Metal Forming ezsetup In LS-PrePost 4.2. LSPP Metal Forming Development Team Janurary, 2015

Transcription

1 Metal Forming ezsetup In LS-PrePost. LSPP Metal Forming Development Team Janurary, 05

2 Table of Contents SECTION WORKSHOPS LS-PrePost Input/Output ezsetup for Metal Forming Tool & blank mesh Workshop Tooling offset & check Workshop Multi-stage process simulation Workshop Multi-flanging setup Workshop Post-Processing Workshop 5 (NUMISHEET 0 fender outer) Configuration run script Practice: setting up a job from CAD IGES Workshop 6 (NUMISHEET 08 B-pillar)

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

4 ezsetup for Metal Forming

5 Installation & File Structure Full installation: ftp://ftp.lstc.com/outgoing/lsprepost/. Process templates Material library 5

6 Application Menu Note: Unit System: mm-second-tonne-newton All tools must be in their home position ezsetup works best with LSDYNA R6..0 and later versions. 6

7 Metal Forming toolbar When you go to application/metal forming/easy setup once, two metal forming toolbars will appear. Metal Forming Pre Metal Forming Post 7

8 Workshop Tool / blank mesh generation 8

9 Open an IGES file: Directory: Workshop 9

10 Meshing binder: Left click to pick the binder surface

11 Meshing die: Left click to pick the binder surface

12 Tool mesh result:

13 Import IGES file: 5

14 Blank mesh: Turn part off 5 6 Left click on surface

15 Workshop Tool mesh check and offset Summary: Check and merge duplicate nodes, tolerance 0.05mm good for most cases; Check for normal consistency all tooling mesh normal should be consistent; Normal orientation: blank normal up, upper tools normal down, lower tools normal up; Free edge use ElEdit to check for free edges; Small gaps mostly okay, big overlaps will be a problem; Check zero or very small Jocabian for collapsed elements; This messes up the normal determinations for contact. Use model check Least amount of work needed for tool mesh if LSPP tool mesher is used. 5

16 Open keyword file: Directory: workshop 5 6

17 Duplicate nodes check and show free edges: 5 6 7

18 Tool mesh normal check: Normal orientations: blank normal up, upper tools normal down, lower tools normal up; Pick the part. Wire frame mode: vector display in wireframe mode. Pick the part. Shaded mode: a color consistent with the PID color indicates normal going up; a color that is different from the PID color indicates normal going down. Wireframe mode for vector display; 8

19 Tool mesh normal reverse by part: 5 Pick any element 9

20 Tool mesh normal align reverse a part normal based on one seed element normal 6 5 Pick the element with the desired normal 7 Note: auto rev. works within one part boundary 0

21 Jacobian Check: check for zero or very small Jacobian, and delete failed 5 Type in 0.05 and enter 6 7

22 Jacobian Check: Contour display: Element 06 has all three nodes on a straight line

23 Offset with Advanced option on: 5 6 offset + is positive of normals 7 8

24 Workshop Stage : gravity, closing and drawing Stage : trimming and springback Stage : tipping Stage : flanging and springback

25 Import blank and forming tools: Directory: Workshop 5 5

26 Rename blank and tools:,right click, type in a name and enter 6

27 Stage : gravity, closing and drawing Insert gravity loading and closing process 7

28 Define tools:, pick part 0, pick part name and right click 8 5 6,pick part 9 0 7, enter 0 8

29 Define blank and material:,pick part 5 8,type in thickness and friction 8 6 Click this button if your material file is in the current working directory. 7 9

30 Define drawbead:,select file 5 6, righr click 0

31 Drawbead force modify:, modify the force % by the table list 5 6, enter 0 as full lock force Drawbead name DBead 50 DBead 50 DBead 50 DBead 50 5 DBead DBead6 0 7 DBead7 0 8 DBead8 0 9 DBead9 0 0 DBead0 0 DBead 0 DBead 0 DBead 0 DBead 0 5 DBead5 0 6 DBead6 0 7 DBead7 0 8 DBead8 0 Force percentage(%)

32 Stage process control: 5 6 7

33 Stage : trimming and springback, remove forming then add trimming and springback process

34 Import trim curve:

35 Stage process control trimming:,pick curve then right click,pick a location inside trim curve 5

36 Stage process control springback:,pick three locations then right click 6

37 Stage : tipping, remove forming then add tipping process 7

38 Stage process control tipping:, RY: ; RX: -0; TZ: 8 8

39 Stage : flanging and springback, remove forming then add flanging and springback process 9

40 Import flanging tools: 0

41 Import flanging direction line:

42 Import pre-adaptive curve:

43 Stage process control flanging control:,pick the curve then right click

44 Stage process control flanging post and pad:,pick part 5 6,pick part

45 Stage process control flanging steels: 6 5 6,pick two end points of line 7,pick part PID 9 5

46 Stage process control add flanging steels:,pick part PID 0 Repeat step to, define one more flanging steel and their direction. 6

