INCSolver User Manual
Contents
1. s nonlinear anisotropic yielding criteria for material modeling Note INCSolver supports the tailor welded blank The parts for the tailor welded blank will be listed under material parameters in the main interface of INCSolver after the blank generator creates the tailor welded blank The user may define the material property for the corresponding part as illustrated in Figure 7 6 16 THE INCSOLVER FUNCTIONS Die Simulation Die Simulation tion Draw Type Single action Inverted draw Upper Tool Blank Blank Parameters Part Material Thickness No Symmetry l BLANK 88304 1 00 i BLK S8304L Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 W Lower Binder Force 1200000 00 Lower Binder Travel 105 00 Lance 0 Trim 0 Advanced Help Apply Unde Preview Submit Job Repor Exit Figure 7 6 15 Tailor welded blank SYMMETRY When clicked it displays an interface window shown in Figure 7 6 16 The pull down menu Type lists three frequently used symmetry conditions used in sheet metal forming e XZ Symmetry defines symmetry plane which parallels to XZ Plane e YZ Symmetry defines symmetry plane which parallels to YZ Plane e Quarter Symmetry defines a quarter symmetry condition 10 THE INCSOLVER FUNCTIONS Symmetry Type Nos YmMe t ry Symmetry Type Center 0 00 0 00 Center Select Node Tolerance bot Tolerance bot Cancel O2. Tool Travel Velocity m sec Binder Force N and First Bend Tool U Velocity It s the travel velocity for upper die punch and the default value is 5000 Tool L Velocity It s the travel velocity for lower die punch and the default value is 2000 First Bend Set the upper or lower tool as the first bending tool e LANCE Lance 0 Provides capabilities for users to integrate a lance operation into a forming 15 THE INCSOLVER FUNCTIONS simulation The setup interface is shown in Figure 7 6 25 Figure 7 6 25 Lance Position This is used to specify the lance position which is defined as the distance from the end of tool travel Add Click this button to pop up a Curve Editor as illustrated in Figure 7 6 26 The user may select an existing curve as the lance curve or create a lance curve by Curve Editor Please refer to Section 7 4 5 for detailed information about the Curve Editor dialog box 16 THE INCSOLVER FUNCTIONS Curve Editor Point Position Snap Cure Remove Pt Edit Tangent Direction Select Line Empty Offs et Peere ere reer err rre terrier rrr rrr rrr OK Figure 7 6 26 Curve Editor Edit Click this button to edit the lance curve in the popped Curve Editor dialog box as illustrated in Figure 7 6 26 Delete Click this button to delete the selected lance curve from the list e TRIM oe This function is used to define a group o
3. users have the flexibility of specifying the moment that each snap shot will be taken for all the snap shots ordered in the form of millimeters to the end of draw Default values are provided Default Reset all parameters back to their default values Confirm all current entries and exits the page Cancel Dismiss the window keeping values of all parameters prior to modification e APPLY 20 THE INCSOLVER FUNCTIONS Spy cick this button in the Die Simulation main page to position the tools and blank after their definitions are complete The setup creates ample distance between upper and lower tools providing sufficient room for the possible blank deformation under gravity loading Such arrangement is due to the fact that in this simulation application the gravity loading and subsequent forming stage are proceed as a seamless process The gap that appears on the screen will be adjusted by the solver correspondent to whether the gravity loading is included The button also performs an updating function whenever a setup related parameter is modified In other words the Preview and Submit Job can be executed only if this button is inactive e UNDO Unda oh ae Baas When clicked it will discard the tool positioning result e PREVIEW Sn The function animates the tooling motion and follows the procedure detailed in section 10 14 Animate e SUBMIT JOB onli n Enable users to include Gravity Load and Spring Back options prior to submitti
