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Metal Forming In LS-PrePost 4.

0
LSPP Metal Forming Development Team July 30, 2012

Table of Contents
SECTION
LS-PrePost Overview General/Nodes/Element/Tool and blank meshing/Tool mesh check eZ-Setup for Metal Forming - Overview eZ-Setup Workshops Post-Processing Command File and Macros Configuration File eZ-Setup from IGES (optional)

WORKSHOPS
Workshops 1~4 Workshops 5~7 Workshop 8 (NUMISHEET02 fender outer Workshop 9 (NUMISHEET08 B-pillar)

LS-PrePost Overview

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)

Online Resources

Latest version (QA metal forming):

ftp://ftp.lstc.com/outgoing/lsprepost/4.0/Metalforming/LS-PrePost-4.0-X64_setup.exe

Official Website
http://www.lstc.com/lspp

User Group
http://groups.google.com/group/ls-prepost

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
Menus
File management & preferences

Right Toolbar
Access to pre and post-processing tools

Graphics Viewport

Command Line
Input (left) / Output (right)

Bottom Toolbar
Model rendering controls

Input/Output
LS-DYNA results file (d3plot) include: dynain file command session file (.cfile) LSPP database file

Job Scheduler

Details later Must install using LSPP_setup.exe


9

Misc. Menu

10

View Menu

11

Geometry Menu

Same menu system with ICONs is at right

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)

12

FEM Menu

Same menu system with ICONs is at right

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)

13

Application Menu

14

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

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

15

Bottom Toolbar
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 Edge Grid Mesh Display elements in feature line mode (default angle=30) Display elements in edge line mode Display each nodal point as a colored pixel Toggle element mesh on/off Persp Frin Unref Toggle Fringe/Line-contours/Iso-surfaces Toggle unreferenced nodes on/off Clear ActAll Anim 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) Toggle Parallel/Perspective view mode Clear all picked or highlighted information Restore all entities to be active Display animation controls or start/stop animation ShfCtr Toggle Off/Shift/Ctrl (for one-handed rotate/pan/zoom) AutCen Automatically center model to fit within window ZoIn Zout Pcen Top Zoom in, click and drag to draw a box Zoom out to previous zoom position Pick node as new center point for model rotation Choose Top, Bottom, Front, Back, Right, or Left view

Shrink Draw elements in shrunken mode (default=0.85)

EdgGeo Display geometry in shaded mode with edges on ShaGeo Display geometry in shaded mode with edges off WirGeo Display geometry in wireframe mode

BacCol Toggle background color black/white (Plain background mode only) SelPart Launch Assembly and Select Part interface ResPart Restore the last removed part (Shift+R)

16

FEM General Selection


Pick Area Poly Sel1 Sphe Box Prox Circ Frin Plan In Select a single entity Select using a rectangular window Select using an irregular polygon Pick 1 entity (only 1 will be in buffer) Select entities within a sphere Select entities within a box Select entities within proximity to a part Select entities within a circle Select entities within a fringe plot range Select entities within a plane Select entities inside Area/Poly ByNode Select nodes ByElem Select elements ByPart Select parts Adjacent Select adjacent elements Attach Select attached elements Clear Save Load Clear selection Save selection to buffer Load selection from buffer

Deselect Undo last selection Whole Select all entities in model Visible Select all visible entities Reverse Reverse selection

Out
Add Rm ID Label

Select entities outside Area/Poly


Add entities to a selection set Remove entities to a selection set Manually key-in entity IDs Turn label on/off for new selection

BySet

Set based selection

ByEdge Edge based selection BySegm Segment based selection Point Curve Select points Select Lines

Surface Select surfaces

3Dsurf Select outer surface (solids only) Prop Adap Ang Propagate selection (pick seed) Propagate across adaptive elements Feature angle for propagation

17

Workshop 1
General Operations

18

Open keyword file and rotate model:


1 2

Directory: Workshop 1

Rotate model using Shift with left mouse button

19

Auto Center:

or Ctrl a

20

Display in standard views:

2 3 4 5 6 7 8

21

Display in different modes and background colors:


12

13

14

11

3 10 1 2 4

22

Select part for display:


3 10 6 4 5

Shift with left click for multiple selection


1

23

Identify nodes/elements:
7

2 3 8

left click to pick nodes

10

left click to pick elements

24

Identify material direction for anisotropic material:


7

left click to pick elements

4 6 8

Note: axis A is rolling direction, see next page

25

Anisotropic material (*MAT_036):


Open in WordPad the file tools_with_blank.k, in directory: Workshop 1
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.

