Ahmetcin Derincekme1

Exercise 1: Explicit Sheet Metal Forming.
In this exercise, we will perform an explicit analysis to simulate a sheet metal forming operation of an automobile suspension A-arm as seen below:
The final shape of the part not only depends on the shape of the dies, but on the amount of elastic energy stored during forming. This elastic energy is a function of many parameters such as material properties and interfacial loads. Accurate prediction of the plastic strain is essential to determine if the blank will tear during the forming process. By simulating the dynamic forming process explicitly with LS/Dyna, we can validate the manufacturing process prior to fabricating costly dies.
Exercise 1: Automobile A-Arm Stamping
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The images below show the Punch (top figure) and the die (bottom figure) that are used to create the A-arm.
Punch
Die
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Summary of Steps:
1. Launch ANSYS/LS-Dyna
1.1. Launch ANSYS using your start Menu
2. Setup:
2.1. Resume Database 2.2. Set LS-Dyna preferences 2.3. Plotting Controls 2.4. Define Element Types 2.5. Define Real Constants
3. Material Properties
3.1. Rigid Properties for Punch 3.2. Sheet Metal Blank Properties 3.3. Rigid Properties for Die 3.4. Shell Thickness Change
4. Meshing
4.1. Mesh Punch 4.2. Mesh Blank 4.3. Define Blank Component 4.4. Mesh Die. 4.5. Create Parts. 4.6. Define Contact Surfaces
5. Loads
5.1. Define Load Arrays 5.2. Apply Loads
6. Solution Options
6.1. Time Controls 6.2. Output Controls. 6.3. Save Model 6.4. Batch Solution Instructions 6.5. Interactive Solution Instructions 6.6. Solution Monitoring
7. Time History Post Processing

7.1. Energy Plots
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8. General Post Processing

8.1. Plot Set up 8.2. Stress Plot
9. Generate HTML Report

9.1. Return to Explicit Results 9.2. Image Capture and Animation Generation 9.3. Report Assembly
10. Conclusions
10.1. Exit Ansys
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Step-by-step Instructions:
Before beginning this problem, create a separate folder on your computer for this job and copy the ANSYS database aarm1.db to this folder. This file is located on CD 1 in a folder called Input Files.
1. Launch ANSYS/LS-Dyna
1.1. Launch ANSYS using your start menu. A. Browse to select the working directory you just created for this job. B. Enter a job name (aarm1). All ANSYS files created for this problem will have a filename of aarm1 followed by a unique extension. C. Change the workspace and database sizes for this job to be 512 and 128 respectively. D. Click RUN to start the ANSYS GUI.
1.1.A
1.1.B
1.1.C
1.1.D
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2. Setup
2.1. Resume database. A. We will start with an ANSYS database thats already been created for you. This database contains only the geometry of the punch, die, and blank. You could create this geometry in any CAD program of your choosing, and import it into ANSYS using one of the many geometry file formats supported to reach this point. In the ANSYS utility menu, pick File B. Resume Jobname.db ANSYS will read the database aarm1.db and plot the model in the graphics window. C. Note that we do not need to model the entire punch and die pieces as solid parts. We only need to model the contacting faces, which will deform the blank.
2.1.A
2.1.B
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2.1.C
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2.2. Set preferences to Structural LS-Dyna A. In the ANSYS main menu, pick Preferences B. LS-Dyna Explicit. Note: Your menu may look slightly different depending on the ANSYS products you have licensed. C. OK.
2.2.A
2.2.B 2.2.C
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2.3. Plotting Controls A. Use the Pan/Zoom/Rotate function to scrutinize all parts of the model. In the utility menu, pick PlotCtrls B. Pan, Zoom, Rotate screen. A view control window will appear on your
C. You may want to keep this window active at all times.

