mar120, workshop 7, december 2001 workshop 7 metal forming a paper clip workshop 7 metal forming a...

Mar120, Workshop 7, December 2001

WORKSHOP 7

METAL FORMING A PAPER CLIP

WORKSHOP 7

METAL FORMING A PAPER CLIP

Mar120, Workshop 10, March 2001 WS 7-2Mar120, Workshop 7, December 2001


Model Description

This workshop illustrates a common metal-forming process by simulating the shaping of the familiar and commonplace paper clip. There are many way of producing the piece. This exercise makes use of simple, straightforward movements of rigid bodies.


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

surfaces charged with shaping a malleable workpiece.

Required No supporting file is required for this problem.


Suggested Exercise Steps1. Create the workpiece.2. Create well appropriated rigid surfaces.3. Fix the inner end of the workpiece.


CREATE NEW DATABASE

Open a new database. Name it Paper_clip.db

a. File: New

b. Enter Paper_clip.db as the file name.

c. Click OK.d. Select MSC.Marc as the

Analysis Code.e. Click OK.

a

Paper_clip b

MSC.Marc d

e

10.0

c

Structural


Step 1. Geometry: Create / Surface / XYZ

<6.4, .035, 0>

[-4.9, .09375, 0]

a

b

c

Use the XYZ method to create a surface

a. Geometry: Create / Surface / XYZ.

b. Enter <6.4, .035, 0> as Vector Coordinates List.

c. Enter [-4.9, .09375, 0] as Origin Coordinates List.


[0.49125, 0, 0]

991

a

b

d

c

e

Point ID List Point Coordinates List991 [0.49125, 0, 0]992 [1.69125, 0.03125, 0]993 [0.191125, 0.48625, 0]

1001 [0.2705, 0.22075, 0]1002 [0.2705, -0.22075, 0]1003 [1.94325, -0.22075, 0]1004 [1.94325, 0.28325, 0]1005 [-0.092125, 0.28325, 0]1006 [-0.092125, -0.28325, 0]

f

Use the XYZ method to create center points.

a. Geometry: Create / Point / XYZ.

b. Enter 991 for Point ID List.c. Uncheck Auto Execute.d. Enter [0.49125, 0, 0] for Point

Coordinates List.e. Click Apply.f. Repeat steps a-e for eight

additional points as shown in the table:

Step 2. Geometry: Create / Point / XYZ

The Point Id MUST match with the Point Coordinates above. All the Point Ids are for later on use. Make sure you have EXACTLY the same Id numbers and coordinate numbers


[1.69125, 0.03125, 0]

992

a

b

d

c

e

[0.191125, 0.48625, 0]

993

a

b

d

c

e

[0.2705, 0.22075, 0]

1001

a

b

d

c

e

[0.2705, -0.22075, 0]

1002

a

b

d

c

e

[1.94325, -0.22075, 0]

1003

a

b

d

c

e

[1.94325, 0.28325, 0]

1004

a

b

d

c

e

[-0.092125, 0.28325, 0]

1005

a

b

d

c

e

[-0.09215, -0.28325, 0]

1006

a

b

d

c

e


g

h

By turning on the point & curve label control, it will become easier to identify each point and curve when selecting them. You should be able to see the points you have just created along with their point labels.

g. Click Label Control.h. Select both the Point and

Curve options.


Curve Radius Point ID1 0.09375 Point 9912 0.125 Point 9923 0.15625 Point 9934 0.09 Point 10015 0.09 Point 10026 0.09 Point 10037 0.09 Point 10048 0.09 Point 10059 0.09 Point 1006

b

Point 991

0.09375

1

a

c

d

f

e

Create the curvesa. Geometry: Create /

Curve / 2D Circle.b. Select Any point icon.c. Enter 0.09375 for Circle

Radius.d. Click in the Center Point

List panel.e. Select Point 991.f. Click Apply.g. Repeat steps c-f for eight

additional curves as shown in the table:

Step 3. Geometry: Create / Curve / 2D Circle


Point 1003

0.09

6

a

c

d

f

Point 1004

0.09

7

a

c

d

f

Point 1005

0.09

8

a

c

d

f

Point 1006

0.09

9

a

c

d

f

Point 992

0.125

2

a

c

d

f

Point 993

0.15625

3

a

c

d

f

Point 1001

0.09

4

a

c

d

f

Point 1002

0.09

5

a

c

d

f


Step 4. Elements: Create / Mesh / Surface

Create the mesh

a. Elements: Create / Mesh / Surface.

b. Select Isomesh for Mesher.

c. Click in Surface List panel.

d. Use Surface or Solid Face picking icon.

e. Select the Surface 1.

f. Uncheck Automatic Calculation.

g. Enter 0.02 for Value.

h. Click Apply.

d

a

b

c

0.02 g

h

Surface 1

f

Clicking Apply creates the mesh.

e


Step 5. Loads/BCs: Create / Contact / Element Uniform

Create contact deformable bodya. Load/BCs: Create / Contact /

Element Uniform.b. Select Deformable Body for

Option.c. Enter touchy for New Set

Name.d. Select 2D for Target Element

Type.e. Click Select Application

Region….f. Select Geometry for

Geometry Filter.g. Click in Select Surfaces

panel.h. Select Surface or face icon.i. Select the surface.j. Click Add.k. Click OK.l. Click Apply.

h

i

Surface 1

Surface 1

f

g

j

ktouchy

a

b

c

d

e

l


Step 6. Loads/BCs: Create / Contact / Element Uniform

Create contact rigid body

a. Create / Contact / Element Uniform.

b. Select Rigid Body for Option.

c. Enter D1 for New Set Name.

d. Select 1D for Target Element Type.

e. Click Input Data….

f. Select Position for Motion Control.

g. Enter <0, 0, 0> for Displacement (vector).

h. Click OK.

i. Click Select Application Region….