4. 5 2025 35 45 55 75 100 125 150 Default OK Cancel Figure 7 6 29 Advanced Tool Offset refers to the offset distance applied to develop the mating die face from its original The default value is 110 of the blank sheet metal thickness The geometrical offset of the mesh model will not be visualized on screen in this application Instead the offset is applied during the computation and reflected in the Postprocess The value of Tool Offset can be in the form of Percentage or Absolute value switchable by checking the corresponding boxes Extra clearance provides options for manual control of binder as well as punch die clearances that are otherwise defined by tool offset For both input fields the default value 0 00 mm indicates that the value of tool offset is also applied as the distance between the closed binder area as well as the punch and die in home position Both fields accept positive and negative inputs for adding or reducing clearances Be particularly careful when applying negative inputs which may introduce tool over travel and lead to wrong simulation results Closing allows users to decide the number of snap shot frames in the binder closing simulation stage the output file will contain Default value is 5 The timings that those snap shots are taken will be evenly distributed along the entire closing stroke Drawing is similar to Closing if the Total Frames option is checked If the Distance from End option is checked
5. K Figure 7 6 16 Define Symmetry Figure 7 6 17 Symmetry Type When either XZ or YZ Symmetry is selected a Y 0 or X 0 plane is displayed on the screen and all the blank nodes in the plane are highlighted Figure 7 6 18 To relocate the symmetry plane click SSO tuae button and select one node that denotes where the plane should be the plane will shift to that node and all the nodes fall into the plane will be highlighted Enlarge the Tolerance to include those nodes not collected by the plane due to model variations Setup is similar for Quarter Symmetry except a center node needs to be selected Figure 7 6 19 Symmetry Type Tolerance 0 01 OK Cancel Figure 7 6 18 Half Symmetry 11 THE INCSOLVER FUNCTIONS Symmetry Quarter Symmetr w Type Center 10 33 11 89 Tolerance 0 01 OK Cancel Figure 7 6 19 Quarter Symmetry e TOOL CONTROL Tool Control section contains parameters relate to tool travel speed m sec binder support force N and lower binder travel mm for single action draw Figure 7 6 20 Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Figure 7 6 20 Tool Control Tool Travel Velocity refers to travel speed of the upper die punch default to 5000 Binder Travel Velocity default value is 2000 Upper Binder Force is available for double action draw activate by checking on the box then key in the value Lower Binder Force 1s avai
6. THE INCSOLVER FUNCTIONS 7 6 1 INCSOLVER INTRODUCTION INCSolver is a nonlinear transient dynamic finite element program using explicit scheme to solve equations of motion commonly referenced as incremental code or explicit code INCSolver is developed for the single purpose of simulating sheet metal forming processes Belytschko Tsay shell element is used for the calculation of sheet metal deformation Penalty method is applied for the simulation of contact between die face and sheet metal in the forming processes Nonlinear material property supports Hill s yielding criteria Both Fusion amp Fission adaptivity are applied to adjust the blank mesh density in every time step during the simulation process INCSolver is designed to tolerate non connected mesh generated from non conforming CAD surfaces Saving a great amount of time and effort usually spent on model preparation INCSolver uses the SMP Shared Memory Processing computing scheme to take full advantage of multiple CPU multiple core and multiple thread configurations of latest computing platforms in Windows environment 7 6 2 INCSOLVER FUNCTIONS The functions enable users to e Set up tooling models that are either built up by using other D Eval functions or directly imported from outside eta D YNAFORM e Set up tooling as following five process types gt Crash Form gt Single action Draw gt Double action Draw gt Single Spring Bend gt Double Spring Ben