2.3.A
2.3.B 2.3.C
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Pan Zoom Rotate Functions:
Zoom by picking a center point and the edge of your window.
These buttons will orient your display to predefined view perspectives.
Zoom by picking two diagonal corners of your window.
Arrows will pan your model in the direction of the arrow. The distance your model is moved can be controlled using the Rate slider below.
Activate dynamic mode. With this button checked, you can use dynamic viewing controls. Use the left mouse button to pan the model. With the middle button depressed, move up/down to zoom in/out, and left/right to rotate about the screen Zaxis. With the right button depressed, move up/down to rotate about the screen Xaxis, and left/right to rotate about the screen Y-axis.
Rotate buttons will incrementally rotate your model about the screen axis and direction shown on the button. The amount of rotation is also controlled by the rate slider.
With dynamic Mode checked, you can use the mouse buttons described at left to move the model or the lights used in light source shading.
The Fit button will scale your model to fit in the window.
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2.4. Define Element Types: We will define an explicit shell element type to use for our model. The SHELL163 element type is appropriate for this analysis. This element type has several formulations for various applications. We will use the Belytschko-WongChiang formulation for its ability to tolerate warping, and because it supports ANSYS implicit analysis capability. A. In the Preprocessor menu, pick Element Type B. Add/Edit/Delete C. Add
2.4.A
2.4.B
2.4.C
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D. LS-DYNA Explicit E. Thin Shell 163 F. OK.
2.4.D 2.4.E
2.4.F
G. Next, we have to choose the formulation and other options available for this element. In the Element Types dialog, pick Options
2.4.G
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H. Under Element Formulation, scroll down the list and pick BelytschkoWong. I. OK.
2.4.H
2.4.I
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2.5. Real Constants: Next, we need to define real constants. These are additional properties required to fully define the behavior of the element type we just selected. Each element type may have a different set of real constants depending on what is required. Some element types have no real constants. A. In the Preprocessor menu, pick Real Constants B. Add
2.5.A
2.5.B
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C. Type 1 SHELL163 is highlighted. If we had multiple element types defined, we would have to select one in order to bring up the correct property input menu for our element type. Pick OK. D. Enter a shear factor of 5/6, which is the suggested value for this element.
2.5.C
E. Enter 5 for the number of integration points through the thickness. This will allow a more accurate prediction of the plasticity due to bending. F. Enter 0.10 for the thickness at node 1. default to this value. G. OK. The other thicknesses will
2.5.D 2.5.E
2.5.F
2.5.G
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3. Material Properties
Next, we will define the elastic and plastic material properties for our sheet metal parts. Also, this is where we define the rigid behavior of our punch and die. We will define three unique sets of material properties for the three parts we have modeled. Material 1: The punch will be a rigid material with all degrees of freedom constrained except the Z-direction. This is the vertical direction of the punch which must be permitted to move. Material 2: This is the sheet metal blank. We will define a bilinear isotropic hardening stress-strain curve for it. Material 3: This is the die and will also be a rigid material. It will be fixed in all degrees of freedom, and therefore cannot move. 3.1. Rigid Properties for the Punch A. In the Preprocessor menu, pick Material Props B. Define MAT Model
3.1.A
3.1.B
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C. Add
3.1.C
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D. A dialog will appear for you to choose the type of material model you want to define. The material ID number defaults to the next available number, which is 1. E. Under Available Material Models, pick Other F. Rigid G. OK.
3.1.D
3.1.F
3.1.E 3.1.G
