pam-stamp 2008 manual de exemplo inverse - 2008

PAM-STAMP 2G 2008 PAM-INVERSE Examples Manual

Courtesy: Jaguar Cars

July 2008

GR/PAST/08/02/00/A

PAM-STAMP 2G 2008

PAM-INVERSE EXAMPLES MANUAL

The documents and related know-how herein provided by ESI Group subject to contractual conditions are to remain confidential. The CLIENT shall not disclose the documentation and/or related know-how in whole or in part to any third party

without the prior written permission of ESI Group.

© 2008 ESI Group. All rights reserved.

PAM-STAMP 2G 2008 i PAM-INVERSE EXAMPLES MANUAL © 2008 ESI Group (released: Jul-08)

CONTENTS

CONTENTS INTRODUCTION 1

Overview-----------------------------------------------------------------------------------1 Conventions Used ------------------------------------------------------------------------- 1

PAM-INVERSE FLATTENING 3 Purpose of the Exercise----------------------------------------------------------------3 Starting-up PAM-STAMP 2G ---------------------------------------------------------4

Import existing parts data files and meshing. --------------------------------------- 5 Setup of the Analysis -------------------------------------------------------------------7

Rename imported parts------------------------------------------------------------------- 7 Data set-up macro for Inverse Standard Forming --------------------------------- 7 Macro for inverse standard forming set-up ---------------------------------------- 10 Link up the Solvers with PAM-STAMP 2G.---------------------------------------- 12

Start of the Calculation --------------------------------------------------------------- 14 Starting the Inverse Solver------------------------------------------------------------- 14

Displaying the Results---------------------------------------------------------------- 15 Visualization of the flattened part ---------------------------------------------------- 15

PAM-INVERSE UNFOLDING ON CURVED SURFACE 21

Purpose of the Exercise-------------------------------------------------------------- 21 Starting-up PAM-STAMP 2G ------------------------------------------------------- 22 Setup of the Analysis ----------------------------------------------------------------- 25

Rename imported parts----------------------------------------------------------------- 25 Selection and lock of elements. ------------------------------------------------------ 25 Data set-up macro for Inverse Standard Forming ------------------------------- 29

Starting the Calculation -------------------------------------------------------------- 34 Starting the Inverse Solver------------------------------------------------------------- 34

Displaying the Results---------------------------------------------------------------- 35 Visualization of flattened part.--------------------------------------------------------- 35 Post-processing -------------------------------------------------------------------------- 35

PAM-STAMP 2G 2008 1 PAM-INVERSE EXAMPLES MANUAL © 2008 ESI Group (released: Jul-08)

INTRODUCTION Overview

INTRODUCTION OVERVIEW

This manual presents two examples that demonstrate the use of the PAM-INVERSE modules:

- Example 1: Final part flattening using PAM-INVERSE.

- Example 2: Unfolding of final part onto a curved surface using PAM-INVERSE.

The user will be able to familiarize with PAM-STAMP 2G concepts, while obtaining an initial idea of the various associated tools.

The functions used in the examples presented, in no way form an exhaustive list of functions available in the context. However the examples make use of a maximum number of functions, and these are associated with a number of pointers for enhanced construction speed.

The application offers numerous object construction and modeling possibilities. The solutions given for these examples are designed to show the user how to handle the software, and should not be considered as the only construction solution, nor the reference solution, for each example.

Conventions Used - Instructions to select submenu items are given in the Menu/Submenu format.

- Throughout the examples, dialog names, control labels and controls are formatted in an Arial bold font.

- Throughout the examples, parameter names and values given by the user are formatted in italic font.

- Throughout the examples, file names and directory locations are formatted in a Courier font.

The example files are available in the Examples directory of PAM-STAMP 2G installation directory. If the user installed in another location, he must navigate to files in that location instead of the location specified in the instructions. The user should check if he has file access permissions to write to these directories; it is advised to copy the files into the user’s working directory.