26

Element/model blanking (for display):


3

27

Element/model blanking (for display):

Left click, hold and drag a box to cover some portion of the die

8 7

3 4

28

Element/model blanking (for display):


6 1

Left click to pick an element on the binder

2 3

29

Find a specific element or node:


2

30

Find a specific element or node:


2 6

Left click, hold and drag a box to zoom in; then free rotate model

3 4

31

Modify part transparency:


2

32

Modify part transparency:


6 9

Left click to pick the top of the model to make upper transparent

Left click to pick again to go back to normal color


7

4 5 2 10

Reset transparency

33

Change part color:


10

12

Left click to pick the part to change color

1 5

7 8 9 6

11

34

Workshop 2
Mesh editing

35

Open keyword file:


1

2
3

Directory: workshop 2 4

36

Merge duplicate nodes:

4 5 3 1 2

37

Merge duplicate nodes:

2 3

38

Replace nodes:
Left click, hold and drag these boxes to include each node pairs whose position are to be replaced

5 1 7 8 2

39

Create a triangular element:

Left click to pick the part

Left click to pick three nodes to form a triangle, right click for Node 4.
2

40

Align nodes:
3

Left click, hold and drag to zoom in this area

Left click to pick these two nodes


4

41

Align nodes:

Left clicks to form a polygon box, right click to finish

10 12

11

42

Split elements:
3

1 7

Left clicks to form a polygon box, right click to finish

2
6

43

Fill a hole:

3 9

Right click on 2 LSHELL2


6 10

Left clicks on a boundary node

44

Auto filling all holes:

11 12

13 15

14

45

Save keyword file:


1 5

46

Open keyword file:


1

2
3

Directory: workshop 4

47

Detach some elements:


5

Pick an element here

2 1

48

Check part separation:


toggle switch
3 2

free edge display

49

Change PID:

3 4 2

Pick an element here

1 5

50

Change PID again:


5

51

Open keyword file:


1

2
3

Directory: workshop 2

52

Element Tools Offset (Tooling surface normal offset)

Element normals must be aligned before offsetting

Questions to consider: 1) How is the offset direction -/+ is decided? 2) Turn on/off Advanced option and see what it does to the offset meshes.

53

Check part normals:

Pick on part

54

Offset with Advanced option on:

2 5

Pick on part

1 4

offset is opposite of normals

Offset result with Advanced option on

55

Offset with Advanced option off:

Pick on part

1
3

Offset result with Advanced option off

56

Translate (make copy) the flat area:

4 5 10 2

Pick an element here


1

10

5 7 6

11

57

Measure part distance (method 1):

10 4

Pick these two nodes

58

Measure part distance (method 2):


3

Alternatively: part separation, and others


3

Pick these two nodes

59

Rotate a tool (make copy):

Rotated part
12

Pick this part as a source


4 5

1 6

Pick this node as origin

13

8 11 10

14

60

Make a mirror image of a tool:


3 11

Pick this part as a source

Reflected part

4 5

1 6

Pick this node as origin


7 10

12

8 9

13

61

Make a projection of part of a tool:


13

Select by Polygon these elements, right click to finish the loop.