<0, 0, 0>

f

g

h

D1

a

b

c

d

e

i


j. Select Geometry for Geometry Filter.

k. Click in Select Curves panel.

l. Select Surface or Face icon.

m. Select Curve 1.

n. Click Add.

o. Click OK.

p. Click -Apply-.

q. Repeat steps a-p for eight additional curves as shown in the table:

Curve New Set Name Disp. Vactor1 D1 <0, 0, 0>2 D2 <0, 0, 0>3 D3 <0, -0.48625, 0>4 act1 <0, -0.4415, 0>5 act2 <1.67275, 0, 0>6 act3 <0, 0.504, 0>7 act4 <-2.035375, 0, 0>8 act5 <0, -0.5665, 0>9 act6 <2, 0, 0>

l

m

j

k

n

o D1

p


Step 7. Fields: Create / Material / Tabular Input

Create a field for the elasto-plastic material data.

a. Fields: Create / Material Property / Tabular Input.

b. Enter workhard for Field Name.

c. Uncheck Temperature.

d. Select Strain (e).

e. Click Input Data.

f. Enter Strain field as given by the table:

g. Click OK.

h. Click Apply.

e Value0 1E+5

0.2 2E+50.3 3E+50.6 4E+51 5E+5

g

workhard

a

b

cd

e

h

The 1D Material Scalar Table Data form needs to be filled out as shown in Table 1. To fill in the table, click on the cell you wish to edit, enter the value in the Input Scalar Data box and and press Return. The table will tab down automatically.

f


Step 8. Materials: Create / Isotropic / Manual Input

Create the material aluminum_1100, with elastic and plastic properties

a. Materials: Create / Isotropic / Manual Input.

b. Enter Steel for Material Name.

c. Click Input Properties….

d. Select Elastic for Conductivity Model.

e. Enter 3E7 for Elastic Modulus.

f. Enter 0.3 for Poisson’s Ratio.

g. Click OK.

h. Click Apply.

3E7

.3

d

ef

g

Steel

a

b

c

h

The material constituitive model used in this analysis is an Incompressible Mooney Rivlin hyperelastic formulation. Make sure that the analysis code is set for MSC.Marc under Preferences- Analysis.


i. Click Input Properties….

j. Select Plastic for Constitutive Model.

k. Select Isotropic for Hardening Rule.

l. Click in Stress vs. Plastic Strain panel.

m. Select workhard in Temperature/Strain/Strain Rate Dependent Fields window.

n. Click OK.

o. Click Apply.

Steel

Steel

i

j

k

l workhard

workhard m


Step 9. Properties: Create / 2D / 2D Solid

Define the element properties

a. Properties: Create / 2D / 2D Solid.

b. Enter workpiece for Property Set Name.

c. Select Plane Stress for Option(s).

d. Select Standard Formulation.

e. Click Input Properties.

f. Click in Material Name panel.

g. Select Steel from Material Property Sets.

h. Enter 0.035 for Thickness.

i. Click OK.

workpiece

a

b

cd

e

Steel

.035

Steel

f

g

h


Surface 1

workpiece

workpiece

Surface 1

j

l

m

j. Click in Select Members panel.

k. Select Surface 1.

l. Click Add.

m. Click Apply.

k


Step 10. Loads/BCs: Create / Displacement / Nodal

Create the Boundary Condition to fix the right edge

a. Loads/BCs: Create / Displacement / Nodal.

b. Enter End for New Set Name.

c. Click Input Data….

d. Enter <0, 0, > for Translations.

e. Click OK.

f. Click Select Application Region….

<0, 0, >

1.

Coord 0

d

e

End

a

b

c

f


g. Select Geometry for Geometry Filter.

h. Click in Select Geometry Entities panel.

i. Select Curve or Edge icon.

j. Select the right edge of surface.

k. Click Add.

l. Click OK.

m. Click Apply.

i

j

Surface 1.3

Surface 1.3

g

h

k

l

End

m


Step 11. Load Case: Create

Create load cases

a. Load Cases: Create.

b. Select Default in Existing Load Cases window.

c. Enter One as Load Case Name.

d. Click in Scale Factor for act2.

e. Enter 0 for Input Scale Factor.

f. Repeat steps d-e for act3-act6.

g. Click OK.

h. Click Apply.

