LSPP_eZSetup1

Metal Forming In LS-PrePost 4.0

LSPP Metal Forming Development Team Oct. 30, 2012

1

Table of Contents

SECTION WORKSHOPS

LS-PrePost Overview -

General/Nodes/Element/Tool and blank meshing/Tool mesh check

Workshops 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)

2

LS-PrePost Overview

3

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)

4

Online Resources

Latest version and training materials (metal forming): http://ftp.lstc.com/anonymous/outgoing/lsprepost/4.0/metalforming/

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

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

5

http://ftp.lstc.com/anonymous/outgoing/lsprepost/4.0/metalforming/


http://www.lstc.com/lspp

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



Mouse and Keyboard

Dynamic Model Operation

• Rotate: Shift + Left-click

• Translate: Shift + Middle-click

• Zoom: Shift + Right-click/Scroll-wheel

(Using Ctrl instead of Shift for edge mode)

Graphics Selection

• Pick (single): Left Click

• Area (rectangle): Left-click + Drag

• Poly (polygon): Left-click at corners / Right-click to finish

List Selection

• Multi-Select: Left-click + Drag / Ctrl + Left-click

Mouse over controls for status bar help comments

6

GUI Layout

7

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

include: dynain file

command session file (.cfile)

LSPP database file

LS-DYNA results file (d3plot)

Input/Output

8

Misc. Menu

9

10

View Menu

text below icon

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, Surface Morphing)

Solid – Access tools for creating and editing solids (Box, Cylinder, Cone, Sphere, Torus, Extrude, Revolve, Sweep, Loft, Fillet, Chamfer, Draft, Thicken, Wedge, Boolean)

Geometry Tools – Access other geometry tools (Delete Face, Extend Curve, Extend Face, Intersection, Offset, Project, Replace Face, Stitch Faces, Trim Transform, Copy Entity, Management, Heal, Topology Simplify, Measure)

11

Same menu system with ICONs is at right

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, SPH Generation)

Model and Part – Access model and part tools (Assembly and Select Part, Keyword Manager, Create Entity, Display Entity, Reference Check, Renumber, Section Plane, Model Selection, Subsystem Manager, Group, View, Part Color, Appearance, Annotation, Split Window, Explode, Lighting Setup)

Element Tools – Access element tools (Identify, Find, Blank, Move or Copy, Offset, Transform, Normals, Detach, Measure, Morph, Smooth, Part Trim, Part Travel)

Post – Access post-processing tools (Fringe Component, Fringe Range, History, XY Plot, ASCII, Binary Output, Follow, Trace, State, Particle, Circle Grid, Chain Model, FLD, Output, Setting, Vector)

Favorites – Customizable toolbar (see Setting → Toolbar Manager)

12

Same menu system with ICONs is at right

Application Menu

13

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

14

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

Edge/mesh line width

Element outline

Bottom Toolbar

15

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 pixel

Mesh 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 shown

Right-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)

FEM General Selection

16

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 buffer

Load 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

Workshop 1 General Operations

17

18

Disable “New Rendering work”:

1 – double click this area

2 –click this area

want to see these

messages

need to remove this

message

3 – hit

keys:

ctrl l l

19

3

1

2

Directory: Workshop 1

4

Rotate model using Shift with left mouse button

5

Open keyword file and rotate model:

20 20

or Ctrl a 1

Auto Center:

21 21

1

2

3

4

5

6

7

8

Display in standard views:

22 22

12

13

14

1 2

3

4

5

6

7

8

9

10

11

Display in different modes and background colors:

23 23

Select part for display:

1

2

3 4

5

6

Shift with left click for multiple selection

7 8 9

10

24 24

Identify nodes/elements:

1

2

3

4 5

6

left click to pick nodes

7

8

9

left click to pick elements

10

left click to pick elements

7

25 25

1

2 3

4 5

6

Identify material direction for anisotropic material:

Note: axis “A “is rolling direction, see next page

8

26 26

Anisotropic material (*MAT_036):

Material axes options, see below.

Vector components ‘a’ for AOPT=2.0, see below

R90

With this explanation, do you know how to change the rolling direction to along global Y-axis, or, in 45 deg. direction between the X- and Y- axis? This is important for Aluminum forming.