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H. Even though this material model is for a rigid contact surface, we need to supply elastic material properties which are used to define the contact stiffness between mating parts. We will use properties of the sheet metal blank. Enter a density of 0.12/386.4. The factor in the denominator is used to convert typical units of Lbs/Cu-inch to appropriate units of mass density. I. Enter 10.5e6 for Youngs Modulus. J. Enter 0.33 for Poissons ratio. K. For Translatl constrnt param, click the arrow to the right of the box, scroll down and select X and Y disps. This will constrain this material to be rigid in these directions. L. Under Rotational constrnt param, scroll down and pick All rotations. M. OK.
3.1.H 3.1.I 3.1.J 3.1.K 3.1.L
3.1.M
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3.2. Sheet Metal Blank Properties A. The materials model dialog will now show a Rigid Body material model for MAT number 1. B. Pick the Add button again to define the properties for the blank. C. The define model dialog appears again with the next available material number highlighted, which is 2. D. Pick Plasticity. E. Bilinear Isotrop. F. OK.
3.2.A
3.2.B
3.2.C 3.2.E 3.2.D
3.2.F
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G. We will enter the same values as before for the elastic properties. Enter 0.12/386.4 for density. H. Enter 10.5e6 for Youngs modulus. I. Enter 0.33 for Poissons Ratio. J. Enter a Yield Stress of 20000. K. Enter a Tangent Modulus of 100000. L. OK.
3.2.G 3.2.H 3.2.I
3.2.J 3.2.K
3.2.L
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3.3. Rigid Properties for the Die A. The Material Model dialog now shows the Bilinear Isotropic hardening model for Material ID 2. Lets add the final properties for the die. Pick Add B. Other. C. Rigid. D. OK.
3.3.A
3.3.C
3.3.B 3.3.D
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E. Enter 0.12/386.4 for density F. 10.5e6 for Youngs modulus. G. 0.33 for Poissons Ratio. H. Make the die completely fixed by constraining All disps. I. Constrain all rotational DOF by picking All rotations. J. OK.
3.3.E 3.3.F 3.3.G 3.3.H 3.3.I 3.3.J
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K. The Material model dialog now shows all three material models define. Pick Close to continue.
3.3.K
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3.4. Shell Thickness Change A. In the Preprocessor menu, pick Shell Elem Ctrls B. The Thickness Change option is set by default by ANSYS. This allows a thickness 3.4.A change due to membrane straining. This step is only for informational purposes. C. Pick OK.
3.4.B
3.4.C
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4. Meshing:
4.1. Mesh Punch: A. Now we are ready to mesh our model. Activate the Meshtool in the Preprocessor menu. Pick Meshtool. This will activate a new dialog that contains the most common functions for creating and modifying a mesh. These features are described on the next page.
4.1.A
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Allows you to assign attributes such as material ID, shell properties, etc. globally, or to individual areas, volumes, etc. SmartSize slider bar. This is the same feature as the mesh slider bar in the MTB.
Specify element sizes on individual areas.
Set a global element edge length for future meshing.
Specify element size or number of elements and biasing on individual lines. Specify element sizes at keypoints.
Set the number of element layers deep from a line edge to maintain mesh refinement before transitioning to a coarser mesh.
Set the element shape.
Refines an existing mesh in a zone of your choosing. I.e. on picked volumes, areas, lines, or picked elements.
Allows you to mesh or clear individual volumes or areas.
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B. We are now ready to use the Meshtool. We will mesh the punch first. Recall that this part should reference the first material property we defined which is Mat ID 1. Under Element Attributes, pick Set.
4.1.B
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C. A dialog will appear for you to set the element type, material number and real constant set number that will be assigned to subsequent meshes. These should all be set to 1. Pick OK.
4.1.C
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D. Next, set the global element size for meshing. In the Meshtool, under size controls, global, pick Set. E. For Element edge length, enter 0.10. F. OK.
4.1.D
4.1.E
4.1.F
