Manual Pam Stamp

PAM-STAMP 2G 2012
Users Guide
PAM-STAMP 2G 2012
USERS GUIDE
The documents and related know-how herein provided by ESI Group subject to
contractual conditions are to remain confidential. The CLIENT shall not disclose
the documentation and/or related know-how in whole or in part to any third party
without the prior written permission of ESI Group.
2012 ESI Group. All rights reserved.
October 2012
GR/PAST/12/03/00/A
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
CONTENTS
ABOUT THIS DOCUMENT
Attributes /Functionalities Chapters -------------------------------------------------- 1
INTRODUCTION
PAM-STAMP 2G Overview ------------------------------------------------------------ 5
PRODUCT START UP
15
ASCII Input ------------------------------------------------------------------------------- 15

Customization ---------------------------------------------------------------------------- 18
Files ---------------------------------------------------------------------------------------- 23
Solver Manager Configuration------------------------------------------------------- 32
Solver Manager Start ------------------------------------------------------------------ 40
Solver Manager Activity --------------------------------------------------------------- 43
Calculation Stop ------------------------------------------------------------------------- 44
FINITE ELEMENT AND NUMERICAL MODELS
45
Algorithm ---------------------------------------------------------------------------------- 45
Time Step & Increments -------------------------------------------------------------- 59
Elements ---------------------------------------------------------------------------------- 68
Material Properties --------------------------------------------------------------------- 76
HILL 48 Material Law ------------------------------------------------------------------ 80
HILLs 90 Material Law ---------------------------------------------------------------- 84
BARLAT89 Material Law -------------------------------------------------------------- 86
BARLAT91 Material Law -------------------------------------------------------------- 87
BARLAT2000 Material Law ---------------------------------------------------------- 89
VEGTER Material Law ---------------------------------------------------------------- 92
Matfem Failure Criterion ------------------------------------------------------------ 100
SUPERPLASTIC Material Law ---------------------------------------------------- 106
Mooney-Rivlin Material Law-------------------------------------------------------- 112
Material Hardening Laws ----------------------------------------------------------- 113
Thermal Material Option ------------------------------------------------------------ 130
MetallurgIcal Material Option ------------------------------------------------------ 137
EWK Rupture Model ----------------------------------------------------------------- 148
Material File Format (.psm) -------------------------------------------------------- 155
SIMULATION CONCEPTS
175
Contact and Friction ------------------------------------------------------------------ 175

Objects & Attributes ------------------------------------------------------------------ 193
Kinematics ------------------------------------------------------------------------------ 200
Force and Pressure ------------------------------------------------------------------ 206
Fluid Cell and Aquadraw ------------------------------------------------------------ 209
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Rigid Body ------------------------------------------------------------------------------ 217

Adaptive Meshing --------------------------------------------------------------------- 223
Drawbead ------------------------------------------------------------------------------- 232
Symmetry Plane----------------------------------------------------------------------- 258
Picking ----------------------------------------------------------------------------------- 260
Distributed Memory Process (DMP) --------------------------------------------- 265
Process Setup ------------------------------------------------------------------------- 271
Offset ------------------------------------------------------------------------------------- 285
Mesh Check and Cleanup ---------------------------------------------------------- 290
Filleting ---------------------------------------------------------------------------------- 297
Substructuring ------------------------------------------------------------------------- 301
Mapping --------------------------------------------------------------------------------- 309
Mapping Files -------------------------------------------------------------------------- 317
User-Defined Attribute --------------------------------------------------------------- 332
ANALYSIS TOOLS
335
Contours--------------------------------------------------------------------------------- 335
Forming Limit Diagram (FLD)------------------------------------------------------ 349
Draw-In Tools -------------------------------------------------------------------------- 356
Blank Shifting -------------------------------------------------------------------------- 362
Solver Analysis Tools ---------------------------------------------------------------- 365
User Interface Analysis Tools ----------------------------------------------------- 371
Scripting --------------------------------------------------------------------------------- 383
Reporting -------------------------------------------------------------------------------- 390
SIMULATION METHODOLOGY FOR DESIGN AND

STAMPING FEASIBILITY
397
Introduction ----------------------------------------------------------------------------- 397

Customization -------------------------------------------------------------------------- 399
Die Design (PAM-DIEMAKER) ---------------------------------------------------- 406
Part Preparation for Die Design (PAM-DIEMAKER) ------------------------ 411
Evaluation of the Tool Design (Pam-QuikStamp PLUS) ------------------- 421
Process Verification (Pam-Autostamp) ----------------------------------------- 441
Binder Generation for Die Design (PAM-DIEMAKER) ---------------------- 461
Run-Offs and Addendum Generation for Die Design (PAMDIEMAKER) --------------------------------------------------------------------------- 465
Re-Engineering the Die Face (PAM-DIEMAKER) --------------------------- 479
Process Verification: Penalty Contact (Pam-autostamp) ------------------- 484
Iteration on Design and Stamping Feasibility---------------------------------- 488
SIMULATION METHODOLOGY FOR STANDARD

FORMING
497
Introduction ----------------------------------------------------------------------------- 497

Customization -------------------------------------------------------------------------- 502
Creation of the Tools ----------------------------------------------------------------- 509
Blank Meshing ------------------------------------------------------------------------- 539
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Creation of DRAWBEADS ---------------------------------------------------------- 547

Analysis Entities ----------------------------------------------------------------------- 549
Process Setup ------------------------------------------------------------------------- 550
Simulation and Postprocess ------------------------------------------------------- 564
SIMULATION METHODOLOGY FOR SPECIFIC

PROCESSES
567
Tailored and Patchwork Blanks --------------------------------------------------- 567

Hot Forming ---------------------------------------------------------------------------- 582
Flanging --------------------------------------------------------------------------------- 617
Roll Hemming -------------------------------------------------------------------------- 623
Hemming -------------------------------------------------------------------------------- 663
Control Table --------------------------------------------------------------------------- 664
Die Compensation and Multi-op -------------------------------------------------- 670
Blank and Trimming Line Optimization ------------------------------------------ 697
Springback Measurement ---------------------------------------------------------- 716
Cosmetic Defects Analysis --------------------------------------------------------- 736
Press Force Analysis ---------------------------------------------------------------- 751
Volume Blank -------------------------------------------------------------------------- 758
Simulation with Ironing - T.T.S Element ---------------------------------------- 765
Gas Springs ---------------------------------------------------------------------------- 768
Drawslit or Lancing ------------------------------------------------------------------- 771
CRASHFORMING -------------------------------------------------------------------- 773
Stamping Inverse --------------------------------------------------------------------- 774
SIMULATION METHODOLOGY FOR TUBE
789
Introduction ----------------------------------------------------------------------------- 789

Customization -------------------------------------------------------------------------- 792
Tube Design Module (PAM-TUBEMAKER)------------------------------------ 799
Bending Simulation Feasibility ---------------------------------------------------- 826
Tube Bending -------------------------------------------------------------------------- 834
Tube Hydroforming ------------------------------------------------------------------- 843
DELTAMESH
855
Introduction ----------------------------------------------------------------------------- 855

CAD Model Exchange from CAD Systems to DeltaMESH ---------------- 858
Meshing Access ----------------------------------------------------------------------- 898
DeltaMESH Parameters ------------------------------------------------------------ 902
Mesh Check and Repair ------------------------------------------------------------ 919
The Remeshing Action -------------------------------------------------------------- 931
The Multipatching Action ------------------------------------------------------------ 937
Other DeltaMESH Actions ---------------------------------------------------------- 942
Configuration of Meshing Parameters ------------------------------------------- 946
CONTENTS
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CONTENTS
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PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
ABOUT THIS DOCUMENT