7. ached to upper die for single action draw and lower die for double action draw e DEFINE BLANK THE INCSOLVER FUNCTIONS Click Blank button to assign geometries to the blank A window will pop up as illustrated in Figure 7 6 11 and follow the procedure detailed in Section 8 2 Blank Generator Blank generator Operation Mesh type Parts Outline Mesh edit Add pat uununnunununnunnnnnnnnnnnnnnnmnnnnnnnnn gi Remove part Import elem Import surface Blank mesh Figure 7 6 11 Blank Generator e BLANK PARAMETERS Blank parameters are active for definition after the blank is assigned geometry Clicking MATOOOO leads to a material definition window Figure 7 6 12 Material Library Contain eta DYNAFORM s material database Figure 7 6 13 THE INCSOLVER FUNCTIONS Material Library DEER WEN fj STEEL Material Hes Mild ca DQ DDBQ DDQIF DOSK Figure 7 6 12 Define Material Figure 7 6 13 Material Library Activate a window page Figure 7 6 14 to define a material model THE INCSOLVER FUNCTIONS Material Name MATOS Mass Density 7 83e 009 Young s Modulus 207000 Poisson s Ratio jo28 Yield Stress hez Initial Strain 10 Hardening Coef 648 Hardening Exp 0 22 Yield Rule Hill 1948 Yield Exponent e o Roo F 87 R45 1 27 R90 Figure 7 6 14 New Material Parameters As mentioned in the introduction section that JVCSolver applies Hill
8. d e Set up draw beads e Set up blank material symmetry conditions and other constraints e Set up binder with either force controlled or displacement controlled motion e Set up Tool Control of First Bend in Double Spring Bend e Set up lance operations e Set up adaptive mesh on blank e Option for blank gravity loading e Option for spring back simulation after forming simulation e Submit the setup model for simulation computation using ETA exclusive INCSolver e View the related formability result with the Report function after the calculation is completed The main window is activated by selecting Die Simulation from D Eval pull down menu and the Die Simulation main page is illustrated in Figure 7 6 2 THE INCSOLVER FUNCTIONS Die Simulation i Draw Type Single action Inverted draw Upper Tool Available Upper Tool Blank Parameters Part Material Thickness Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 W Lower Binder Force 1200000 00 Preparation Binder Modification Trim Check Lance 0 Trim 0 Advanced Help Die Design Check F5 i Undo Preview Submit Job Report Exit a Figure 7 6 1 D EVAL Menu Figure 7 6 2 Die Simulation Main Page e DEFINE TOOL In Figure 7 6 2 red colored graphic symbols indicate that none of the blank draw beads and tools has been defined for the simulation Click the Upper Tool Lower Tool Pad or Binder buttons to assign geometr
9. evels 10 T Contour Range MIN 5 000000 MAX 25 000000 Contour Notation Decimal bw Decimal Points 1 Figure 7 6 32 Contour Setting dialog box Thickness Evaluate the forming quality through thickness of different areas of part Thinning Evaluate the morphing quality through thickness variation FLD is used to evaluate the formability of blank There is the result display option behind the Define button which is used for the user to select the display mode of each formability diagram in the formability report There are two display modes for the result Nodal Result and Element Result Nodal Result is used to plot the result by taking the node as the unit and Element Result is used to plot the result by taking the element as the unit Report Type 22 THE INCSOLVER FUNCTIONS This option offers three report formats PDF format JPEG format and XLS format Open Post Once this option is selected the program will automatically open the corresponding postprocessor by sequence according to the selection of postprocessor analysis options and read in the analysis results The program will open as many postprocessors as the post analysis options selected by the user Apply This button is only highlighted after the user uses MSTEP for analysis solution Clicking this button will cause the program to automatically use the postprocessor to read in the dynain file show the results from four different angles in the report accordi
10. ies to the tools A window will pop up and list related tasks as illustrated in Figure 7 6 3 Define Tool Import CAD Data Tool Mesh Mesh Check Repair EXIT DONE ABORI Figure 7 6 3 Define Tool select Part Display Define Tool window Figure 7 6 4 and enables users to select geometries using 2 THE INCSOLVER FUNCTIONS two approaches Add Display the Select Part dialog Figure 7 6 5 allowing users to select parts either from the part list or on the screen if the parts are currently displayed Add Elements Allow users to assign all elements of the parts selected from part list or a number of elements selected from the screen to the designated piece of tool Figure 7 6 6 Either way a new part will be created containing the selected elements Please keep in mind that in this function elements are relocated not copied from one part to another Select Elements Select by Cursor Select Part Select by Cursor Select by Name Define Upper Tool Include Part List Exclude Total selected 0 Exclude Displayed All Parts Total Selected 0 Reject Last Part Reject Last Selection Figure 7 6 4 Define Tool Figure 7 6 5 Add Part Figure 7 6 6 Add Elements After successful execution of either Add or Add Elements the part assigned to the tool will appear under Include Part List Figure 7 6 7 Multiple parts can be added to a piece of tool REMOVE Disassociate the assigned pa