6

Pick this node as location


Elements selected

4
5

2 7

Elements projected

8 14

11 12

10

15

62

Scale (make copy) of a tool:

13

Pick PID 2 as a source


4

Scaled part 16
6

Pick this node as origin


14 8 12 10

11

15

63

Workshop 3

64

Mesh generation

65

Import IGES file:


1

Directory: Workshop 2

66

N-line meshing/4-line meshing:


5

12

Left click to pick four curves in the order shown

6 7 8

2 1

9
10 11

67

Import IGES file:


1

Directory: Workshop 2 4

68

N-line meshing/Line sweep:

Left click to pick the square curve

4 2 6

Left click to pick this curve

7 8

69

Creating a circle:
6 3 1 4 2

Left click to pick this point as the center of the circle

70

Creating a circle:

2 3

71

N-line meshing/Line sweep:


12 5 Left click to pick this circle 7

Left click
6

Left click to pick this curve


8

Left click

9 10 11

72

Tool meshing

73

Import IGES file:


1

Directory: Workshop 3 4

74

Meshing binder:
2 6 3

Left click to pick the binder surface


4

5 5 6

75

Meshing die:

Left click to pick the binder surface

1 4 5

6 3

76

Change meshing parameter for a finer mesh:

5 1

Right click on 2 LSHELL2

7 8 9

77

Compare tool meshes:

For advance feasibility

30

For springback

20 0.2 0.05 10

78

Workshop 4
Blank Meshing

79

Open keyword file:


1

2
3

Directory: workshop 4

80

Blank Meshing
(method 1 no surface required)

81

Shape meshing/4N_shell:

2 4 5 3

Pick nodes Pick these four nodes More options

82

Blank Meshing
(method 2 surface required)

83

Create two boundary lines:


4

Pick these two nodes two create a line

Pick these two nodes two create a line

5 7

84

Create a planar surface:


3

Pick the line just created

Pick the line just created

85

Blank meshing:
6

Pick the surface just created

3 4

1 5 7 8

86

Toggle geomtry display on/off:

Toggle geometry display on/off 87

Display mesh just created:

Note: do not exit LSPP this model will be used for next step.

88

Blank Meshing
(method 3 Requires points/nodes, curves, or, surfaces)

89

Translate (make copy) a line:


4 3

Right click to blank out the BSpline Face

1 6

7
8 5 9

Pick this line created as Source Entity


2

Line translated

90

Meshing by two line:


3 4

Pick these two lines

2 5

6 7

Mesh created

91

Workshop 4
Tool mesh Check
Summary: Check and merge duplicate nodes, tolerance 0.05mm good for most cases; 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 work needed for tool mesh if LSPP tool mesher is used.

92

Open keyword file:


1

2
3

Directory: workshop 4

93

Duplicate nodes check:


3

Tool mesh normal check:


Normal orientations: blank normal up, upper tools normal down, lower tools normal up;

4 5

1 2 6 5

pick the part, more details next page

Note: no duplicated nodes in this model

94

Tool mesh normal check:

Pick the part. Wire frame mode: vector display in wireframe mode.
4

Pick the part. Shaded mode: a color consistent with PID color indicates normal going up.

A color that is different from the PID color indicates normal going down.

Wireframe mode for vector display; Shaded element mode for color display;

95

Tool mesh normal reverse by part:

Pick any element

96

Tool mesh normal Auto Reverse reverse a part normal based on one seed element normal

3 7 6 4

x 8 pick the same element 2

Pick any element

1 10

Note: auto rev. works within one part boundary

97

Tool mesh free edge check:


Toggle this switch to turn on/off free edge display
3

Make sure background color is black:

98

Jacobian Check:

check for zero or very small Jacobian, and save into a buffer for deletion
1

Read keyword file zeroJacobia_30632.k into LSPP and do the following check:

3 2

4 0.05

6 8

99

Jacobian Check: Contour display:


Element 30632 has all three nodes on a straight line

100

Jacobian Check: Identify element with ID:


2
3

Message indicate this is a triangular element


101

Jacobian Check: Delete bad elements from the buffer:


3 4

5 6 7

8 9

102

eZ-Setup for Metal Forming

103

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 postprocessing of metal forming results

104

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;

105

Current Capability (Cont)


Automatic recognition of ELFORM and NIP from incoming 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
106

Installation & File Structure


First installation: fully QAed metal forming version:
ftp://ftp.lstc.com/outgoing/lsprepost/4.0/Metalforming/LS-PrePost-4.0-X64_setup.exe

Updates can be made by directly replacing these files:

107

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
Opening a DYNAIN file (forming result of sheet blank)

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. 108

Metal Forming Application


Keyboard shortcut: Ctrl q

Metal Forming Graphics User Interface (GUI) is designed to ease the simulation set up and inputs in LS-DYNA.

