w03 Break Forming Mar101

WORKSHOP 3 BREAK FORMING

MAR101, Workshop 3, September 2008 Copyright 2008 MSC.Software Corporation

WS3-1

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Model Description ●

A flat sheet is formed into an angled bracket by punching it through a hole in a rigid table. The cylindrical punch drives the sheet (workpiece) to a total stroke of 0.3 inch. The punch then returns to its original position. This exercise makes use of simple, straightforward movements movements of rigid bodies.











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Objective ●

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Illustrate setting up of a multi-step analysis and the use of rigid surfaces charged with shaping a malleable workpiece.

Required ●

break_forming.igs











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Suggested Exercise Steps 1. 2. 3. 4. 5. 6. 7.

Import the geometry from an IGES file. Mesh the workpiece. Create the material properties. Apply boundary conditions, and contact bodies. Create two Loadcases. Create and submit the analysis job. Post-process results.











Step 1. Files: Save As a

Open a new database named bracket: a. Open the FILES menu. b. Click SAVE AS. AS . c. Enter SELECTION: \ brack brack et d. Click OK. OK. RETURN . e. Click RETURN.

b

c d













Step 2. Files: Import / Iges a

Import the IGES file: a. Open the FILES menu. b. Click INTERFACES IMPORT. IMPORT .

c











Step 3. Mesh Generation: Convert / Surfaces to Elements c a

Create mesh for the model: a. Click MESH GENERATION. GENERATION . b. Click CONVERT. CONVERT . Click DIVISIONS











Step 4. Mesh Generation: Sweep / All

Remove duplicate nodes: a. Click SWEEP. SWEEP. b. Click ALL. ALL.

b











Step 5. Material Properties: New / Tables / Plastic_Strain c

d a











Step 5. Material Properties: New / Tables / Plastic_Strain (Cont.)

e e. Click Table TYPE. TYPE . f. Click eq_plastic_strain. eq_plastic_strain.













Step 5. Material Properties: New / Tables / Plastic_Strain (Cont.)













Step 6. Material Properties: New / Isotropic













Step 6. Material Properties: New / Isotropic (Cont.)













Step 6. Material Properties: New / Isotropic (Cont.)













Step 7. Create Punch Position History Table



















































































































Step 15. Jobs: Run / Submit 1

a. b. c. d. e. f. g.

Submit the analysis job: Click RUN RUN.. Click SAVE MODEL Click SUBMIT (1). (1). Click MONITOR. MONITOR. Click OK. OK. Click MAIN MAIN..

b c d











Step 16. Results: Open Default / Monitor / Def Only

b h Read Results, and postprocess: a. Click RESULTS. RESULTS. b. Click OPEN DEFAULT. DEFAULT. c. Click DEF ONLY. ONLY. d. Click CONTOUR BANDS. BANDS. e. Click SCALAR. SCALAR. f. Select Total Equivalent Equivalent Plastic Strain. Strain. g. Click OK. OK. h. Click MONITOR. MONITOR.

c d

e











Step 16. Results: Open Default / Monitor / Def Only (Cont.)

i

i.

Click SCAN SCAN,, Select the Increment corresponding to Time = 0.5, and Click OK.











Step 16. Results: Open Default / Monitor / Def Only (Cont.)

k

k. Click LAST. LAST.











Step 17. Create a graph Punch Force Vs. Time d

f b e a

a. b. c. d. e.

Click HISTORY PLOT. PLOT. Click COLLECT GLOBAL DATA. DATA. Click NODES/VARIABLES. NODES/VARIABLES . Click ADD GLOBAL CRV. CRV . Enter Time as X-axis variable and Force Y punch as Y-axis variable.

c













Step 18. Re-analyze the model with more accuracy ●

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The Punch Force Vs. Time graph obtained from the analysis does not seem to be very smooth. This is a typical outcome when the convergence tolerance is too large. Re-analyze the model with a tighter convergence tolerance, and draw a new Punch Force Vs. Time graph. Use Relative Residual Force of 0.01 (Default = 0.1). Hints: Modify both the load cases using the following following steps, and re-submit re-submit the job: LOADCASES: STATIC

Select the load case











When you are done working with this model

a. Click on

w03 Break Forming Mar101

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