ATTRIBUTES /FUNCTIONALITIES CHAPTERS
Here is a list of the chapters on the Users Guide describing the attributes and
functionalities available in PAM-STAMP 2G.
For Pam Quikstamp plus project, the user must also refer to the Evaluation of the tool
design (Pam Quikstamp) chapter in the Simulation Methodology for design and
stamping feasibility section.
For Inverse project, the user must refer to the Stamping Inverse chapter in the
Simulation concepts section and to the Tube Inverse chapter in the Simulation
methodology for tube section.
ATTRIBUTES:
/FUNCTIONALITIES
SECTION
CHAPTER
PAGE
Analysis
Simulation methodology for Analysis entities

Standard Forming
556
Aquadraw
Simulation Concepts
209
Autopositioning
Behavior
Blank Meshing
Boundary Condition on
points
Fluid Cell
Simulation methodology for Process setup

Standard Forming
557
Simulation methodology for Gas Springs

Specific Processes
777
Simulation methodology for Evaluation of the

Standard Forming
tool design
Simulation methodology for

Specific Processes
Simulation concepts
Specific Processes
545
Optimization
706
Kinematics
Springback
measurement
200
725
ABOUT THIS DOCUMENT

Attributes /Functionalities Chapters
USERS GUIDE
(released: Oct-12)
Cartesian kinematics
Contact
Cooling Channel
PAM-STAMP 2G 2012
2012 ESI Group
Kinematics
Contact and
Friction
Simulation methodology for HotForming
Simulation concepts
Simulation concepts
200
175
609
Time Step &

Increments
EWK Rupture
Model
Drawbead
137
Drawbead Forces
Specific Processes
Finite element and
numerical models
Finite element and
numerical models
Simulation concepts
Drawbead definition
Simulation concepts
Drawbead
237
DMP
Simulation concepts
Simulation for Specific
Processes
DMP
Rollhemming
266
631
Simulation concepts
Kinematics
204
Rollhemming
631
Element elimination

Processes /
Analysis tools /
368
Fluid Cell
Simulation concepts /
Solver analysis
tools
Fluid Cell
CPU Control
Damage
Dynamic Freeze
Follower force
Force
Freeze
Gravity
Gluing Contact
Kinematic Path
Ironing
Mapping
Mesh
Multi body system
Optimization
ABOUT THIS DOCUMENT

Simulation concepts /
Processes
Simulation concepts
Simulation concepts
Force & Pressure

Rollhemming
Force & Pressure
Kinematics
Simulation methodology for Process setup

Standard Forming
Algorithms
Finite element and
numerical models
Contact and
Simulation concepts
Processes
Processes
Simulation concepts
Standard Forming
Simulation concepts
Processes
Processes
Friction
Rollhemming
Simulation with
Ironing-TTS
Element
Mapping
process setup
59
237
209
207
206
203
557
45
175
631
774
311
557
Rigid Body
Rollhemming
217
Optimization
706
631
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2012 ESI Group
Path Definition
Phase transformation
Picking
Press Force Analysis
Pressure
Quenching
Refinement
Rigid Body
Robot Components

Processes
Simulation for Numerical
Models
Simulation concepts
Rollhemming
631
Metallurgical
material option
Picking
163

Specific Processes
Simulation concepts
Specific Processes
Simulation concepts
Press Force
analysis
Force & Pressure
HotForming
760
Adaptive
meshing
Rigid body
Rollhemming
264
Kinematics
200
Rotational kinematics
Simulation concepts
Processes
Simulation concepts
Solver Manager
Product startup
Springback
USERS GUIDE
(released: Oct-12)
Solver
configuration
Simulation methodology for Springback

measurement
Specific Processes
261
206
590
217
631
32
725
Substructure
Substructure
Simulation concepts
Simulation methodology for Surface defect
analysis
Specific Processes
Symmetry Plane
Simulation concepts
Symmetry plane
259
Thermal properties
Thermal material
option
Hotforming
590
Process setup
557
User-Defined
Finite element and

numerical models
Specific Processes
Standard Forming
Simulation concepts
130
Values scaling
Simulation concepts
User Defined
Attribute
Picking
Trimming
303
504
261
ABOUT THIS DOCUMENT

PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
INTRODUCTION
PAM-STAMP 2G OVERVIEW
PAM-STAMP 2G is available as a professional package. Essentially, it offers the user
access to a significant number of options by using a flexible license token approach.
Included in PAM-STAMP 2G v2012:
PAM-STAMP INVERSE: for estimation of the developed part blank shape and
very early feasibility studies on part.
PAM-DIEMAKER: for the design of the die
DELTAMESH: as meshing module
PAM-QUIKSTAMP: for feasibility analysis
PAM-AUTOSTAMP: for validation and optimization of sheet metal forming

processes
PamStamp 2G v2012 proposes:

the simulation of major sheet metal
forming processes, like:
optimization and modification

functionalities, like:
Die compensation combined
with surface reconstruction
with iCapp PanelShop
Rollhemming
Hotforming
Super Plastic forming
Hydro forming
Blank
and
optimization
Tube forming
Morphing
The Stamp Toolkit enables

the customization of all
processes like Rubber pad
forming or stretch forming.
Filleting with Deltamesh fillet

Substructuring
iterations
trim
for
line
local
INTRODUCTION
PAM-STAMP 2G Overview
USERS GUIDE
(released: Oct-12)
dedicated analysis tools, like
PAM-STAMP 2G 2012
2012 ESI Group
dedicated material models, like:
Cosmetic defect analysis
Corus Vegter material Model
Draw-in analysis
Matfem Crach material Model
Reporting tools
Yoshida material Model

Ito-Goya material model
Superplastic material models
Environment
Common environment
All modules proposed within PAMSTAMP 2G share the same
environment.
Switching between modules is easy
and guided when necessary
Dedicated contexts
Dedicated contexts are proposed for an
automatic customization of the
environment based on the selected
process.
INTRODUCTION
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
Customized environment
PamStamp 2G environment is fully
customizable by company or by user.
It can be adapted to the customer
needs, by creating his own toolbars,
process macro-commands, userdefined contours, or by defining the
default parameters he wants to use.
PAM-INVERSE
PAM-INVERSE is a one step or inverse solver, designed to make;
Developed part blank shape estimation for costing purposes.
Very early feasibility studies on PART geometry, prior to die design
Inverse solvers are designed to run very fast, but only to give 1st impression of
component feasibility. Basic usage is to make 2 simulations to test the two extremes of
material movement free boundary and locked boundary. In this sense it can be
considered as a go / no-go gauge for component feasibility checking.
INTRODUCTION
USERS GUIDE
(released: Oct-12)
PAM-STAMP 2G 2012
2012 ESI Group
PAM-DIEMAKER
From an imported CAD geometry, PAM-DIEMAKER allows the user to design and
optimize the binder surface and die addendum in just minutes. Its rapid and iterative
parametric approach generates a realistic simulation model, allowing the user to quickly
evaluate the parts formability with QUIKSTAMP. Tipping direction, binder surface
and addendum geometry can easily be modified, allowing total control of upfront
design processes such as the number of stages and multi-parts grouping.
Highlights:
Parametric modeling
PAM-DIEMAKER can be used starting