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

Steel_DP500-36

Steel_DP500-36

Steel_DP500-36

27 27

Element/model blanking (for display):

1

2

3

28 28


1

2 3

4

5 3

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

6

7

8

29 29

1

2

3

4

Left click to pick an element on the binder

6


7

1

6

9

7

8

30 30

Find a specific element or node:

10

3

5, uncheck

4, uncheck

2

31 31

Find a specific element or node:

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

6

1

2

3

4

5

32 32

Modify part transparency:

1

2

3

33 33

1

2

3

4

5

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

6

7

Modify part transparency:

Left click to pick again to go back to normal color

8

Reset transparency

9

10

34

1

2

3

4

5

6

7 8

9

Left click to pick the part to change color

10

12

13 Change part color:

12

11

Workshop 2 Mesh editing

35

36

Open keyword file:

3

1

2

4

Directory: workshop 2

37

3

1

2

4

5

6

Merge duplicate nodes:

38

3

1

2

4

Merge duplicate nodes:

Replace nodes:

39

1

2

3

4

5

Left click, hold and drag these boxes to include nodes in each node pair whose position are to be replaced

6

7

8

40

3

4

1

2

Left click to pick the part 5

Left click to pick three nodes to form a triangle, right click for node #4.

6

Create a triangular element:

7

41

Fix free edge:

Left click, hold and drag these boxes to include nodes in each node pair whose position are to be replaced

5

1

2

4

6

7

3

42

1 2

Left click, hold and drag to zoom in this area

3

4

5

6

Left click to pick these two nodes

7

Align nodes:

43

8

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

9

10 11

12

Align nodes:

44

1

2

3

4

5

6

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

7

8 9

Split elements:

45

1

2

3

4

5

Left clicks on a boundary node

6

7 8

Fill a hole:

Left click to show, right click on “2 LSHELL2” to delete

9

10

46

13 14

11

12

15

Auto filling all holes:

NOTE: when using “Autofill” option, all free edges within the part will be considered as ‘holes’ and filled .

47

Save keyword file:

3

1

2

5

4

48

Open keyword file:

3

1

2

4


49

Pick an element here

2 1

3

4

5

6 7

Detach some elements:

50

free edge display

2

1

3

Check part separation:

toggle switch


51

Change PID:

2

1

3

4

5

8

6

9

7

52

Change PID again:

2

1

3 4

5, no saving

53

Open keyword file:

3

1

2

4


54

1

Check part normals:

2

3

Pick on part

55 Offset result with “Advanced” option on

“offset –” is opposite of normals

1

2

3

4

7 8

Pick on part 6

Offset with Advanced option on (always recommended):

5

56

Translate (make copy into a new PID) the flat area:

10


1

2

3

4

5

6

7 8

9

10

11

12

57

10

Pick these two nodes

Measure part distance (method 1):

2

4

3

5

measured distance shown here

1, show only PID 2 in display

58

Measure part distance (method 2):


Alternatively: part separation, and others

1

2

3

4

3

measured distance shown here; double click this area to expand to a new window.

59

Pick this node as origin

Pick this part as a source

Rotated part

Rotate a tool (make copy into a new PID):

1

2

3

4

7

8 9

10 11

12

13

14

5

6

60

Make a mirror image of a tool:

Pick this node as origin

Pick this part as a source

Reflected part

1

2

3

4

5

7 8

9 10

11

6

12

13

61

Make a projection of part of a tool:

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

Elements selected

Elements projected

Pick this node as location

1

2

3

4

5

6

7

8

9

10 11

12

13

14

15

62

Scale (make copy) of a tool:

Pick PID 2 as a source

Scaled part 16

Pick this node as origin 1

2

3

4

5

6

7

8 9

10

12 11

13

14

15

16, no saving

Workshop 3

63

Mesh generation

64

65

Import IGES file:

3

1

2


4

66

N-line meshing/4-line meshing:

3

1

2

4

Left click to pick four curves in the order shown

5

6

7

8

9

10

11

12

13 – no saving

67

Import IGES file:

3

1

2


4

68

N-line meshing/Line sweep:

1

2

3

4

Left click to pick the square curve

5

Left click to pick this curve

6

7

8

69

1

2

3

4

5

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

6

7

Creating a circle:

70

1

2

3

Creating a circle:

71

12

1

2

3

4

Left click to pick this circle

Left click to pick this curve

6

Left click 7

Left click 8

9

10

11

N-line meshing/Line sweep:

5

Tool meshing

72

73

Import IGES file:

3

1

2


4

74

1

2

3

4

6

Left click to pick the binder surface

7

8 9

Meshing binder:

5 - uncheck

75

1


2

3

4 5

6 7

Meshing die:

76

Left click on “2 LSHELL2” to highlight, right click to delete

1

2

3

4

6

5

7

10 11

Change meshing parameter for a finer mesh:


8

9

77

For advance feasibility

30

0.2

0.05

10

For springback

20

Compare tool meshes: 1, no

saving

Workshop 4 Blank Meshing/Tool Mesh Checking

78

79

Open keyword file:

3

1

2

4


Blank Meshing (method 1 – no surface required)

80

81

Pick nodes

More options

Pick these four nodes

1

2

3 4

5

7

8 9

Shape meshing/4N_shell:

6, increase if needed

Blank Meshing (method 2 – surface required)

82

83

Pick these two nodes to create a line

Pick these two nodes to create a line

Create two boundary lines:

1 2 3

4

5 6

7

84

Pick the line just created

Pick the line just created

Create a planar surface:

1

2

3

4

5

85

Pick the surface just created

Blank meshing:

1

2 3

4

6

7

8 9

5 - uncheck

86

Toggle geomtry display on/off:

Toggle geometry display on/off

1

87

Display mesh just created:

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

1

2

3

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

88

89

Pick this line created as ‘Source Entity’

Right click to blank out BSpline Face 1

Line translated

1

2

5 4

7

8

9

10

11

Translate (make copy) a line:

Pick source when the box is shaded . Right click on an entity to delete

Unblank these two edges if needed 6

Toggle ‘ON’ geometry display

3

90

Pick these two lines

Mesh created

1

2

3

5

6

7

4

8 9

Meshing by two line: 10, no saving

Tool Mesh Checking

91

Summary: Check and merge duplicate nodes, tolerance 0.05mm – good for most cases; In this

workshop, 0.3mm tolerance was used. 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 re-work needed for tool mesh if LSPP tool mesher is used.

92

Open keyword file:

3

1

2

4


3

1

2

93

Duplicate nodes check: measure distance


4

measured distance shown: 0.234

94

Duplicate nodes check: merge duplicate nodes

1

2

3

4

5

6

set tolerance slightly bigger than the smallest distance measured

95

Tool mesh normal check:

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

1

2

3

4

pick the part, more details next page

5

s

Rotate the part to see the underside color – positive normal side shade color same as PID color

6

96

Wireframe mode for vector display;

Tool mesh normal check:

1

2 Shade mode for normal display;

97

Tool mesh normal reverse by part:

1

2

4

3 Pick any element

5 Pick again on any element

6

98

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

1

2

3

6

Pick any element

7

8 – pick the same element

x

9

10

4

Note: auto reverse works within one part boundary

5

99

Tool mesh free edge check:

3

1

2

Toggle this switch to turn on/off free edge display

4

5

Make sure background color is black:

100

1

2

3

4

0.05 5

6

7

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

save to buffer

101

Element 30632 has all three nodes on a straight line

Jacobian Check: Contour display:

102

Jacobian Check: Identify element with ID:

1

2

3

4

Message indicate this is a triangular element

103

3

2

4

5

6 7

8

1

9

Jacobian Check: Delete bad elements from the buffer:

10

104

Save keyword file:

3

1

2

4

save the keyword in Workshop 4 as newmesh.k

eZ-Setup for Metal Forming

105

Development Objective

To provide LS-DYNA® metal forming users the best tool to set up

various simulation processes

To closely integrate up-to-date LS-DYNA metal forming features

To provide a simplified and streamlined capabilities for post-

processing of metal forming results

106

Current Capability - eZ-Setup

Guided GUI features:

Air and toggle draw, flanging;

Air draw with upper pad;

User-specifiable cushion travel;

One LS-DYNA run for typical process simulation

combination;

Gravity with pre-bending;

Binder closing and flanging simulation in implicit static;

Tipping (*CONTROL_FORMING_TIPPING);

Adaptive 2-D trimming and 3-D trimming, with element

checking/fixing;

Springback - constrained and constraints-free;

Versatile and easy draw bead definition;

Adaptive box definition;

Mesh pre-adaptive along curves for flanging simulation;

Tool kinematics simulation/checking; 107

Current Capability (Con’t) Automatic recognition of ELFORM and NIP from dynain file;

User material library.

Three-levels of computing options in Forming for optimal balance of

speed and accuracy:

Advance feasibility – very fast and reliable, w/ some inertia

effect;

For formability – fast and accurate, inertia minimized;

For springback – most accurate, for springback and

compensation.

Three-levels of computing options in Flanging:

Fast – initial flangebility check, explicit dynamic;

Accurate – explicit dynamic with minimum inertia effect;

Implicit Static – no inertia effect.

Tailor-welded blanks capable

Optional selective mass scaling for all explicit computing

108

Installation & File Structure Installation: fully QA’ed metal forming version:


Updates/customization can be made by directly replacing these files:

109


110

Opening a DYNAIN file (forming result of sheet blank)

110

DYNAIN Project file When using a dynain file for a new simulation

always move the dynain file (renamed it to last.dynain) to the current directory,

same location as the new project file will be located

always read the last.dynain file first into LSPP for eZ-Setup

always answer ‘YES’ to skip reading stress/strain

when sending the project file to other people, include the last.dynain file

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

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

Easy Setup

General Setup

111

Keyboard shortcut: Ctrl q

111

Metal Forming → Toolbar

112

Metal Forming Pre

Metal Forming Post

112

Metal Forming → eZ Setup

Forming draw type

Air draw

Toggle draw

Support contact offset

Multiple forming processes

Gravity

Forming

Trimming

Spring Back

Flanging

Closing (implicit)

Tipping

113

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

113

Metal Forming → Die definition

Pick a part

Import a part

Mesh generation

114 114

Metal Forming → Binder definition

Pick a part

Import a part

Mesh generation

Offset from Die

Travel limitation

115 115

Metal Forming → Punch definition

Pick a part

Import a part

Mesh generation

Offset from Die

116 116

Metal Forming → Blank definition

Pick a part

Import a part

Blank mesher

Translate

Symmetry condition

Adaptive box define

Support tailor welded blank

material

thickness

117 117

Metal Forming → DrawBead definition

Draw bead generator

Import IGES curve

Draw bead project

Draw bead modify

Full lock force calculate

118 118

Metal Forming → Control option (Gravity Loading)

Blank Pre-bending

119 119

Metal Forming → Control option (Forming)

For early feasibility

For formability

For spring back

User define parameters

Allow additional pad

Kinematics simulation

120 120

Metal Forming → Control option (Trimming)

2-D or 3-D trim

Pick trim curves

Select seed location

Define trim vector

Pre-adaptive mesh along trim line

Check and fix shell after trimming

121 121

Metal Forming → Control option (Spring back)

Constrained

Inertia Relief

Pick node

Pick Location

Enter coordinate

122 122

Metal Forming → Control option (Flanging)

Pre-adaptive along curve

Contact offset

Multiple flanging steels

123 123

Metal Forming → Control option (Tipping)

Define tipping center

Translation

Rotation along an axis

124 124

Metal Forming → Job submit

File folder browse

Subdirectory (option)

Input file name

Case files for multiple processes.

125 125

Workshop 5

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

126

127

3

1

5 6

2

9

8

4

7, use “import offset”

10


11

12

1

2

3

4

5

8

128

6

7

Define the following process:

Flanging

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

Pick blank to define, right click to return

1

2

3

7

0.7 6

4 Click this button if your

material file is in the current working directory.

129

5

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

Optional tool kinematics simulation

Select these curves to define mesh pre-adapt,

right click to return

1

2

5

0.9 4

3

130

Blinking yellow prompting for flanging post definition; turns

green when it is defined. Pick post to define, right click to return

1

2

3

131

Blinking yellow prompting for pad definition; turns green

when it is defined.