11. lable when draw type is set to single action draw activate by checking on the box then key in the value Lower Binder Travel is also available when draw type is set to single action draw activate by checking on the box then key in the value The preferred amount of lower tool interference can be achieved by using this feature 12 THE INCSOLVER FUNCTIONS Note INCSOLVER is added to display the Tool Control option is Edit Default Config The user is allowed to select yes or no as the default value and it is yes by default If the user selects no it will not display the Tool Control option Edit Default Config i Dynaform Config Keyword Value ae f e File C Preprocess BSE ee Soup pa INCSoNer Tool Offset Vawe 11 Figure 7 6 21 Edit Default Config The user can also set the default value for each tool in Tool Control such as travel velocity binder force and travel Edit Default Config Dynaform Config Keyword System abe INCSoWver Too Travel velocity 50000 LG Proprocee i ae ge son pee INCSover Tool Offset Vawe 11 SS Figure 7 6 22 Edit Default Config e SINGLE SPRING BEND It is a newly added process type which is not completely identical to other existing draw types The 13 THE INCSOLVER FUNCTIONS setting interface for it is illustrated in Figure 7 6 23 Die Simulation i Draw Type single spring bend Upper Tool Available Upper Tool Blank Parameters Mate
12. ng job Figure 7 6 30 Gravity Load M Draw Die Spring Back Adaptive Level 3 T Figure 7 6 30 Submit Job Adaptive Level Adaptive level from none up to 6 can be selected from the pull down menu CPU Specify the CPU numbers for INCSolver calculation Single When Single is selected the program will automatically call a solver for a CPU and assign a CUP for calculation Multi When Multi is selected the program will automatically call solvers for multi CPUs and assign multiple CPUs for calculation Clicking Submit button will start computation or put the job onto the waiting list at Job Submitter Cancel will return to the Die Simulation main page e FORMABILITY REPORT 21 THE INCSOLVER FUNCTIONS Report This function is available only when the INCSOLVER calculation is completed It allows the user to view the related formability report as illustrated in Figure 7 6 31 Formability Report Thickness r Nodal Result w W Thinning a Nodal Result FLD Elem Result Report Type POF l Open Post Apply View Exit Figure 7 6 31 Formability Report e POST ANALYSIS OPTION There is one defining button _ _ behind each analysis option which allows the user to set the scope of contour for the corresponding analysis option as illustrated in Figure 7 6 32 Refer to the eta POST User s Manual for detailed description of each option Contour Setting Contour L
13. ng to different postprocessor analysis options and mark the maximum and minimum values of contour results on the part model e EXIT ot The button dismisses the Die Simulation page retaining all the setup parameters Note If close eta DYNAFORM database is terminated without saving all the setting will be lost 23
14. r Binder Force 120 0000 00 Lower Binder Travel 105 00 aes E ee eee Undo Preview Submit Job Repor Exit Figure 7 6 9 Tool If a die face model has been defined before the D Eval Die Simulation is activated etasD YNAFORM memorizes the model as a component of the tool set Upon opening the D Eval Die Simulation main page will look similar to Figure 7 6 10 showing the draw type determined by the tipping operation in D Eval and the D Eval created die face as the original lower tool THE INCSOLVER FUNCTIONS Die Simulation Draw Type Single action Inverted draw Lower Tool Blank Parameters Part Material Thickness Quarter Symmetry ll BLANK 88304 1 00 Tool Control Tool Travel Velocity 5000 00 Jpper Binder Force 200000 00 Binder Close Velocity 2000 00 W Lower Binder Force 120 0000 00 Lower Binder Travel 105 00 Lance 0 Trim 0 Advanced Help Apply Unde Preview Submit Job Repor Exit Figure 7 6 10 D Eval Tool In such cases change of draw type is still allowed as long as the draw tip is not violated In shown example crash form and single action draw are available by choice but not double action draw Switching of the original side of die face is always available e DEFINE DRAW BEAD Define Draw beads by clicking si button and follow the procedure detailed in Section 10 3 Draw Beads To effectively complete the definition of draw beads all the draw bead have to be att