from a CAD file of the part, with no
tooling information available: the user
constructs the die geometry from nothing
by preparing the part geometry, by
defining a binder surface and by
constructing the run-off. In many cases, a
new die design would be based on an
already existing geometry. As such, it is
much easier to just take this geometry as a
reference and make the appropriate
changes to certain zones rather than to
entirely re-construct this die.
The parametric re-engineering covers
this latter methodology and allows the
user to re-construct a parametric surface
model in very short time. The reengineering starts from an existing die
geometry (CAD or scanned data) and recreates the necessary surface information
step-by-step, resulting in a 3D parametric
model of the initial tool, that can e.g. be
used to perform binder or run-off
modifications or to exchange the part
geometry.
INTRODUCTION
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
PAM-QUIKSTAMP Plus
PAM-QUIKSTAMP allows the die designer to check and evaluate different die
geometry parameters like binder surface and die addendum, including swages and die
walls. PAM-QUIKSTAMP provides a fast formability evaluation, and represents the
optimal compromise between accuracy, time and computing resources.
Since PAM-QUIKSTAMP does not require high quality mesh for tools, it is very easy
to iterate and optimize the process.
Taking into account elasto-plastic behavior, friction, blankholder pressure, drawbead
and cutting pattern, it carries out a fast and reliable 3D evaluation within minutes and
eliminates erroneous choices at the conceptual design stage.
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PAM-AUTOSTAMP
PAM-AUTOSTAMP allows the user to master virtual try-out of the stamping process
taking into account the full process with industrial conditions such as gravity, binder
development, multi-stage forming, draw, restrike, trimming, springback, flanging and
hemming. PAM-AUTOSTAMP guides the user through the final validation of forming
process, tolerances and overall quality control, helping to avoid costly and timeconsuming downstream problems. PAM-AUTOSTAMP also includes a state-of-the-art
implicit solver technology, enabling fast accurate springback predictions.
The scope of processes which could be modeled is continuously increasing, and
includes hotforming, rollhemming, double blank forming, spot-welded blanks, rubberpad forming, super-plastic forming and multistage tube forming processes, in addition
to the standard stamping, tube bending, tube and sheet hydroforming processes.
Problems which can be detected include conventional formability issues of splits and
wrinkles, but also subtle quality issues such as cosmetic defects, slip lines, marks, and
dimensional stability after springback.
Optimization tools help finding solutions to the detected problems. Blank or trim line
optimization are useful for designing the correct initial blank shape and right trim lines,
and Die compensation modifies automatically the die for reaching the good final shape
after springback.
Courtesy of SKODA Auto
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PAM-TUBE
PAM-TUBE INVERSE
PAM-INVERSE offers a very fast simulation tool for non-critical bending operations
and for general feasibility checks as a preforming step for hydroforming. An advisor is
included that will determine if PAM-INVERSE is a suitable simulation method.
With PAM-INVERSE bending operations of any circular, conical or user-defined
profile can be simulated.
PAM-TUBEMAKER
From an imported CAD geometry, PAM-TUBEMAKER allows the user to design and
optimize the bending or hydroforming process in just minutes. Its rapid and iterative
parametric approach generates a realistic simulation model, allowing the user to quickly
evaluate the parts formability. Process and tool design can easily be modified, allowing
total control of upfront design processes such as the number of stages and multi-parts
grouping.
PAM-TUBEMAKER easily reads CAD data in IGES and VDA format. While reading
the CAD surface information, it automatically meshes the surfaces as well using state of
the art meshing technology from DeltaMESH. Next to the direct treatment of CAD
surfaces, PAM-TUBEMAKER also imports various mesh formats, such as PAMSYSTEM, universal (.unv) and Nastran (.nas).
On user interface level, PAM-TUBEMAKER tries to propose for the user process and
tool design parameters by following as much as possible the objective of finding a
feasible process setup. At the same time full flexibility is given, and the user has at all
points the full control on the design.
INTRODUCTION
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(released: Oct-12)
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DELTAMESH
The complete integration of DeltaMESH Stamping into PAM-STAMP 2G offers full
functionality of automatic meshing within the software. With DeltaMESH meshing the
user is certain to obtain a high quality mesh allowing to rapidly start the design process.
As a good simulation result requires a good mesh, DeltaMESH will do just that: based
on the initial CAD file, the program will automatically generate a connected mesh.
Fully automatic surface mesher integrated into

the PAM-STAMP 2G environment that
delivers high quality mesh results
Consecutive steps for import / joining /

meshing can be handled automatically or
interactively:
o Reads IGES / VDA format
o Joins surfaces with thin surface, hole,
gap or overlap tolerance
o Automatic meshing algorithms based
on uniform, parametric and
progressive meshing
Optional post-meshing operation:

Automatic localized re-meshing according
to some element quality criteria
DeltaMESH Fillet
DeltaMESH Fillet integrated in PAM-STAMP 2G offers full functionality of automatic
filleting. With DeltaMESH Fillet the user is certain to obtain a high quality fillet mesh
on sharp edges allowing to start the process simulation as early as possible. Basically,
good stamping simulation results require a good mesh on radii in order to accurately
represent the metal flow phenomena and related physics. This will allow the user to
control the global filleting and the local radii as well.
DeltaMESH Stamping Inverse

This integration of DeltaMESH Stamping Inverse into PAM-STAMP 2G allows
generating fully automatically a FEM quality mesh dedicated to the inverse method
solver. The generation of this patch-independent mesh, consists in importing either a
CAD model or a DeltaMESH geometrical database and joining it (topological model
creation). DeltaMESH Stamping Inverse will create zones from connected face groups
(for example, blankholder ). Thus, we obtain a mesh coarser than DeltaMESH
Stamping mesh but with finite element quality
INTRODUCTION
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
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Calculation Code
PAM-STAMP2G is a calculation code that uses the finite element method (FEM). All
the components of a calculation (metal sheet or tube, tools, ) are shown as meshes,
i.e. a discrete representation of the geometry.
For non-deformable tools, the mesh is only a representation of the geometry, and the
finite elements are only facets to be used for contact description. On the contrary, for
the blank, the tube or a deformable tool, the finite elements forming this mesh represent
small pieces of the material with a prescribed behavior.
The mechanical phenomena that occur in a blank or in a tube are faithfully reproduced
using a large number of these elements. Within reason, the finer the mesh to be
generated, the better the quality of the results, whereas the higher the number of
elements, the longer the calculation time. Note that in a simulation, a detail whose size
is smaller than that of the elements cannot be represented: the size of the elements
defines the precision of the simulation.
A finite element can be a 2-node (bar), a 3-node element (triangle), a 4-node element
(quadrangle), a 6- or 8-node volume element (hexahedron), and it is constructed from
nodes that are defined in its corners. Each node has two types of degrees of freedom:
translation and rotation. The translation degree of freedom of a node represents its
ability to move in translation along a direction, whereas a rotation degree of freedom of
a node represents its ability to rotate about an axis. A node with three degrees of
freedom in translation and three degrees of freedom in rotation can move along three
axes X, Y and Z and can rotate about these three axes.
Depending on the calculation type
(implicit or explicit) the calculation is
sub-divided into increments or timesteps. Generally, implicit increments are
large with respect to the explicit timesteps.
Positions, velocities, accelerations and
forces are permanently calculated at the
nodes, which are points linked to the
material. Within the elements, strains are
calculated from positions.
nodes
element
mesh
Corresponding stresses are then obtained, which result in forces on the nodes. This
calculation is repeated over all the elements for the entire duration of the calculation.
Boundary conditions are used to remove degrees of freedom (locking), while velocities
and forces further define the kinematic behavior of the finite element model.
To describe the actual deformation process, material properties and thickness must be
assigned to an element.
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USERS GUIDE
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PRODUCT START UP
ASCII INPUT
Purpose
For all projects, the data set-up is stored in the .pre file of the project, which is a
binary file. However, the application offers the user the possibility of having ASCII
input files, enabling him to modify manually or automatically the data set-up without
opening the GUI.
Data Input File