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G. In the Meshtool, pick the Mesh button. H. A dialog will appear for you to choose areas for meshing. You can pick areas individually, by box, polygon, circle, or loop. Pick the Loop button. With this feature, when you pick one area on the punch, it will automatically select all areas that are connected to it. This way, you can easily select all areas associated with a part.
4.1.H
4.1.G
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I. You may need to orient the model to the bottom view using the Pan/Zoom/Rotate function showed earlier. Using the left mouse button, pick any area on the upper part (punch) as shown. When you 0 release the mouse button, ANSYS will also select all areas connected to this one. They will change color indicating that they are selected. J. OK. ANSYS will begin meshing the punch. This may take several minutes.
4.1.J
Pick an area on this part.
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Your mesh should look like this. Use the pan/zoom/rotate function to view all sides of the mesh.
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4.2. Mesh blank. A. In the Meshtool, under Element Attributes, pick Set. B. Change the material ID to 2. C. OK.
4.2.A
4.2.B
4.2.C
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D. Using the Pan/Zoom/Rotate function and dynamic viewing controls, orient the model as shown below. This will give us a better perspective for picking the blank in the next operation. In the Utility menu, pick Plot. E. Lines.
4.2.D
4.2.E
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F. Your view should look like the one below.
4.2.F
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G. We are now ready to mesh. In the Meshtool, pick the Mesh button.
4.2.G
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H. The blank is the irregular area outlining the shape of the finished A-arm stamping. When selecting, a point roughly near the center of the area is the hot spot. Click and hold the left mouse button near the center of the blank as shown in the plot below. The nearest area should be highlighted. If the wrong area is selected, drag the mouse around while the left mouse button is still depressed. The selection isnt made until you release the button.
4.2.H
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I. Pick OK. It may take a few minutes to mesh the blank. It will be hard to see the blank mesh when ANSYS plots the elements because they will blend in with the punch.
4.2.I
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J. Lets plot lines again. As before, in the Utilities menu, pick Plot K. Lines.
4.2.J
4.2.K
L. We can use the ANSYS select logic to isolate the blank mesh to get a better view of it. In the Utilities menu, pick Select. M. Entities.
4.2.L
4.2.M
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N. A dialog box will appear for you to choose what type of entities you want to select. Change Nodes to Areas. O. There are several options for selecting entities as shown below. We will use the default setting, which is to select from the full set in the model. P. Pick Apply.
Select a new set of entities from the entire model.
4.2.N
Replace the current set of entities with a subset of those entities Select additional entities to be added to the current set. Remove entities from the current selection.
4.2.O
4.2.P
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Q. A select box will appear similar to the one used previously for meshing. As before, pick the blank area. R. OK.
4.2.R
4.2.Q
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S. We have just select the blank area. In the Utilities menu, pick Plot T. Areas. The plot should look like the one below.
4.2.S
4.2.T
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U. If we were to plot lines or elements at this point, we would still see the entire model as we have previously. That is because we have only selected a subset of areas. All other entity types are unaffected by this selection. We can select all entities (line keypoints, nodes, elements) associated with the blank area by picking the Sele Belo button in the Select entities dialog.
4.2.U
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V. Now, in the utilities menu, pick Plot W. Elements. You should only see the blank elements similar to the plot below.
4.2.V
4.2.W