Easy Setup General Setup

109

Metal Forming Toolbar

Metal Forming Pre

Metal Forming Post

110

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

Note: current version does not support the use of the same process twice.

111

Metal Forming Die definition


Pick a part Import a part Mesh generation

112

Metal Forming Binder definition


Pick a part Import a part Mesh generation Offset from Die Travel limitation

113

Metal Forming Punch definition


Pick a part Import a part Mesh generation Offset from Die

114

Metal Forming Blank definition


Pick a part Import a part Blank Mesher Translate Symmetry condition Adaptive Box Define

Support Tailor welded Blank Material Thickness

115

Metal Forming DrawBead definition


Draw bead generator Import IGES curve Draw bead project Draw bead modify

Full lock force calculate

116

Metal Forming Control option


(Gravity Loading)

Blank Pre-bending

117

Metal Forming Control option


(Forming)

For early feasibility For formability For spring back User define parameters

Allow additional pad Kinematics simulation

118

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

119

Metal Forming Control option


(Spring back)

Constrained Inertia Relief

Pick node Pick Location Enter coordinate

120

Metal Forming Control option


(Flanging)

Pre-adaptive along curve Contact offset Multiple flanging steels

121

Metal Forming Control option


(Tipping)

Define tipping center Translation Rotation along an axis

122

Metal Forming Job submit


File folder browse Subdirectory (option) Input file name

Case files for multiple processes.

123

Workshop 5
A flanging process set up with multiple flanging steels moving in local directions

124

1 2 5 8 3 6

Directory: Workshop 5 4 7, use import offset 10

11 12

125

3 5

126

2 Pick blank to define, right click to return 1

Blinking yellow prompting for blank definition; turns green when it is defined.

3 0.7 Click this button if your material file is in the current working directory.

5
6

127

Selective mass scaling option 3 Select these curves to define mesh pre-adapt. Mesh Pre-adapt option Three computing options to balance speed and accuracy. Show lists detailed pre-set default variables, changeable by users.

1 2

0.9

5 Optional tool kinematics simulation

128

Pick post to define, right click to return

Blinking yellow prompting for flanging post definition; turns green when it is defined.

129

2 Pick pad to define, right click to return

Blinking yellow prompting for pad definition; turns green when it is defined.

Optional force on pad

130

Pick this flanging steel to define, right click to return

Blinking yellow prompting for flanging steel definition; turns green when it is defined.

3 - details next page

131

Click to add an extra flanging steel. Pick two END points of the line to define the flanging steel moving direction Blinking yellow prompting for flanging direction definition; turns green when it is defined.

From

2
1

3 To

Default option: geometric points; other options as shown

132

Pick this flanging steel to define, right click to return

From 4

5
To

Repeat the process to define Flg3 and Flg4


6

133

All green all defined; Next to output.

134

Output LS-DYNA input file eZ-Setup complete.

2 Key in file name as: sim.dyn

135

Save project file (overwrite existing project file):


1

2 3

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.
136

METHOD #1
2 3

3 1

9 4 5 6

Disadvantage: Cant use LSPP when running LS-DYNA

137

METHOD #2
Running LS-DYNA in windows with a command file:
R6s.cmd use edit to add the following command; double click the file to execute the LS-DYNA solver run.

Use: single precision for this 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

C:\LSDYNA\program\ls971_s_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=200M

Beginning of simulation

End of simulation

138

Processing Results
Open d3plot files from your running directory Animate the flanging process

1 2 3

6 5

139

Processing Results
2

Plot thinning/thickness Change contour range

1 7

140

Workshop 6
A process of gravity, draw, trimming, tipping, flanging and springback set up

141

1 2 5 8 3

Directory: Workshop 6 4 7 10

11 12

142

Define the following process:

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. 3

143

left click to pick the die, right click to return

144

Left click to pick the binder, right click to return

145

Left click to pick the punch, right click to return

146

Left click to pick the blank, right click to return

Define material/thickness

3 5 6

147

6 Left click to pick BOTH curves to define draw beads; right click to return.

Input tensile strength in MPa (default is for mild steel) 3 4

1 7 8

148

Picked curves automatically projected to binder.