The data set-up of a simulation is described with the attributes. The .att file is the
ASCII file that contains the multistage data set-up that means the attributes of all the
simulations that will be launched one after each other.
Writing of the file

The .att file is automatically written
when starting the simulation if the option
Write the input file and start the
calculation is activated.
It is also possible to write the .att file

without running the simulation, with the
option Write input file only.
Default
By default the option Write the

input file and start the calculation
is always activated.
PRODUCT START UP
ASCII Input
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(released: Oct-12)
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Simulation launching
When the simulation is launched, if there are in the same project directory both the
projectname.pre and a projectname.att files, the information of the .att file is
transmitted to the solver instead of the information of the .pre file.
Data reading
If there are in the same project directory both a projectname.pre and a
projectname.att files, the information of the .att file is read instead of the
information of the .pre file. The user can so modify manually the .att file and update
then the .pre file by opening the project and saving it.
Mesh Input File

The mesh used for a simulation is contained in the .pre file. However it is possible to
write ASCII mesh input file (.mif).
Writing of the file

The .mif file can be exported using the Export mesh menu with the mesh input file
format (.mif). A name different from the project name can be given.
The Mif format is as follow:
-
The .mif file contains all the mesh needed by the solver to run a calculation (nodes,
elements, 3D curves, objects, and picked restart files information).
The file is divided in sections starting by a keyword with DEF_ prefix, and ending
by the start of another section or the end of the file. Each section can occur once in
the file. The section can be associated to a parameter, which is the count of entities
that are written in the section (to accelerate the loading time in allocating once the
entities).
Within each section, several entries can be defined, with associated parameters
(each parameter which is preceded by / character).
Blank lines are authorized (i.e. lines without character or with space or tab
characters).
Comment lines can be added, if they start with a # character. They will not be read
by the GUI nor the solver.
The lines must not exceed 256 characters.
Remarks:
The difference with the other export formats management is that not only the
visible entities will be exported, but all the mesh, and that picking data will be
exported also.
It is also possible to do a .mif export from a .res file.
PRODUCT START UP
ASCII Input
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Simulation launching
The launch of a simulation with a MIF file, is done by a command line using the .att
file instead of the .pre file.
The .att file must be modified to specify the mesh input file that the user wants to use
for the simulation:
After the section DEF_SOLVER, the following section has to be manually added:
DEF_MODEL_INPUT_FILE
FILENAME = name of the .mif file to be used
Data reading
The results of the simulation will be loaded, when the user loads any of the result files.
A .psp file is then automatically created.
Note:
It is possible to import the mesh with the .mif format via the import mesh
menu, using the options Keep identifiers and Keep thicknesses.
PRODUCT START UP
ASCII Input
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CUSTOMIZATION
The software allows the user to adapt the program to his needs, by creating his own
toolbars and process macro-commands, or by easily defining the default parameters he
wants to use. All such customizations are described in this chapter.
Some of the customization data is stored in a separate configuration file (both in the
installation directory and the main users directory) and can be manually modified. This
is also further explained.
Customization stored in the users file, can be copied into the installation file if you
require specific site customization, for example to implement standards across a
company.
Toolbars
It is possible for the user to create his own
toolbars with the View / Toolbars /
Customize option. This dialog box
contains five tabs:
Commands:
All the options available for pre-processing, solver and post-processing

are summarized according to their order in the Menu Bar. Individual tasks are
chosen and added to the new users toolbar from this list.
Toolbars:
External tools:
Keyboard:
Default toolbars available in the program are listed. They can be

activated or not. If activated, the toolbar tasks are shown in the upper part of a
graphical window. If the user prefers to have icons of tasks coupled with text labels,
the Show text labels option has to be activated too. New toolbars can be created, the
options available in this toolbar must be chosen in the Commands list. These custom
toolbars can be modified, renamed or deleted whenever necessary.
This allows the user to define links from within the GUI to external
software tools, for example a calculator, or a spreadsheet etc.
This allows the user to define shortcut keys, which can be assigned to
any action, making routine work more efficient.
PRODUCT START UP
Customization
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Menu:
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(released: Oct-12)
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It is used for the Menu Bar and a Context menus definition:
Menu Bar:
It can be chosen from several menu types (Curve Editor, Macro edit,
etc.) specified for each kind of users work.
Context menu:
Four context menu options (2D Settings, 2D View, 3D View and

FLD View) can be used. The 3D View Menu called "right-click" menu is
automatically activated. Most of the options of this "right-click" menu are also
accessible through the Menu Bar, but some of them can only be used through the
former. New items can be added from the Commands list.
Positions: Enables
Options:
reset all windows and toolbar positions.
Enables defining some menu properties like displaying screen tips on

toolbars, large icons, etc.
Advanced Mode
Advanced mode currently is used to access the Stamp Tool Kit options. This function is
generally designed to be used by the site Advanced User. If Advanced user mode is not
activated, the Stamp Tool Kit options will not be available.
It is possible to activate permanently the Advanced Mode in the Customize Macro page
Licenses
It is possible to select here which options will
be available; the corresponding tokens will be
taken by the program.
If the user does not have enough tokens, a
message will be displayed in the console.
The status of the Customize tokens menu is
stored in the configuration file.
If there are not enough tokens when launching
the application with the saved license
customize configuration, a message appears
and the Customize tokens menu is opened.
Warning:
The license configuration is saved

when a user saves a new configuration
in the general customize menu.
PRODUCT START UP
Customization
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Default Parameters
The default parameters and settings
proposed by the program can be defined for
each user (user login). They are stored in the
configuration file.
The Customize / Options menu allows the
user to specify the following parameters:
Design:
Default PAM-DIEMAKER and PAM-TUBEMAKER parameters can be

defined in this page. See Simulation Methodology for Design and Stamping
feasability and Simulation Methodology for Tube sections for further information.
DeltaMesh:
The Import, Joining, Meshing, Inverse meshing and Remeshing default

parameters are defined here. The Meshing strategy can also be created and
customized as default in this page. See Deltamesh section for further information.
Process: Default values of AutoStamp attributes are defined in the Process page.
The Default unit system is also defined here, as the Check data before starting option
(It forces an attribute check to be done prior to launching the solver, giving the user
the possibility to detect input errors without wasting solver time). Automatic Blank
meshing can be deactivated here. See Blank editor chapter for further information.
Parameters of Die compensation are defined on this page as well. Users, who want
to use Tool editor before Blank editor in general workflow can deactivate Blank
editor before Tool editor option through this page.
-
Files location:
This page enables the user to define the default files location,
especially when using Import Export and functionalities. It is also used when
opening a Project or the Material Database. The Solver Host definition with the
location of the executable used for the simulation as the eventual equivalences
between disk names must be defined here.
GUI Parameters: All the default Display options are saved in this page, as the
Camera movement and the 2D Section display. Reporting tools setting are defined
here. The Activate undo feature allows the user to activate the undo function. By
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21
default it is on. See User interface analysis tools chapter for further information. It is
possible to define Search radius for Local Min/Max annotations here as well.
Geometry: In this page are saved the default values used for the mesh Orientation,
for the Offset functionality and for the 3D curve editor. See offset chapter for
further information.
Contours: Each contours option is by default activated or not in this page. See
Contours chapter for further information. FLD contours options and Maximum
angle on a face for Thickness of solids contour are defined on this page.
ToolEditor: Default Tool editor values are saved in this page. See the offset chapter
for further information. Default initial blank mesh size (used if automatic meshing is
not active) can be set here. See Blank editor chapter for further information. It is
possible to define Flanging tool parameters on this page as well.
Macro: Process macro options are defined here. See Process macro chapter for
further information.
Note :
Refer to the Reference manual for more detailed information on each

