Workshop 10

Springback Analysis
14.5 Release

ANSYS LS-DYNA
in Mechanical APDL
2012 ANSYS, Inc. February 5, 2013 1 Release 14.5
 Springback Analysis
This workshop demonstrates the procedure for a springback analysis. A sheet
metal blank (1/4 symmetry) is stamped into a rigid die by the downward
displacement of a rigid punch. The material properties, loading scenario, and
boundary conditions have already been defined. Surface-to-surface contact is
used. After solving the explicit dynamic portion of the analysis (i.e., the
stamping), the thickness and stress results for the blank elements and the nodal
displacements will be read into ANSYS and an implicit springback analysis will be
conducted. Linear elastic unloading is assumed from the formed state (stamped
configuration). The required input file is stamp.inp
Step-by-step instructions are shown on the following slides. Your instructor will
give those details particular to your site.
stamp.inp is fully commented. A /EOF command stops the input stream after
the majority of the model is created, allowing you to complete the exercise
yourself. The GUI generated commands appear after the /EOF command, so
you can compare them to your .LOG file, if you experience any problems.

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 Springback Analysis
Start ANSYS/Multiphysics/LS-DYNA in the GUI mode

Read in the input file stamp.inp

Utility Menu > File > Read input from > stamp.inp > OK
OR issue:
/input, stamp.inp Punch Blank
Holder
SHELL163 elements used throughout
Belytschko-Wong-Chiang formulation for
blank material (power law plasticity used).

Surface-to-Surface contact with friction

Velocity profile used to displace punch

downward by 45 mm in 6.0 milliseconds
Blank Die
Mass scaling used to reduce solution time
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 Springback Analysis
Save the model and solve it:
ANSYS Toolbar > SAVE_DB
Solution > Solve > OK
ANSYS Toolbar > SAVE_DB
OR issue:
save $solve $save Vertex
Enter POST1 and animate the stress results for the blank only:
General Postproc > Read Results > Last Set
Utility Menu > Select > Entities > Elements > By Attributes > Material num > 1 > OK
Utility Menu > Select > Entities > Nodes > Attached To > Elements > From Full > OK
Utility Menu > PlotCtrls > Animate > Over Results > Current Load Step
> Increment result set: 3 > Stress > von Mises SEQV > OK

OR issue:
/post1 $set, last Close the animation
esel, s, mat, , 1 $nsle before continuing on.
plnsol, s, eqv $andata, 0.5, , 0, 0, 0, 3, 0, 1
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 Springback Analysis
Next, switch over to POST26 (Time History postprocessor) and plot the motion of a
node on the blank:
TimeHist Postpro > File > Open Results > Files of Type: Explicit Dynamics
Results (*.his) > stamp.his > Open > stamp.db > Open
Continue with the mouse picks shown below:

8 1 10
2

6 = Pick node at vertex

3
of the blank (node 1)

7 4 5
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 Springback Analysis
OR issue:
/post26
file, stamp, his
nsol, 2, 1, u, y, uy_2
store, merge
plvar, 2

The plot shows that the motion of

the blank has tapered off enough to
perform the implicit springback
solution. Oscillatory motion at the
end of the run would indicate a need
to repeat the explicit analysis with
either increased damping (EDDAMP)
or with corrected load curves (e.g., Exit the Variable Viewer
infinite accelerations can occur from
before proceeding.
unrealistic displacement-controlled
loading invalidating the results).
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 Springback Analysis
Reselect everything in the model, save the database, and change the
Jobname to spring for the implicit springback analysis:
Utility Menu > Select > Everything
ANSYS Toolbar > SAVE_DB
Utility Menu > File > Change Jobname > spring > Yes > OK
OR issue:
allsel, all
save
/filnam, spring, 1

The Jobname is renamed to prevent overwriting the explicit dynamic

results stored in stamp.rst. The implicit springback results will be
saved to the file spring.rst. The corresponding database should be
used when reviewing the results, since explicit elements are not valid
in an implicit analysis and implicit elements are not valid in an explicit
analysis.

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 Springback Analysis
Enter PREP7 and convert the explicit element types to implicit:
Preprocessor > Element Type > Switch Elem Type > Explic to Implic > OK
OR issue:
/prep7
etchg, eti

The ETCHG command converts companion elements automatically. For

other destination element types, the EMODIF command must be used.

SHELL163 formulation #10 (Belytschko-Wong-Chiang) was used in the

stamping analysis, as recommended for explicit-to-implicit sequential
solutions. When the element types are converted, the keyopts and real
constants are set to their default values. Although the SHELL181s will
not have the original thickness information stored as real constants, the
final stamping thicknesses will be imported into the model (along with
the element stress data) before the implicit springback solution is run.

