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9: Break Forming
Summary 2
Chapter Overview 3
Detailed Session Description of Break Forming 4
Run Job and View Results 9
Discussion 13
Modeling Tips 14
Input Files 15
Animation 16
3.9-2 Marc User’s Guide
Summary
Summary
u=1
Z X
0.6
Material properties E = 30x106 Psi, = 0.3, = 5x10 4 1 + p
Analysis type Static with elastic plastic material behavior
Boundary conditions Ux = 0 at center nodes, cylindrical rigid body bends metal sheet
0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)
CHAPTER 3.9 3.9-3
Break Forming
Chapter Overview
A flat sheet is formed into an angled bracket by punching it though a hole in a table using the
contact option.
Inc: 50 Inc: 70
Time: 5.000e-001 Time: 1.000e+000
4.600e-001 4.600e-001
4.140e-001 4.140e-001
3.680e-001 3.680e-001
3.220e-001 3.220e-001
2.759e-001 2.759e-001
2.299e-001 2.299e-001
1.839e-001 1.839e-001
1.379e-001 1.379e-001
Y
9.184e-002 9.184e-002
4.581e-002 4.581e-002
Z X
-2.149e-004 Y -2.149e-004 Y
Z X Z X
lcase1 lcase2
Total Equivalent Plastic Strain 1 Total Equivalent Plastic Strain 1
The cylindrical punch drives the sheet down into the hole of the table to a total stroke of 0.3”. The punch
then returns to its original position. The material is elastic plastic with workhardening.
A B
job1
Force Y cbody2 (x1000)
1.289 28 26
27 25
3029 Equivalent Von Mises Stress Node 63
333231 8 100000
3534
36 242322 12019
1817
50 37
38
1615
141312
11
9
10 Strength
39
40
41
42
43
44
80000
45
48 46 765
4 32
49 47 1
60000
20000
0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0 0
-3 0 0.0 0.2 0.4 0.6 0.8 1.0
Pos Y cbody2 (x.1) 1
Total Equivalent Plastic Strain
Figure 3.9-2 (A) Vertical Punch Load versus Stroke (B) Stress versus Plastic Strain
At the bottom of the stroke, the total plastic strain is nearly 45%. The vertical punch force is plotted
versus its vertical position. This force rises quickly, hardens though about half of the stroke, then softens
near the end of the stroke. Upon lifting the punch, the punch force drops rapidly and the sheet has very
little springback.
The stress-plastic strain response of a point in the sheet under the punch is plotted and shown to overlay
the material data. This workshop problem exemplifies how every point in the sheet must follow the
material’s constitutive behavior as well as being in equilibrium throughout the deformation. The vertical
line in the history plot to the right is the elastic unloading of this point in the sheet.
This is a break forming problem where a punch indents a sheet over a table to make an bracket.
The problem geometry is shown below:
3.9-4 Marc User’s Guide
Detailed Session Description of Break Forming
u=1
table1
F (x1e5)
1 11
10
9
8
0.5 1
0 1
V1
eq_plastic_strain
OK
FORMULA
ENTER
5E4*(1+V1^.6) The equation describing the flow
4 .6
FIT stress is y = 5 x 10 1. + p
NEW
1 IND. VARIABLE
TABLE TYPE time
OK
ADD POINT
0, 0, .5, -.3, 1, 0
FIT
SHOW MODEL
RETURN
CHAPTER 3.9 3.9-7
Break Forming
table2
F (x.1)
0 1 3
-3 2
V1
STRUCTURAL
PLASTICITY (twice)
INITIAL YIELD STRESS
1
TABLE1
table1 (eq_plastic_strain)
OK (twice),
MAIN
CONTACT
CONTACT BODIES
DEFORMABLE
OK
ELEMENTS ADD
ALL:EXISTING
NEW
RIGID
POSITION PARAMS
Y=1
TABLE
table2 (time),
OK (twice)
3.9-8 Marc User’s Guide
Detailed Session Description of Break Forming
cbody1
cbody2
cbody3
Z X
LOADCASES
MECHANICAL
STATIC
LOADCASE TIME
.5
# OF STEPS
50
CONVERGENCE TESTING
DISPLACEMENTS
RELATIVE DISPLACEMETN TOLERANCE
0.001
OK (twice)
COPY
STATIC
LOADCASE TIME
.5
# OF STEPS
20
OK
MAIN
JOBS
NEW
MECHANICAL
PROPERTIES
ANALYSIS OPTIONS
LARGE STRAIN
OK
lcase1
CHAPTER 3.9 3.9-9
Break Forming
lcase2
ANALYSIS DIMENSION: PLANE STRAIN
JOB RESULTS
EQUIVALENT VON MISES STRESS
TOTAL EQUIVALENT PLASTIC STRAIN
OK
CONTACT CONTROL
ADVANCED CONTACT CONTROL
SEPARATION FORCE
.1
OK
OK (thrice)
SAVE
Inc: 50
Time: 5.000e-001
