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    Hot Forming Introduction

    Uploaded by

    Elaine Johnson
    This document introduces new features for hot forming simulations in LS-DYNA, including thermal thick shells for tools, thermal gravity loading, press hardening simulation, default friction coefficients, initial temperature definitions, and support for temperature-dependent material properties. It describes the basic unit system used, outlines the typical hot forming process stages, and provides details on setting up thermal thick shells, gravity loading simulations, friction parameters, temperature-dependent material definitions, initial blank and tool temperatures, and configuring the hot forming simulation in LS-DYNA.

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    Hot Forming Introduction

    Uploaded by

    Elaine Johnson
    90 views19 pages
    This document introduces new features for hot forming simulations in LS-DYNA, including thermal thick shells for tools, thermal gravity loading, press hardening simulation, default friction coefficients, initial temperature definitions, and support for temperature-dependent material properties. It describes the basic unit system used, outlines the typical hot forming process stages, and provides details on setting up thermal thick shells, gravity loading simulations, friction parameters, temperature-dependent material definitions, initial blank and tool temperatures, and configuring the hot forming simulation in LS-DYNA.

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    This document introduces new features for hot forming simulations in LS-DYNA, including thermal thick shells for tools, thermal gravity loading, press hardening simulation, default friction coefficients, initial temperature definitions, and support for temperature-dependent material properties. It describes the basic unit system used, outlines the typical hot forming process stages, and provides details on setting up thermal thick shells, gravity loading simulations, friction parameters, temperature-dependent material definitions, initial blank and tool temperatures, and configuring the hot forming simulation in LS-DYNA.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    90 views19 pages

    Hot Forming Introduction

    Uploaded by

    Elaine Johnson
    This document introduces new features for hot forming simulations in LS-DYNA, including thermal thick shells for tools, thermal gravity loading, press hardening simulation, default friction coefficients, initial temperature definitions, and support for temperature-dependent material properties. It describes the basic unit system used, outlines the typical hot forming process stages, and provides details on setting up thermal thick shells, gravity loading simulations, friction parameters, temperature-dependent material definitions, initial blank and tool temperatures, and configuring the hot forming simulation in LS-DYNA.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 19

    Hot Forming Introduction

    2014.6.16

    New features

    Thermal thick shells for the tools (TSHELL=1)


    Thermal gravity loading simulation
    Thermal press hardening simulation
    Default friction coefficient for hot forming (0.46)
    Initial temperatures for both blanks and tools
    Support of *DEFINE_TABLE_3D for *MAT_106/
    *MAT_244
    Thermal time step for hot forming

    Unit system
    Basic unit system
    Mass

    Length

    Time

    Force

    Pressure

    Work or Energy

    Density

    Elas:c
    modulus

    ton

    mm

    MPa

    N mm

    ton/mm^3

    MPa

    All the units will be converted to basic unit [ton, mm , s, N] in the input deck.

    Unit in the GUI


    Commonly used unit is provided in the GUI, user does not need to convert
    them to the basic unit system manually in the hot forming setup.

    Hot forming process


    Full processes of hot forming in eta/Dynaform 5.9.2
    The stages of gravity loading and press hardening are optional.

    Gravity loading

    Hot forming

    Press hardening

    Thermal thick shells


    Thermal thick shells for the tools
    The heat transfer from blank to the tools is proportional to the temperature
    gradient of the contact partners.
    The thermal thick shells give us higher accuracy for longer contact times.
    This is necessary for the gravity phase and slow tool velocity.

    *CONTROL_SHELL
    TSHELL=1
    *CONTROL_CONTACT
    ITHOFF=1

    Thermal thick shells


    Thermal thick shells for the tools
    The artificial thickness can be calculated from the thermal effusivity

    Thermal gravity loading


    Thermal gravity loading simulation
    Since the blank material is very soft at high temperatures, the bending
    of the blank during the insertion might be significant. This could affect
    the initial blank position before the press hardening process.
    The material properties change significantly with the temperature.
    During the insertion of the hot blank into the press, some areas of the
    blank get in contact with the tools, some do not. In those areas where
    contact occurs, the temperature of the blank decreases significantly due
    to the cooling of the tools. Thus, the initial temperature distribution in the
    blank before the forming stage is NOT uniform.

    Thermal friction
    Friction
    Since there is no lubricant in hot forming, the friction is very high, the
    default friction coefficient is 0.46. The user can change this if necessary.

    Support of *DEFINE_TABLE_3D
    Supports *DEFINE_TABLE_3D for stress/strain

    Temperature
    Strain rate

    Thermal time step


    Thermal time step
    Thermal time step is higher than the mechanical time step with dynamic
    explicit time integration:

    TMAX = 1/tool velocity

    GUI of hot forming


    Hot Forming is a separate module.

    GUI of hot forming

    The tools of gravity/hardening are


    referred to as the tools of forming.

    Blank sheet material definition

    Blank material definition:

    Structural
    Thermal

    Blank sheet material definition


    Select the material type and
    define the parameters of the
    material.
    Structural material

    MAT106
    *MAT_ELASTIC_VISCOPLASTIC_THERMAL

    MAT244
    *MAT_UHS_STEEL

    Thermal material
    1. *MAT_THERMAL_ISOTROPIC
    2. *MAT_THERMAL_ORTHOTROPIC
    3. *MAT_THERMAL_ISOTROPIC_TD
    4. *MAT_THERMAL_ORTHOTROPIC_TD
    5. *MAT_THERMAL_ISOTROPIC_PHASE
    _CHANGE
    6. *MAT_THERMAL_ISOTROPIC_TD_LC

    Tool material definition


    Select the material type and
    define the parameters of the
    material.
    Structural material

    MAT20 *MAT_RIGID
    Tool structural material is defined
    automatically.

    Thermal material
    1. *MAT_THERMAL_ISOTROPIC
    2. *MAT_THERMAL_ORTHOTROPIC
    3. *MAT_THERMAL_ISOTROPIC_TD
    4. *MAT_THERMAL_ORTHOTROPIC_TD
    5. *MAT_THERMAL_ISOTROPIC_PHASE
    _CHANGE
    6. *MAT_THERMAL_ISOTROPIC_TD_LC

    Contact parameters
    Setup the contact parameters for
    each tool.

    Initial temperature for tools


    Setup the initial temperature for
    each tool.
    Used for all tools All tools have
    the same initial temperature.

    Boundary condition
    The initial temperature of the
    blank is defined in the boundary
    of the 1st stage.
    The temperature information file
    *.new_temp_ic.inc will be
    included.
    User can select Celsius (C) or
    Kelvin (K) as the unit of
    temperature.

    Configuration for hot forming


    User can modify the default parameters for hot forming in default config.

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