1. Mar120, Workshop 7, December 2001 WORKSHOP 7 METAL FORMING A PAPER CLIP WORKSHOP 7 METAL FORMING A PAPER CLIP

2. Mar120, Workshop 10, March 2001 WS 7-1 Mar120, Workshop 7, December 2001

3. Mar120, Workshop 10, March 2001 WS 7-2 Mar120, Workshop 7, December 2001 Model Description  This workshop illustrates a common metal-forming process by simulating the shaping of the familiar and commonplace paper clip. There are many way of producing the piece. This exercise makes use of simple, straightforward movements of rigid bodies.

4. Mar120, Workshop 10, March 2001 WS 7-3 Mar120, Workshop 7, December 2001 Objective  Illustrate setting up a multi-step analysis and the use of rigid surfaces charged with shaping a malleable workpiece. Required  No supporting file is required for this problem.

5. Mar120, Workshop 10, March 2001 WS 7-4 Mar120, Workshop 7, December 2001 Suggested Exercise Steps 1. Create the workpiece. 2. Create well appropriated rigid surfaces. 3. Fix the inner end of the workpiece.

6. Mar120, Workshop 10, March 2001 WS 7-5 Mar120, Workshop 7, December 2001 CREATE NEW DATABASE Open a new database. Name it Paper_clip.db a.File: New b.Enter Paper_clip.db as the file name. c.Click OK. d.Select MSC.Marc as the Analysis Code. e.Click OK. a Paper_clip b MSC.Marc  d e 10.0 c Structural 

7. Mar120, Workshop 10, March 2001 WS 7-6 Mar120, Workshop 7, December 2001 Step 1. Geometry: Create / Surface / XYZ [-4.9,.09375, 0] a b c Use the XYZ method to create a surface a.Geometry: Create / Surface / XYZ. b.Enter as Vector Coordinates List. c.Enter [-4.9,.09375, 0] as Origin Coordinates List.

8. Mar120, Workshop 10, March 2001 WS 7-7 Mar120, Workshop 7, December 2001 [0.49125, 0, 0] 991 a b d c e f Use the XYZ method to create center points. a.Geometry: Create / Point / XYZ. b.Enter 991 for Point ID List. c.Uncheck Auto Execute. d.Enter [0.49125, 0, 0] for Point Coordinates List. e.Click Apply. f.Repeat steps a-e for eight additional points as shown in the table: Step 2. Geometry: Create / Point / XYZ The Point Id MUST match with the Point Coordinates above. All the Point Ids are for later on use. Make sure you have EXACTLY the same Id numbers and coordinate numbers

9. Mar120, Workshop 10, March 2001 WS 7-8 Mar120, Workshop 7, December 2001 [1.69125, 0.03125, 0] 992 a b d c e [0.191125, 0.48625, 0] 993 a b d c e [0.2705, 0.22075, 0] 1001 a b d c e [0.2705, -0.22075, 0] 1002 a b d c e [1.94325, -0.22075, 0] 1003 a b d c e [1.94325, 0.28325, 0] 1004 a b d c e [-0.092125, 0.28325, 0] 1005 a b d c e [-0.09215, -0.28325, 0] 1006 a b d c e

10. Mar120, Workshop 10, March 2001 WS 7-9 Mar120, Workshop 7, December 2001 g h By turning on the point & curve label control, it will become easier to identify each point and curve when selecting them. You should be able to see the points you have just created along with their point labels. g.Click Label Control. h.Select both the Point and Curve options.

11. Mar120, Workshop 10, March 2001 WS 7-10 Mar120, Workshop 7, December 2001 b Point 991 0.09375 1 a c d f e Create the curves a.Geometry: Create / Curve / 2D Circle. b.Select Any point icon. c.Enter 0.09375 for Circle Radius. d.Click in the Center Point List panel. e.Select Point 991. f.Click Apply. g.Repeat steps c-f for eight additional curves as shown in the table: Step 3. Geometry: Create / Curve / 2D Circle

12. Mar120, Workshop 10, March 2001 WS 7-11 Mar120, Workshop 7, December 2001 Point 1003 0.09 6 a c d f Point 1004 0.09 7 a c d f Point 1005 0.09 8 a c d f Point 1006 0.09 9 a c d f Point 992 0.125 2 a c d f Point 993 0.15625 3 a c d f Point 1001 0.09 4 a c d f Point 1002 0.09 5 a c d f