4.600e-001
4.140e-001
3.680e-001
3.220e-001
2.759e-001
2.299e-001
1.839e-001
1.379e-001
9.184e-002
4.581e-002
-2.149e-004 Y
Z X
lcase1
Total Equivalent Plastic Strain 1
RESULTS
SKIP TO INCREMENT 70
Inc: 70
Time: 1.000e+000
4.600e-001
4.140e-001
3.680e-001
3.220e-001
2.759e-001
2.299e-001
1.839e-001
1.379e-001
9.184e-002
4.581e-002
-2.149e-004 Y
Z X
lcase2
Total Equivalent Plastic Strain 1
RESULTS
HISTORY PLOT
SET LOCATIONS
n:63 # (pick bottom middle node n:63)
ALL INCS
ADD CURVES
GLOBAL
Pos Y cbody2
Force Y cbody2
FIT
job1
Force Y cbody2 (x1000)
1.289 28 26
27 25
3029
333231 8
3534
50 36 2423
22 12019
1817
16 9
37
38 1 5
1 4
1312
1110
39
40
41
42
43
44
45
48 46 765
4 32
49 47 1
0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)
RESULTS
HISTORY PLOT
CLEAR CURVES
ALL INCS
ADD CURVES
ALL LOCATIONS
Total Equivalent Plastic Strain
Equivalent Von Mises Stress
FIT
80000
60000
20000
0
0.0 0.2 0.4 0.6 0.8 1.0
Total Equivalent Plastic Strain
Figure 3.9-11 Stress versus Plastic Strain Node 63
CHAPTER 3.9 3.9-13
Break Forming
Discussion
Since the sheet will completely wrap around the rigid cylinder an the end of the bending, we can estimate
the strain assuming that the sheet completely surrounds the cylinder, and by knowing the strain, the stress
can also be estimated as shown in Figure 3.9-12.
r = 0.1
t = 0.1 εCD = CD – C’ D’
--------------------------
-
C’ D’
A’ B’ C’D’ = A’B’
A’ B’ = AB
Figure 3.9-12 Estimating the bending strain and stress in the center of the sheet
With the stresses estimated we can assume that a fully plastic hinge forms in the center of the sheet and
estimate the punch load as shown in Figure 3.9-13.
y
σ(y)
x M
y
M x
0.3
P/2 P/2
Figure 3.9-13 Estimating the bending moment and maximum punch load
The estimate for the maximum punch load, 1250 lbf, is very close to that found by the analysis as shown
in Figure 3.9-10 of 1289 lbf. Finally, although the final angle after spring back appears close to 90o, its
actual value is 84o, and the punch stroke should be slightly reduced to form a right angle after springback.
3.9-14 Marc User’s Guide
Modeling Tips
Modeling Tips
The punch force in Figure 3.9-10 has an abrupt jump at increment 50 which is caused by a new node
entering contact between the sheet and the rigid table. This can be improved by using segment to
segment contact and entered in the modeling under contact control; the comparison between node to
segment and segment to segment contact is shown in Figure 3.9-14.
JOBS
NEW
MECHANICAL
PROPERTIES
CONTACT CONTROL
METHOD: SEGMENT TO SEGMENT
OK (twice)
RUN, SUBMIT....
Segment to Segment Contact
Y (x1000) Force Y cbody2
Node to Segment Contact
1.289 28 26
27 2 5
313029
3332 28272625242322 1201918171615 8
35343332313029
36 242322 12019181716 1413 9
50 4544 40 37 3534 1514131211 0
46 4241 39383736
47 43 40 121110
48 41 987
49 42 654
50 43 32
44
48 4645 765
4 32
49 47 1
0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)
Inc: 50
Time: 5.000e-001
Contact Normal Force
6.869e+002
6.011e+002
5.152e+002
4.293e+002
3.435e+002
2.576e+002
1.717e+002
8.587e+001
0.000e+000 Y
Z X
Input Files
The files below are on your delivery media or they can be downloaded by your web browser by clicking
the links (file names) below.
File Description
s4.proc Mentat procedure file to run the above example
Also this problem can be automatically run from the HELP menu under DEMONSTRATIONS > RUN
A DEMO PROBLEM > CONTACT as shown below.
3.9-16 Marc User’s Guide
Animation
Animation
Click on the figure below to activate the video; it lasts about 10
minutes and explains how the steps above are done. Once the video is Close Floating Window
activated, a right click of the mouse will open the menu shown at the Full Screen Multimedia
right; you can switch to various screen sizes or stop the video by
disabling the content. Properties...
Disable Content