Pick pad to define, right click to return

Optional force on pad

1

3

2

132

Blinking yellow prompting for flanging steel definition; turns

green when it is defined.

Pick this flanging steel to define, right click to return

1

2

133

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

Default option: geometric points; other

options as shown

Click to add an extra flanging steel.

2

4

134 3

From

To

1

1

5

7

3

From

To

4

Repeat the process to define Flg3 and Flg4

135

Pick this flanging steel to define, right click to return

2

6

8

All green – all defined; ‘Next’ to output.

1

136

Output LS-DYNA input file – eZ-Setup complete.

1

2

3

137

Key in file name as: sim.dyn

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.

138

1

2

3

Save project file (overwrite existing project file): 4

Running LS-DYNA in windows with a command file:

139

Windows Explorer

1 - Right click here

2

3

4 – rename to R6s.cmd

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

Use: single precision for this run 6 – input following command in R6s.cmd and save

5 – right click on R6s.cmd and

select ‘Edit’

7- double click to run LS-DYNA

End of simulation Beginning of simulation

Simulation Results:

140

Processing Results

Open d3plot files from your running directory

Animate the flanging process

141

1

2 3

4 6 7

5

8 9

Processing Results

Plot thinning/thickness

Change contour range

142

1

2

4

3 4

5

6

7

8

9

Workshop 6

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

143

144

3

1

2

6

5

11

12


4

10

7

8

9

Define the following process:

1

2

3

145

Gravity Forming

Trimming Tipping Flanging

Springback

Append to the last

Click on one already “selected process” in the left box, click on the “available process”, then click on this button, it will insert the latter in front of the former.

left click to pick the die, right click to return

1

2

3

146

Left click to pick the binder, right click to return

1

2

3

147

Left click to pick the punch, right click to return

1

2

3

148

Define material/thickness

1

3

5

6

Left click to pick the blank, right click to return

2

149

4

150

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

5

6

1

2

3 4

9

7

8

Input tensile strength in MPa (default is for

mild steel)

151

Picked curves automatically

projected to binder. Default lockage: 50%

1

10

next screen

Modify % lockage (next screen)

Default lockage: 50%.

152

Bead lock % modification

2 You can pick bead here directly

3

4

3 – pick here or pick directly on

the bead

5

7 6 – pick here or pick directly on

the bead

8

You can pick bead here directly

6

9, then go back to previous page


153

1

2

3

Save project file (overwrite existing project file):

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

1

154

Three computing levels to balance speed and accuracy.

Optional selective mass scaling – for inertia effect reduction.

Optional tool kinematics simulation.

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

Optional upper pad (for air draw)

1

155

156

Additional control on accuracy/speeds:

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.

1 3

2 4

5

6

157 More options to define vector.

For Information Only: merge curves into a single ENCLOSED curve (loop) – requited for 3-D trimming:

1

2

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

3

4

5 – pick curves

158

2

3

159

1

Three computing options to balance speed and accuracy.

Selective mass scaling option to reduce inertia effect (not for

implicit option)

Optional tool kinematics simulation.

160

1

Blinking yellow prompting for flanging post definition; turns

green when it is defined. Left pick post to define,

right click to return

1

2

3

161

Blinking yellow prompting for pad definition; turns green

when it is defined.

Left pick pad to define, right click to return

Optional force on pad

1

2

3

162

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

1

2

3 – follow next page

163

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

6 164

3

7

1

2

Constraint-free springback

165

Output LS-DYNA input file – eZ-Setup complete.

1

2

3

166



167

1

2

3


LS-DYNA input files for running the process simulation:

Control files copied from Lspp_forming

Primary simulation file to run LS-DYNA – linking all processes together

Individual single process simulation input file – “.k” file

168

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


R6d.cmd

use ‘edit’ to add the following command;

double click the file to execute the LS-DYNA solver run.

