9.

DIE STRESS ANALYSIS

9.1. Introduction 9.2. Creating a New Problem 9.3. Loading a Database Step 9.4. Setting Simulation Controls 9.5. Adding Additional Tools and Deleting the Billet
9.5.1. Billet 9.5.2. Top Die 9.5.3. Bottom Die 9.5.4. Object 4 9.5.5. Object 5

9.6. Defining Inter-Object Relationships 9.7. Saving the Problem and Running the Simulation 9.8. Post-Processing

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9. Die Stress Analysis

9.1. Introduction
The objective of this lab is to run a die stress analysis. When the stress analysis is being done on only one tool, a one step simulation is sufficient to get accurate stresses. When the stress analysis is being done on die assemblies where there is interaction between the tools, more than one step is typically needed for the die stack to come to a state of equilibrium under the applied load. In a typical die stress simulation, the workpiece is removed and the forces exerted onto the dies by the workpiece are interpolated onto the tools. In this lab, a shrink fit will also be modeled.

9.2. Creating a New Problem

Click to create a new problem. Call the problem DieStress.

9.3. Loading a Database Step

We would like to perform a die stress analysis on the tools at the end of the first blow of the Spike simulation (Labs 5 - 8). Use the Import DB button to load Spike.DB (located in the Problem\Spike directory). Load Step 90 which corresponds to the end of Blow 1.

9.4. Setting Simulation Controls

Click to enter SIMULATION CONTROLS. Change both the Simulation Title and Operation Name to Die Stress and set the Operation Number back to 1. Make sure that English units are being used and that Deformation is on and Heat Transfer is off. Two supports will be added to the simulation which will interact with the top and bottom dies. Since there will be interaction between the tooling, more than one step should be modeled so that the parts can come to equilibrium. Set the Starting Step Number to -1, the Number of Simulation Steps to 6 and the Step Increment to Save to 1. Set the Solution Steps Definition to a Constant Time Increment of 1 sec.

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9.5. Adding Additional Tools and Deleting the Billet

Use to add two additional objects (Objects 4 and 5) in the Object Tree. Follow the instructions below for each of the objects.

9.5.1. Billet
The Billet is not needed for the die stress analysis, so use the button to delete it.

9.5.2. Top Die

Change the Type of the Top Die to Elastic.

1) Select the Symmetry plane boundary condition, and then add a boundary condition to each of the Top Die symmetry planes. 2) Apply a Vz = 0 Velocity boundary condition on the top surface of the Top Die. This boundary condition prevents the die from flying off when the forces are applied. 3) Select the Force boundary condition. To interpolate the forming loads from the workpiece to the die, click the button. Browse to find the Spike.DB database, and then select Step 90, which is the same step that was loaded into the Pre-processor. Interpolate forces from the Billet, and use an Error Tolerance of 0.1 (should be approximately equal to an element size in the workpiece).

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A summary window should appear, showing the forces on the billet and the forces that were interpolated to the die. These forces will generally not be exactly equal. The Error tolerance controls this to some degree. Putting in a higher tolerance will interpolate the forces from more of the billets surface nodes, increasing the forces interpolated to the dies. As long as the forces for the Workpiece and the Die are pretty close, the interpolation is considered successful.

If you make the object transparent (by clicking the Object Tree) the interpolated forces can be seen.

icon while the Top Die is highlighted in the

9.5.3. Bottom Die

Change the Type of the Bottom Die to Elastic.

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1) Select the Symmetry plane boundary condition, and then add a boundary condition to each of the symmetry surfaces. 2) Select the Force boundary condition and interpolate forces from the Billet just as you did for the Top Die.

9.5.4. Object 4
Change the name of Object 4 to Upper Support and set it's Type to Elastic.

Import the geometry UpperSupport.STL. Mesh the support using Absolute mesh with the settings Min Element Size of 0.15 and Size Ratio of 1. Assign H-13 as the material of this support. 1) Specify Symmetry plane boundary conditions on the two symmetry surfaces of the Upper Support. 2) Apply a Vz = 0 Velocity boundary condition on the top surface so that the top surface cannot move in the Z-direction. 3) This object also gets a shrink fit applied to it, so select the Shrink Fit boundary condition. Shrink fit is defined radially, so an axis and a point need to be defined. For this analysis, (0, 0, 0) is the point at the center of the dies, and the Z axis is the axis of the objects. If the shrink fit is applied to the inner object, the value should be negative. If the shrink fit is applied to the outer

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object then the value should be positive. Since we are applying the shrink to the outer object, use a value of 0.004 for the Interference.

Once the above circles parameters have been set, select the inner surface of the support and then use nodes, click to apply the shrink fit. When prompted if you want to move the coordinates of the .

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For a better look at the applied shrink fit, click the

button and then the

button. Click the next to Displacement to view the applied shrink fit on the Upper Support (making the object transparent helps in visualization).

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9.5.5. Object 5
Change the name of Object 5 to Lower Support and set it's Type to Elastic. Import the geometry LowerSupport.STL. Mesh the object using Absolute mesh with the settings Min Element Size of 0.15 and Size Ratio of 1. Assign H-13 as the material of this support. 1) Specify Symmetry plane boundary conditions on the two symmetry surfaces of the Lower Support. 2) Apply a Vz = 0 Velocity boundary condition on the bottom surface so that the bottom surface cannot move in the Z-direction.

9.6. Defining Inter-Object Relationships

Relationships need to be defined between the Top Die and the Upper Support and also the Bottom Die and the Lower Support. Click relationships using the to open the INTER-OBJECT window, add several

button, and then define the relationships as shown below.

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Use

to set a suitable contact tolerance and then click

9.7. Saving the Problem and Running the Simulation

Click to save the data as DieStress.KEY. Click and the database. After the .

database is generated, return to the MAIN window and start the simulation by clicking

9.8. Post-Processing
When the simulation has finished, click on Click the .

to switch to User-Defined Object Mode, which allows you to change the appearance to turn on contact for both the Top Die and the Bottom Die and make both icon for each.

of the objects. Use

supports transparent by clicking the

This simulation was run with multiple steps so that the contact and stresses could stabilize and come to equilibrium. Play through the steps and observe how the contact changes. The Top Die contact remains essentially the same throughout the analysis but the contact on the Bottom Die changes quite a bit. The applied load pushes the center of the die downward, causing the OD of

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the die to raise off of the support. At the end of the simulation the contact has stabilized and no longer changes much from one step to the next. Using the State Variable pull-down menu, plot Effective stress and Max Principal stress, two of the most important variables in die stress simulations. Use the Summary SUMMARY window. Select the bottom die in object window, and click the Stress. icon to open the next to Eff.

The Max and Min effective stresses are graphed for Object 3 (Bottom Die). You can see that at the end of the simulation, when the contact is no longer changing, the stresses stabilize and do not change any further.

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When finished, click

to return to the MAIN window.

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