Chapter 18: Demonstration of Springback

18 Demonstration of Springback


Summary 306

Introduction 307

Reference Solution 307

FEM Solutions 307

Modeling Tips 310

Input File(s) 310

Video 311
306 MD Demonstration Problems
CHAPTER 18

Summary
Title Chapter 18: Demonstration of Springback
Contact features Rigid-deformable contact, velocity driven rigid cylinder, load controlled rigid cylinder,
and release of a contact bodies
Geometry Rigid cylinder, D = 0.4375 in
A

Material properties 6
E = 10.6 10 psi  = 0.33  y = 4.29 10 psi
4

Elastic plastic material with work-hardening

Analysis type Quasi-static analysis
Boundary conditions • Left side is constrained with u x = 0
• A spring is used to constrain the motion in the y-degree of freedom
• Contact between rigid cylinder and the deformable body
Applied loads Two types of load introduction will be used:
• Constant “velocity” vx = 0.1125 applied on the rigid body
• Control node ux = 0.1125 applied on the load controlled rigid body
Element type 2-D 4-node plane strain elements
Contact properties Friction coefficient =0.2
FE results Contour of equivalent stress at the end of forming, equivalent stress after the springback;
displacement history of point A.
X-Displacement (in) Point A
0.20
forming springback

0.15

0.10
MD Nastran Sol400

0.05 MSC.Marc

% of Load
0.00
0 50 100 150 200
 CHAPTER 18 307
Demonstration of Springback

Introduction
Significant permanent deformation and large strains occur during the forming step by moving a cylindrical rigid body
into the metal structure. The metal structure springs back upon removal of the cylindrical rigid body using the contact
table definition.

Reference Solution
MSC.Marc 2005r3 will be used to create a reference solution.

FEM Solutions
The finite element model is shown in Figure 18-1. There are two contact bodies: one deformable and one rigid body.
BCBODY 1 2D DEFORM 1 0
BSURF 1 1 2 3 4 5 6 7
...
BCBODY 4 2D RIGID 1 1 0
0 0. 0. 0. 1. 0.1125 0. 0.
RIGID 0 72 CYL
NURBS2D -7 4 50
.85875 .51775 .85875 .95525
...

The deformable contact body is simply a collection of mutually exclusive elements and their associated nodes. The
rigid cylindrical body is defined using 2-D NURBS line.
Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other. Since the master body
is a rigid one, this actually means that the deformable body is the slave one.
BCTABLE 0 1
SLAVE 1 0. 0. .2 0. 0 0.
0 0 0
MASTERS 4
BCTABLE 1 1
SLAVE 1 0. 0. .2 0. 0 0.
0 0 0
MASTERS 4

During the springback analysis, the contact forces on the deformable body due to the contact with the rigid body are
removed immediately. It is done using BCMOVE option. To prevent the two bodies cylinder reclaims contact, a new
BCTABLE has to be defined that does not include the cylinder.
BCMOVE 2 RELEASE 0
4
BCTABLE 2 1 1

The geometric nonlinear analysis is requested using the following LGDISP parameter. The large strain option is also
set in this model
PARAM LGDSIP 1
NLMOPTS LRGSTR 1
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CHAPTER 18

To activate the friction behavior, the user should use the BCPARA option as follows:
BCPARA 0
FTYPE 6

Figure 18-1 Finite Element Mesh

Plane strain elements for large strain elastic-plastic analyses are chosen by the PSHLN2 entry referring to the
PLPLANE entry on the CQUAD4 option as shown below.
PLPLANE 1 1
PSHLN2 1 1 1

The material property is isotropic and elastic-plastic with hardening. The Young’s modulus, Poisson’s ratio, and
plasticity parameters are defined as follows:
MAT1 1 1.06+7 .33
MATEP 1 TABLE 1 ISOTROP ADDMEAN
TABLES1 1 2
* 0. 42900. 0.001733 43110.2
…

The nonlinear procedure used during the forming and springback are set using the following options:
NLPARM 1 30 PFNT U
NLPARM 2 1 PFNT U

Here the PFNT option is selected to update the stiffness matrix during every recycle using the Newton-Raphson
iteration strategy, and the default displacement convergence tolerances will be used.

The simulation process is controlled by the case control section. The first step is the forming process and the second
one is the springback analysis:
BCONTACT=0
SPC = 2
STEP 1
TITLE=Forming Step
NLPARM = 1
BCONTACT = 1
LOAD = 1
 CHAPTER 18 309
Demonstration of Springback

STEP 2
TITLE=Springback Step
NLPARM = 2
BCONTACT = 2

BCONTACT=0 is meant to bring both bodies just in contact. Since there is no explicit external load applied in this
analysis, a dummy LOAD is introduced in the case control parameters.
The deformed structure plot (magnification factor 1.0) is shown in Figure 18-2 along with the von Misses stress
contour. The maximum stresses are located at the expected location.

UNDEFORMED

DEFORMED

Figure 18-2 Deformed Configuration with von Misses Stress Contour at the End of the Forming Step

The deformation after the springback analysis is shown in Figure 18-3. There is significant permanent deformation
during the forming process as obviously seen from this figure. The von Misses stresses of the residual stresses are also
plotted.

UNDEFORMED

DEFORMED

Figure 18-3 Deformed Configuration with von Misses Stress Contour After the Springback
310 MD Demonstration Problems
CHAPTER 18

The displacement of point A is plotted versus time (percentage of load) in Figure 18-4 illustrating the elastic
springback upon unloading the structure. This behavior is compared with a reference plot obtained with MSC.Marc
2005r3. The result of MD Nastran matches the referenced one very nicely.

X-Displacement (in) Point A

0.20
forming springback

0.15

0.10
MD Nastran Sol400

0.05 MSC.Marc

% of Load
0.00
0 50 100 150 200

Figure 18-4 Displacement Plot for Point A During Forming and Springback Step

Modeling Tips
Force control applied via a control node associated with the rigid cylinder may be used instead of displacement (or
equivalently velocity) control. Using this technique, the release of the load requires less difficulty with the contact
table (please see nug_18b.dat). In terms of CPU time, removing the rigid body from contact table is more efficient
since there is no need to do contact manipulation (please see nug_18c.dat).

Input File(s)
File Description
nug_18a.dat “Velocity” driven rigid body
nug_18b.dat Load controlled rigid body without BCMOVE
nug_18c.dat Load controlled rigid body with BCMOVE
 CHAPTER 18 311
Demonstration of Springback

Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately 18 minutes and
explains how the steps are performed.

UNDEFORMED

DEFORMED

Figure 18-5 Video of the Above Steps