169

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

Use: double precision for this run

Processing Results

Open the following d3plot files in LSPP, in the order shown:

case5.d3plot

case10.d3plot

case15.d3plot

case20.d3plot

case25.d3plot

case30.d3plot

Select case10 (forming) as shown:

Animate punch contact

Plot thinning/thickness for forming

170

2

1

3

Processing Results

Select case15 (trimming) as shown:

Plot thinning/thickness for trimming

171

2

1

3

4

Processing Results

Select case20 (tipping) as shown:

Plot thinning/thickness for tipping

172

2

1

3

Processing Results

Select case25 (flanging) as shown:

Animate flanging action

Plot thinning/thickness for flanging

173

2

1

3

Processing Results

Select case30 (springback) as shown:

Animate springback

Plot dZ and resultant Z (next page)

174

2

1

3

Change contour range (optional)

175

Plot springback amount in Z

1

2

4

3

Forming complete – case10.d3plot

Gravity complete – case5.d3plot Trimming complete –

case15.d3plot

Tipping complete – case20.d3plot

Flanging complete – case25.d3plot

Springback complete – case30.d3plot

176

Workshop 7

TWB Forming + Springback (constrained)

177

178

3

1

2

4


Hit “next” to define die, binder, punch.

179

Define process:

Pick the red piece as “blank1”

180

Use BH210.k

Define blank1:

Define “blank2”

181

Define blank2:

Use BH210.k

2

3

4

6

182

Check for and delete existing boundary conditions:

1

5

1

2

3

4

Pick on this edge of any element along the symmetry

5

6

7 183

Redefine symmetric boundary conditions:

8 9

skip “draw bead”

Select constraints before picking node/location

Always pick nodes/locations on final tool position (where the blank will be in contact)

184

Define springback constraints:

1

2

3

A

A

B

B

C

C

9

Coordinates X, Y,Z (constraints X, Y, Z)

If needed, select the defined constraints then Modify

6

6

5

4

7

8

Not much to do here

185

Define Forming control:

Output simulation input files:


186


187

1

2

3


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


R6d.cmd

use ‘edit’ to add the following command;

double click the file to execute the LS-DYNA solver run.

188


All other dynamic explicit simulation (for example, draw or flanging) use SP solver


Use: double precision for this run

Processing Results

Open the following d3plot files in LSPP, one after another:

case5.d3plot

case10.d3plot

Select case5 (forming) as shown:

Animate punch contact

Plot THINNING for forming

189

2

1

3

Processing Results

Select case10 (springback) as shown:

Animate springback

Plot dZ and resultant Z (next page)

190

2

1

3

Change contour range (optional)

191

Plot springback amount in Z

1

2

4

3

Future Work - eZ-Setup

Unlimited, flexible processes allows for progressive dies simulation

in one setup and one run.

Flanging with multiple CAM pads.

Sequential flanging – flanging process 2 following flanging process 1,

with auto move.

Guide pins in gravity, forming.

Multiple 2-D trimming with own Cam trim vectors.

Springback on fixture nets.

Mutli-beads support and physical bead generation based on force.

Blank size and trim line development with *CONTROL_BLANKSIZE_

DEVELOPMENT.

Unfolding with *CONTROL_FORMING_UNFLANGING.

Material property creation GUI.

Directional and pressure sensitive friction.

Springback compensation.

GUI for a one step simulation with *CONTROL_FORMING_ONESTEP.

Stoning

Post-processor for metal forming. 192

Workshop 8 Post-Processing

193

194

Animate punch contact/part breakdowns:

2 1

3

4

5

6

workshop8

195

Create a movie (AVI):

3

1

5

2

4

196 196

Cut a section plane:

2

1

3

5

Pick this node 4

6

7

197

2

1

3

4 5

3

2

1

4

Cut multiple planes:

Save multiple cut sections in keyword format:

Read in the saved cut sections into a fresh LSPP session as keyword file, and check for the saved cuts – useful in springback measurement comparison.

Optional:

198

Plot Thickness/thinning contour: 2

3

5

6

1

4

7

8

199

Set contour range for thickness/thinning contour:

Thickness range: Thinning range:

1

2 2

3 3

4 4

200

Save a JPG file for the screen display:

1

2

3

4

5

201

Plot thickness distribution along a section:

1

2

3

5

Pick a node close to this location

4

6

202

Plot thickness distribution along a section:

7

8

203

Changing the thickness of a section plot in contour:

2

1

204

Identify detailed results in value:

1

2

3

4

Left click and drag over the part for live updates.

