LS-PrePost Forming Aug1st

240
Metal Forming In LS-PrePost 4.0 LSPP Metal Forming Development Team July 30, 2012 1

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Metal Forming In LS-PrePost 4.0

LSPP Metal Forming Development Team July 30, 2012

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Table of Contents

SECTION WORKSHOPS

LS-PrePost Overview -

General/Nodes/Element/Tool and blank

meshing/Tool mesh checkWorkshops 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

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LS-PrePost Overview

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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

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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

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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

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Input/Output

8

include:

dynain file

commandsession file(.cfile) 

LSPPdatabase file 

LS-DYNAresults file(d3plot)

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Job Scheduler

Details later

Must install using LSPP_setup.exe 

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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, SurfaceMorphing)

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, ReplaceFace, Stitch Faces, Trim Transform, Copy Entity, Management,

Heal, Topology Simplify, Measure)

12

Same menu system

with ICONs is at right  

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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, SPHGeneration)

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)

13

Same menu system

with ICONs is at right  

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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

15

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

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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 pixelMesh  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 shownRight-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)

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FEM General Selection

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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 bufferLoad 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

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Workshop 1General Operations

18

O k d fil d t t d l

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3

1

2

Directory: Workshop 1

4

Rotate model using Shift

with left mouse button

5

Open keyword file and rotate model:

A t C t

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2020

or Ctrl a1

Auto Center:

Di l i t d d i

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Display in standard views:

Display in different modes and background colors

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Display in different modes and background colors:

Select part for display: 2

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Select part for display:

1

2

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5

6

Shift with left click for

multiple selection

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10

Identify nodes/elements:

2

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Identify nodes/elements:

1

2

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left click to pick nodes

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8

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left click to pick elements

10

Identify material direction for anisotropic material:

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left click to pick elements

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1

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45

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Identify material direction for anisotropic material:

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

8

Anisotropic material (*MAT 036):

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Material axes

options, see below. 

Vector components ‘a’ for

AOPT=2.0, see below 

2626

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.

Anisotropic material (*MAT_036):

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

Element/model blanking (for display): 2

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Element/model blanking (for display):

1

2

3

Element/model blanking (for display):

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Element/model blanking (for display):

1

23

4

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Left click, hold and drag a box to

cover some portion of the die

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7

8

Element/model blanking (for display):

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1

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3

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Left click to pick an

element on the binder

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Element/model blanking (for display):

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Find a specific element or node:

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Find a specific element or node:

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2

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6

3

4

Find a specific element or node:

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Find a specific element or node:

Left click, hold and drag a box to

zoom in; then free rotate model

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1

2

3

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5

Modify part transparency:

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Modify part transparency:

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2

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Modify part transparency:

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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

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Reset transparency

9

10

12Change part color:

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1

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Left click to pick the part to

change color

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11

12Change part color:

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Workshop 2Mesh editing

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Open keyword file:

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p y

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Directory: workshop 2

Merge duplicate nodes:

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g p

Merge duplicate nodes:

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g p

Replace nodes:6

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p

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1

2

3

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5

Left click, hold and drag these boxes to include each

node pairs whose position are to be replaced

6

7

8

Create a triangular element:

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3

4

1

2

Left click to pick the part5

Left click to pick three

nodes to form a triangle,

right click for Node 4.

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g

Align nodes:

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12

Left click, hold and drag

to zoom in this area

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4

5

6

Left click to pick

these two nodes

7

Align nodes:

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Left clicks to form a polygonbox, right click to finish

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Split elements:

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Left clicks to form a polygon

box, right click to finish

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Fill a hole:

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Left clicks on a

boundary node

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Right click on

“2 LSHELL2” 

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Auto filling all holes:

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Save keyword file:

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Open keyword file:

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Directory: workshop 4

Detach some elements:

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Pick an element here

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3

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Check part separation:

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free edge display

2

1

3

p p

toggle switch

Change PID:

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Pick an element here

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g

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Change PID again:

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g g

2

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3 4

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Open keyword file:

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Directory: workshop 2

Element Tools → Offset (Tooling surface normal offset)

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Element Tools → Offset (Tooling surface normal offset) 

Element normals must be aligned before

offsetting

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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.  