PAM-INVERSE FLATTENING Purpose of the Exercise

PAM-INVERSE FLATTENING PURPOSE OF THE EXERCISE

The purpose of this example is to learn how to set-up an inverse calculation using PAM-INVERSE, further to the flattening of the final part. The user will be guided step-by-step through the main functionality of the software through various steps.

- Create new project, import the geometry and mesh it: Import the part data file in PAM-STAMP 2G with meshing set-up.

- Set-up an inverse calculation: Set-up the model and boundary conditions for simulation.

- Results: Post-processing and analysis of the results.

The geometrical data of final part and die are stored in files: Final_part.igs

PAM-INVERSE EXAMPLES MANUAL 4 PAM-STAMP 2G 2008 (released: Jul-08) © 2008 ESI Group

PAM-INVERSE FLATTENING Starting-up PAM-STAMP 2G

STARTING-UP PAM-STAMP 2G

Start PAM-STAMP 2G by using its dedicated icon or an equivalent alias.

Create a new project

· Select the icon from the standard toolbar: this will open the file dialog box. In this dialog box choose your working directory, input name of the new project and click on OK.

· After clicking on OK, open the next dialog box, where basic information about the project is stored.

· In the Solver type dialog box, to Mesh is set by default. Change it to “Inverse”.

· You can add Title and Comment to the new project.



Import existing parts data files and meshing.

· Select the icon in the project window.

· In the opened context menu select Import CAD: this will open the Inverse CAD meshing dialog box.

· In the in File section, select the imported part through the button: go to the example directory and select the file named Final_part.igs.

· Set up the Meshing. Choose Uniform algorithm. Minimum element size set to 2 and Maximum element size set to 4.

· Validate all settings by clicking on the Mesh button.

· Click Close to close the dialog box

This should display the following geometry:



Notes:

· Geometry on this picture is turned against initial positioning for a better view.

· The coordinate system triad is not displayed. You can display it through the: View/Show/Coordinate system triad menu.

After importing the geometries, save the project. Select the icon and then choose Save in the context menu. With the saving of the first project, the program offers (in the message dialog box) addition of default unit system “mm.kg.ms” – click OK to validate it.


PAM-INVERSE FLATTENING Setup of the Analysis

SETUP OF THE ANALYSIS

Rename imported parts · As you have noticed in the previous

pictures, imported part was named DeltaMESH by default “”, so it is better to rename it.

· Go to the Project toolbar on the left side of main window of PAM STAMP 2G, click on Visibility then right click with the mouse button on DeltaMESH and select the information option. This will open the Object information dialog box.

· Write down the new name “final_part” in the field Name in this dialog box and click on Apply. Change is promptly displayed in the Object field too. You can change color of the part too.

· Click Close.

Data set-up macro for Inverse Standard Forming

To open the data set-up macro dialog box :

- Go tothe Data setup toolbar, then the CAD tab. finally click the“Data setup macro button .

- This will open a dialog box for macro data set-up named Inverse standard forming.



Macro type definition:

- In the Macro section use the button to add the right type of macro for flattening.

- This button opens the file dialog box, where the user selects the right macro file: c:\Program Files\ESI Group\PAM-STAMP\ 2008.0\ Common\ Public_Macros_mmkgms\Inverse\Flat_Blank.ksi.

- The program will ask you to choose the color of the objects.

Notes:

· The options colored in pink in the macro data set-up dialog box means that they are not defined. The user can define these options by clicking on them.

· In the lower left corner of this dialog box you can see an outline of the part we are working on. If the part outline is dashed, this means that some properties of the part are not yet defined.. As soon as all part properties are defined, the outline becomes solid, as shown below.



Customize dialog box

After defining the macro file, the Customize dialog box is opened. In the Groups field of this dialog box, check the option Part and in the Stages field check the option Flattening.

Click OK to validate. Part definition

- In the Group section use the button to define the Part object.