functionality of the Custom options menu.
Customization File
All of the above customizations are actually stored in an ASCII file that can reside in
two locations. The main customization file is located within the installation directory
and ensures general customization for all users. For more personalized customization
the software also generates a customization file in the users main directory. For
Windows it is:
C:\Documents and Settings\<user_name>
while on Unix this would be depending on the system that is used, e.g.:
/usr/local/<user_name>
The name of the personal configuration file is defined by default as stamp2G.cfg, but
can be modified by the user. For Windows users, modifying the startup batch script that
resides in the installation directory can do this.
When starting the application, the main configuration file is read first, followed by the
personal customization file. Any settings already defined by the main customization are
overwritten by the personal customization file.
The customization files are in ASCII format, so they can be read and modified by
administrators if necessary.
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Macro-Command
The software is able to automatically perform successive operations, which generally
occur during the data setup of each step of a standard simulation. These tools, thanks
to which the user does not have to perform several manipulations during the data setup,
are the macros. For standard processes, nearly the whole data setup is performed by
the process macro; therefore a full data setup can be done in a few minutes.
Further explanations about the Stamp Tool Kit are given in the Process Macro and
offset chapters of this document.
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FILES
Numerous files are used by PAM-STAMP 2G. Each has a very precise function.
Herein, the generic name of the project will be designated as gn.
Data Bases
Material
-
material.psm:
Material data.
ASCII files.
One file per material.
Macro from Stamp Tool Kit

-
macro.ksa:
Definition of PAM-AUTOSTAMP standard forming macro.
ASCII file.
One file per process macro-command.
Macro.ksp
Definition of PAM-QUIKSTAMP Plus macro
ASCII file.
macro.ktf:
Definition of PAM-AUTOSTAMP tube hydroforming macro.
ASCII file.
macro.ktb:
Definition of PAM-AUTOSTAMP tube bending macro.
ASCII file.
macro.ksi:
Definition of PAM-INVERSE standard forming macro.
ASCII file.
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macro.kti:
Definition of PAM-INVERSE tube bending macro.
ASCII file.
Template from PAM-DIEMAKER

-
profile.udt:
Definition of user-defined profile template.
ASCII file.
One file per profile.
profile.pfl:
Definition of parameters of standard profile template.
ASCII file.
One file per profile.
Project
-
gn.psp:
Data common to all modules of the project (for example alarms, section planes,
active state).
Preprocessor
-
gn.pre:
Setting up of the project data and mesh description of the project.
Binary file.
Multistage file.
It is used to run a simulation.
gn.att:
Project data setup.
ASCII file.
Multistage file.
It can be used with the gn.pre file or with the gn.mif file to run the
calculation.
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gn.mif:
Mesh description of the project.
ASCII file.
It can be used with the gn.att file to run the calculation.
gn.[i].und:
Temporary undo file that contains information for undo. If n undo are possible
there are n files from gn.1.und to gn.n.und. Files are removed when closing
the project.
Binary file.
Deleted when the project is closed.
CAD Meshing Module

If the project comprises several modules, the following files correspond to the Ith
module:
-
gn.I.msh:
Definition of the CAD model, the elements, nodes and groups of the module.
Binary file.
gn.I.cmd:
Command file of DeltaMESH containing the input for meshing.
ASCII file.
gn.Ir.dtc:
DeltaMESH data base after import. Results of CAD import.
Binary file.
gn.Ia.dtc:
DeltaMESH data base after joining. Results of CAD joining.
Binary file.
gn.Im.dtc:
DeltaMESH data base after meshing. Results of CAD meshing.
Binary file.
gn.Im.fma:
Results of CAD meshing.
ASCII file.
PAM-STAMP 2G temporary file that can be imported.
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gn.I.his:
DeltaMESH Stamping messages file for all operations.
ASCII file.
Design Module (PAM-DIEMAKER and PAMTUBEMAKER)

If the project comprises several modules, the following files correspond to the Jth
module:
-
gn.J.add:
Definition of the model used by PAM-DIEMAKER and PAM-TUBEMAKER

(mesh, profiles, ).
Binary file.
gn.J.msh:
Definition of the CAD model, the elements, nodes and groups of the module.
Binary file.
gn.Jr.dtc:
DeltaMESH data base after import. Results of CAD import.
Binary file.
gn.Jm.dtc:
DeltaMESH data base after meshing. Results of CAD meshing.
Binary file.
gn.Jm.fma:
Results of CAD meshing.
ASCII file.
PAM-STAMP 2G temporary file that can be imported.
gn.J.trm:
Definition of the model used for Die Trimming.
ASCII file.
gn.J.ptl:
Definition of the user-defined PTL.
ASCII file.
gn.bending:
Definition of bending data.
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ASCII file.
Die Compensation
-
Gn_Outifo.input:
Input file for Outifo containing the settings.
ASCII file.
Gn_Outifo.lis:
Output file of Outifo, containing all information about the computation. Used by
the GUI in Show all messages
ASCII file.
Gn_Outifo.output:
Output file of Outifo containing the status of the computation. It can be seen in
the GUI, in the Outifo console.
ASCII file.
Gn_Outifo.history:
History file written by Outifo, containing the points of Outifo history curves
(max distance, average distance .).
ASCII file.
Gn_Outifo.results:
Contours results of Outifo.
ASCII file.
Gn_linear.asc & Gn_linear_depla.asc:
Files used by the linear solver
ASCII file.
Linearsolver.LOG:
Output file of linear solver
ASCII file.
Substructure
-
Gn.ini:
File containing the data stored from the main simulation (Id of node, position
and Id of center of gravity). There is one file per stage.
Binary file.
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Gn.S0i:
File containing the data stored from the main simulation (border node
displacement). There is one file per stage.
Binary file.
Gn_ids.bf:
File used by the subrun simulation to do correspondence between node

identification of main run and node identification of subrun. There is one file per
stage.
Binary file.
Solver restart
-
gn.irs:
input file to restart a calculation, contains the restart