Check part normals:

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1

2

3

Pick on part

Offset with Advanced option on:

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55Offset result with “Advanced” option on 

“offset –” is

opposite of normals

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Pick on part

5

Offset with Advanced option off:

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1

Pick on part2

3

Offset result with “Advanced” option off  

Translate (make copy) the flat area:

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10

Pick an element here

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2

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Measure part distance (method 1):

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10

Pick these two

nodes

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3

2

4

Measure part distance (method 2):

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Pick these two

nodes

Alternatively: part

separation, and others

1

2

3

4

3

Rotate a tool (make copy):

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Pick this node

as origin

Pick this part

as a source

Rotated part

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1011

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13

14

5

6

Make a mirror image of a tool:

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Pick this node as origin

Pick this part

as a source

Reflected part

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910

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6

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Make a projection of part of a tool:

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Select by ‘Polygon’ these

elements, right click to

finish the loop.

Elements selected

Elements projected

Pick this node as

location

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2

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1011

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13

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Scale (make copy) of a tool:

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Pick PID 2 as a

source

Scaled part 16

Pick this node as origin 1

2

3

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5

6

7

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10

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13

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15

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Workshop 3

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Mesh generation

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Import IGES file:

1

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3

1

2

Directory: Workshop 2

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N-line meshing/4-line meshing: 12

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3

1

2

4

Left click to pick four curves

in the order shown

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Import IGES file:

1

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3

1

2

Directory: Workshop 2

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N-line meshing/Line sweep:

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1

2

3

4

Left click to pick

the square curve

5

Left click to pick

this curve

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7

8

Creating a circle:

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1

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3

4

5

Left click to pick this point

as the center of the circle

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7

Creating a circle:

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1

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12N-line meshing/Line sweep:

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1

2

3

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Left click to pick this circle

Left click to pickthis curve

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Left click7

Left click8

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11

5

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Import IGES file:1

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3

2

Directory: Workshop 3

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Meshing binder:

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1

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3

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5

Left click to pick thebinder surface

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5 6

Meshing die:

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1

Left click to pick thebinder surface

2

3

4 5

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Change meshing parameter for a finer mesh:

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Right click on

“2 LSHELL2” 

1

2

3

4

6

5

7

8 9

For advance

feasibility

Compare tool meshes:

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78

30

0.2

0.05

10

For springback

20

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Workshop 4Blank Meshing

79

Open keyword file:1

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80

32

4

Directory: workshop 4

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Shape meshing/4N_shell:

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82

Pick nodes

More

options

Pick these four nodes

1

2

34

5

6

7 8

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Blank Meshing(method 2 – surface required)

83

Create two boundary lines:

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84

Pick these two nodes

two create a line

Pick these two nodes

two create a line

123

4

56

7

Create a planar surface:

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85

Pick the line

 just created

Pick the line

 just created

1

2

3

4

5

Blank meshing:

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86

Pick the surface

 just created

1

23

4

5

6

7 8

Toggle geomtry display on/off:

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87

Toggle geometry

display on/off1

Display mesh just created:

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88Note: do not exit LSPP – this model will be used for next step.

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Translate (make copy) a line:

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90

Pick this line created as

‘Source Entity’ 

Right click to blank out

the BSpline Face

Line translated

1

2

4

3

5

6

7

8

9

Meshing by two line:

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91

Pick these two lines

Mesh created

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2

3

5

6

7

4

8 9

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Workshop 4Tool mesh Check  

92

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. 

Open keyword file:1

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32

4

Directory: workshop 4

Duplicate nodes check: Tool mesh normal check:

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94

Normal orientations:

blank normal up, upper

tools normal down,

lower tools normal up;

1

2

3

4

5

6

1

2

3

Note: no duplicated nodes in this model

4pick the part, moredetails next page

5

Tool mesh normal check:

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95

Shaded element mode

for color display;

Wireframe mode for vector display;

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.

Pick the part. Wire frame

mode: vector display in

wireframe mode.

