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LSPP Metal Forming Development Team July 30, 2012
Table of Contents
SECTION
LS-PrePost Overview General/Nodes/Element/Tool and blank meshing/Tool mesh check eZ-Setup for Metal Forming - Overview eZ-Setup Workshops Post-Processing Command File and Macros Configuration File eZ-Setup from IGES (optional)
WORKSHOPS
Workshops 1~4 Workshops 5~7 Workshop 8 (NUMISHEET02 fender outer Workshop 9 (NUMISHEET08 B-pillar)
LS-PrePost Overview
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)
Online Resources
ftp://ftp.lstc.com/outgoing/lsprepost/4.0/Metalforming/LS-PrePost-4.0-X64_setup.exe
Official Website
http://www.lstc.com/lspp
User Group
http://groups.google.com/group/ls-prepost
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
GUI Layout
Menus
File management & preferences
Right Toolbar
Access to pre and post-processing tools
Graphics Viewport
Command Line
Input (left) / Output (right)
Bottom Toolbar
Model rendering controls
Input/Output
LS-DYNA results file (d3plot) include: dynain file command session file (.cfile) LSPP database file
Job Scheduler
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, 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)
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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, 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)
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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
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
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 Edge Grid Mesh Display elements in feature line mode (default angle=30) Display elements in edge line mode Display each nodal point as a colored pixel Toggle element mesh on/off Persp Frin Unref Toggle Fringe/Line-contours/Iso-surfaces Toggle unreferenced nodes on/off Clear ActAll Anim 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) Toggle Parallel/Perspective view mode Clear all picked or highlighted information Restore all entities to be active Display animation controls or start/stop animation ShfCtr Toggle Off/Shift/Ctrl (for one-handed rotate/pan/zoom) AutCen Automatically center model to fit within window ZoIn Zout Pcen Top Zoom in, click and drag to draw a box Zoom out to previous zoom position Pick node as new center point for model rotation Choose Top, Bottom, Front, Back, Right, or Left view
EdgGeo Display geometry in shaded mode with edges on ShaGeo Display geometry in shaded mode with edges off WirGeo Display geometry in wireframe mode
BacCol Toggle background color black/white (Plain background mode only) SelPart Launch Assembly and Select Part interface ResPart Restore the last removed part (Shift+R)
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Deselect Undo last selection Whole Select all entities in model Visible Select all visible entities Reverse Reverse selection
Out
Add Rm ID Label
BySet
ByEdge Edge based selection BySegm Segment based selection Point Curve Select points Select Lines
3Dsurf Select outer surface (solids only) Prop Adap Ang Propagate selection (pick seed) Propagate across adaptive elements Feature angle for propagation
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Workshop 1
General Operations
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Directory: Workshop 1
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Auto Center:
or Ctrl a
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2 3 4 5 6 7 8
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3 10 1 2 4
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Identify nodes/elements:
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2 3 8
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4 6 8
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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.
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Left click, hold and drag a box to cover some portion of the die
8 7
3 4
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2 3
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Left click, hold and drag a box to zoom in; then free rotate model
3 4
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Left click to pick the top of the model to make upper transparent
4 5 2 10
Reset transparency
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12
1 5
7 8 9 6
11
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Workshop 2
Mesh editing
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2
3
Directory: workshop 2 4
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4 5 3 1 2
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2 3
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Replace nodes:
Left click, hold and drag these boxes to include each node pairs whose position are to be replaced
5 1 7 8 2
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Left click to pick three nodes to form a triangle, right click for Node 4.
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Align nodes:
3
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Align nodes:
10 12
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Split elements:
3
1 7
2
6
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Fill a hole:
3 9
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11 12
13 15
14
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2
3
Directory: workshop 4
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2 1
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Change PID:
3 4 2
1 5
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2
3
Directory: workshop 2
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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.
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Pick on part
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2 5
Pick on part
1 4
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Pick on part
1
3
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4 5 10 2
10
5 7 6
11
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10 4
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Rotated part
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1 6
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8 11 10
14
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Reflected part
4 5
1 6
12
8 9
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4
5
2 7
Elements projected
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11 12
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15
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Scaled part 16
6
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Workshop 3
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Mesh generation
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Directory: Workshop 2
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6 7 8
2 1
9
10 11
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Directory: Workshop 2 4
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4 2 6
7 8
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Creating a circle:
6 3 1 4 2
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Creating a circle:
2 3
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Left click
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Left click
9 10 11
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Tool meshing
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Directory: Workshop 3 4
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Meshing binder:
2 6 3
5 5 6
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Meshing die:
1 4 5
6 3
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5 1
7 8 9
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For springback
20 0.2 0.05 10
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Workshop 4
Blank Meshing
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2
3
Directory: workshop 4
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Blank Meshing
(method 1 no surface required)
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Shape meshing/4N_shell:
2 4 5 3
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Blank Meshing
(method 2 surface required)
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5 7
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Blank meshing:
6
3 4
1 5 7 8
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Note: do not exit LSPP this model will be used for next step.
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Blank Meshing
(method 3 Requires points/nodes, curves, or, surfaces)
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1 6
7
8 5 9
Line translated
90
2 5
6 7
Mesh created
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Workshop 4
Tool mesh Check
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.
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2
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Directory: workshop 4
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4 5
1 2 6 5
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Pick the part. Wire frame mode: vector display in wireframe mode.
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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.
