5
224
Measure blank edge draw-ins (method 3):
Create blank edge curves for state #6.
1
3
1
2 – pick the blank
225
Measure blank edge draw-ins (method 3):
Turn off all FEM parts
1
2
226
Measure blank edge draw-ins (method 3):
Translate state #6 blank edge down 141mm
1
2
3 4 – pick this curve
5
6
7
8
129
227
Measure blank edge draw-ins (method 3):
Measure edge distance
2
1
3
4 – pick edge points
228 228
Plot tool tonnage: Open ‘rcforc’ file in Workshop 8/Forming In MPP, the file name is ‘binout0000’.
1
2
3 4
5
6
7
7
Note: 1 English ton=8900 Newton
In MPP, read ‘binout0000’ file here
229 229
Plot sheet blank mass increase:
Note: total weight of the model is used to calculate the %.
1
2
3 4
5
6
7
Other Post-Processing Details
230 230
Post → History Purpose: plot time history data (from d3plots)
Global – energies and kinematic data for full model
Part – energies and kinematic data for parts
Nodal – kinematic data for nodes
Element – stress and strain data for elements • Value – set to element value or min/max value for the part
• E-Type – choose element type to plot history
• E-Axes – global or local
• Surface – choose shell location (through-thickness)
Int Pt – integration point data
Scalar – plot scalar value that is being fringed (choose component in Fcomp interface)
231
Post → History (continued...)
Standard plotting options... • Plot – plot selected value in current Plot Window
• New – plot selected value in new Plot Window
• Padd – add selected value to current Plot Window
• Raise – bring forward all open plot windows
• Pop – open and bring forward all closed plot windows
Interfaces that use these plot functions... • History
• XYPlot
• ASCII
• Binout
• FLD
• Measure
• Section > Force
232
Plot Window Title – modify main, axis, legend, and curve titles
233
Post → XYPlot Purpose: create and manipulate XY-Plots (all saved XY
data is automatically added to the file list)
File – show list of all loaded XY-Plot files
Window – show list of all XY-Plot windows
Add – import XY data (use CRV, CSV, XY formats)
Remove – remove files from list
Info – display number of data points
Show – show selected plot
Cross – create cross plot (e.g., combine Force/Time and Disp/Time to create Force/Disp)
Curve Clip – clip curve
Interpolate – modify number of points in curve
234
Command File and Macros
235
Command File
All commands are written to lspost.cfile
• Created in same directory as input file
• Can be modified to help automate repetitive tasks
• Call other command files using “include” statements
• Skip commands using “skip” and “endskip”
• Enter interactive mode using “interactive” (us Esc key to continue)
3 ways to execute command files: • File > Open > Command File
• lsprepost c=commandfile.ses
• lsprepost c=commandfile.ses –nographics
236
Command File (continued...)
Parameters can be used in command file
• Parameter definition can be numbers or strings
parameter directory “c:\Home\Test\problem\”
parameter rotang “45.0, 0.0, 30.0”
parameter filename “testcase1.key”
• Use “&” to mark parameters
open d3plot &filename
• Use “{“ and “}” when combining parameters
open d3plot &{directory}&{filename}
Command file structure is not yet fully documented, but more commands and details can be found here: • http://www.lstc.com/lspp/content/other/command/command.shtml
237
Misc. → Macro Interface Purpose: load and execute macros
Macros allow multiple commands to be grouped and executed as often as desired
Parameters can be used in macro files
Parameters can be defined on the fly (see “matid” and “fname”)
Macro syntax... • *macro begin name
Command 1
Command 2
Command 3
• *macro end
238
Misc. → Macro Interface (continued...)
Macro example... • *macro begin plot_matsum
ascii matsum plot 2 &matid
raisewin
xyplot 1 savefile curve_file C:\temp\&fname 1 all
• *macro end
239
Function Keys
F1 launches Function Key interface shown below (shows layout of the function keys)
Except for F1 and F10, all other function keys can be programmed to act as a button
Also, a command file with the name F#.cfile can be called using F# (place file in current working directory)
Function keys can be customized in the configuration file (lsppconf)
240
Configuration File
241
Configuration File (lsppconf)
LS-PrePost searches for this file in these directories in the following order...
• LSTC_FILE directory
• User’s home directory (Linux)
• \user\youlongin\AppData\Roaming\LSTC\LS-PrePost (Window 7)
• Current working directory
For parameters that are defined multiple times, the last one found will be used
Not all parameters are required (to simplify, define changed parameters only)
Use File > Save > Save Config to save file lsppconf in your application data folder
242
Workshop 9 (optional)
eZ-Setup From IGES Surfaces – NUMISHEET2008 B-pillar
243
244
NUMISHEET2008 B-pillar
Procedures
Import IGES files:
Numisheet08-BM03-Blank.igs
Numisheet08-BM03-Blankholder.igs
Numisheet08-BM03-Dies.igs
Numisheet08-BM03-Punch.igs
drawbeads.iges
Automesh/deviation, use these parameters
Mesh blank, element size=20mm;
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 eZ-Setup, air draw:
Process: gravity (prebend along Y-axis) + forming;
Use material BH210.
245
246
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 a command file (METHOD 2)
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.
Simulation involving gravity, springback, static implicit must use double precision (DP) solver
DP solver slower than SP solver
Pre-bending for Gravity
From true flat shape, all blanks have tendency to bend either in concave or convex shape.
Most blanks sent to a draw die (in air) are made sure it is in convex shape, either by pre-bending, suction cups, mechanical means, etc.
This new feature allows for SLIGHT AMOUNT of pre-bending of blank in either convex, or concave shape prior to loading onto the tools.
Done at the same time before the gravity loading is started
247
Pre-bending for Gravity
Allow for pre-bending of blank prior to loading onto the tools
Bending axis
Sheet blank normal direction
Negative “R” means center of bending is on the opposite side of the positive
blank normal
Initial model set up
248
Pre-bending for Gravity
Allow for pre-bending of blank prior to loading onto the tools
Gravity loaded blank without
prebending – Blank sags in the die
cavity (concave shape)
Pre-bending with R=10000.0mm using
this keyword (1st state of D3plots)
Gravity loaded shape (last state of D3plots) –
Convex shape blank achieved and binder
closing distance reduced
95mm
60mm
concave shape here
249
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