2

3

4

4

Tool mesh normal reverse by part:

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96

1

2

3

Pick any element

4

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

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97

1

2

3

6

Pick any element

7

8 – pick the

same element

x

9

10

4

Note: auto rev. works within one part boundary

5

Tool mesh free edge check:

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98

3

1

2

Toggle this switch to turn

on/off free edge display

4

5

Make sure background

color is black:

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

Read keyword file ‘zeroJacobia_30632.k’ into LSPP and do the following check: 

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99

1

2

3

4

0.055

6

7

8

Jacobian Check: Contour display:

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100

Element 30632 has all three nodes on a straight line

Jacobian Check: Identify element with ID:

2

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101

1

2

3

4

Message indicate this is a triangular element

3

Jacobian Check: Delete bad elements from the buffer:

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102

2

4

5

6 7

8

1

9

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eZ-Setup for Metal Forming

103

Development Objective

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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

104

Current Capability - eZ-Setup

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Guided GUI features:

Air and toggle draw, flanging;

Air draw with upper pad;

User-specifiable cushion travel;

One LS-DYNA run for typical process simulationcombination;

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 elementchecking/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; 105

Current Capability (Con’t)

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Automatic recognition of ELFORM and NIP from incoming dynain

file; User material library.

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

106

Installation & File Structure

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108

Opening a DYNAIN file (forming

result of sheet blank)

108

g y

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

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Metal Forming Graphics User Interface(GUI) is designed to ease the simulation

set up and inputs in LS-DYNA. 

Easy Setup

General Setup

109

Keyboard shortcut:

Ctrl q 

109

Metal Forming → Toolbar 

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110

Metal Forming Pre

Metal Forming Post

110

Metal Forming → eZ Setup

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Forming draw type

  Air draw

  Toggle draw

Support contact offset

Multiple forming

processes

  Gravity

  Forming

  Trimming

  Spring Back

  Flanging

  Closing (implicit)   Tipping

111

Note: current version does not support

the use of the same process twice.

111

Metal Forming → Die definition 

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Pick a part

Import a part

Mesh generation

112112

Metal Forming → Binder definition 

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Pick a part

Import a part

Mesh generation

Offset from Die

Travel limitation

113113

Metal Forming → Punch definition 

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Pick a part

Import a part

Mesh generation

Offset from Die

114114

Metal Forming → Blank definition 

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Pick a part

Import a part

Blank Mesher

Translate

Symmetry condition

Adaptive Box Define

Support Tailor welded Blank

Material

Thickness

115115

Metal Forming → DrawBead definition

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Draw bead generator

Import IGES curve

Draw bead project

Draw bead modify

Full lock force calculate

116116

Metal Forming → Control option (Gravity Loading)

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( y g)

Blank Pre-bending

117117

Metal Forming → Control option (Forming)

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( g)

For early feasibility

For formability

For spring back

User define parameters

 Allow additional pad

 Kinematics simulation

118118

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Metal Forming → Control option (Spring back)

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( p g )

Constrained

Inertia Relief

Pick node

Pick Location

Enter coordinate

120120

Metal Forming → Control option (Flanging)

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g g

Pre-adaptive along curve

Contact offset

Multiple flanging steels

121121

Metal Forming → Control option (Tipping)

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Define tipping center

Translation

Rotation along an axis

122122

Metal Forming → Job submit 

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File folder browse

Subdirectory (option)

Input file name

Case files for multiple

processes.

123123

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Workshop 5

A flanging process set up with multiple flanging steels moving

in local directions 

124

3

1

5 6

2

8

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125

9

4

7, use “import offset” 10

Directory: Workshop 5

11

12

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1

23

4

5

6

126

Pick blank to define,

right click to return

1

2

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Blinking yellow prompting

for blank definition; turns

green when it is defined.

3

6

0.7 5

4

Click this button if your

material file is in the

current working directory.

127

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

Select these curves to

define mesh pre-adapt.

3

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Optional tool

kinematics simulation

12

5

0.9 4

128

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Blinking yellow prompting for

pad definition; turns green

when it is defined.

Pick pad to define,

right click to return

2

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Optional force on pad

1

3

130

Blinking yellow prompting for

flanging steel definition; turns

green when it is defined.

Pick this flanging steel to

define, right click to return

2

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1

131

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

Click to add an extra flanging steel.

5

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Default option:geometric points; other

options as shown

3

1

1324

From

To

2

Pick this flanging steel to

define, right click to return

2

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1

5

7

3

From

To

4

Repeat the process to

define Flg3 and Flg4

1336

8

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

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1

134

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

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1

2

3

135

Key in file name as:

sim.dyn

1

Save project file (overwrite existing project file):

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Note: Project file is an important database file,

containing complete model information andeZ-Setup information. It can be reloaded back

into LSPP for changes in process or models.