1

1

1

1

1

1

0

0

0

0

0

d

e

g

One

a

b

c

h


i. Repeat steps a-h for five additional load cases named Two, Three, Four, Five, and Six. Each time select the previous load case and enter the new name as Load Case Name. Also, change the scale factor of the act2-act6 Load/BC corresponding to the new load case to 1, leaving the other Scale Factors unchanged (for example, case Two act1-act2 Scale Factors equal 1, act3-act6 Scale Factors equal 0).

Load Case Two

Load Case Three

1

1

1

1

1

1

1

1

0

0

0

1

1

1

1

1

1

1

0

0

0

0


Load Case Four Load Case Five

1

1

1

1

1

1

1

1

1

1

0

1

1

1

1

1

1

1

1

1

0

0

Load Case Six

1

1

1

1

1

1

1

1

1

1

1


Step 12. Analysis: Analyze / Entire Model / Full Run

Set up and launch the analysis

a. Analysis: Analyze / Entire Model / Full Run.

b. Enter Pclip_job1 as Job Name.

c. Click Translation Parameters….

d. Click Solver Options….

e. Select Non-Positive Definite.

f. Click OK.

g. Click OK.

h. Click Load Step Creation….

e

f

Pclip_job1

Full Run

Entire Model

a

b

c

h

d

g


i. Enter S1 for Job Step Name.

j. Click Select Load Case.

k. Select load case one.

l. Click OK.

m. Click Solution Parameters…. k

l

S1 i

j

m


n. Click Load Increment Parameters….

o. Select Adaptive for Increment Type.

p. Select None for Arclength Method.

q. Enter 33 for Number of Cutbacks.

r. Enter 0.025 for Trial Time Step Size.

s. Click OK.

t. Click Iteration Parameters….

u. Enter 50 for Max # of Iterations per Increment.

v. Enter 5 for Desired # of Iterations per Increment.

w. Click OK.

n

t

50

5

uv

w

s

o

p

.025

1.2

r33 q


x

aa

x. Click Contact Table.

y. Remove all T’s in the table except for rows 2-D1 and 5-act1.

z. Click OK.

aa. Click OK.

T

T

T T

y

z

Remove the T’s in the first column by double clicking on them. You don’t have to worry about all the T’s in the horizontal direction, because they are symmetric with the vertical direction T’s as we are using two-way contact.


S2

Default Static StepS1

bb

cc

dd

ab. Click Apply.

ac. Select S1.

ad. Enter S2 for Job Step Name.

ae. Click Select Load Case.

af. Click Load case two.

ag. Click OK. ee

ff

gg

By clicking on S1 all data is copied from S1. There are only some minor changes for S2.


ah. Click Solution Parameters….

ai. Click Contact Table….

S2


hh

ii

The contact table will pop out and you can check to see if the previous steps were done correctly. The Contact Table should look like the one created previously.


aj. Click to add T for both 3-D2 and 6-act2.

ak. Click OK.

al. Click OK.

am. Click Apply.

T

T

T

T

T T T T

jj

kk

ll

S2


mm


an. Repeat steps bb-ll to create Contact Tables with Job Step names S3, S4, S5 and S6. Each time click on the last Job Step created, then change the Job Step Name to the new Job Step name. Then select the corresponding load case.

T

T

T

T

T T T T

Step S2

T

T

T

T

T T T T

Step S3

Notice that only the last two Act# rigid surfaces are kept in each step. Also notice that the D3 rigid surface is added in Job Step S4 (next slide) and kept together with D1 and D2 in the subsequent Job Steps.


T

T

T

T

T

T T T T T

Step S4

T

T

T

T

T

T T T T T T

Step S5

T

T

T

T

T

T T T T T

Step S6


S2


oo

ao. Click Cancel.

ap. Click Load Step Selection.

aq. Select job steps S1-S6 in order, then deselect Default Step Selection.

ar. Click OK.

as. Click Apply.

Make sure that the Default Static Step does not appear in the Selected Job Steps panel. Further, make sure steps S1-S6 appear in the correct order.

Pclip_job1

Full Run

Entire Model

pp

ss

qq

rr


Step 13. Analysis: Read Results / Result Entities / Attach

Read (attach) the results

a. Analysis: Read Results / Result Entities / Attach.

b. Select Pclip_job1.

c. Click Select Results File.

d. Select Pclip_job1.t16.

e. Click OK.

f. Click Apply.

Pclip_job1.t16

Pclip_job1.t16

d

e

Pclip_job1

a

b

c

f


g. Group / Create.

h. Create / Select Entity.

i. Enter All Fem for New Group Name.

j. Click -Apply-.

All Fem

g

h

j

i


Step 14. Results: Create / Quick Plot

Display the results

a. Results: Create / Quick Plot.

b. Select Deform Attributes icon.

c. Select True Scale.

d. Enter 1.0 for Scale Factor.

e. Uncheck Show Undeformed.

f. Select Fringe Attributes icon.

g. Select Free Edges for Display.

a

b

c

de

f

g


h. Click on Select Results icon.

i. Select the last result case.

j. Select Strain, Total.

k. Select Displacement Translation.

l. Click Apply.

h

j

k

l

i

mar120, workshop 7, december 2001 workshop 7 metal forming a paper clip workshop 7 metal forming a...

Documents