Add object dialog box

- In the Add object dialog box Select final_part.

- Click OK to validate.

Material definition

- In the Material section, click on the option colored in pink (name). It opens the material properties dialog box. The user can defined all material properties here and add new materials to the material database. In this example we defined the material in a different way – predefined material from the Material database.

Material database

- Use the button to open the Material database. In the directory tree in the“unsorted” group material select “DC05_0.8mm”.

- Click Apply to validate.



Projection frame definition

- In the Parameters section - flattening click on Projection frame (the option colored in pink). It opens the Edit parameter dialog box.

Edit parameter dialog box

- In this dialog box the user defines the projection frame of the flattened part. In the field name the user can write down the name of the frame and in the field Value chose the current frame. For this example use the default setting.


Macro for inverse standard forming set-up Click Apply to validate all set properties.



Checking set properties Opening the Objects attributes dialog box:

- Go to Data setup toolbar, then the CAD tab.

Click the Objects attributes button - .

- This will open the dialog box containing the attributes of all objects used in the simulation – the attributes tree. If you set all properties by this tutorial, the tree should look like this:

Notes:

· After opening the Objects attributes dialog box, the section All stages is packed. Click on the plus symbol on the left side of this option to unpack the All stages attribute tree (like on picture).

· Check all these attributes, eventually correct your mistakes.

· Click OK to close the dialog box.



Link up the Solvers with PAM-STAMP 2G. - Go to the main menu and select

the options Solver Hosts to open the Hosts dialog box.

- Use the button to add links to the solver. It opens the Calculation host dialog box (picture on next page).

- In Label for this host tab– Write down Inverse_solver.

- On the Machine tab leave settings by default.

- Select the Solver tab and choose the Solver type - Inverse solver.

- Then select the Launch tab in the “Solver’s launcher field” use the button to select the right solver file ivstamp.bat, which is in the following directory: C:\Program Files\ESI Group\PAM-STAMP\2008.0.Beta1\Binary\Solver-32Bit\ivstamp.bat

- Click OK to validate all settings.


PAM-INVERSE FLATTENING Start of the Calculation

START OF THE CALCULATION

Starting the Inverse Solver For a successful calculation it is necessary to start the inverse solver.

- Go to main menu and select the options Solver - Start.

- The Start a calculation dialog box is opened.

- Select the correct solver – Inverse solver!

- Click OK to start the calculation.

The program will open the window with the following information: SOLVER LAUNCHING PARAMETERS, SOLVER HOST and LAUNCHING REPORT. Check and close it by clicking OK.

Calculation process

During the calculation, the user can view and control the actual results of the process by clicking on the main menu, the options Solver - Messages.

When the calculation is successfully carried-out, the user is informed in the next window.


PAM-INVERSE FLATTENING Displaying the Results

DISPLAYING THE RESULTS

Visualization of the flattened part Go to the Project toolbar on the left side of the main window of PAM STAMP 2G, and double click on the option State 1. . The flattened part is now visible. The program displays the results in chronological sequence, with the final part marked as State end.

The flattened part should looks like this:



Creating result 3D curve

- Go to the main menu and select the options Geometry - Edition – 3D curves.

- It opens the 3D curves dialog box.

- At first select button Create from…. Create polycurves dialog box is opened. Here, From free edges is set-up by default. Leave it and click Apply.

The names of the 3D curves created from free edges of the flattened part are displayed on the left pane of the dialog box

Curves are assigned to the part as shown in the following picture:



- Select the Add to object button to create an object from the 3D curves.

- It opens the Add selection to object dialog box. Type the name of new 3D_curves object: and click Add.

- Now go to the project toolbar and display the 3D_curves object. It should look like this:

Export the 3D_curves object to IGES

Now that the 3D_curves object is displayed.

- Go to the main menu and select options Project – Export –Mesh.

- They open the Mesh file export dialog box. Here select your work directory, put the name of export object and select IGES as the file type.