136

23

2 3

METHOD #1

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13

4

5

6

7

8

9

Disadvantage: Can’t use LSPP

when running LS-DYNA 137

Running LS-DYNA in windows with a command file:

R6s.cmd

METHOD #2

Simulation involving gravity, springback,

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End of simulationBeginning of simulation

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

use ‘edit’ to add the following command; 

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

138

static implicit must use double precision

(DP) solver

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

DP solver slower than SP solverUse: single precision for this run

Processing Results

Open d3plot files from your running directory

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Open d3plot files from your running directory Animate the flanging process

139

1

2 3

46 7

5

89

Processing Results

Plot thinning/thickness

2

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Plot thinning/thickness Change contour range

140

1

4

34

5

6

7

8

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Workshop 6 

A process of gravity, draw, trimming, tipping, flanging and

springback set up

141

3

1

2

5

8

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142

6

11

12

Directory: Workshop 6

4

10

7

9

Define the following process:

Gravity

Forming

Trimming

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1

2

3

143

Trimming

Tipping

FlangingSpringback

Append to the last

Click on one already “selected

process” in the left box, click on

the “available process”, thenclick on this button, it will insert

the latter in front of the former.

left click to pick the die,

right click to return

2

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1

3

144

Left click to pick the binder,

right click to return

2

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1

3

145

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1

Left click to pick the blank,

right click to return

2

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Define

material/thickness

1

3

5

6

147

4

Left click to pick BOTH curves to define

draw beads; right click to return.

6

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148

5

1

2

3 4

9

7

8

Input tensile strength

in MPa (default is for

mild steel)

Picked curves automatically

projected to binder.

Default lockage: 50%

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149

1

9

next screen

Modify % lockage (next

screen)

Default lockage: 50%.

Bead lock %

modification2You can pick bead

here directly

3

3 – pick here orpick directly onthe bead

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150

4

5

76 – pick here orpick directly on

the bead

8

You can pick bead

here directly

6

9

1

Save project file (overwrite existing project file):

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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.

151

23

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Three computing levels tobalance speed and accuracy.

Optional selective mass scaling – for inertia effect reduction.

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Optional tool kinematics simulation.

Show/modify tool

speeds, etc.

(details next page)

Optional upper

pad (for air draw)

1

153

 Additional control on accuracy/speeds:

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154

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.

2

4

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1 3

5

6

155

More options to

define vector.

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

1

5 – pick curves

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1

2

Note: 2-D trimming can have multiple curves

 forming a ENCLOSED loop .

3

4

156

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2

3

157

1

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Blinking yellow prompting for

flanging post definition; turns

green when it is defined.

Left pick post to define,

right click to return

2

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1

3

159

Blinking yellow prompting for

pad definition; turns green

when it is defined.

Left pick pad to define,

right click to return

2

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Optional force on pad

1

3

160

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

2

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1

3 – follownext page

161

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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

162

3

7

Constraint-free springback

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1

2

163

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

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1

2

3

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Key in file name as:

sim.dyn

1

Save project file (overwrite existing project file):

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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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2

3

LS-DYNA input files for running the process simulation:

Control files copied from Lspp_forming

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

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

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Processing Results

Select case15 (trimming) as shown:

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Plot thinning/thickness for trimming

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4

Processing Results

Select case20 (tipping) as shown:

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Plot thinning/thickness for tipping

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3

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Processing Results

Select case30 (springback) as shown:

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Animate springback Plot dZ and resultant Z (next page)

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2

1

3

Change contour range (optional)Plot springback amount in Z2

4

3

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1

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Workshop 7

TWB Forming + Springback (constrained)

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3

1

2

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4

Directory: Workshop 7

Define process:

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Hit “next” to define die,

binder, punch.