15. r groups of curves for Pierce and Trim operation and the setup interface is illustrated in Figure 7 6 27 17 THE INCSOLVER FUNCTIONS Mode _ Pierce 1 Trim npts 108 Pierce npts 5 Figure 7 6 27 Trim and Pierce Add Click this button to pop up a Curve Editor as illustrated in Figure 7 6 28 The user may select an existing curve as the trim line or create a trim line by Curve Editor Please refer to Section 7 4 5 for detailed information about the Curve Editor dialog box 18 THE INCSOLVER FUNCTIONS Curve Editor Edit Tangent Direction Select Line Empty Offset 0D e ee ee Figure 7 6 28 Curve Editor Edit Click this button to edit the trim line in the popped Curve Editor dialog box as illustrated in Figure 7 6 28 Delete Click this button to delete the selected trim line from the list Note 1 At present the scrape trim operation for Double Attached is not supported by the trim operation so after define one group of curve the Add button will be deactivated 2 At present the hole piercing operation does not support CAM e ADVANCED __ Advanced e Display more controlling parameters Figure 7 6 29 19 THE INCSOLVER FUNCTIONS Tool Offset Value Type Absolute Percentage Tool Offset f 10 cxtra Clearance Binder 0 000 Punch 0 000 Output Frame Closing 5 Drawing amp Total Frames Distance from End 1 3 5 10 1
16. rial Thickness YZ Symmetry Tool Control Tool Travel Velocity 5000 00 Pad Force Pad Close Velocity 2000 00 pi Undo Preview Submit Job Repor Eyit Figure 7 6 23 Single Spring Bend Tool Definition Click the Upper Tool or Lower Tool and Pad buttons to pop up the Tool Definition dialog box Please refer to the above section for detailed operations about the tool definition Tool Control The parameters for Tool Control include Tool Travel Velocity m sec and Binder Force N Tool Travel Velocity It s the travel velocity for upper die punch and the default value is 5000 Pad Close Velocity It s the travel velocity for pad and the default value is 2000 e DOUBLE SPRING BEND It is a newly added process type and its setting interface is illustrated in Figure 7 6 24 14 THE INCSOLVER FUNCTIONS Die Simulation a Draw Type Upper Tool Available Upper Tool U Upper Tool L Blank Parameters Part Material Thickness YZ Symmetry i BLANK 0 DASK 0 80 Tool Control Tool U Velocity 5000 0 0 Pad Force Tool L Velocity 20 00 00 First Bend ToolL Undo Preview Submit Job Repor Eyit Figure 7 6 24 Double Spring Bend Tool Definition Click the Upper Tool or Lower Tool and Pad buttons to pop up the Tool Definition dialog box Please refer to the above section for detailed operations about the tool definition Tool Control The parameters for Tool Control include
17. rt from the designated tool The removed parts will remain on the part list and the added elements if any stays within this part Display Shows only the selected part on the screen for visual clarification or shows the part that is currently displayed THE INCSOLVER FUNCTIONS Define Upper Tool Include Part List Add Elements OK Figure 7 6 7 Tool Part List Import Mesh Enable users to import element mesh into eta DYNAFORM database usually in NASTRAN format Import CAD Data Thnport surface and line data generated by other CAD systems in various formats Figure 7 6 8 IGES igs iges IGES igs iges VDA vda vdas LINE DATA Jin CATIA4 model CATIAS CATPart STEP stp NX C prt Figure 7 6 8 Import CAD Data Tool Mesh Provide same procedures and guide lines detailed in section 5 3 4 Surface Mesh of eta DYNAFORM User s Manual Mesh Check Repair provide same procedures and guide lines detailed in section 5 5 Model Check amp Repair of eta DYNAFORM User s Manual After geometries have been assigned to the tools the corresponding graphic symbols will turn to green color Figure 7 6 9 THE INCSOLVER FUNCTIONS Die Simulation Draw Type Upper Tool Available Upper Tool Blank Parameters Part Material ll BLANK 35304 Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Thickness Quarter Symmetry iH 00 mE anh ELAI Ww Lowe
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