Now validate all and export the file by clicking Save.



Visualize contour results

- In the Project toolbar select the option State end. The final part is now visible.

- Go to the Analysis toolbar, then the Contour tab. In the open field at the left side of the Go button. Select the options Thickness and then Value for displaying thickness. To display thinning select Thickness – Thinning.

It should look like this:

Thickness:



Thinning:


PAM-INVERSE UNFOLDING ON CURVED SURFACE Purpose of the Exercise

PAM-INVERSE UNFOLDING ON CURVED SURFACE PURPOSE OF THE EXERCISE

The purpose of this example is to learn how to set-up an inverse calculation using PAM-INVERSE, further the unfolding of final part onto curved surface. The user will be guided step-by-step through the main functionality of the software through various steps.

Create new project, import the geometry and mesh it: Import the part data file in PAM-STAMP 2G with meshing set-up.

Set-up an inverse calculation: Set-up the model and boundary conditions for simulation.

Results: Post-processing and analysis of the results.

The geometrical data of final part and die are stored in files: Final_part.igs and Operation_20_die.igs


PAM-INVERSE UNFOLDING ON CURVED SURFACE Starting-up PAM-STAMP 2G

STARTING-UP PAM-STAMP 2G

Start PAM-STAMP 2G by using its dedicated icon or an equivalent alias.

Create a new project

- Select the icon from the standard toolbar: this will open the file dialog box. In this dialog box choose your working directory, input the name of the new project and click OK.

- After clicking on OK, open the next dialog box, where basic information about the project is stored.

- In the Solver type dialog box; the option Mesh is set by default. Change it to Inverse.

- You can also add Title and Comment to the new project.

Import an existing parts data file and meshing

- Select the icon in the project window.

- In the opened context menu select Import CAD: this will open the Inverse CAD meshing dialog box.

- In this dialog box select imported part through the button: go to the example directory and select the file named Final_part.igs.

- Set up the Meshing. Choose Uniform algorithm .Set Minimum element size to 2 and Maximum element size to 4.

- Validate all settings by clicking on the Mesh button.



This should display the following geometry:

Note:

· Geometry on this picture is turned against initial positioning for a better view.

· Here, the coordinate system triad is not displayed. You can display it through the: View/Show/Coordinate system triad menu.

Do not close the Inverse CAD meshing dialog box, in the same way and with the same settings, import the geometry of the die – file: Operation_20_die.igs




Click “Close” to close the dialog.

After importing the geometries save the project; select the icon and then choose Save in the context menu. With the saving of the first project, the program offers (in the message dialog) addition of default unit system “mm.kg.ms” – click OK to validate it.


PAM-INVERSE UNFOLDING ON CURVED SURFACE Setup of the Analysis

SETUP OF THE ANALYSIS

Rename imported parts As you have noticed in the previous pictures, imported parts was named DeltaMESH by default and DeltaMESH2, it is therefore better to rename them.

- Go to the Project toolbar on the left side of the main window of PAM STAMP 2G, click the right mouse button on DeltaMESH and select option information. This will open the Object information dialog box.

- Write down the new name final_part in the field Name in this dialog box and click on Apply. The change is promptly displayed in the Object field too. You can change the color of the part if needed.

- In same dialog box in the Object field select a second object DeltaMESH2 and change its name in the same way to Die_1st_OP.

- Click Close.

Selection and lock of elements. - You can see that some elements of the final

part and the die are the same. They are outlined in red in the picture. For the flattening of the final part it is important to lock these elements.



- In the Analysis toolbar then in the Contour tab, choose the option Distance and then Distance between objects

- The Distance between objects dialog box is opened (see picture below).

- In the section 1st set of object select final_ part and check the option distance to 2nd set.

- In the section 2nd set of object select Die_1st_OP.

- Other settings are left by default.

- Click OK to validate it.

