Robustness of Metal Forming

Home Screen Process Flowchart

1. Double click on the Trimming box to define the solver step in the simulation process.

The Stage dialog window shall open.

Define Stage Setup for Forming

1. Select the Setup tab.
2. Select the Package Name LS-DYNA.
3. For Command enter smpR7.1.2_95028 (or the respective command available on your system). On Windows, the command has to be specified using the absolute path. 
4. For Input File browse the LS-DYNA keyword file sheet_metal_forming_trimming.key. Parameters are defined in this file using *PARAMETER keyword. LS-OPT parses this LS-DYNA keyword automatically for parameters and includes.
5. Provide trim.igs as an Extra Input File to be copied in the run directories.
6. For efficient usage of the computing power from the machine, choice on handling number of concurrent jobs can be made suitable in this section. For more details see FAQ resources.
7. Click on the OK button to proceed.

Home Screen Process Flowchart

 Add Stage

1. Click on the Add menu in the control bar.
2. Select Add Stage --> in Sampling Sampling for the second step Trimming in the metal forming process.

Enter Simulation as the Name for new stage.

Dependencies of Stages

1. The dependency of the stages is set by dragging the arrow head from the stage Trimming to the stage Simulation.

• After connecting the two stages to each other we can re-position the stage Trimming for the sake of nice view of flowchart by dragging with simple left-mouse click, or use the Re-layout Stages option from the Tools menu.

File Transfers

1. Since the stage Simulation uses the output file of the stage Trimming as an include file (dynain), the definition of a file transfer is necessary. Click on the File Transfers icon between the two stages. Another option to make the files available for the Trimming stage is to use the Run in directroy of stage option in the Stage dialog Setup tab.

 The File Transfers dialog will open.

2. Click on Add option to define a file transfer.
3. Select the file transfer Operation as Copy.
4. Enter the filename of the Source File as dynain.
5. Enter the name of the Destination File as dynain.
6. In case the operations fails (on Error) select the operation to be applied as fail. The job will return an error termination and LS-OPT won't run the downstream stages for this sampling point.

7. Click on the OK button to proceed.

 Define Solver Setup for Simulation

1. Open the Simulation - Stage dialog as done for the previous Stage - Forming by double clicking on it. Then select the Setup tab.
2. Select the Package Name LS-DYNA.
3. For Command enter smpR7.1.2_95028 (or the respective command available on your system). On Windows, the command has to be specified using the absolute path. 
4. For Input File browse the LS-DYNA keyword file sheet_metal_forming.key.
5. For efficient usage of the computing power from the machine, choice on handling number of concurrent jobs can be made suitable in this section. For more details see FAQ resources.

Define Responses

Define FLD_upper_surface

1. Select the Responses tab in Stage dialog.
2. Select the response as the LS-DYNA d3plot result FLD (Forming Limit Diagram) on the right side of the stage dialog among the response types list.
3. Enter the response Name as FLD_upper_surface.
4. Enter the List of Parts to be included as 1.
5. Select Sampling location as Upper surface.
6. Enter the Load curve ID as 90.
7. Click on the OK button to end the response definition.

Define FLD_lower_surface

1. Select the response as the LS-DYNA d3plot result FLD (Forming Limit Diagram) on the right side of the stage dialog among the response types list.
2. Enter the response Name as FLD_lower_surface.
3. Enter the List of Parts to be included as 1.
4. Select Sampling location as Upper surface.
5. Enter the Load curve ID as 90.
6. Click on the OK button to end the response definition.

Define FLD_center_surface

1. Select the response as the LS-DYNA d3plot result FLD (Forming Limit Diagram) on the right side of the stage dialog among the response types list.
2. Enter the response Name as FLD_center_surface.
3. Enter the List of Parts to be included as 1.
4. Select Sampling location as Upper surface.
5. Enter the Load curve ID as 90.
6. Click on the OK button to end the response definition.

Define THICKNESS

1. Select the response as the LS-DYNA d3plot result THICK on the right side of the stage dialog among the response type list.
2. Enter the name as THICKNESS.
3. Select All Parts to be included.
4. Select the Reported Value Type as Percentage thickness reduction.
5. Select the Maximum for the Extracted response.
6. Click on the OK button to end the response definition.
7. Click on the OK button to proceed.

Home Screen Process Flowchart

1. Click on the Open the viewer icon in the contral bar on the Home Screen Process Flowchart window.

A New Plot window shall open.

2. Choose Surface under Metamodel.

Surface Plot Settings

1. Select the Setup tab.
2. Select the response FLD_upper_surface for the z-axis of the plot.
3. Select two of the design variables, e.g. f_force and SCALE, for the x- and y-axis, respectively.
4. Set the third design variable, e.g. FRIC, to an arbitrary value. In this case we set FRIC to its mean value, 0.125.
5. Display the Constraints on the plot.
6. Select Points tab.
7. Select the Current Iteration to be displayed on the plot.
8. Show the Feasible and Infeasible points on the plot.
9. Activate Show Residuals to put forward an idea about the quality of the metamodel.

New Plot - Statisctical Tools

1. Click on the New Plot icon in the menu bar - (or click on the Open the viewer icon on the Home Screen Process Flowchart).

A New Plot window shall open.

2. Select Replace current plot icon.
3. Select Statistical Tools under Stochastic analysis.

Histogram

1. Select Setup tab in the new opened Statictical Tools plot window.
2. Select the Plot type as Histogram.
3. Select the response FLD_upper_surface to plot its histogram.
4. Select Options tab.
5. Select Frequency as Y-axis scaling.
6. Display Mean Value, Standard deviation and Contraints with Feasibility on the histogram.

New Plot - Stochastic Contribution

1. Click on the New Plot icon in the menu bar - (or click on the Open the viewer icon on the Home Screen Process Flowchart).

A New Plot window shall open.

2. Select Replace current plot icon.
3. Select Stochastic Contribution under Stochastic analysis.

Stochastic Contribution Settings

1. Select the Response FLD_upper_surface to display the stochastic contributions of the design variables on this response in the Setup tab.

• Select the Response FLD_lower_surface to display the stochastic contributions of the design variables on this response by selecting it in step 1:

• Select the Response THICKNESS to display the stochastic contributions of the design variables on this response by selecting it in step 1: