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Autostamp v2004Autostamp v2004

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AutostampAutostamp

Autostamp:

Accurate simulation and quality control

Simulated processes:

Gravity, Holding, Forming simulations

Flanging operations

Springback

Pressure forming (hydroforming, aquadrawing, rubber pad)

Tube bending processes

Fully multistage

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Flowchart autostampFlowchart autostamp

Flowchart AUTO-Stamp

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Open projectOpen project

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ImportImport

Import

CAD Mesh Computed model Diemaker

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Create objectsCreate objects

Stamp 2G is fully OBJECT oriented…

Group of entities (elements, nodes …) on which attributes are defined

NB:

Entity can belong to several objects

Only one definition of an attribute per entity

Plane object Symmetry attribute

Coordinate system object No attribute

Material

Kinematics

Loading

…

Surfaces

Elements

Edges

Nodes

OBJECT

Entities (Hierarchy)Attributes

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Object oriented

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Create objectsCreate objects

Which objects are required depends on the type of simulation :

•Gravity simulation (Double action)

•Holding simulation (Double action)

Necessary objects : full die

blanksheet

Optional objects : symmetry plane

guides

locator pins

Necessary objects : full die

blanksheet

blankholder

Optional objects : symmetry plane

guides

locator pins

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Which objects are required depends on the type of simulation :

•Forming simulation (Double action)

•Springback simulation (Implicit)

Necessary objects : full die

blanksheet

blankholder

punch

Optional objects : symmetry plane

support

drawbeads

Necessary objects : blanksheet

3 fixation points

Optional objects : symmetry plane

trimming line

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Which objects are required depends on the type of simulation :

•Pressure forming

Necessary objects : full die

blanksheet

Optional objects : symmetry plane

punch

blankholder

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Minimum requirement at this stage: Full die geometry

Also possible to import ALL the tools

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

How???

First create two objects from the full die geometry :

• The lower blankholder area (offset will be the upper blankholder)

• The die bottom area (offset will be the punch)

Autostamp requires the definition of all the tools used in reality :

If you have imported just 1 object (the full die geometry) you can

create the punch and the blankholder by using the toolbuilder

macro

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Create objects by selecting entities

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Create objectsCreate objects

Then :

Use the toolbuilder macro

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Toolbuilder macro

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Create objectsCreate objects

Now all TOOL geometries needed for a basic simulation are

available:

- Lower blankholder

- Die bottom

- Punch

- Upper blankholder

BLANKSHEET???

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

1. Import CAD <ref import tools>

2. Import MESH <ref import tools>

3. Use the blanksheet macro

Options for BLANKSHEET :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Blanksheet macro

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Create objectsCreate objects

Now all TOOL geometries and the BLANKSHEET geometry needed

for a basic simulation are available:

- Lower blankholder

- Die bottom

- Punch

- Upper blankholder

- Blanksheet

Are drawbeads present in the reality?

If so, they should be implemented also in the simulation model. Simulations make use of EQUIVALENT drawbead models, where the actual drawbead geometries are represented by bar elements which exert forces (opening <ONLY AUTOSTAMP> and restraining) on the blanksheet

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

1. Import CAD <ref import tools, line import>

2. Import MESH <ref import tools>

3. Create the BAR elements manually (Geometry – Edition – Elements)

Options for geometry DRAWBEADS :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Options:

Pick/enter points

Pick nodes

Transform edges

Transform curves

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

1. Import CAD <ref import tools, line import>

2. Import MESH <ref import tools>

3. Create the BAR elements manually (Geometry – Edition – Elements)

Options for geometry DRAWBEADS :

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Create objectsCreate objects

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

1. Import CAD <ref import tools, line import>

2. Import MESH <ref import tools>

3. Create the BAR elements manually (Geometry – Edition – Elements)

4. Drawbeads are exported from diemaker module

these are 3D curves, transform to bar elements!!!

NOTE:

If a drawbead is a straight line, only 1 bar element suffice

Options for geometry DRAWBEADS :

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If your model is symmetrical, it saves a lot of calculation time if you only consider one half (quarter, …) of the model and use symmetry conditions instead

Create objectsCreate objects

Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed

for a basic simulation are available :

- Lower blankholder

- Die bottom

- Punch

- Upper blankholder

- Blanksheet

- Drawbeads

How????

Use symmetry planes

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Creation of a symmetry plane :

Create object

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

NOTE:

perform the creation of a symmetry plane before

doing offsets of symmetrical tools

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Create objectsCreate objects

Creation of a symmetry plane :

Best to choose a node on the symmetry edge of your tool

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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What else needs to be defined???