- Select the Contour icon in the selection toolbar. If the Selection toolbar is not displayed go to the main menu and select the options: View – Toolbars – Selection toolbar



- The Contour icon opens the Selection by contour value dialog box.

- Here, check the options From and To and put values of ranging from 0 to 0.1.

The selected area should look like this:

- Click the right mouse button on the selected area. It opens the context menu like on picture. Select the option Add selection to object.

- In this dialog box, put the name of the new object – locked.

- Click the Add button.



Select the locked option in the projection toolbar. It displays the selected area as a new separate object.

Deactivate displaying of the distance by checking off the Display option in the Analysis toolbar in the Contour tab.

Choose the Deselect all icon in the Selection toolbar.

Now you can see the new object locked in full color. It should look like the picture below.

To be sure that computation will converge it is better to have a smooth border of the locked objects

- Go to the Analysis toolbar, then to the Visibility tab. Use the Edges button to display the elements. Select irregular elements and remove them from the locked object by clicking on the Remove selection from object option with the right mouse button menu (you can eventually use the Add selection to object to add the selection to the locked object).




Data set-up macro for Inverse Standard Forming Opening data set-up macro dialog:

- Go to the Data setup toolbar, then the CAD tab. Click the Data setup macro button .

- This will open the macro data set-up dialog box named Inverse standard forming.

Macro type definition:

- In the Macro section use the button to add the right type of macro for flattening.

- This button opens the file dialog box, where the user selects the right macro file: c:\Program Files\ESI Group\PAM-STAMP\ 2008.0\ Common\ Public_Macros_mmkgms\Inverse\Curved_Blank.ksi.

- The program will ask you to choose the color of the objects.



Customize dialog box

- After defining the macro file, the Customize dialog box is opened. In the Groups field of this dialog box; check the options Part, Curved Surface and Locked. In the Stages field check the option Curved_analysis.

- Click OK to validate. Part definition

- In the Group section are three undefined terms Part, Curved_surface and Locked. Use the button to define them.

Add object dialog

- This dialog gradually assigns the objects to the current terms: Part ► final_part, Curved_surface ► Die_1st_OP, Locked ► locked.

Material definition

- Use the button to open the Material database. In the directory tree select unsorted then DC05_0.8mm in the material group.

- Click Apply to validate.



Projection frame definition

- In the Parameters section then in flattening (colored in pink), click on Projection frame. It opens the Edit parameter dialog box.

- For this example use the default setting.


Note:

· After a full definition of all properties the lines become solid lines:



Macro for inverse standard forming set-up

- Click Apply to validate all set properties.

Checking set properties

To open the Objects attributes dialog box:

- Go to the Data setup toolbar, then CAD.

Click Objects attributes button.

- If you set all properties by this tutorial, the tree should look like this:



- Check all these attributes, eventually repair your mistakes.

- Click OK to close dialog box.


PAM-INVERSE UNFOLDING ON CURVED SURFACE Starting the Calculation

STARTING THE CALCULATION

Starting the Inverse Solver For a successful calculation is necessary to start the inverse solver.

- Go to main menu and select the options Solver - Start.

- The Start a calculation dialog box is opened.

- Select the correct solver – Inverse solver!

- Click OK to start the calculation.

- The program will open the window with the following information: SOLVER LAUNCHING PARAMETERS, SOLVER HOST and LAUNCHING REPORT. Check and close it by clicking OK.

Calculation process

- During the calculation the user can view and control the actual results of the process by clicking on the options Solver - Messages from the main menu.

- When the calculation successfully carried out, the user is informed in the next window.


PAM-INVERSE UNFOLDING ON CURVED SURFACE Displaying the Results

DISPLAYING THE RESULTS

Visualization of flattened part. - Go to the Project tab, double click on the

option State 1. Now you can see the flattened part.

Flattened part should looks like this:

Post-processing Displaying contours, creating 3D curves results and then post-processing, are similar to the actions explained in the first Flattening example.

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