Default lockage: 50%

Modify % lockage (next screen) Default lockage: 50%.

1 next screen

149

Bead lock % modification You can pick bead here directly 4

3 pick here or pick directly on the bead 2

5 6 pick here or pick directly on the bead

You can pick bead here directly 8 9

150

Save project file (overwrite existing project file):


1

2 3

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.
151

Optional pre-bending for air draw (not for toggle draw)

152

Three computing levels to balance speed and accuracy.

Optional selective mass scaling for inertia effect reduction.

Show/modify tool speeds, etc. (details next page)

Optional upper pad (for air draw)

Optional tool kinematics simulation.

153

Additional control on accuracy/speeds:

154

4 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

2 Turns green when defined. Default adaptive mesh for trimming Default element checking/fixing.

Define vector

More options to define vector.

155

For Information Only: merge curves into a single ENCLOSED curve (loop) requited for 3D trimming:
5 pick curves 1 3 4

Note: 2-D trimming can have multiple curves forming a ENCLOSED loop .

156

157

Selective mass scaling option to reduce inertia effect (not for implicit option)

Three computing options to balance speed and accuracy.

Optional tool kinematics simulation.

158

2 Left pick post to define, right click to return

Blinking yellow prompting for flanging post definition; turns green when it is defined.

159

Left pick pad to define, right click to return

Blinking yellow prompting for pad definition; turns green when it is defined.

Optional force on pad

160

Left click to pick flanging steel to define, right click to return

Blinking yellow prompting for flanging steel definition; turns green when it is defined.

3 follow next page

161

5 4

Pick the two END points along this line to define the flanging steel moving direction

Default option: geometric points; other options as shown

162

Constraint-free springback

163

Output LS-DYNA input file eZ-Setup complete.

2 Key in file name as: sim.dyn

164

Save project file (overwrite existing project file):


1

2 3

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.
165

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

166

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

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.

C:\LSDYNA\program\ls971_d_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=200M

Use: double precision for this run

167

Gravity complete case5.d3plot

Forming complete case10.d3plot

Trimming complete case15.d3plot

Tipping complete case20.d3plot

Flanging complete case25.d3plot

Springback complete case30.d3plot


168

Processing Results
Open the following d3plot files in LSPP, one after another: case5.d3plot case10.d3plot case15.d3plot case20.d3plot case25.d3plot case30.d3plot Select case10 (forming) as shown:
3 1

Animate punch contact Plot thinning/thickness for forming 169

Processing Results
Select case15 (trimming) as shown:

Plot thinning/thickness for trimming

170

Processing Results
Select case20 (tipping) as shown:

Plot thinning/thickness for tipping

171

Processing Results
Select case25 (flanging) as shown:

Animate flanging action Plot thinning/thickness for flanging

172

Processing Results
Select case30 (springback) as shown:

Animate springback Plot dZ and resultant Z (next page)

173

Plot springback amount in Z


2

Change contour range (optional)


4

174

Workshop 7
TWB Forming + Springback (constrained)

175

1 2 3

Directory: Workshop 7 4

176

Define process:

Hit next to define die, binder, punch. 177

Define blank1:

Pick the red piece as blank1

Use BH210.k

178

Define blank2:

Define blank2

Use BH210.k

179

Check for and delete existing boundary conditions:


2 4

5 6

180

Redefine symmetric boundary conditions:


1

Pick on this edge of any element along the symmetry


3 4

181

Define springback constraints:

Select these before picking node/location

skip draw bead

1 2 2 3

Always pick locations on final tool position (where blank is in contact)

182

Define Forming control:

Not much to do here

183

Output simulation input files:

Key in file name as: sim.dyn

184

Save project file (overwrite existing project file):


1

2 3

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.
185

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

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.

