ls-prepost forming aug1st
TRANSCRIPT
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Metal Forming In LS-PrePost 4.0
LSPP Metal Forming Development Team July 30, 2012
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Table of Contents
SECTION WORKSHOPS
LS-PrePost Overview -
General/Nodes/Element/Tool and blank
meshing/Tool mesh checkWorkshops 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)
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LS-PrePost Overview
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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)
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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 Grouphttp://groups.google.com/group/ls-prepost
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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
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GUI Layout
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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
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Input/Output
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include:
dynain file
commandsession file(.cfile)
LSPPdatabase file
LS-DYNAresults file(d3plot)
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Job Scheduler
Details later
Must install using LSPP_setup.exe
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Misc. Menu
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View Menu
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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, SurfaceMorphing)
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, ReplaceFace, Stitch Faces, Trim Transform, Copy Entity, Management,
Heal, Topology Simplify, Measure)
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Same menu system
with ICONs is at right
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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, SPHGeneration)
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)
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Same menu system
with ICONs is at right
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Application Menu
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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
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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
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Bottom Toolbar
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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 pixelMesh 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 shownRight-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)
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FEM General Selection
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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 bufferLoad 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
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Workshop 1General Operations
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O k d fil d t t d l
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1
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Directory: Workshop 1
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Rotate model using Shift
with left mouse button
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Open keyword file and rotate model:
A t C t
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2020
or Ctrl a1
Auto Center:
Di l i t d d i
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Display in standard views:
Display in different modes and background colors
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Display in different modes and background colors:
Select part for display: 2
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Select part for display:
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2
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Shift with left click for
multiple selection
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Identify nodes/elements:
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Identify nodes/elements:
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left click to pick nodes
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left click to pick elements
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Identify material direction for anisotropic material:
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left click to pick elements
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23
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Identify material direction for anisotropic material:
Note: axis “A “is rolling direction, see next page
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Anisotropic material (*MAT 036):
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Material axes
options, see below.
Vector components ‘a’ for
AOPT=2.0, see below
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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.
Anisotropic material (*MAT_036):
Open in WordPad the file “tools_with_blank.k”, in directory: Workshop 1
Element/model blanking (for display): 2
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Element/model blanking (for display):
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2
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Element/model blanking (for display):
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Element/model blanking (for display):
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4
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Left click, hold and drag a box to
cover some portion of the die
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7
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Element/model blanking (for display):
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Left click to pick an
element on the binder
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Element/model blanking (for display):
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Find a specific element or node:
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Find a specific element or node:
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Find a specific element or node:
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Find a specific element or node:
Left click, hold and drag a box to
zoom in; then free rotate model
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1
2
3
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Modify part transparency:
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Modify part transparency:
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2
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Modify part transparency:
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Left click to pick the top of the
model to make upper transparent
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Modify part transparency:
Left click to pick again to
go back to normal color
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Reset transparency
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12Change part color:
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Left click to pick the part to
change color
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12Change part color:
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Workshop 2Mesh editing
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Open keyword file:
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p y
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2
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Directory: workshop 2
Merge duplicate nodes:
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g p
Merge duplicate nodes:
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g p
Replace nodes:6
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p
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1
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Left click, hold and drag these boxes to include each
node pairs whose position are to be replaced
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Create a triangular element:
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2
Left click to pick the part5
Left click to pick three
nodes to form a triangle,
right click for Node 4.
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g
Align nodes:
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Left click, hold and drag
to zoom in this area
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4
5
6
Left click to pick
these two nodes
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Align nodes:
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Left clicks to form a polygonbox, right click to finish
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Split elements:
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Left clicks to form a polygon
box, right click to finish
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Fill a hole:
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Left clicks on a
boundary node
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Right click on
“2 LSHELL2”
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Auto filling all holes:
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Save keyword file:
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Open keyword file:
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Directory: workshop 4
Detach some elements:
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Pick an element here
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3
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Check part separation:
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free edge display
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1
3
p p
toggle switch
Change PID:
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Pick an element here
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g
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Change PID again:
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g g
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3 4
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Open keyword file:
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Directory: workshop 2
Element Tools → Offset (Tooling surface normal offset)
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Element Tools → Offset (Tooling surface normal offset)
Element normals must be aligned before
offsetting
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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.