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4.3. Define Components: A. Before we proceed, lets store this group of elements as a component. This will come in handy later on. Components are a way to name a group of entities for identification and retrieval later on. In the Utilities menu, pick Select B. Component/Assembly. C. Create Component. D. Enter Blank for Component name. E. Change Nodes to Elements. F. OK.
4.3.A
4.3.B
4.3.C
4.3.D 4.3.E 4.3.F
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4.4. Mesh Die: A. Before we can mesh the Die, we must restore all the entities to the selected set. In the utilities menu, pick Select. B. Everything.
4.4.A
4.4.B
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C. Using the pan/zoom/rotate function, restore the view to the bottom view and plot areas. In the Utilities menu, pick Plot. D. Areas.
4.4.C
4.4.D
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E. Set the material attribute to ID number 3 for the die. In the Meshtool, pick Set under element attributes. F. Change the material ID number to 3. G. OK
4.4.E
4.4.F
4.4.G
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H. Pick the Mesh button.
4.4.H
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I. Change the method of picking to Loop. J. Pick any area on the die. K. OK
4.4.I
4.4.K
4.4.J
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L. Use the dynamic viewing controls to view the entire mesh.
4.4.L
4.5. Create parts: In LS-Dyna, certain commands used to define loads and contact surfaces reference part IDs. We can easily create parts in our model with the Create parts command. ANSYS will assign a part ID to each group of elements that make up a unique combination of MAT, TYPE, and REAL set numbers.
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A. In the Preprocessor menu, pick LS-DYNA Options B. Parts Options C. Create Parts. D. OK.
4.5.B
4.5.A
4.5.C
4.5.D
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E. Since the only attribute that varies in our model is MAT ID, ANSYS creates part numbers that correspond to the material ID numbers as shown in the listing that appears. When you are through viewing this list. Pick the close button.
4.5.E
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4.6. Define Contact Surfaces We are now ready to create the contact surfaces. As we mentioned above, contact is defined by part numbers. We will use a forming surface to surface contact definition with a static coefficient of friction of 0.2, and a dynamic coefficient of 0.1. A viscous damping value of 10% will be used to stabilize the solution. A. In the Preprocessor menu, pick LS-DYNA Options. B. Contact. C. Define Contact.
4.6.B
4.6.C
4.6.A
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D. Pick Surface to Surface. E. Forming (FSTS). F. For static Friction Coefficient, enter 0.2 G. For Dynamic Friction Coefficient, enter 0.1 H. For Viscous Damping Coefficient, enter 10 I. Apply.
4.6.D 4.6.E
4.6.F 4.6.G
4.6.H
4.6.I
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J. In metal forming, the rigid surfaces should always be the target surface. For this contact pair, enter the blank (part 2) for the contact surface, and the punch (part 1) for the target surface. K. OK.
4.6.J
4.6.K
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L. For the next contact pair, we can use the same options. Pick OK in the contact parameter definition window.
4.6.L
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M. This contact pair will be between the die (target part number 3) and the blank (contact part number 2). N. OK.
4.6.M
4.6.N
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O. We can list our contact pairs to make sure they were entered correctly. In the LS-Dyna Contact window, pick List Entities P. Change Contact ID number to ALL. Q. OK. R. Your contact definition list should match the one below. Close this window when you are through studying it.
4.6.O
4.6.P 4.6.Q
4.6.R
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5. Loads:
5.1. Define Arrays for Punch Deflection vs. Time Curve. The loading for our punching operation will consist of a deflection vs. time curve describing motion of the punch during the forming operation. To do this, we must define array parameters defining the time vs. deflection as shown in the table below. The deflection of the punch will be in the negative Z direction, hence the minus sign for the deflection values. Time/Deflection Curve for Explicit-Implicit Analysis: Time 0.000 0.006 0.007 0.009 0.011 0.012 0.014 0.015 Deflection 0.000 -1.100 -1.200 -1.270 -1.300 -1.320 -1.340 -1.344