13. Mar120, Workshop 10, March 2001 WS 7-12 Mar120, Workshop 7, December 2001 Step 4. Elements: Create / Mesh / Surface Create the mesh a.Elements: Create / Mesh / Surface. b.Select Isomesh for Mesher. c.Click in Surface List panel. d.Use Surface or Solid Face picking icon. e.Select the Surface 1. f.Uncheck Automatic Calculation. g.Enter 0.02 for Value. h.Click Apply. d a b c 0.02 g h Surface 1 f Clicking Apply creates the mesh. e

14. Mar120, Workshop 10, March 2001 WS 7-13 Mar120, Workshop 7, December 2001 Step 5. Loads/BCs: Create / Contact / Element Uniform Create contact deformable body a.Load/BCs: Create / Contact / Element Uniform. b.Select Deformable Body for Option. c.Enter touchy for New Set Name. d.Select 2D for Target Element Type. e.Click Select Application Region…. f.Select Geometry for Geometry Filter. g.Click in Select Surfaces panel. h.Select Surface or face icon. i.Select the surface. j.Click Add. k.Click OK. l.Click Apply. h i Surface 1 f g j k touchy a b c d e l

15. Mar120, Workshop 10, March 2001 WS 7-14 Mar120, Workshop 7, December 2001 Step 6. Loads/BCs: Create / Contact / Element Uniform Create contact rigid body a.Create / Contact / Element Uniform. b.Select Rigid Body for Option. c.Enter D1 for New Set Name. d.Select 1D for Target Element Type. e.Click Input Data…. f.Select Position for Motion Control. g.Enter for Displacement (vector). h.Click OK. i.Click Select Application Region…. f g h D1 a b c d e i

16. Mar120, Workshop 10, March 2001 WS 7-15 Mar120, Workshop 7, December 2001 j.Select Geometry for Geometry Filter. k.Click in Select Curves panel. l.Select Surface or Face icon. m.Select Curve 1. n.Click Add. o.Click OK. p.Click -Apply-. q.Repeat steps a-p for eight additional curves as shown in the table: l m j k n o D1 p

17. Mar120, Workshop 10, March 2001 WS 7-16 Mar120, Workshop 7, December 2001 Step 7. Fields: Create / Material / Tabular Input Create a field for the elasto-plastic material data. a.Fields: Create / Material Property / Tabular Input. b.Enter workhard for Field Name. c.Uncheck Temperature. d.Select Strain (e). e.Click Input Data. f.Enter Strain field as given by the table: g.Click OK. h.Click Apply. g workhard a b c d e h The 1D Material Scalar Table Data form needs to be filled out as shown in Table 1. To fill in the table, click on the cell you wish to edit, enter the value in the Input Scalar Data box and and press Return. The table will tab down automatically. f

18. Mar120, Workshop 10, March 2001 WS 7-17 Mar120, Workshop 7, December 2001 Step 8. Materials: Create / Isotropic / Manual Input Create the material aluminum_1100, with elastic and plastic properties a.Materials: Create / Isotropic / Manual Input. b.Enter Steel for Material Name. c.Click Input Properties…. d.Select Elastic for Conductivity Model. e.Enter 3E7 for Elastic Modulus. f.Enter 0.3 for Poisson’s Ratio. g.Click OK. h.Click Apply. 3E7.3 d e f g Steel a b c h The material constituitive model used in this analysis is an Incompressible Mooney Rivlin hyperelastic formulation. Make sure that the analysis code is set for MSC.Marc under Preferences- Analysis.