Check part normals:
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1
2
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Pick on part
Offset with Advanced option on:
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55Offset result with “Advanced” option on
“offset –” is
opposite of normals
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Pick on part
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Offset with Advanced option off:
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1
Pick on part2
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Offset result with “Advanced” option off
Translate (make copy) the flat area:
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Pick an element here
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Measure part distance (method 1):
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Pick these two
nodes
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3
2
4
Measure part distance (method 2):
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Pick these two
nodes
Alternatively: part
separation, and others
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2
3
4
3
Rotate a tool (make copy):
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Pick this node
as origin
Pick this part
as a source
Rotated part
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2
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8 9
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5
6
Make a mirror image of a tool:
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Pick this node as origin
Pick this part
as a source
Reflected part
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910
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6
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Make a projection of part of a tool:
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Select by ‘Polygon’ these
elements, right click to
finish the loop.
Elements selected
Elements projected
Pick this node as
location
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Scale (make copy) of a tool:
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Pick PID 2 as a
source
Scaled part 16
Pick this node as origin 1
2
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Workshop 3
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Mesh generation
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Import IGES file:
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Directory: Workshop 2
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N-line meshing/4-line meshing: 12
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2
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Left click to pick four curves
in the order shown
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Import IGES file:
1
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Directory: Workshop 2
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N-line meshing/Line sweep:
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Left click to pick
the square curve
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Left click to pick
this curve
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7
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Creating a circle:
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Left click to pick this point
as the center of the circle
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Creating a circle:
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Left click to pick this circle
Left click to pickthis curve
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Left click7
Left click8
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Import IGES file:1
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3
2
Directory: Workshop 3
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Meshing binder:
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2
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Left click to pick thebinder surface
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5 6
Meshing die:
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1
Left click to pick thebinder surface
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3
4 5
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Change meshing parameter for a finer mesh:
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Right click on
“2 LSHELL2”
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2
3
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5
7
8 9
For advance
feasibility
Compare tool meshes:
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78
30
0.2
0.05
10
For springback
20
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Workshop 4Blank Meshing
79
Open keyword file:1
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80
32
4
Directory: workshop 4
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Shape meshing/4N_shell:
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82
Pick nodes
More
options
Pick these four nodes
1
2
34
5
6
7 8
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Blank Meshing(method 2 – surface required)
83
Create two boundary lines:
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84
Pick these two nodes
two create a line
Pick these two nodes
two create a line
123
4
56
7
Create a planar surface:
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85
Pick the line
just created
Pick the line
just created
1
2
3
4
5
Blank meshing:
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86
Pick the surface
just created
1
23
4
5
6
7 8
Toggle geomtry display on/off:
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87
Toggle geometry
display on/off1
Display mesh just created:
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88Note: do not exit LSPP – this model will be used for next step.
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Translate (make copy) a line:
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90
Pick this line created as
‘Source Entity’
Right click to blank out
the BSpline Face
Line translated
1
2
4
3
5
6
7
8
9
Meshing by two line:
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91
Pick these two lines
Mesh created
1
2
3
5
6
7
4
8 9
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Workshop 4Tool mesh Check
92
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.
Open keyword file:1
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93
32
4
Directory: workshop 4
Duplicate nodes check: Tool mesh normal check:
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94
Normal orientations:
blank normal up, upper
tools normal down,
lower tools normal up;
1
2
3
4
5
6
1
2
3
Note: no duplicated nodes in this model
4pick the part, moredetails next page
5
Tool mesh normal check:
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95
Shaded element mode
for color display;
Wireframe mode for vector display;
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.
Pick the part. Wire frame
mode: vector display in
wireframe mode.
2
3
4
4
Tool mesh normal reverse by part:
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96
1
2
3
Pick any element
4
Tool mesh normal Auto Reverse – reverse a part normal based on one seed element normal
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97
1
2
3
6
Pick any element
7
8 – pick the
same element
x
9
10
4
Note: auto rev. works within one part boundary
5
Tool mesh free edge check:
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98
3
1
2
Toggle this switch to turn
on/off free edge display
4
5
Make sure background
color is black:
Jacobian Check: check for zero or very small Jacobian, and save into a buffer for deletion
Read keyword file ‘zeroJacobia_30632.k’ into LSPP and do the following check:
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99
1
2
3
4
0.055
6
7
8
Jacobian Check: Contour display:
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100
Element 30632 has all three nodes on a straight line
Jacobian Check: Identify element with ID:
2
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101
1
2
3
4
Message indicate this is a triangular element
3
Jacobian Check: Delete bad elements from the buffer:
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102
2
4
5
6 7
8
1
9
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eZ-Setup for Metal Forming
103
Development Objective
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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
104
Current Capability - eZ-Setup
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Guided GUI features:
Air and toggle draw, flanging;
Air draw with upper pad;
User-specifiable cushion travel;
One LS-DYNA run for typical process simulationcombination;
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 elementchecking/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 (Con’t)
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Automatic recognition of ELFORM and NIP from incoming dynain
file; User material library.