C:\LSDYNA\program\ls971_d_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=800M

Use: double precision for this run

186

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 187

Processing Results
Select case10 (springback) as shown:

Animate springback Plot dZ and resultant Z (next page)

188

Plot springback amount in Z


2

Change contour range (optional)


4

189

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.
190

Workshop 8
Post-Processing

191

Animate punch contact/part breakdowns:


1 2

6 workshop8 3

192

Create a movie (AVI):

2 1

193

Cut a section plane:


4

Pick this node

3 2

194

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.

1 3

195

Plot Thickness/thinning contour:


2 6

7 5

196

Set contour range for thickness/thinning contour:


Thickness range: Thinning range:

197

Save a JPG file for the screen display:


1

3 4

198

Plot thickness distribution along a section:


2

Pick a node close to this node

199

Plot thickness distribution along a section:

200

Changing the thickness of a section plot in contour:

201

Identify detailed results in value:


5

Left click and drag over the part for live updates.
4

202

Display trim lines on post-processing results, follow square box 1, 2, 3 in sequence:


1 1 - Import IGES file: newtrim1.iges 2 - Translate curves: 3 3 - Change curve color: 4 red color box means current pick 1 right click 2 6 3 5 1

8 multiple times

203

Plot mean stress (pressure) contour (wrinkles):


3

4
2

204

Set contour range for mean stress:

negative tensile 2 positive yield

205

Similarly, plot In-plane major/minor strain contour:

206

Plot FLD:

If use File option, open fld_true.fld

2 6 need to select

7 1

0.2 8

207

Plot In-plane major/minor strain vectors:

Pick location

1 2

208

Measure blank edge draw-ins: Write closing blank meshing as a keyword file.

5 3

Write file as S6.k

6 2

209

Measure blank edge draw-ins: Write formed blank mesh as keyword file

Write file as S17.k

210

Measure blank edge draw-ins: Open new session of LSPP, and import s6.k and s17.k, use Import Offset for the 2nd file.

211

Measure blank edge draw-ins: Translate binder closed blank mesh down.

7 pick part

4 5 129 2

212

Measure blank edge draw-ins: Measure distance between edge nodes.

4 pick edge nodes in pairs

213

Alternatively, blank edge curves can be created using d3plot files:

6 pick the blank

214

Create blank edge curves for state #6:


2 pick the blank

215

Turn off all FEM parts:

216

Translate state #6 blank edge down 141mm:


4 pick this curve

6 7

129

217

Measure edge distance:

4 pick edge points 3 1

218

Plot tool tonnage:

Open rcforc file in Workshop 8/Forming In MPP, the file name is binout0000

3 5

1 Note: 1 English ton=8900 Newton

219

Plot sheet blank mass increase:


4

3 5

2 6 1 Note: total weight of the model is used to calculate the %.

220

Other Post-Processing Details

221

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)

222

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 History XYPlot ASCII Binout FLD Measure Section > Force
223

Interfaces that use these plot functions...


Plot Window

Title modify main, axis, legend, and curve titles

224

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
225

Command File and Macros

226

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

227

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
228

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

229

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

230

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)

231

Configuration File

232

Configuration File (lsppconf)

LS-PrePost searches for this file in these directories in the following order... LSTC_FILE directory Users 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

233

Workshop 9 (optional)
eZ-Setup From IGES Surfaces NUMISHEET2008 B-pillar

234

NUMISHEET2008 B-pillar
235

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.

236

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. Simulation involving gravity, Save a project file, and output simulation file. springback, static implicit must Run simulation using a command file (METHOD 2) use double precision (DP) solver Try removing gravity from the process, just run the DP solver slower than SP solver 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. 237

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

238

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 239

Pre-bending for Gravity

Allow for pre-bending of blank prior to loading onto the tools

concave shape here

Pre-bending with R=10000.0mm using this keyword (1st state of D3plots)


95mm Gravity loaded blank without prebending Blank sags in the die cavity (concave shape)

60mm Gravity loaded shape (last state of D3plots) Convex shape blank achieved and binder closing distance reduced

240