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Pick the red piece as “blank1”

Define blank1:

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Pick the red piece as blank1  

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Use BH210.k

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1

2

Redefine symmetric boundary conditions:

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3

4

Pick on this edge of any

element along the symmetry

5

6

7

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skip “draw bead” 

Select these before

picking

node/location

Define springback constraints:

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1

2

3

1

23

node/location

Always pick locations on

final tool position (whereblank is in contact)

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Not much to do here

Define Forming control:

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Output simulation input files:

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Key in file name as:

sim.dyn

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1

Save project file (overwrite existing project file):

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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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2

3

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

Running LS-DYNA in windows with a command file:

R6d.cmd

use ‘edit’ to add the following command; 

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

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Use: double precision for this run

Processing Results

Open the following d3plot files in LSPP, one after another: case5.d3plot case10 d3plot

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case10.d3plot Select case5 (forming) as shown:

Animate punch contact Plot THINNING for forming

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Processing Results

Select case10 (springback) as shown:

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Animate springback Plot dZ and resultant Z (next page)

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2

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3

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Future Work - eZ-Setup

Unlimited, flexible processes allows for progressive dies simulationin one setup and one run.

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p 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.

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Animate punch contact/part breakdowns:

21

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5

6

workshop8

Create a movie (AVI):

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2

1

3

Cut a section plane:

2

3Pick this node

4

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194194

1

5

6

7

2

Cut multiple planes:

Save multiple cut sections

in keyword format:

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31

4

2

1

3

45

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.

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Set contour range for thickness/thinning contour:

Thickness range: Thinning range:

1

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2 2

3 3

4 4

Save a JPG file for the screen display:

1

3

4

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2

5

Plot thickness distribution along a section:

1

2

3

Pick a node close

to this node

4

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5

6

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Changing the thickness of a section plot in contour:

2

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1

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

2 - Translate curves:

3

3 - Change curve color:

1 - Import IGES file: newtrim1.iges1

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right click

1

2

4 – red color boxmeans current pick

5

6

8 – multiple

times

7

12

3

4

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Set contour range for mean stress:

1

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negative tensile

 positive yield2

3

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

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1

2

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Measure blank edge draw-ins:

Write closing blank meshing as a keyword file.

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209209

1

2

3

4

5

67Write file as S6.k

3

Measure blank edge draw-ins:

Write formed blank mesh as keyword file4

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210210

1

23Write file as S17.k

Measure blank edge draw-ins:

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

1 2

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3

Measure blank edge draw-ins:

Translate binder closed blank mesh down.

37 – pick part

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4

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8

1295

Measure blank edge draw-ins:

Measure distance between edge nodes.

34 – pick edge

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1

2

3nodes in pairs

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Create blank edge curves for state #6:

2 – pick the blank

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1

3

1

Turn off all FEM parts:

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1

2

Translate state #6 blank edge down 141mm:

3

4 – pick this curve

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8

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Plot tool tonnage: Open ‘ rcforc ’ file in Workshop 8/Forming

In MPP, the file name is ‘binout0000’  

34

5

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219219

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Note: 1 English ton=8900 Newton

Plot sheet blank mass increase:

34

5

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220220

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

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2

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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

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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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Post → History (continued...) 

Standard plotting options...

• Plot – plot selected value in current Plot Window

• New – plot selected value in new Plot Window

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• 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

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

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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

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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 and Macros

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Command File (continued...) 

Parameters can be used in command file

• Parameter definition can be numbers or strings

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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 

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Misc. → Macro Interface Purpose: load and execute macros

Macros allow multiple commands to be grouped and

executed as often as desired

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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

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Misc. → Macro Interface (continued...)  Macro example...

• *macro begin plot_matsum

ascii matsum plot 2 &matid

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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)

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Except for F1 and F10, all other function keys can beprogrammed 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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Configuration File (lsppconf) LS-PrePost searches for this file in these directories in the following

order...

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• 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 willbe 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

Procedures Import IGES files:

Numisheet08-BM03-Blank.igs

Numisheet08-BM03-Blankholder.igs

Numisheet08-BM03-Dies.igs

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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.

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

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.

Simulation involving gravity,

springback, static implicit must

use double precision (DP) solver

DP solver slower than SP solver

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.

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

Done at the same time before the gravity loading is started

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

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Bending axis

Sheet blank

normal

direction

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

Initial model set up

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

concave shape here

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Gravity loaded blank withoutprebending – Blank sags in the diecavity (concave shape)

Pre-bending with R=10000.0mm usingthis keyword (1st state of D3plots)

95mm