Three-levels of computing options in Forming for optimal balance ofspeed 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
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First installation: fully QA’ed 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
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108
Opening a DYNAIN file (forming
result of sheet blank)
108
g y
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
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Metal Forming Graphics User Interface(GUI) is designed to ease the simulation
set up and inputs in LS-DYNA.
Easy Setup
General Setup
109
Keyboard shortcut:
Ctrl q
109
Metal Forming → Toolbar
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110
Metal Forming Pre
Metal Forming Post
110
Metal Forming → eZ Setup
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Forming draw type
Air draw
Toggle draw
Support contact offset
Multiple forming
processes
Gravity
Forming
Trimming
Spring Back
Flanging
Closing (implicit) Tipping
111
Note: current version does not support
the use of the same process twice.
111
Metal Forming → Die definition
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Pick a part
Import a part
Mesh generation
112112
Metal Forming → Binder definition
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Pick a part
Import a part
Mesh generation
Offset from Die
Travel limitation
113113
Metal Forming → Punch definition
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Pick a part
Import a part
Mesh generation
Offset from Die
114114
Metal Forming → Blank definition
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Pick a part
Import a part
Blank Mesher
Translate
Symmetry condition
Adaptive Box Define
Support Tailor welded Blank
Material
Thickness
115115
Metal Forming → DrawBead definition
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Draw bead generator
Import IGES curve
Draw bead project
Draw bead modify
Full lock force calculate
116116
Metal Forming → Control option (Gravity Loading)
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( y g)
Blank Pre-bending
117117
Metal Forming → Control option (Forming)
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( g)
For early feasibility
For formability
For spring back
User define parameters
Allow additional pad
Kinematics simulation
118118
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Metal Forming → Control option (Spring back)
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( p g )
Constrained
Inertia Relief
Pick node
Pick Location
Enter coordinate
120120
Metal Forming → Control option (Flanging)
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g g
Pre-adaptive along curve
Contact offset
Multiple flanging steels
121121
Metal Forming → Control option (Tipping)
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Define tipping center
Translation
Rotation along an axis
122122
Metal Forming → Job submit
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File folder browse
Subdirectory (option)
Input file name
Case files for multiple
processes.
123123
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Workshop 5
A flanging process set up with multiple flanging steels moving
in local directions
124
3
1
5 6
2
8
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125
9
4
7, use “import offset” 10
Directory: Workshop 5
11
12
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1
23
4
5
6
126
Pick blank to define,
right click to return
1
2
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Blinking yellow prompting
for blank definition; turns
green when it is defined.
3
6
0.7 5
4
Click this button if your
material file is in the
current working directory.
127
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
Select these curves to
define mesh pre-adapt.
3
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Optional tool
kinematics simulation
12
5
0.9 4
128
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Blinking yellow prompting for
pad definition; turns green
when it is defined.
Pick pad to define,
right click to return
2
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Optional force on pad
1
3
130
Blinking yellow prompting for
flanging steel definition; turns
green when it is defined.
Pick this flanging steel to
define, right click to return
2
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1
131
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
Click to add an extra flanging steel.
5
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Default option:geometric points; other
options as shown
3
1
1324
From
To
2
Pick this flanging steel to
define, right click to return
2
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1
5
7
3
From
To
4
Repeat the process to
define Flg3 and Flg4
1336
8
All green – all defined; ‘Next’ to output.
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1
134
Output LS-DYNA input file – eZ-Setup complete.
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1
2
3
135
Key in file name as:
sim.dyn
1
Save project file (overwrite existing project file):
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Note: Project file is an important database file,
containing complete model information andeZ-Setup information. It can be reloaded back
into LSPP for changes in process or models.