5

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

right click

2 - Translate curves:

1

2

3

4 – red color box means current pick

5

6

8 – multiple

times

7

3 - Change curve color:

1 2

3

4

1 - Import IGES file: newtrim1.iges 1

205

206

Plot mean stress (pressure) contour (wrinkles):

2

3

4

1

5

6

207

Set contour range for mean stress:

negative tensile

positive yield 2

3

1

208

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

1

2

209

Plot FLD:

1

2

3 4

5

6 –pull down and

select

7

8

If use ‘File’ option, open ‘fld_true.fld’

0.2

210

Plot In-plane major/minor strain vectors:

1

2

3

4

5

Pick location

6

211 211

Measure skid marks:

create the definition of a feature line

1

2

3

4

5

Pick on the edge of an element on the styling feature line

6

7

Select only PID 3 lower punch to display on screen

212 212

Measure skid marks:

definition of parts and curve

1

2

3

Display all parts on screen

Pick tool

4

Pick blank

5

6

7

8

213 213

Measure skid marks:

show only skid marks on display

9

214 214

Measure skid marks:

show skid amount on display

10

click on the skid lines to show skid amount on display, good for JPG capture.

215 215

Measure blank edge draw-ins (method 1):

define parts, state and show draw-in map

1

2

Pick blank

4

Pick blank

5

9

3

6

10

7

8

216 216


change display density of edge draw lines

1

2

click on upper arrow or double click on the blue ‘INTERVAL’ to change the density of the edge drawin lines

217 217


show detailed draw-in amounts on screen

1

click on the drawin lines to show draw-in amounts on screen, good for JPG capture.

218 218


Write closing blank meshing as a keyword file.

1

2

3

4

5

6 7 Write file as S6.k

3

219 219

1

2 3 Write file as S17.k


Write formed blank mesh as keyword file 4

220


Open new session of LSPP, and import s6.k and s17.k, use “Import Offset’ for the 2nd file.

1 2

3

221


Translate binder closed blank mesh down.

1

2

3

4

6

7 – pick part

8

129 5

222


Measure distance between edge nodes.

1

2

3 4 – pick edge nodes in pairs

223


Alternatively, blank edge curves can be created using d3plot files

1

2

3 6 – pick the blank

4

7

5

224


Create blank edge curves for state #6.

1

3

1

2 – pick the blank

225


Turn off all FEM parts

1

2

226


Translate state #6 blank edge down 141mm

1

2

3 4 – pick this curve

5

6

7

8

129

227


Measure edge distance

2

1

3

4 – pick edge points

228 228

Plot tool tonnage: Open ‘rcforc’ file in Workshop 8/Forming In MPP, the file name is ‘binout0000’.

1

2

3 4

5

6

7

7

Note: 1 English ton=8900 Newton

In MPP, read ‘binout0000’ file here

229 229

Plot sheet blank mass increase:

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

1

2

3 4

5

6

7

Other Post-Processing Details

230 230

Post → History Purpose: plot time history data (from d3plots)

Global – energies and kinematic data for full model

Part – energies and kinematic data for parts

Nodal – kinematic data for nodes

Element – stress and strain data for elements • Value – set to element value or min/max value for the part

• E-Type – choose element type to plot history

• E-Axes – global or local

• Surface – choose shell location (through-thickness)

Int Pt – integration point data

Scalar – plot scalar value that is being fringed (choose component in Fcomp interface)

231

Post → History (continued...)

Standard plotting options... • Plot – plot selected value in current Plot Window

• New – plot selected value in new Plot Window

• Padd – add selected value to current Plot Window

• Raise – bring forward all open plot windows

• Pop – open and bring forward all closed plot windows

Interfaces that use these plot functions... • History

• XYPlot

• ASCII

• Binout

• FLD

• Measure

• Section > Force

232

Plot Window Title – modify main, axis, legend, and curve titles

233

Post → XYPlot Purpose: create and manipulate XY-Plots (all saved XY

data is automatically added to the file list)

File – show list of all loaded XY-Plot files

Window – show list of all XY-Plot windows

Add – import XY data (use CRV, CSV, XY formats)

Remove – remove files from list

Info – display number of data points

Show – show selected plot

Cross – create cross plot (e.g., combine Force/Time and Disp/Time to create Force/Disp)

Curve Clip – clip curve

Interpolate – modify number of points in curve

234

Command File and Macros

235

Command File

All commands are written to lspost.cfile

• Created in same directory as input file

• Can be modified to help automate repetitive tasks

• Call other command files using “include” statements

• Skip commands using “skip” and “endskip”

• Enter interactive mode using “interactive” (us Esc key to continue)

3 ways to execute command files: • File > Open > Command File

• lsprepost c=commandfile.ses

• lsprepost c=commandfile.ses –nographics

236

Command File (continued...)