file identifier and possibly new calculation parameters
ASCII file
gn.[i].rst:
ith RESTART file written by the solver.
Binary file.
Warning:
When the maximum number of restart files is n, and the solver wants to write the
(n + 1)th restart file, it will overwrite the first restart file, then overwrite the
second, etc. Thus, the user should not just rely on the filename for identifying the
most recent file, but look also for the progression value to which they
correspond.
gn.[i].rst_P:
DMP calculation
ith RESTART file on the node P written by the solver. All these restart files per
node must be located in the same physical disk space (be careful /home can
correspond to different disk for each node of a cluster).
Binary file.
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USERS GUIDE
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Post-Processor
-
gn.[i].res:
ith state file written by the solver, contains the results of a given state.
Binary file.
gn.end.res:
State file written by the solver at the end of the calculation.
Binary file.
gn.0.res:
Scanner state file written by the solver on users request during the calculation.
Binary file.
Temporary file.
gn.0[j].res:
Instant state file written by the solver on users request during the calculation.
Binary file.
Saved file.
gn.his:
History file written by the solver, contains the points of history curves.
Binary file.
The size depends on the number of points, on the number of entities stored and
on the settings defined for history.
gn.out:
Solver listing.
ASCII file.
gn.err:
Solver messages. Written if the solver stops with an error message after cycle 0.
Binary file.
gn.msg:
Solver messages.
Binary file.
gn.qst:
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Temporary status file that contains the request from the interface to the solver,
for example when solver interaction is requested. File is removed after action is
performed.
ASCII file.
Deleted when the solver reads the request.
gn.asw:
File which contains the answer of the solver to the request from the interface.
ASCII file.
gn_M01:
Mapping result file, contains requested data for computed model at end of
calculation.
ASCII file.
gn.pda:
Post-processing data archive, contains modifications in post-processing stage

with respect to main project file (created curves, modified objects etc.)
Binary file.
gn*.rib:
input files for the renderer (master file, model definition, lights definition, scene
definition)
Binary files, except that the master file gn.rib is an ASCII file.
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Archiving a Project
-
Pre-processor:
CAD meshing module, for each selected module:
gn.pre.
gn.I.msh.
Design Module, for each selected module:
gn.J.msh.
gn.J.add.
For the post-processor:
gn.1.res.
a few intermediate view files, for PAM-AUTOSTAMP projects.
gn.end.res.
gn.his, for PAM-AUTOSTAMP projects.
gn.err.
gn.out.
gn.msg.
gn.[i].rst : The restart file used for the picking of the next project, if
necessary, for PAM-AUTOSTAMP projects.
gn_M01, if available.
gn.pda.
Data common to all modules:
gn.psp.
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SOLVER MANAGER CONFIGURATION

Introduction
The solver manager is a daemon that runs on a calculation host.
Its purpose is to wait for and then process the calculation requests sent by GUIs running
on the same machine or on remote machines.
The solver manager is a single executable file delivered with the standard installation.
In the following, this executable file name is assumed to be solvermanager.exe.
Configuration Modes
The solver manager can be configured either:
-
by arguments in the command line used to launch the solver manager
by a configuration file
Configuration priority:
-
the configuration file options redefine the default options.
the command line arguments redefine the configuration file options.
Warning:
On Windows systems, if the solver manager is started as a service (see the

Solver Manager start chapter), no option can be set by the command line, except
the log file path. The configuration file is then the only way to configure the
solver manager for other options.
The configuration file read by the solver manager is either :

-
the file specified by the -config argument in the command line used to launch the
solver manager.
or
-
a file named solvermanager.exe.cfg if no file was specified in the command

line. This file must be located in the same directory as the solver manager.
The presence of a configuration file is not mandatory but if it is necessary, a default

configuration file can be generated by typing the command:
solvermanager.exe -genconfig [-config <file>]
The name of the generated file is solvermanager.exe.cfg if no filename is

specified by the optional -config argument (.cfg is appended to the solver manager
executable file name)
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Configuration File Description

This is a default configuration file:
#############################################################
##
##
##
##
##
E S I
S O F T W A R E
##
##
##
##
##
#############################################################
#############################################################
##
##
##
##
##
SOLVER MANAGER CONFIGURATION FILE
##
##
##
##
##
#############################################################
#
##################################################
#
SERVER PARAMETERS
#
#
##################################################
#
# SERVER_PORT
| 1201
# SERVER_PROTOCOL_VERSION | 2
# SERVER_LOG_FILE
#
##################################################
#
#
#
SOLVER LAUNCHING PARAMETERS
#
#
##################################################
#
# SCRIPT_TEMPLATE
# BATCH_COMMAND
| batch
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# LIBRARY_PATH
| NONE
# LIBRARY_VARIABLE
| DEFAULT
# MP_VARIABLE
| NONE
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#
##################################################
#
#
#
OTHER PARAMETERS
##################################################
#
# TEMP_DIRECTORY
| /usr/tmp
# SAVE_LAUNCH_SCRIPT
| NO
# SOURCE_PROFILE
| YES
# FORCE_AUTOMOUNT
| NO
# SCRIPT_CLEANUP_DELAY
| 5
A '#' character at the beginning of a line means that the line is commented and therefore
ignored.
To modify an option, the user must remove the '#' character and set the option value
after the '|' character.
An option value containing space characters must appear within double quotes.
Available Options
The following items can be configured:
Usage of a template for launch script generation [New in v2.2]
configuration file line
SCRIPT_TEMPLATE
command line argument :
-script <template file path>
default value
no script template
<template file path>
<template file path> is the path of a template file containing keywords that are replaced
by the solver manager with the launch parameters received from the GUI. The filled
template is then executed by the solver manager. If no template file is specified, the
solver manager uses its own built-in template (same behavior than previous versions).
This option is available on Unix/Linux systems only.
See Defining a Template File for the Launch Script , below, for more details about
defining a template file.
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Command used to launch a calculation in "batch" mode
BATCH_COMMAND
-batchcmd <batch cmd>
default value
batch
<batch cmd>
<batch cmd> is the name of the command used in batch mode to launch the solver.
Name of the linked library path environment variable on Unix/Linux systems
LIBRARY_VARIABLE
-libvariable <lib var>
default value
DEFAULT
<lib var>
<lib var> can be an environment variable name (LD_LIBRARY_PATH for example) or a

keyword:
DEFAULT
: the environment variable name depends on the operating system:
IRIX
: LD_LIBRARY_PATH
HPUX
: SHLIB_PATH and LD_LIBRARY_PATH are both set
SOLARIS : LD_LIBRARY_PATH
AIX
DIGITAL : LD_LIBRARY_PATH
: LIBPATH and LD_LIBRARY_PATH are both set
Automatic setting of the linked library path environment variable on Unix/Linux

systems
LIBRARY_PATH
-libpath <lib path>
default value
NONE
<lib path>
<lib path> can be a standard path (/usr/lib for example) or a keyword:

NONE
do not set the library path environment variable
SOLVER_DIRECTORY
set the library path environment variable as the solver

directory path
Automatic setting of the multi-processor environment variable
MP_VARIABLE
-mpvariable <mp var>
default value
NONE
<mp var>
<mp var> can be an environment variable name or a keyword:

NONE
: do not set any environment variable
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DEFAULT
: set an environment variable whose name depends on the operating

system:
IRIX
MP_SET_NUMTHREADS
HPUX
MP_NUMBER_OF_THREADS
SOLARIS :
PARALLEL
AIX
XLSMPOPTS='parthds...
DIGITAL :
MP_STACK_SIZE
Path and name of the solver manager log file
SERVER_LOG_FILE
-output <log file>
default value
blank (no file)
<log file>
<log file> is the full name of the log file (eg: /usr/tmp/solvermanager.log)
Port number on which the solver manager listens to requests
SERVER_PORT
-port <port id>
default value
1201
<port id>
<port id> is the port number on which the solver manager listens to the requests.
Version of the communication with the GUIs protocol
SERVER_PROTOCOL_VERSION
<version>
not available by command line
default value
depends on the version of the solver manager (2 for v2.2)
<version> is a number from 1 to n.