136
23
2 3
METHOD #1
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13
4
5
6
7
8
9
Disadvantage: Can’t use LSPP
when running LS-DYNA 137
Running LS-DYNA in windows with a command file:
R6s.cmd
METHOD #2
Simulation involving gravity, springback,
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End of simulationBeginning of simulation
C:\LSDYNA\program\ls971_s_Dev_73895_winx64_p.exe i=sim.dyn ncpu=8 memory=200M
use ‘edit’ to add the following command;
double click the file to execute the LS-DYNA solver run.
138
static implicit must use double precision
(DP) solver
All other dynamic explicit simulation (forexample, draw or flanging) use SP solver
DP solver slower than SP solverUse: single precision for this run
Processing Results
Open d3plot files from your running directory
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Open d3plot files from your running directory Animate the flanging process
139
1
2 3
46 7
5
89
Processing Results
Plot thinning/thickness
2
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Plot thinning/thickness Change contour range
140
1
4
34
5
6
7
8
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Workshop 6
A process of gravity, draw, trimming, tipping, flanging and
springback set up
141
3
1
2
5
8
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142
6
11
12
Directory: Workshop 6
4
10
7
9
Define the following process:
Gravity
Forming
Trimming
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1
2
3
143
Trimming
Tipping
FlangingSpringback
Append to the last
Click on one already “selected
process” in the left box, click on
the “available process”, thenclick on this button, it will insert
the latter in front of the former.
left click to pick the die,
right click to return
2
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1
3
144
Left click to pick the binder,
right click to return
2
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1
3
145
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1
Left click to pick the blank,
right click to return
2
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Define
material/thickness
1
3
5
6
147
4
Left click to pick BOTH curves to define
draw beads; right click to return.
6
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148
5
1
2
3 4
9
7
8
Input tensile strength
in MPa (default is for
mild steel)
Picked curves automatically
projected to binder.
Default lockage: 50%
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149
1
9
next screen
Modify % lockage (next
screen)
Default lockage: 50%.
Bead lock %
modification2You can pick bead
here directly
3
3 – pick here orpick directly onthe bead
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150
4
5
76 – pick here orpick directly on
the bead
8
You can pick bead
here directly
6
9
1
Save project file (overwrite existing project file):
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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
23
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Three computing levels tobalance speed and accuracy.
Optional selective mass scaling – for inertia effect reduction.
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Optional tool kinematics simulation.
Show/modify tool
speeds, etc.
(details next page)
Optional upper
pad (for air draw)
1
153
Additional control on accuracy/speeds:
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154
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.
2
4
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1 3
5
6
155
More options to
define vector.
For Information Only: merge curves into a single ENCLOSED curve (loop) – requited for 3-D trimming:
1
5 – pick curves
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1
2
Note: 2-D trimming can have multiple curves
forming a ENCLOSED loop .
3
4
156
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2
3
157
1
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Blinking yellow prompting for
flanging post definition; turns
green when it is defined.
Left pick post to define,
right click to return
2
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1
3
159
Blinking yellow prompting for
pad definition; turns green
when it is defined.
Left pick pad to define,
right click to return
2
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Optional force on pad
1
3
160
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
2
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1
3 – follownext page
161
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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
162
3
7
Constraint-free springback
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1
2
163
Output LS-DYNA input file – eZ-Setup complete.
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Key in file name as:
sim.dyn
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Save project file (overwrite existing project file):
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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.
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LS-DYNA input files for running the process simulation:
Control files copied from Lspp_forming
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Primary simulation file to run LS-DYNA – linking all processes together
Individual single process simulation input file – “.k” file
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Processing Results
Select case15 (trimming) as shown:
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Plot thinning/thickness for trimming
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Processing Results
Select case20 (tipping) as shown:
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Plot thinning/thickness for tipping
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Processing Results
Select case30 (springback) as shown:
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Animate springback Plot dZ and resultant Z (next page)
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Change contour range (optional)Plot springback amount in Z2
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3
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Workshop 7
TWB Forming + Springback (constrained)
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Directory: Workshop 7
Define process:
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Hit “next” to define die,
binder, punch.
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Pick the red piece as “blank1”
Define blank1:
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Pick the red piece as blank1
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Use BH210.k
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Redefine symmetric boundary conditions:
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Pick on this edge of any
element along the symmetry
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skip “draw bead”
Select these before
picking
node/location
Define springback constraints:
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node/location
Always pick locations on
final tool position (whereblank is in contact)
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Not much to do here
Define Forming control:
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Output simulation input files:
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Key in file name as:
sim.dyn
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1
Save project file (overwrite existing project file):
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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.
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3
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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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.