47 Stage process control springback: 7

48 Submit job: LS-dyna input deck output 8

49 Output folder: 9

50 Workshop A flanging process set up with multiple flanging steels moving in local directions 50

51 Import keywords: Directory: Workshop 5

52 Import iges: 5

53 Stage : flanging 5 Remove forming then insert flanging process 5

54 Define blank and material:,pick part PID,type in thickness

55 Flanging control: Select these curves to define mesh pre-adapt, right click to finish the selection. 55

56 Flanging post and pad: Pick part Pick part

57 Flanging steel part: Blinking yellow prompting for flanging steel definition; turns green when it is defined. Pick part 57

58 Flanging steel direction: 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 58

59 Add flanging steel to : Add a new flanging steel. Pick part 5 6 Repeat the process to define Flg and Flg 7 59

60 Submit job: LS-dyna input deck output 60

61 Output folder: 6

62 Save project file (overwrite existing project file): Note: Project file is an important database file, containing complete model and ezsetup information. It can be reloaded back into LSPP for changes in process or models. 6

63 Running LS-DYNA in windows: Submit test.bat to execute the LS-DYNA solver run. Simulation involving gravity, springback, static implicit must use double precision (DP) solver All other dynamic explicit simulation (for example, draw or flanging) use SP solver DP solver slower than SP solver Beginning of simulation End of simulation 6

64 Workshop 5 Post-Processing 6

65 Animate punch contact/part breakdowns: 6 workshop5 5 65

66 Create a movie (wmv): Use MediaPlayer to open and play the movie file. 66

67 Cut a section plane: Pick a location

68 move the cut planes: Save multiple cut sections in keyword format: 5 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. 68

69 Plot Thickness/thinning contour:

70 Set contour range for thickness/thinning contour: Thickness range: Thinning range:

71 Save a JPG file for the screen display: optional 6 7

72 Plot thickness distribution along a section: Pick a location close to this node 5 6 7

73 Plot thinning distribution along a section: 8 7 7

74 Changing the thinning of a section plot in contour: 7

75 Identify detailed results in value: Left click and drag over the part for live updates. 5 75

76 Display trim lines on post-processing results, follow square box A, B, C in sequence: A - Import IGES file: newtrim.iges B - Translate curves: C - Change curve color: right click red color box means current pick multiple times 7 76

77 Plot mean stress (pressure) contour (wrinkles):

78 Set contour range for mean stress: negative tensile positive yield

79 Similarly, plot In-plane major/minor strain contour: 79

80 Plot FLD: If use File option, open fld_true.fld pick this part anywhere need to select Hit enter after input values 80

81 Plot In-plane major/minor strain vectors: 6 Pick location 5 8

82 Blank draw-in: pick blank pick binder 6 Display blank and binder only left click on the colored lines to show exact values The state when closing is done

83 Plot tool tonnage: Open rcforc file in Workshop 8/Forming In MPP, the file name is binout Note: English ton=8900 Newton 7 8

84 Plot sheet blank mass increase: 5 Note: total weight of the model is used to calculate the %. 6 8

85 Configuration and run script 85

86 LS-PrePost configuration file location (each version has its own directory) Windows C:\Users\uname\AppData\Roaming\LSTC\LS- PrePost. Linux - $HOME/LSTC/LS-Prepost. ezsetup parameter file and LS-Dyna run script file are under LSPP installation folder and subfolder lspp_forming 86

87 ezsetup parameter file(lspp_parameter): Solver location. Process executable commands. ezsetup default parameters. 87

88 LS-Dyna run script file (Windows): 88

89 Workshop 6 (Practice) ezsetup From IGES Surfaces NUMISHEET008 B-pillar 89

90 NUMISHEET008 B-pillar 90

91 Procedures Import IGES files: Numisheet08-BM0-Blank.igs Numisheet08-BM0-Blankholder.igs Numisheet08-BM0-Dies.igs Numisheet08-BM0-Punch.igs drawbeads.iges Mesh tools: Mesh/AutoM/deviation, use these parameters Mesh blank, element size=mm (Mesh/BlankM/Curve by Surface, size ) Check model free edge, dup nodes, Jacobian, normals etc.; Position tools into home position, blank thickness=.95mm; Measure distance first, then EleTol/Transf/translate by part; Blank position does not need to be moved. Activate ezsetup, air draw: Stage: gravity, forming, springback; Use material Steel /DQSK/M7_Curve_DQSK5Ksi_t069.k 9

92 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 0% lock. In Control-gravity, check for gravity prebend along Y-axis. In Control-forming, change nothing. Save a project file, and output simulation file. Run simulation using output bat file. Try removing gravity from the process, just run the forming with single precision solver Post-processing results For static implicit simulations, e.g. gravity loading and springback, double precision (DP) must used. DP solver slower than SP solver Open case5.dplot (gravity). Animate gravity simulation. Can you see a slight bending in the blank in the start of the simulation? Open case0.dplot (forming) Animate punch contact; Plot thinning contour, range 0 ~ 0%; 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. 9

93 Thanks 9