Option: If you do not want to perform an Implicit spring back analysis, we can speed up our explicit punching operation in order to reduce run time. The table above provides a relatively slow punching operation, which requires an extremely long run time. This is necessary to reduce dynamic oscillations which can cause convergence difficulties in the Implicit analysis.
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If you are performing an Explicit only analysis, we can use a much faster punching speed to reduce run time. For this option, use the time/deflection curve below instead of the one on the previous page. Time/Deflection Curve for Explicit Only Analysis: Time 0.000 0.006 0.007 0.009 0.010 Deflection 0.000 -1.100 -1.200 -1.270 -1.344
A. In the ANSYS Utilities menu, pick Parameters. B. Array Parameters. C. Define/Edit
5.1.A
5.1.C 5.1.B
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D. Add.
5.1.D
E. The array name can be up to eight characters long. We will start with the Time array. Enter pnchtime for the array name. F. From the table on the previous page, note that there are 8 time points. Enter 8 for the number of rows. G. OK.
5.1.E
5.1.F
5.1.G
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H. The Array Parameters dialog will show the newly dimensioned parameter name. Pick the Edit button. I. Enter the eight time values from the previous table. J. Save this data by picking File >Apply/Quit.
5.1.H
5.1.J
5.1.I
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K. In the Array Parameters dialog, Pick Add again to dimension the punch deflection array. L. Enter pnchdefl for the array name. M. Enter 8 for number of rows. N. OK.
5.1.K
5.1.L
5.1.M
5.1.N
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O. Make sure the pnchdefl parameter is highlighted in the Array Parameters dialog. P. Pick Edit. Q. Enter the 8 values for punch deflection corresponding to the times we previously entered. R. Save our changes by picking File >Apply/Quit.
5.1.O
5.1.P
5.1.R
5.1.Q
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S. We have completed the load parameter definition. Pick close in the Array Parameters dialog.
5.1.S
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5.2. Apply Loads: The load definition for our punch is will be defined as a rigid body deflection in the UZ direction. A. In the main menu, pick LS-DYNA Options. B. Loading Options. C. Specify Loads.
5.2.B
5.2.C
5.2.A
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D. A dialog will appear for you to define the loads. There are many options available. Scroll down the list and pick RBUZ for rigid body deflection in the Z direction. Be careful not to pick RBVZ, which is rigid body velocity. E. The part number to apply this to is 1 for the punch. F. The parameter name for time values is PNCHTIME. G. The parameter name for data values is PNCHDEFL. H. OK.
5.2.D
5.2.E 5.2.F 5.2.G
5.2.H
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I. ANSYS will draw green arrows on the punch indicating the loads are applied. The arrows are pointing upwards indicating the positive RBUZ direction. Our deflection will be correctly applied in the negative direction based in the values we specified in the parameter definition.
5.2.I
J. We can plot our load curve see if we defined the values correctly. In the Loading Options dialog, pick Plot Load Curve
5.2.J
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K. Two windows will appear. An EDLOAD command window showing a summary our loads. Verify that we have defined a RBUZ load on Part 1, and check that the time vs. deflection points are correct. L. In the Plot Loads dialog, for Load reference number, enter 1. M. OK.
5.2.K
5.2.L
5.2.M
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N. The load curve will be plotted in the graphics window.
5.2.N
6. Solution:
Before we perform the solution, we need to set some analysis options. 6.1. Time Controls: A. Enter the solution module by picking Solution in the ANSYS Main Menu. B. Time Controls
6.1.A 6.1.B
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C. Solution Time D. Enter an ending time for the analysis of 0.015 corresponding to the final time in our load curve. (Use 0.010 if you are using the explicit only time/displacement curve). E. OK.
6.1.C
6.1.D
6.1.E
6.2. Output Controls: Next, we need to define the type of output we want saved during the analysis. LS-Dyna will perform several thousand iterations during this analysis, so we obviously dont want to save results for every time step. A. In the solution menu, pick Output Controls. B. File Output Freq. C. Number of Steps