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Use: double precision for this run
Processing Results
Open the following d3plot files in LSPP, one after another: case5.d3plot case10 d3plot
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case10.d3plot Select case5 (forming) as shown:
Animate punch contact Plot THINNING for forming
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Processing Results
Select case10 (springback) as shown:
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Animate springback Plot dZ and resultant Z (next page)
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Future Work - eZ-Setup
Unlimited, flexible processes allows for progressive dies simulationin one setup and one run.
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p 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.
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Animate punch contact/part breakdowns:
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workshop8
Create a movie (AVI):
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Cut a section plane:
2
3Pick this node
4
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Cut multiple planes:
Save multiple cut sections
in keyword format:
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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.
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Set contour range for thickness/thinning contour:
Thickness range: Thinning range:
1
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Save a JPG file for the screen display:
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Plot thickness distribution along a section:
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Pick a node close
to this node
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Changing the thickness of a section plot in contour:
2
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Display trim lines on post-processing results, follow square box 1, 2, 3 in sequence:
2 - Translate curves:
3
3 - Change curve color:
1 - Import IGES file: newtrim1.iges1
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right click
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2
4 – red color boxmeans current pick
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6
8 – multiple
times
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Set contour range for mean stress:
1
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negative tensile
positive yield2
3
Similarly, plot In-plane major/minor strain contour:
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Measure blank edge draw-ins:
Write closing blank meshing as a keyword file.
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67Write file as S6.k
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Measure blank edge draw-ins:
Write formed blank mesh as keyword file4
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Measure blank edge draw-ins:
Open new session of LSPP, and import s6.k and s17.k, use “Import Offset’ for the 2nd file.
1 2
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Measure blank edge draw-ins:
Translate binder closed blank mesh down.
37 – pick part
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Measure blank edge draw-ins:
Measure distance between edge nodes.
34 – pick edge
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3nodes in pairs
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Create blank edge curves for state #6:
2 – pick the blank
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Turn off all FEM parts:
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Translate state #6 blank edge down 141mm:
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4 – pick this curve
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Plot tool tonnage: Open ‘ rcforc ’ file in Workshop 8/Forming
In MPP, the file name is ‘binout0000’
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Note: 1 English ton=8900 Newton
Plot sheet blank mass increase:
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Note: total weight of the model is used to calculate the %.
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Post → History Purpose: plot time history data (from d3plots)
Global – energies and kinematic data for full model
Part – energies and kinematic data for parts
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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)
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Post → History (continued...)
Standard plotting options...
• Plot – plot selected value in current Plot Window
• New – plot selected value in new Plot Window
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• 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
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Plot Window Title – modify main, axis, legend, and curve titles
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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
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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
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Command File and Macros
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Command File (continued...)
Parameters can be used in command file
• Parameter definition can be numbers or strings
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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
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Misc. → Macro Interface Purpose: load and execute macros
Macros allow multiple commands to be grouped and
executed as often as desired
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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
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Misc. → Macro Interface (continued...) Macro example...
• *macro begin plot_matsum
ascii matsum plot 2 &matid
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raisewin
xyplot 1 savefile curve_file C:\temp\&fname 1 all
• *macro end
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Function Keys F1 launches Function Key interface shown below (shows
layout of the function keys)
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Except for F1 and F10, all other function keys can beprogrammed 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)
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Configuration File
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Configuration File (lsppconf) LS-PrePost searches for this file in these directories in the following
order...
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• 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 willbe 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
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Workshop 9 (optional)
eZ-Setup From IGES Surfaces – NUMISHEET2008 B-pillar
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NUMISHEET2008 B-pillar
Procedures Import IGES files:
Numisheet08-BM03-Blank.igs
Numisheet08-BM03-Blankholder.igs
Numisheet08-BM03-Dies.igs
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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.
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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.
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In “Control-gravity”, check for gravity prebend along Y-axis. In “Control-forming”, changenothing.
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.
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This new feature allows for SLIGHT AMOUNT of pre-bending of blank in eitherconvex, or concave shape prior to loading onto the tools.
Done at the same time before the gravity loading is started
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Pre-bending for Gravity Allow for pre-bending of blank prior to loading onto the tools
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Bending axis
Sheet blank
normal
direction
Negative “R” means center of bending is on the opposite side of the positiveblank normal
Initial model set up
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Pre-bending for Gravity Allow for pre-bending of blank prior to loading onto the tools
concave shape here