Create objectsCreate objects

Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed

for a basic simulation are available and symmetry is applied.

- Lower blankholder

- Die bottom

- Punch

- Upper blankholder

- Blanksheet

- Drawbeads

- Plane symmetry

In case the global +Z axis is not the stamping direction, a local axis system should be created if the macro is to be used

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Creation of objects :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Create object

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Create objectsCreate objects

Creation of a local axis system :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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What else needs to be defined???

Create objectsCreate objects

Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed

for a basic simulation are available and symmetry is applied.

- Lower blankholder

- Die bottom

- Punch

- Upper blankholder

- Blanksheet

- Drawbeads

- Plane symmetry

- Local axis system

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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1. Import CAD <ref import tools>

2. Import MESH <ref import tools>

3. Use accessory macro

Create objectsCreate objects

Guides / Locator pins :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Accessory macro

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1. Import CAD <ref import tools>

2. Import MESH <ref import tools>

3. Create a line manually : Geometry – Edition – 3D curves

Create objectsCreate objects

Trimline (3D curve) :

Pick/enter points

From bars

From edges

From 3D curves

From section

From free edges

Elliptic

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

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Create objectsCreate objects

Other manipulations of objects :

Surface tool Surface blank Drawbead Coord system Symmetry plane Other

Object manipulations Object transformations

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Create objectsCreate objects

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MaterialMaterial

Starting point: All necessary objects are present

Surface tool: Non deformable material

function: Geometry representation

Surface blank: Deformable material

Material in database Material introduction

Deformable Non-deformable

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MaterialMaterial

REMINDER: use consistent unit system, eg:

mm – kg – ms kg/mm3, kN, kNmm, kN/mm2 (GPa)

Deformable Non-deformable

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Process parametersProcess parameters

2 approaches to define the process:

1. Use the AUTOSTAMP-macro (for BASIC simulations)

2. Define the process manually

Macro User-defined

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Process parametersProcess parameters

1. AUTOSTAMP macro

Macro User-defined

Autostamp macro

Auto-position

Control

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SolverSolver

Starting point: -All necessary objects are created

-Attributes are added to objects

Solver can be started from within the program environment:

Solver - Start

Type Location

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SolverSolver

Starting point: -All necessary objects are created

-Attributes are added to objects

Name reference name

Type Location

Host local host or network workstation (IP adress or name)

Exe find the psolid.x (UNIX) or pamstamp_SMP-SP (PC)

every .exe should have it’s own host entryMessages $PAMHOME/stamp/2004_COMMON/Messages$PAMHOME\2004.0\Common\Messages

Solver type UNIX or Windows, Mono, SMP, DMP

Script UNIX: $PAMHOME/pamstamp/v2004/pamworld

PAMHOME in case of nfs/samba: UNIX installation directory

Equivalence if the solver is on another PC/workstation the user needs

to define the equivalent mounting points (shared!!!)

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SolverSolver

The solver can also be started from the UNIX command line:

Pamstamp –nt NPROC Input.pre > Input.out &

Pamstampdp –nt NPROC Input.pre > Input.out &

Pamstampdmp –np NPROC Input.pre > Input.out &

Pamstampdmpdp –np NPROC Input.pre > Input.out &

In Windows a pamstamp v2004 solver icon is available :

Type Location

PAM-STAMP 2G Solver 2004.0.lnk

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SolverSolver

1. Use SINGLE PRECISION (SP) solver for all calculations except implict springback (DOUBLE PRECISION, DP)

2. The attribute ‘Surface tool with material’ must be defined once for every entity (solver related) in the ‘all stages’ object definition

3. Autostamp is fully incremental: it is possible to view the initial state, the final state AND intermediate states

4. DMP and SMP runs are available and can be started from within the program (also from prompt)

5. If convergence problems are encoutered with the implicit gravity, try :

- the DP solver

- eliminate the blankholder walls

- check normal orientation

Important:

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SolverSolver

Before running the autostamp calculation, it’s also possible to use the

‘Save As…’ option to save the file as a Quikstamp FP file and do a fast

initial run to see quickly qualitative results…

Note:

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SolverSolver

Note:

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Post analysisPost analysisAnalyse possibilities:

Global:

1. Radii and angles2. Distances3. Entities4. Model differences5. Section check

Contour plots:

1. Thickness [thickness, thinning]2. Stress [major, minor, plastic…]3. Strain [major, minor, plastic…]4. FLD [stress, strain]5. Kinematic [displacements]6. Energy [internal, shear…]7. Mesh quality [inner angles, area…]8. Undercut9. Numerical [refinement level, wrinkle criterion]10. Contactpressure [normal, tangential]

Post analysis