Note:
A GUI and a solver manager can always communicate whatever their version is
(full compatibility). The user should never need to modify this option.
Path of the temporary directory
TEMP_DIRECTORY
-tmpdir <tmp dir>
default value
/usr/tmp
<tmp dir>
<tmp dir> is the path of the directory where the solver manager will write launch
scripts
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Save the launch script generated by the solver manager
SAVE_LAUNCH_SCRIPT
-savelaunchscript
default value
NO
YES / NO
When this option is enabled, the launch script generated by the solver manager in its
temporary directory is not deleted once the solver is launched but renamed to
smgr_launch_script. This allows for example to check / modify this script and
restart it in a console to track a launch problem. Note that all scripts are renamed to the
same name; it is advised to work with a copy of smgr_launch_script which will be
overwritten by subsequent launches.
Enable the sourcing of profiles files (sh and ksh environments)
SOURCE_PROFILE
-nosourceprofile
default value
YES
YES / NO
When this option is disabled, the launch script generated by the solver manager will not
include execution of /etc/.profile and $HOME/.profile files. This can be useful
if these files contain instructions that make the launch fail.
Force automount before entering directories [New in v2.2]
FORCE_AUTOMOUNT
-forceautomount
default value
NO
YES / NO
When this option is enabled, the solver manager calls some list directory commands
to trigger automount of some directories before trying to enter them (just entering a
directory might not trigger automount on old systems). This option should not be
activated if no problem occurs with automount.
Delay before deleting scripts [New in v2.2]
SCRIPT_CLEANUP_DELAY
-scriptcleanupdelay <delay>
default value
5 (seconds)
<delay>
This option allows defining the delay (in seconds) before the solver manager deletes a
script it has just launched.
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Defining a Template File for the Launch Script

This option is available on Unix/Linux systems only.
A template file is a text file that can be located anywhere. It can contain keywords that
are replaced by the solver manager with the launch parameters received from the GUI.
To enable the usage of a template file, define its path in the solver managers
configuration file or in the solver managers command line or simply copy it in the
same directory than solvermanager.exe and name it solvermanager_script.tpl
(this is the default name for templates)
A default template file, very close to the built-in script, can be generated by the
command:
solvermanager.exe genscript [-script <new templates name>]
This is an example of a template file (the keywords that will be replaced by the solver
manager are highlighted in this example):
#!/bin/sh
case $SHELL in
/bin/sh | /bin/ksh | /bin/bsh )
if [ -f /etc/profile ] ; then
$SHELL /etc/profile
fi
if [ -f $HOME/.profile ] ; then
$SHELL $HOME/.profile
fi
;;
/bin/bash )
if [ -f /etc/profile ] ; then
$SHELL /etc/profile
fi
if [ -f $HOME/.bash_profile ] ; then
$SHELL $HOME/.bash_profile
fi
;;
esac
# --- Enter work directory
cd $PAMPARAM_WORKDIR
# --- Set environment variables
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PAMPARAM_VAR1_LABEL="PAMPARAM_VAR1_VALUE";export PAMPARAM_VAR1_LABEL
# --- Run the command
nohup $PAMPARAM_CMDLINE > $PAMPARAM_OUTPUT
# --- Normal termination
exit 0
Note:
If a keyword is preceded by a $ character, this $ character will also be

removed by the solver manager. This allows writing a template file, based on
environment variables, that could also be directly executed from a terminal or
from another script, just by setting the environment variables corresponding to
the keywords before calling the script (for testing...)
Example:
setenv PAMPARAM_WORKDIR
/usr/temp
setenv PAMPARAM_CMDLINE ls
setenv PAMPARAM_OUTPUT ls.out
./solvermanager_script.tpl
The keywords that are accepted in this version are:

- PAMPARAM_WORKDIR :
work directory of the calculation
- PAMPARAM_CMDLINE :
full command line that launches the solver
- PAMPARAM_OUTPUT
file where solver output must be written
- PAMPARAM_NBPROC
number of processors requested for the calculation
- PAMPARAM_RUNMODE :
launch mode (0 for immediate, 1 for batch)
- PAMPARAM_USER
name of the user which sent the calculation request
- PAMPARAM_SHELL
users shell (/bin/sh, /bin/csh, ...), equivalent to

systems $SHELL
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SOLVER MANAGER START

The solver manager is a single executable file that is launched differently according to
the host operating system.
On Unix/Linux Systems
Start the solver manager from a term window:
-
logon as the root user
type the command:

cd <manager directory>
where <manager directory> is the directory where the solver manager executable
file is located.
-
type the command:

nohup solvermanager.exe [-output <manager logfile>] > /dev/null &
where <manager logfile> is the full path of the solver manager log file
(/usr/tmp/solvermanager.out for example)
The output <manager logfile> argument is optional (the user can also define the log
file path in a configuration file). If the user does define any log file path, no solver
manager messages will be stored or displayed.
Start the solver manager at boot time:

-
locate in the system the script file whose purpose is to start the daemons at boot time
(consult the system administrator)
insert the following command in this file:

<manager directory>/solvermanager.exe [-output <manager logfile>] >
/dev/null &
where <manager directory> is the full path of the solver manager executable file
directory and <manager logfile> is the full path of the solver manager log file
file path in a configuration file). If the user does define any log file path, no solver
manager messages will be stored or displayed.
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On Windows Systems
The solver manager is normally installed as a service and launched by the installation
tool. This is however the procedure to install and/or launch it manually.
Start the solver manager from a command window:

-
type the command:

file is located.
-
type the command:

solvermanager.exe noservice -output <manager logfile>
where <manager logfile> is the full path of the solver manager log file
file path in a configuration file). If the user does not add it to the command line and no
log file is specified in a configuration file, the solver manager messages will be
displayed in the command window.
Warning:
If the user starts the solver manager from a command window, all the
calculations launched by the solver manager will be attached to the user
account the user is logged on. Therefore, these calculations will be killed by the
system when the user closes his session.
Start the solver manager as a Windows service:

A specific user account must have been created with the log on as a service privilege.
This account is named pamservice in the following.
The pamservice account will be assigned to the solver manager service so that the
calculations launched by the solver manager are also attached to this account. This
prevents the calculations from being killed when a session is closed (assuming that the
pamservice account is reserved to calculations and that nobody logs on this account).
Note that the calculations are attached to pamservice, not to the user that requests the
calculation. This must be taken into account, particularly for network access settings.
This is the procedure to install and start the solver manager as a service:
-
open a command window
type the command:

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file is located.
-
type the command:

solvermanager.exe service user pamservice
enter the password of pamservice
If another solver manager service is installed and is running (whatever its version is),
this service is first stopped and removed before installing and starting the new one.
If no configuration file is present or if the log file is not specified in this configuration
file, the solver manager messages will be saved in a default log file. This default log file
is located in user profile directory and it is named solvermanager.out.
More generally, the user cannot configure the solver manager by command line
arguments if the he starts it as a service, except the log file path. If the user needs to
modify some other options, he must generate a configuration file and set the options
inside it (see the Solver Manager Configuration chapter).
PRODUCT START UP
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SOLVER MANAGER ACTIVITY

If the user has defined a log file path when starting the solver manager (in the command
line or in the configuration file), he can read in this file a processing report of all the
requests received by the solver manager.
Example of log file:
### 12/03/2003
13:57:58 : Starting the solver manager...
-> Solver manager started (Version 2.2 Protocol v2)

[ Copyright ESI GROUP 2007 ]
-> Waiting for requests on port 1201...
### 12/03/2003
13:58:45 : Request received from 'remote GUI'
-> Processing script...