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 Springback Analysis
Next, remove the nonlinear material properties left over from the
explicit stamping analysis, as they are not valid for the linear elastic
unloading that is assumed for the implicit springback analysis.
Since the material model used (power law plasticity) does not
correspond to any implicit material model, you cannot use the GUI to
delete it
Issue:
tbdele, all, all

As recommended, next turn off the element shape checking:

Preprocessor > Checking Ctrls > Shape Checking > Off > OK
OR issue:
shpp, off

Although not a big issue in this particular case, the elements could
have undergone considerable deformation in the LS-DYNA analysis.
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 Springback Analysis
Update the geometry to the stamped configuration and plot the
elements:
Preprocessor > Modeling > Update Geom > 1 > 1 > 51 > stamp.rst >
OK
Utility Menu > Plot > Elements
OR issue:
upgeom, 1, 1, 51, stamp, rst
eplot

The final configuration from the explicit

solution is now the initial configuration for the
springback solution. All displacements will be
referenced from this new starting point.

The actual motion of the blank will be in

relation to the restraints that are applied. It is
important to use reasonable boundary
conditions.
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 Springback Analysis
Since the punch, blank holder, and die are rigid bodies, they are
irrelevant in a springback analysis. Therefore, just select the blank:
Utility Menu > Select > Entities > Elements > By Attributes > Material num > 1 > OK
Utility Menu > Select > Entities > Nodes > Attached To > Elements > From Full > OK
Utility Menu > Plot > Elements
OR issue:
esel, s, mat, , 1
nsle
eplot

Note that the current boundary conditions

(left over from the stamping analysis), are
for the symmetry condition. However,
there is no restraint to prevent rigid body Use /PBC,ALL,,1 to
motion in the Y translational direction, so view the DOF
this constraint must now be included symbols
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 Springback Analysis
Enter the solution module and apply the additional required restraint.
Assume that the entire flat surface of the rim will be constrained in UY:
Utility Menu > Select > Entities > Nodes > By Location
> Y coordinates > -0.1, 0.1 > Reselect > OK
Solution > Define Loads > Apply > Structural >
Displacement > On Nodes > Pick All > UY >
Constant value > 0.0 > OK
OR issue:
nsel, r, loc, y, -0.1, 0.1
/solu
d, all, uy, 0.0

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 Springback Analysis
Import the shell thicknesses and stresses from the explicit analysis
after selecting back all of the nodes belonging to the blank:
Utility Menu > Select > Entities > Nodes > Attached To > Elements > From Full > OK
Utility Menu > Plot > Elements
Solution > Define Loads > Apply > Structural > Other > Import Stress > DYNA
run > 1 > 51 > stamp.rst > OK

OR issue: Note newly applied UY

nsle boundary conditions
eplot
rimport, dyna, stress, elem, 1, 51, stamp, rst

Next to last
substep used
in case there
was sudden
unloading at
the very end.

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 Springback Analysis
Specify the analysis options for the implicit solution and solve it:
Solution > Analysis Type > Soln Controls > Large Displacement Static > Time at end of
loadstep: 1.0 > OK (accept remaining default values)
ANSYS Toolbar > SAVE_DB
Solution > Solve > Current LS > OK > Yes > Yes (to warning prompts)
ANSYS Toolbar > SAVE_DB

OR issue:
nlgeom, on
time, 1.0
save
solve
save
Although the material behavior is
linear elastic, large deformations
are allowed, so this feature is
activated just in case. The Default NSUBST, 1, 1000, 1 will
sparse solver is used by default. be used.
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 Springback Analysis
Finally, review the springback analysis results. To save time, the macro
mypost.mac has been created for you. It pauses between plots. The
results from the explicit stamping solution are first examined:
Issue:
mypost
(Rerun the macro as often as needed).

The final blank thicknesses (at the end of the explicit stamping
analysis) vary from 0.829 mm to 1.065 mm. Why do the rim region
thicknesses exceed the initial 1.0 mm thickness?

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 Springback Analysis
As the blank is drawn down into
the die, the rim region material
experiences high compressive
hoop stress. The final stamped
configuration cylindrical (hoop)
stress is shown to the right.

The final springback thicknesses

(plotted to the left) show only a
minor change from the final
stamped blank thicknesses. The
change in overall shape (see next
slide) is more important

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 Springback Analysis
The final springback
geometry shows how the
blank springs back in the
direction opposite to the
punch stamping motion.

The displacement
magnification has been
increased to 10 times the
actual displacement scale
to better visualize the
motion which results from
the release of the stored
elastic energy in the blank. When done, exit ANSYS:
ANSYS Toolbar > Quit > OK

Rerun the mypost macro as OR issue:

often as needed /eof

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