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Autostamp v2004Autostamp v2004
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AutostampAutostamp
Autostamp:
Accurate simulation and quality control
Simulated processes:
Gravity, Holding, Forming simulations
Flanging operations
Springback
Pressure forming (hydroforming, aquadrawing, rubber pad)
Tube bending processes
Fully multistage
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Flowchart autostampFlowchart autostamp
Flowchart AUTO-Stamp
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Open projectOpen project
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ImportImport
Import
CAD Mesh Computed model Diemaker
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Create objectsCreate objects
Stamp 2G is fully OBJECT oriented…
Group of entities (elements, nodes …) on which attributes are defined
NB:
Entity can belong to several objects
Only one definition of an attribute per entity
Plane object Symmetry attribute
Coordinate system object No attribute
Material
Kinematics
Loading
…
Surfaces
Elements
Edges
Nodes
OBJECT
Entities (Hierarchy)Attributes
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Object oriented
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Create objectsCreate objects
Which objects are required depends on the type of simulation :
•Gravity simulation (Double action)
•Holding simulation (Double action)
Necessary objects : full die
blanksheet
Optional objects : symmetry plane
guides
locator pins
Necessary objects : full die
blanksheet
blankholder
Optional objects : symmetry plane
guides
locator pins
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Which objects are required depends on the type of simulation :
•Forming simulation (Double action)
•Springback simulation (Implicit)
Necessary objects : full die
blanksheet
blankholder
punch
Optional objects : symmetry plane
support
drawbeads
Necessary objects : blanksheet
3 fixation points
Optional objects : symmetry plane
trimming line
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Which objects are required depends on the type of simulation :
•Pressure forming
Necessary objects : full die
blanksheet
Optional objects : symmetry plane
punch
blankholder
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Minimum requirement at this stage: Full die geometry
Also possible to import ALL the tools
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
How???
First create two objects from the full die geometry :
• The lower blankholder area (offset will be the upper blankholder)
• The die bottom area (offset will be the punch)
Autostamp requires the definition of all the tools used in reality :
If you have imported just 1 object (the full die geometry) you can
create the punch and the blankholder by using the toolbuilder
macro
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Create objects by selecting entities
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Create objectsCreate objects
Then :
Use the toolbuilder macro
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Toolbuilder macro
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Create objectsCreate objects
Now all TOOL geometries needed for a basic simulation are
available:
- Lower blankholder
- Die bottom
- Punch
- Upper blankholder
BLANKSHEET???
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
1. Import CAD <ref import tools>
2. Import MESH <ref import tools>
3. Use the blanksheet macro
Options for BLANKSHEET :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Blanksheet macro
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Create objectsCreate objects
Now all TOOL geometries and the BLANKSHEET geometry needed
for a basic simulation are available:
- Lower blankholder
- Die bottom
- Punch
- Upper blankholder
- Blanksheet
Are drawbeads present in the reality?
If so, they should be implemented also in the simulation model. Simulations make use of EQUIVALENT drawbead models, where the actual drawbead geometries are represented by bar elements which exert forces (opening <ONLY AUTOSTAMP> and restraining) on the blanksheet
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
1. Import CAD <ref import tools, line import>
2. Import MESH <ref import tools>
3. Create the BAR elements manually (Geometry – Edition – Elements)
Options for geometry DRAWBEADS :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Options:
Pick/enter points
Pick nodes
Transform edges
Transform curves
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
1. Import CAD <ref import tools, line import>
2. Import MESH <ref import tools>
3. Create the BAR elements manually (Geometry – Edition – Elements)
Options for geometry DRAWBEADS :
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Create objectsCreate objects
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
1. Import CAD <ref import tools, line import>
2. Import MESH <ref import tools>
3. Create the BAR elements manually (Geometry – Edition – Elements)
4. Drawbeads are exported from diemaker module
these are 3D curves, transform to bar elements!!!
NOTE:
If a drawbead is a straight line, only 1 bar element suffice
Options for geometry DRAWBEADS :
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If your model is symmetrical, it saves a lot of calculation time if you only consider one half (quarter, …) of the model and use symmetry conditions instead
Create objectsCreate objects
Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed
for a basic simulation are available :
- Lower blankholder
- Die bottom
- Punch
- Upper blankholder
- Blanksheet
- Drawbeads
How????
Use symmetry planes
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Creation of a symmetry plane :
Create object
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
NOTE:
perform the creation of a symmetry plane before
doing offsets of symmetrical tools
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Create objectsCreate objects
Creation of a symmetry plane :
Best to choose a node on the symmetry edge of your tool
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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What else needs to be defined???
Create objectsCreate objects
Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed
for a basic simulation are available and symmetry is applied.