19. Mar120, Workshop 10, March 2001 WS 7-18 Mar120, Workshop 7, December 2001 i.Click Input Properties…. j.Select Plastic for Constitutive Model. k.Select Isotropic for Hardening Rule. l.Click in Stress vs. Plastic Strain panel. m.Select workhard in Temperature/Strain/Strain Rate Dependent Fields window. n.Click OK. o.Click Apply. Steel i j k l workhard m

20. Mar120, Workshop 10, March 2001 WS 7-19 Mar120, Workshop 7, December 2001 Step 9. Properties: Create / 2D / 2D Solid Define the element properties a.Properties: Create / 2D / 2D Solid. b.Enter workpiece for Property Set Name. c.Select Plane Stress for Option(s). d.Select Standard Formulation. e.Click Input Properties. f.Click in Material Name panel. g.Select Steel from Material Property Sets. h.Enter 0.035 for Thickness. i.Click OK. workpiece a b c d e Steel.035 Steel f g h

21. Mar120, Workshop 10, March 2001 WS 7-20 Mar120, Workshop 7, December 2001 Surface 1 workpiece Surface 1 j l m j.Click in Select Members panel. k.Select Surface 1. l.Click Add. m.Click Apply. k

22. Mar120, Workshop 10, March 2001 WS 7-21 Mar120, Workshop 7, December 2001 Step 10. Loads/BCs: Create / Displacement / Nodal Create the Boundary Condition to fix the right edge a.Loads/BCs: Create / Displacement / Nodal. b.Enter End for New Set Name. c.Click Input Data…. d.Enter for Translations. e.Click OK. f.Click Select Application Region…. 1. Coord 0 d e End a b c f

23. Mar120, Workshop 10, March 2001 WS 7-22 Mar120, Workshop 7, December 2001 g.Select Geometry for Geometry Filter. h.Click in Select Geometry Entities panel. i.Select Curve or Edge icon. j.Select the right edge of surface. k.Click Add. l.Click OK. m.Click Apply. i j Surface 1.3 g h k l End m

24. Mar120, Workshop 10, March 2001 WS 7-23 Mar120, Workshop 7, December 2001 Step 11. Load Case: Create Create load cases a.Load Cases: Create. b.Select Default in Existing Load Cases window. c.Enter One as Load Case Name. d.Click in Scale Factor for act2. e.Enter 0 for Input Scale Factor. f.Repeat steps d-e for act3- act6. g.Click OK. h.Click Apply. 1 1 1 1 1 1 0 0 0 0 0 d e g One a b c h

25. Mar120, Workshop 10, March 2001 WS 7-24 Mar120, Workshop 7, December 2001 i.Repeat steps a-h for five additional load cases named Two, Three, Four, Five, and Six. Each time select the previous load case and enter the new name as Load Case Name. Also, change the scale factor of the act2-act6 Load/BC corresponding to the new load case to 1, leaving the other Scale Factors unchanged (for example, case Two act1-act2 Scale Factors equal 1, act3-act6 Scale Factors equal 0). Load Case Two Load Case Three 1 1 1 1 1 1 1 1 0 0 0 1 1 1 1 1 1 1 0 0 0 0

26. Mar120, Workshop 10, March 2001 WS 7-25 Mar120, Workshop 7, December 2001 Load Case Four Load Case Five 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 0 0 Load Case Six 1 1 1 1 1 1 1 1 1 1 1

27. Mar120, Workshop 10, March 2001 WS 7-26 Mar120, Workshop 7, December 2001 Step 12. Analysis: Analyze / Entire Model / Full Run Set up and launch the analysis a.Analysis: Analyze / Entire Model / Full Run. b.Enter Pclip_job1 as Job Name. c.Click Translation Parameters…. d.Click Solver Options…. e.Select Non-Positive Definite. f.Click OK. g.Click OK. h.Click Load Step Creation…. e f Pclip_job1 Full Run  Entire Model  a b c h d g

28. Mar120, Workshop 10, March 2001 WS 7-27 Mar120, Workshop 7, December 2001 i.Enter S1 for Job Step Name. j.Click Select Load Case. k.Select load case one. l.Click OK. m.Click Solution Parameters…. k l S1 i j m

29. Mar120, Workshop 10, March 2001 WS 7-28 Mar120, Workshop 7, December 2001 n.Click Load Increment Parameters…. o.Select Adaptive for Increment Type. p.Select None for Arclength Method. q.Enter 33 for Number of Cutbacks. r.Enter 0.025 for Trial Time Step Size. s.Click OK. t.Click Iteration Parameters…. u.Enter 50 for Max # of Iterations per Increment. v.Enter 5 for Desired # of Iterations per Increment. w.Click OK. n t 50 5 u v w s o p.025 1.2 r 33 q

30. Mar120, Workshop 10, March 2001 WS 7-29 Mar120, Workshop 7, December 2001 x aa x.Click Contact Table. y.Remove all T’s in the table except for rows 2-D1 and 5-act1. z.Click OK. aa.Click OK. T T T T y z Remove the T’s in the first column by double clicking on them. You don’t have to worry about all the T’s in the horizontal direction, because they are symmetric with the vertical direction T’s as we are using two-way contact.

31. Mar120, Workshop 10, March 2001 WS 7-30 Mar120, Workshop 7, December 2001 S2 Default Static Step S1 bb cc dd bb.Click Apply. cc.Select S1. dd.Enter S2 for Job Step Name. ee.Click Select Load Case. ff.Click Load case two. gg.Click OK. ee ff gg By clicking on S1 all data is copied from S1. There are only some minor changes for S2.

32. Mar120, Workshop 10, March 2001 WS 7-31 Mar120, Workshop 7, December 2001 hh.Click Solution Parameters…. ii.Click Contact Table…. S2 Default Static Step S1 hh ii The contact table will pop out and you can check to see if the previous steps were done correctly. The Contact Table should look like the one created previously.

33. Mar120, Workshop 10, March 2001 WS 7-32 Mar120, Workshop 7, December 2001 jj.Click to add T for both 3-D2 and 6-act2. kk.Click OK. ll.Click OK. mm.Click Apply. T T T T T T T T jj kk ll S2 Default Static Step S1 mm

34. Mar120, Workshop 10, March 2001 WS 7-33 Mar120, Workshop 7, December 2001 nn.Repeat steps bb-ll to create Contact Tables with Job Step names S3, S4, S5 and S6. Each time click on the last Job Step created, then change the Job Step Name to the new Job Step name. Then select the corresponding load case. T T T T T T T T Step S2 T T T T T T T T Step S3 Notice that only the last two Act# rigid surfaces are kept in each step. Also notice that the D3 rigid surface is added in Job Step S4 (next slide) and kept together with D1 and D2 in the subsequent Job Steps.

35. Mar120, Workshop 10, March 2001 WS 7-34 Mar120, Workshop 7, December 2001 T T T T T T T T T T Step S4 T T T T T T T TT T T Step S5 T T T T T TT T T T Step S6

36. Mar120, Workshop 10, March 2001 WS 7-35 Mar120, Workshop 7, December 2001 S2 Default Static Step S1 oo oo.Click Cancel. pp.Click Load Step Selection. qq.Select job steps S1-S6 in order, then deselect Default Step Selection. rr.Click OK. ss.Click Apply. Make sure that the Default Static Step does not appear in the Selected Job Steps panel. Further, make sure steps S1-S6 appear in the correct order. Pclip_job1 Full Run  Entire Model  pp ss qq rr

37. Mar120, Workshop 10, March 2001 WS 7-36 Mar120, Workshop 7, December 2001 Step 13. Analysis: Read Results / Result Entities / Attach Read (attach) the results a.Analysis: Read Results / Result Entities / Attach. b.Select Pclip_job1. c.Click Select Results File. d.Select Pclip_job1.t16. e.Click OK. f.Click Apply. Pclip_job1.t16 d e Pclip_job1 a b c f

38. Mar120, Workshop 10, March 2001 WS 7-37 Mar120, Workshop 7, December 2001 g.Group / Create. h.Create / Select Entity. i.Enter All Fem for New Group Name. j.Click -Apply-. All Fem g h j i

39. Mar120, Workshop 10, March 2001 WS 7-38 Mar120, Workshop 7, December 2001 Step 14. Results: Create / Quick Plot Display the results a.Results: Create / Quick Plot. b.Select Deform Attributes icon. c.Select True Scale. d.Enter 1.0 for Scale Factor. e.Uncheck Show Undeformed. f.Select Fringe Attributes icon. g.Select Free Edges for Display. a b c d e f g

40. Mar120, Workshop 10, March 2001 WS 7-39 Mar120, Workshop 7, December 2001 h.Click on Select Results icon. i.Select the last result case. j.Select Strain, Total. k.Select Displacement Translation. l.Click Apply. h j k l i

41. Mar120, Workshop 10, March 2001 WS 7-40 Mar120, Workshop 7, December 2001