Metal Forming eZSetup In LS-PrePost 4.2

LSPP Metal Forming Development Team Janurary, 2015

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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

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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.

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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;

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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

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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

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Import blank and forming tools:

3

2

1

Directory: Workshop 3

4

25

5

Rename blank and tools:

2

1,right click

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3, type in a name and enter

1

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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

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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

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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

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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

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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

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Submit job: LS-dyna input deck output

2

48

3

4

1

Output folder:

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Workshop 4

A flanging process set up with multiple flanging steels moving in local directions

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2 1

3

Directory: Workshop 4

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Import keywords:

4

Import iges:

3

52

2

1

3

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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

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Flanging control:

1

Select these curves to define mesh pre-adapt, right click to

finish the selection.

4

2

3

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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

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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:

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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):

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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

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Workshop 5 Post-Processing

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Animate punch contact/part breakdowns:

2 1

3

4

5

6

workshop5

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Create a movie (wmv):

2 1

3

4

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Use MediaPlayer to open and play the movie file.

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Cut a section plane:

2

1

3

5

Pick a location

4

6

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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:

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Plot Thickness/thinning contour:

2

3

5

6

1

4

7

8

69

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Set contour range for thickness/thinning contour:

Thickness range: Thinning range:

1

3 3

4 5

5 6

2 2

4

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Save a JPG file for the screen display:

1

2

3

4

6

optional

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Plot thickness distribution along a section:

1

2

3

5

Pick a location close to this node

4

6

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Plot thinning distribution along a section:

7

8

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Changing the thinning of a section plot in contour:

2

1

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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

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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

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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

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11

pick binder

Blank draw-in:

The state when closing is done

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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

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Plot sheet blank mass increase:

Note: total weight of the model is used to calculate the %.

3

4

5

6

1

2

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Configuration and run script

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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

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eZSetup parameter file and LS-Dyna run script file are under LSPP

installation folder and subfolder lspp_forming

eZSetup parameter file(lspp_parameter):

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Solver location.

Process executable commands.

eZsetup default parameters.

LS-Dyna run script file (Windows):

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Workshop 6 (Practice)

eZSetup From IGES Surfaces – NUMISHEET2008 B-pillar

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NUMISHEET2008 B-pillar

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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

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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

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Thanks

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