Parameters can be used in command file

• Parameter definition can be numbers or strings

parameter directory “c:\Home\Test\problem\”

parameter rotang “45.0, 0.0, 30.0”

parameter filename “testcase1.key”

• Use “&” to mark parameters

open d3plot &filename

• Use “{“ and “}” when combining parameters

open d3plot &{directory}&{filename}

Command file structure is not yet fully documented, but more commands and details can be found here: • http://www.lstc.com/lspp/content/other/command/command.shtml

237

http://www.lstc.com/lspp/content/other/command/command.shtml

Misc. → Macro Interface Purpose: load and execute macros

Macros allow multiple commands to be grouped and executed as often as desired

Parameters can be used in macro files

Parameters can be defined on the fly (see “matid” and “fname”)

Macro syntax... • *macro begin name

Command 1

Command 2

Command 3

• *macro end

238

Misc. → Macro Interface (continued...)

Macro example... • *macro begin plot_matsum

ascii matsum plot 2 &matid

raisewin

xyplot 1 savefile curve_file C:\temp\&fname 1 all

• *macro end

239

Function Keys

F1 launches Function Key interface shown below (shows layout of the function keys)

Except for F1 and F10, all other function keys can be programmed to act as a button

Also, a command file with the name F#.cfile can be called using F# (place file in current working directory)

Function keys can be customized in the configuration file (lsppconf)

240

Configuration File

241

Configuration File (lsppconf)

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

• 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 will be used

Not all parameters are required (to simplify, define changed parameters only)

Use File > Save > Save Config to save file lsppconf in your application data folder

242

Workshop 9 (optional)

eZ-Setup From IGES Surfaces – NUMISHEET2008 B-pillar

243

244

NUMISHEET2008 B-pillar

Procedures

Import IGES files:

Numisheet08-BM03-Blank.igs

Numisheet08-BM03-Blankholder.igs

Numisheet08-BM03-Dies.igs

Numisheet08-BM03-Punch.igs

drawbeads.iges

Automesh/deviation, use these parameters

Mesh blank, element size=20mm;

Check model – free edge, dup nodes, Jacobian, normals, etc.;

Position tools into home position, blank thickness=1.95mm;

Measure distance first, then EleTol/Transf/translate by part;

Blank position does not need to be moved.

Activate eZ-Setup, air draw:

Process: gravity (prebend along Y-axis) + forming;

Use material BH210.

245

246

Procedures

Draw beads definition

Select all four draw bead curves and define them as draw beads;

Check for tensile value;

Modified fore and aft draw beads to 40% lock.

In “Control-gravity”, check for gravity prebend along Y-axis. In “Control-forming”, change

nothing.

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.



Pre-bending for Gravity

From true flat shape, all blanks have tendency to bend either in concave or convex shape.

Most blanks sent to a draw die (in air) are made sure it is in convex shape, either by pre-bending, suction cups, mechanical means, etc.

This new feature allows for SLIGHT AMOUNT of pre-bending of blank in either convex, or concave shape prior to loading onto the tools.

Done at the same time before the gravity loading is started

247


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

Bending axis

Sheet blank normal direction

Negative “R” means center of bending is on the opposite side of the positive

blank normal

Initial model set up

248


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

Gravity loaded blank without

prebending – Blank sags in the die

cavity (concave shape)

Pre-bending with R=10000.0mm using

this keyword (1st state of D3plots)

Gravity loaded shape (last state of D3plots) –

Convex shape blank achieved and binder

closing distance reduced

95mm

60mm

concave shape here

249

LSPP_eZSetup1

Documents

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linux lsprepost

morphing curve

support of ls

merge curve