This exercise uses the model file bwrap_form_Radioss.hf file for Radioss and bwrap_form_.hf file for LsDyna and bwrap_form_blank.hf for both profiles.
Step 1: Load the file
1. Click on and browse the directories to find the file
<installation_directory>\tutorials\mfs\hf\incremental\bwrap_form_Radioss.hf file for Incremental_Radioss and
<installation_directory>\tutorials\mfs\hf\incremental/bwrap_form_.hf file for Incremental_LsDyna
2. Double click on the file to load into the session.
Step 2: Import a second file
1. Click the Import icon to open the Import dialog.
2. Click the Import HM Model icon and use the Open File icon to browse to the file bwrap_form_blank.hf.
3. Click Open in the dialog, and then click Import.
Note: Import brings the file into the current session without erasing the existing file. Load model brings
the model into the current session and will erase the existing file. 4. Click Close to close the Import dialog.
Step 3: Create blank section properties
1. Click Setup > Sections.
2. In the section: field, type blank_section. 3. In the thickness = field, type 1.0 (mm).
4. Click card image= and select the respective card image from the list. For Radioss, select SH_ORTH as the card image.
For Dyna, select SectShll as the card image. 5. Click create.
6. Click return.
Step 4: Create blank material properties
1. Click Setup > Materials. The Material definition panel displays. 2. Click material: and enter CRDQ_steel.
For Radioss, select HillOrthotropic Tabulated For Dyna, select TransAnisoElasticPlastic
4. Click import curve.
5. Click curve: and enter stress_strain_curve. 6. Click sigy = and enter 185 (MPa).
7. Click k = and enter 550 (MPa). 8. Click n = and enter 0.21. 9. Click create.
10. Click back. 11. Click create.
12. Click on add to database. A folder browser is displayed, allowing you to browse for a folder into which the newly created material file will be saved. This will be a one time operation for every new material created, after which you can access the material using the Material Database option in the Setup menu.
13. Click OK to close the folder browser. 14. Click return to close the Materials panel.
Step 5: Assign section and material properties to the blank component
2. Double-click component: and select blank. 3. Click section: and select blank_section. 4. Click material: and select CRDQ_steel. 5. Select the adaptive checkbox.
6. Click update. 7. Click return.
Note: By default, two levels of adaptivity are enabled. If the starting element size in the blank is, for example, approximately 8 mm, the smallest element after maximum refinement will be
approximately 1 mm. The adaptive levels can be changed by using the Control Cards panel, and editing the AdaptiveGlobalMesh card. The parameter to edit is LevelMax. Refer to the
RADIOSS Starter Manual for more detailed information.
Step 6: Display a top view of the die component only
1. Click on the Model tab to display the Model Browser. If it is not available, click on View and select
Model Browser to display it.
2. Expand the Component folder.
3. Click on the mesh icon as shown in the figure below to turn off the blank mesh.
4. On the toolbar, click the user views icon and select top.
Step 7: Build the punch and binder
1. From the Preferences menu, select Meshing Options. 2. Click feature angle and enter 2.0 (degrees).
3. Click return.
Note: Changing the feature angle to 2.0 will make element selection on the binder area easier. 4. From the Setup menu, select Tool Setup.
5. Select the Build and setup tool from DIE surface subpanel. 6. For Machine Type, choose Double acting.
7. In the Binder Source: field, click Elements. The element selection panel is displayed. 8. Select one element on the binder area of the die as shown below.
Figure 1: Element to select
9. Click elems and select by face option from the extended entity selection. This highlights all the elements on the binder area of the die as shown below.
10. Click proceed. 11. Click Build. 12. Click Close.
Note:
Notice after executing the build, the binder and punch components are generated. The punch offset amount is set using the blank thickness value. The punch offset is calculated to be thickness plus 10%. In this case, it is 1.1*1.0 mm = 1.1 mm.
The Tool Build macro creates tool sections and tool materials. If these were already created, they are updated.
This macro also creates 3 contacts viz between Blank-Die, Blank-Punch and Blank-Binder
Step 8: Define the tool motion for the binder
1. Click Setup > Tool Motion.
2. Click moving tool and select the binder component. 3. Click max velocity and type –2000 (mm/s).
4. Click total travel and type 5.7 (mm).
Note: The total travel of the binder is the distance the binder has to travel rest on the die holding the
blank. This value is the distance between the binder and die, minus the blank thickness and a tolerance (typically 10-20%). This distance between the binder and die are calculated using the
Distance (F4) panel. (Try to select identical nodes on the die and binder).
Total travel - Distance Binder to Die - (Blank thickness + 20% Blank Thickness) Total travel = 6.9 - (1.0 + 0.2) = 5.7
5. Verify all options (at right hand side) are set to
translation
velocity linear
termination, load curve and loadcol are also checked.
6. Click set up.
7. Click the history subpanel.
Note the calculated termination time is T = 4.850e-03 seconds. This time will be used again later in the exercise.
8. Click the motion subpanel. 9. Click edit card.
– For Radioss, click Tstop field and enter 4.850e-03 (s). – For Dyna, click DEATH time field and enter 4.850e-03(s).
This is the time at which the prescribed motion of the binder is killed, and is also the time at which the force load is applied to the binder later in this exercise.