- Lower blankholder
- Die bottom
- Punch
- Upper blankholder
- Blanksheet
- Drawbeads
- Plane symmetry
In case the global +Z axis is not the stamping direction, a local axis system should be created if the macro is to be used
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Creation of objects :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Create object
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Create objectsCreate objects
Creation of a local axis system :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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What else needs to be defined???
Create objectsCreate objects
Now all TOOL, BLANKSHEET and DRAWBEAD geometries needed
for a basic simulation are available and symmetry is applied.
- Lower blankholder
- Die bottom
- Punch
- Upper blankholder
- Blanksheet
- Drawbeads
- Plane symmetry
- Local axis system
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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1. Import CAD <ref import tools>
2. Import MESH <ref import tools>
3. Use accessory macro
Create objectsCreate objects
Guides / Locator pins :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Accessory macro
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1. Import CAD <ref import tools>
2. Import MESH <ref import tools>
3. Create a line manually : Geometry – Edition – 3D curves
Create objectsCreate objects
Trimline (3D curve) :
Pick/enter points
From bars
From edges
From 3D curves
From section
From free edges
Elliptic
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
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Create objectsCreate objects
Other manipulations of objects :
Surface tool Surface blank Drawbead Coord system Symmetry plane Other
Object manipulations Object transformations
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Create objectsCreate objects
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MaterialMaterial
Starting point: All necessary objects are present
Surface tool: Non deformable material
function: Geometry representation
Surface blank: Deformable material
Material in database Material introduction
Deformable Non-deformable
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MaterialMaterial
REMINDER: use consistent unit system, eg:
mm – kg – ms kg/mm3, kN, kNmm, kN/mm2 (GPa)
Deformable Non-deformable
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Process parametersProcess parameters
2 approaches to define the process:
1. Use the AUTOSTAMP-macro (for BASIC simulations)
2. Define the process manually
Macro User-defined
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Process parametersProcess parameters
1. AUTOSTAMP macro
Macro User-defined
Autostamp macro
Auto-position
Control
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SolverSolver
Starting point: -All necessary objects are created
-Attributes are added to objects
Solver can be started from within the program environment:
Solver - Start
Type Location
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SolverSolver
Starting point: -All necessary objects are created
-Attributes are added to objects
Name reference name
Type Location
Host local host or network workstation (IP adress or name)
Exe find the psolid.x (UNIX) or pamstamp_SMP-SP (PC)
every .exe should have it’s own host entryMessages $PAMHOME/stamp/2004_COMMON/Messages$PAMHOME\2004.0\Common\Messages
Solver type UNIX or Windows, Mono, SMP, DMP
Script UNIX: $PAMHOME/pamstamp/v2004/pamworld
PAMHOME in case of nfs/samba: UNIX installation directory
Equivalence if the solver is on another PC/workstation the user needs
to define the equivalent mounting points (shared!!!)
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SolverSolver
The solver can also be started from the UNIX command line:
Pamstamp –nt NPROC Input.pre > Input.out &
Pamstampdp –nt NPROC Input.pre > Input.out &
Pamstampdmp –np NPROC Input.pre > Input.out &
Pamstampdmpdp –np NPROC Input.pre > Input.out &
In Windows a pamstamp v2004 solver icon is available :
Type Location
PAM-STAMP 2G Solver 2004.0.lnk
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SolverSolver
1. Use SINGLE PRECISION (SP) solver for all calculations except implict springback (DOUBLE PRECISION, DP)
2. The attribute ‘Surface tool with material’ must be defined once for every entity (solver related) in the ‘all stages’ object definition
3. Autostamp is fully incremental: it is possible to view the initial state, the final state AND intermediate states
4. DMP and SMP runs are available and can be started from within the program (also from prompt)
5. If convergence problems are encoutered with the implicit gravity, try :
- the DP solver
- eliminate the blankholder walls
- check normal orientation
Important:
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SolverSolver
Before running the autostamp calculation, it’s also possible to use the
‘Save As…’ option to save the file as a Quikstamp FP file and do a fast
initial run to see quickly qualitative results…
Note:
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SolverSolver
Note:
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Post analysisPost analysisAnalyse possibilities:
Global:
1. Radii and angles2. Distances3. Entities4. Model differences5. Section check
Contour plots:
1. Thickness [thickness, thinning]2. Stress [major, minor, plastic…]3. Strain [major, minor, plastic…]4. FLD [stress, strain]5. Kinematic [displacements]6. Energy [internal, shear…]7. Mesh quality [inner angles, area…]8. Undercut9. Numerical [refinement level, wrinkle criterion]10. Contactpressure [normal, tangential]
Post analysis