6.2.B
6.2.A
6.2.C
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D. Enter 20 for the results file output interval. deflection/stress/strain output.
This controls
E. Enter 50 for the Time-History output interval. This controls the other types of output that will be written, such as energy, forces, contact data, etc. F. OK.
6.2.D 6.2.E
6.2.F
G. Next, we will specify the blank component for output. This tells LSDyna to write output for only for the blank. Since the punch and die are rigid components, the output for these parts are meaningless. Under Output Controls, pick Select Component H. Select BLANK from the list of components I. OK.
6.2.G
6.2.H
6.2.I
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6.3. Save Model A. We are now ready to solve our model. Before proceeding, lets make sure we have all entities selected. If we have a subset of elements selected such as when we were working with the blank, ANSYS/LSDyna would only use those elements during the solution. Its always prudent to issue a Select Everything command prior to solving. In the Utilities Menu, pick Select B. Everything.
6.3.A
6.3.B
C. Since this model is fairly large, we will need to increase the default memory option used when the LS-Dyna job is started. In the Solution menu, pick Analysis Options. D. Restart Option
6.3.D
6.3.C
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E. For Words of Memory Requested, enter 20000000 (20 million). F. OK.
6.3.E
6.3.F
G. Next, lets save our work. In the Toolbar Menu, pick Save_DB. All of our work is now saved to the file aarm1.db
6.3.G
6.4. Batch Solution Instructions: We can solve our model interactively, or in a batch mode. If you choose to solve your model as a batch solution outside of ANSYS, you will first need to create an LS-Dyna input file. A. In the Solution menu, pick Write Jobname.k.
6.4.A
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B. The first option (Write results files for..) allows you to choose the format for the results data. The options are ANSYS, TAURUS, or both. TAURUS is the post processor provided by LS-Dyna. The default settings are acceptable for our analysis. Pick OK. C. This may take a few minutes. ANSYS will create an LS-Dyna input file by the name of aarm1.k A solution summary will appear when completed. Close this when you are through reviewing it.
6.4.B
6.4.C
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D. You can now safely exit ANSYS and solve this model as a batch job. The procedure for launching the LS-Dyna batch job is system dependant. Please see your ANSYS/LS-Dyna installation guide, or consult your system administrator for details. 6.5. Interactive Solution Instructions: A. We are now ready to solve the LS-Dyna solution. In the Solution menu, pick Solve.
6.5.A
B. ANSYS will display a window with a summary of solution options. Review this window to make sure the options you have set match the ones shown below. Close this window when you are finished.
6.5.B
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C. Pick OK in the Solve Current Load Step window.
6.5.C
D. You may receive a warning message about element shape. Close this window.
6.5.D
E. ANSYS will ask you to verify that you do want to solve the model. Pick Yes.
6.5.E
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F. Just to make sure, ANSYS will ask you again if you want to solve this model. Pick Yes.
6.5.F
6.6. Solution Monitoring: This solution may take several hours to complete. LS-Dyna will display a status window as the job is executing. You can monitor the solution as it is progressing.
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A. Note that LS-Dyna provides controls for you to stop or interrupt the solution. Hitting the Ctrl-c buttons will stop the solution and allow you to enter one of four switches shown below.
6.6.A
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B. One useful switch is the sw2. option. After your solution runs for several minutes, Hit ctrl-c, type sw2. and hit enter. LS-Dyna will print out the current time, energy values, and estimated run time remaining. The hourglass energy should be significantly lower than the total energy, if its not, your solution may be diverging.
6.6.B
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7. Time History Postprocessing:

7.1. Energy Plots: Once our analysis is completed, we are ready to Postprocess the results. The time history postprocessor is used to evaluate results over a period of time. This differs from the General Postprocessor which is used to evaluate results at a specific time point. We will use the Time History postprocessor to plot the various energy quantities over the entire stamping operation to verify that we have a robust solution. A. In the ANSYS Main Menu, pick TimeHist Postpro B. Settings C. File
7.1.B
7.1.A
7.1.C
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D. Highlight the aarm1.his file. E. OK F. In the TimeHist Postpro menu, pick Read LSDYNA Data G. GLSTAT file
7.1.D
7.1.E
7.1.G
7.1.F
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H. This command reads in data from LS-Dyna ASCII file output. By Default, the global data (GLSTAT) data was written during solution which contains various energy values. Pick the help button to see what these are.
7.1.H
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I. Scroll down the help file to the table that shows the data that can be plotted. For our analysis, we only have the GLSTAT data (column 2) available to us by default. The other columns reference data that we would have to specifically request prior to running the solution. To verify our solution, we would like to plot the Kinetic, Internal, Sliding Interface, Total, and Hour Glass energies as a function of time.
7.1.J
J. Note the Variable Numbers for each of these values. The NSTART value defaults to 2, so for example, the Kinetic Energy is NSTART+1 or 2+1=3. Do this for the remaining data we are interested in. The variable numbers are: 3: Kinetic Energy 4: Internal Energy 6: System Damping Energy 7: Sliding Interface Energy 9: Total Energy 14: Hour Glass Energy
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K. In the Read data from the GLSTAT file window, accept the default, which is to read in data for all load steps. Pick OK.
7.1.K
L. We are ready to plot this data. In the TimeHist Postpro menu, pick Graph Variables.
7.1.L
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M. In the Graph Time-History Variables dialog that pops up, enter the six variable numbers corresponding to the data we want to plot. N. Pick OK.
7.1.M
7.1.N
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O. ANSYS will plot the energy quantities in the graphic window. A good solution will have damping and hour glass energies substantially lower than the total energy of the system. Note that for our solution, these values are near zero.
7.1.O
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8. General Postprocessing:
8.1. Plot Set Up.
8.1.A
A. Now that we have verified that we have an accurate solution, lets plot the results at the end of the analysis. Pick General Postproc from the ANSYS main menu. B. We must tell ANSYS what data to read, and from what file to read it from. Pick Data & File Opts C. All Items. D. Aarm1.rst E. OK.
8.1.B
8.1.C
8.1.D
8.1.E
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F. Next, we want to read in results from the last load step. Pick Results Summary from the General Postproc menu.
8.1.F
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G. Note the times corresponding to the various results that are available. Highlight the last step. H. Read. I. Close.
8.1.G 8.1.H 8.1.I
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J. Next, we want to select only the blank for display since the die and punch are not of interest and will obscure our view of the blank. In the Utility Menu, pick Select. K. Comp/Assembly. L. Select Comp/Assembly. M. Highlight Blank. N. OK.
8.1.J
8.1.K
8.1.L
8.1.M
8.1.N
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O. Before we plot our results, lets set a displaced shape scale option. By default, ANSYS scales the deformed shape such that the maximum displacement on the screen equals 5% of the maximum model length. This is fine for small displacement analyses, but for our model, we want true scaling. In the Utility Menu, pick PlotCtrls. P. Style. Q. Displacement Scaling.
8.1.O
8.1.P
8.1.Q
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R. Pick 1.0 (true scale). S. OK.
8.1.R
8.1.S
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8.2. Stress Plot: A. Now lets plot the von mises stress. In the General Postproc menu, pick Plot Results. B. Nodal Solution
8.2.B
8.2.A
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C. Highlight Stress. D. von Mises SEQV. E. OK.
8.2.C 8.2.D
8.2.E
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F. ANSYS will plot the von Mises stress. function to view all areas of the stamping.
Use the pan/zoom/rotate
8.2.F
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9. Conclusions
9.1. Exit ANSYS A. In the ANSYS toolbar, pick Quit. B. Highlight Quit No Save? C. OK.
9.1.A
We are finished. What have we learned from this analysis? Did you notice the wrinkling of the blank during the animation? This could be due to dynamic effects of stamping the sheet at such a fast rate. Is this a realistic stamping speed? Try repeating this analysis with a longer stamping period. What would that do to your run time? Is the plastic strain level in the blank acceptable?
9.1.B
9.1.C
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Exercise 1: Explicit Sheet Metal Forming.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

7. Time History Post Processing

Exercise 1: Automobile A-Arm Stamping

8. General Post Processing

9. Generate HTML Report

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

C. You may want to keep this window active at all times.

Exercise 1: Automobile A-Arm Stamping

Pan Zoom Rotate Functions:

Zoom by picking a center point and the edge of your window.

These buttons will orient your display to predefined view perspectives.

Zoom by picking two diagonal corners of your window.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

D. LS-DYNA Explicit E. Thin Shell 163 F. OK.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

3.1.H 3.1.I 3.1.J 3.1.K 3.1.L

Exercise 1: Automobile A-Arm Stamping

3.2.C 3.2.E 3.2.D

Exercise 1: Automobile A-Arm Stamping

3.2.G 3.2.H 3.2.I

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

3.3.E 3.3.F 3.3.G 3.3.H 3.3.I 3.3.J

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Specify element sizes on individual areas.

Set a global element edge length for future meshing.

Set the element shape.

Allows you to mesh or clear individual volumes or areas.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Pick an area on this part.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

F. Your view should look like the one below.

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Exercise 1: Automobile A-Arm Stamping

Select a new set of entities from the entire model.

Exercise 1: Automobile A-Arm Stamping