Wireframe mode for vector display; Shaded element mode for color display;
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Tool mesh normal Auto Reverse reverse a part normal based on one seed element normal
3 7 6 4
1 10
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Jacobian Check:
check for zero or very small Jacobian, and save into a buffer for deletion
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Read keyword file zeroJacobia_30632.k into LSPP and do the following check:
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4 0.05
6 8
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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 postprocessing of metal forming results
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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
Opening a DYNAIN file (forming result of sheet blank)
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. 108
Metal Forming Graphics User Interface (GUI) is designed to ease the simulation set up and inputs in LS-DYNA.
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Note: current version does not support the use of the same process twice.
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Pick a part Import a part Mesh generation Offset from Die Travel limitation
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Pick a part Import a part Blank Mesher Translate Symmetry condition Adaptive Box Define
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Draw bead generator Import IGES curve Draw bead project Draw bead modify
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Blank Pre-bending
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For early feasibility For formability For spring back User define parameters
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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
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Workshop 5
A flanging process set up with multiple flanging steels moving in local directions
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1 2 5 8 3 6
11 12
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3 5
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Blinking yellow prompting for blank definition; turns green when it is defined.
3 0.7 Click this button if your material file is in the current working directory.
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6
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Selective mass scaling option 3 Select these curves to define mesh pre-adapt. Mesh Pre-adapt option Three computing options to balance speed and accuracy. Show lists detailed pre-set default variables, changeable by users.
1 2
0.9
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Blinking yellow prompting for flanging post definition; turns green when it is defined.
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Blinking yellow prompting for pad definition; turns green when it is defined.
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Blinking yellow prompting for flanging steel definition; turns green when it is defined.
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Click to add an extra flanging steel. Pick two END points of the line to define the flanging steel moving direction Blinking yellow prompting for flanging direction definition; turns green when it is defined.
From
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1
3 To
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From 4
5
To
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2 3
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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METHOD #1
2 3
3 1
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METHOD #2
Running LS-DYNA in windows with a command file:
R6s.cmd use edit to add the following command; double click the file 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
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Processing Results
Open d3plot files from your running directory Animate the flanging process
1 2 3
6 5
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Processing Results
2
1 7
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Workshop 6
A process of gravity, draw, trimming, tipping, flanging and springback set up
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1 2 5 8 3
Directory: Workshop 6 4 7 10
11 12
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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. 3
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Define material/thickness
3 5 6
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6 Left click to pick BOTH curves to define draw beads; right click to return.
1 7 8
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1 next screen
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2 3
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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4 Pick trim seed on a punch or die node/ location where trimmed part will remain
2 Turns green when defined. Default adaptive mesh for trimming Default element checking/fixing.
Define vector
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For Information Only: merge curves into a single ENCLOSED curve (loop) requited for 3D trimming:
5 pick curves 1 3 4
Note: 2-D trimming can have multiple curves forming a ENCLOSED loop .
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Selective mass scaling option to reduce inertia effect (not for implicit option)
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Blinking yellow prompting for flanging post definition; turns green when it is defined.
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Blinking yellow prompting for pad definition; turns green when it is defined.
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Blinking yellow prompting for flanging steel definition; turns green when it is defined.
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5 4
Pick the two END points along this line to define the flanging steel moving direction
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Constraint-free springback
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2 3
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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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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Processing Results
Open the following d3plot files in LSPP, one after another: case5.d3plot case10.d3plot case15.d3plot case20.d3plot case25.d3plot case30.d3plot Select case10 (forming) as shown:
3 1
Processing Results
Select case15 (trimming) as shown:
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Processing Results
Select case20 (tipping) as shown:
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Processing Results
Select case25 (flanging) as shown:
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Processing Results
Select case30 (springback) as shown:
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Workshop 7
TWB Forming + Springback (constrained)
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1 2 3
Directory: Workshop 7 4
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Define process:
Define blank1:
Use BH210.k
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Define blank2:
Define blank2
Use BH210.k
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5 6
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1 2 2 3
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2 3
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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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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Processing Results
Open the following d3plot files in LSPP, one after another: case5.d3plot case10.d3plot Select case5 (forming) as shown:
Processing Results
Select case10 (springback) as shown:
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Workshop 8
Post-Processing
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6 workshop8 3
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2 1
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3 2
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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.
1 3
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3 4
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Left click and drag over the part for live updates.
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8 multiple times
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2
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Plot FLD:
2 6 need to select
7 1
0.2 8
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Pick location
1 2
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Measure blank edge draw-ins: Write closing blank meshing as a keyword file.
5 3
6 2
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Measure blank edge draw-ins: Write formed blank mesh as keyword file
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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.
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Measure blank edge draw-ins: Translate binder closed blank mesh down.
7 pick part
4 5 129 2
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6 7
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Open rcforc file in Workshop 8/Forming In MPP, the file name is binout0000
3 5
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3 5
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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 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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Plot Window
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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 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
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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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Macro example...
*macro begin plot_matsum ascii matsum plot 2 &matid 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) 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)
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Configuration File
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LS-PrePost searches for this file in these directories in the following order... LSTC_FILE directory Users 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
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Workshop 9 (optional)
eZ-Setup From IGES Surfaces NUMISHEET2008 B-pillar
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NUMISHEET2008 B-pillar
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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.
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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. In Control-gravity, check for gravity prebend along Y-axis. In Control-forming, change nothing. Simulation involving gravity, Save a project file, and output simulation file. springback, static implicit must Run simulation using a command file (METHOD 2) use double precision (DP) solver Try removing gravity from the process, just run the DP solver slower than SP solver 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. 237
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
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Bending axis
Negative R means center of bending is on the opposite side of the positive blank normal
60mm Gravity loaded shape (last state of D3plots) Convex shape blank achieved and binder closing distance reduced
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