+ Action requested
: Start a calculation
+ User name
: 'user1'
+ Executable path
: '/usr/local/bin/solver.exe'
+ Command line
: '/usr/local/bin/solver.exe -if "test.pre"'
+ Work directory
: '/usr/projects/'
+ Output file
: 'test.out'
+ Nb of processors
: 1
+ Execute action immediately

-> Setting work directory
: OK
-> Script template loaded
: OK (solvermanager_script.tpl)
-> Writing script
: OK
-> Creating output file
: OK
-> Creating the process
: OK
The lines beginning with ### report the solver manager start-up and termination and
the date and origin of all the requests.
The lines beginning with + describe the requests.
The lines beginning with -> report the solver manager actions and the result (success
or failure with error message) of these actions.
Moreover, version 2.0 and later of the solver manager sends a full report to the GUI so
that a clear message can be displayed in the GUI to inform the user about the success or
failure of his request (and the reason it failed if necessary).
PRODUCT START UP
Solver Manager Activity
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CALCULATION STOP
A calculation should normally be stopped by the GUI so that the process can cleanly
terminate (writing of restart files), using the solver/stop option.
The user might however need to kill the calculation process because it does not respond
anymore, he does not need a clean termination or because he does not want to use the
GUI.
On Unix/Linux systems, the user can use the system command kill provided if the he
has the right to kill the process. If the user is not logged on the calculation account (or
he is not the super user), he will have to switch to the calculation account before.
On Windows systems, the user can use the task manager provided if he has the right to
kill the process. If the solver manager is running as a service with a different account
than the one he is logged on, he will not have the right to kill the calculation because it
is attached to the service account. In this case, the solver manager executable file must
be used to send a kill request to the running solver manager. This is the procedure:
-
get the process id of the calculation (get it from the task manager window)
open a command window
go to the solver manager executable file directory
type the following command:

solvermanager.exe killpid <pid> [-port <port number>]
where <pid> is the process id of the calculation and <port number> is the port
number on which the solver manager listens to requests.
Note:
port <port number> is optional. If it is not specified, the default port is used.
This procedure is not available on Unix/Linux systems.
PRODUCT START UP
Calculation Stop
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FINITE ELEMENT AND

NUMERICAL MODELS
ALGORITHM
Explicit, Implicit and Advanced Implicit Algorithms
Algorithms used by the solver of numerical simulation, work step-by-step in order to
find dynamic equilibrium at each step. Different types of algorithms can be used:
explicit, implicit and advanced implicit. The main differences are highlighted through
this section and a comparison table at the end of the section summarizes it all.
The principle of the explicit and the implicit time integration of a 1D system with one
degree of freedom can be represented by a linear spring system:
c
f(t),x,v,a
A linear damped spring system

The equilibrium equation of the spring system is:
m.an c.vn k.xn f n ,
where n means the time increment.
Explicit
In the explicit method, the nodal velocities are written down at times tn-1/2, tn+1/2 and
nodal displacements and accelerations at times tn-1, tn, tn+1. At time tn the nodal
displacement xn is known and the acceleration an is computed from the internal and
external forces. Nodal velocity vn-1/2, is known at time tn-1/2. The algorithm searches for
the nodal velocity vn+1/2 at time tn+1/2 and the nodal displacement xn+1 at time tn+1.
The application of the central difference method gives nodal velocity at time tn+1/2 and
the nodal displacement at time tn+1 (assuming that Tn is small):

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an
an
. (f n
t k . x n
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in case of no damping applied.
V 1 V 1
n
n
2
( T
T ) / 2
n -1
n
V 1
n
X n 1 X n
T
n
For complex processes (other than 1D system) m is a matrix, it is diagonal and can be
immediately calculated without any matrix inversion. Unfortunately, this method is
stable only if a small time step Tn is used (see TimeStep & Increments)
Implicit
Purpose
Stamping simulations are considered as static, using an incremental method (based on
loading or tool kinematics).
The dynamic effects are neglected, the velocity and the acceleration are set to zero.
Calculation of each increment

Within one increment, (see TimeStep & Increments) the solver automatically tries to
find the solution of a set of nonlinear equations, using linear iterations, also known as
Newton iterations, with convergence criteria.
Newton iterations:
F(u)=Fext (Fext=0 in springback case)
F(u)=F(0) + F/u(0) u
u1=K-1(0)(Fext-F(0))
u1= u1
F(u)=F(u1) + F/u(u1) u
u2=K-1(u1)(Fext-F(u1))
u2= u1+ u2
So un= u1+ u2 ++ un, the displacement convergence is reached when

|un|/Max(|ui|)<Tol

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solution
F(u)
2nd Newton iteration

1st Newton iteration
R=Fext
The maximum number of non-linear iterations is a parameter that is defined in

the Implicit calculation page of the global objects Advanced parameters attribute.
Default value:
The Maximum number of non-linear iteration is 20 for gravity and springback by

default. It is 200 for QUIKSTAMP holding or forming simulation.
Convergence criteria

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Two criteria are used to check the convergence of the solution, the displacement
convergence tolerance and the energy convergence tolerance.
Displacement convergence tolerance
|un|/Max(|ui|)<Told
Energy convergence tolerance
|En|/Max(|Ei|)<TolE
Where: En=un . ( Fext - F(un-1))
The energy convergence tolerance is used only for springback simulation.
If the enforced option is activated, once the maximum iteration number is reached the
convergence criterion is supposed to be acceptable.
Default values:
By default the Displacement convergence tolerance is 0.01 for springback and

QUIKSTAMP holding and forming simulations, and 0.1 for gravity.
By default the Energy convergence tolerance is 0.01 for springback. . It is not

used for QUIKSTAMP holding and forming simulations.
Matrix inversion
At each Newton iteration, there is a matrix inversion K-1 that can be done by several
methods (Direct, Preconditioned Conjugate Gradient (PCG), iterative, MUMPS Direct
and MUMPS Direct Out of Core).
Direct
The matrix is directly inverted using the decomposition method of K into two triangular
matrices (K=LU). The solver uses by default the direct solver of the optimized
mathematical libraries of each platform, when it is available. Otherwise, the direct
Skyline solver is used.
PCG
The Preconditioned Conjugate Gradient method solves Ku=R with an iterative

technique.
With this method, the matrix is not really inverted, iterations are performed on vectors
ui which converge to the solution un = K-1R.
Iterative
The linear system Ku=R is solved also with an iterative technique. The solver uses by
default the iterative solver of the optimized mathematical libraries of each platform,
when it is available. Otherwise, the iterative Sparse solver is used.
With this method, the matrix is not really inverted, iterations are performed on vectors
ui which converge to the solution un = K-1R.

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MUMPS Direct and MUMPS Direct Out of Core
This is a homemade ESI direct matrix solver.

The Out of core mode uses the disk memory storage to reduce the RAM allocation.
With this method the CPU time is network dependent. The default Disk path is the
project directory but it can be customized with the ELS_OOC_PATH variable.
Default setting:
By default the MUMPS Direct solver is used for gravity and springback
simulations
The PCG solver is used for QUIKSTAMP holding and forming simulations.
Options
Some divergence problems may appear, they can be solved with the options available in
PAM-STAMP:
F
Fext
u2
u1
Line search
un=K-1(un-1)(Fext-F(un-1))
With the line search option, the algorithm tries to find to minimize:
|F(un-1+ un)-Fext |
with: =k/N (k=1,.,N) where N is the input line search parameter
un=un-1+nun

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Default setting:
Default is 10 for springback and it is imposed to 2 for QUIKSTAMP PLUS.
F
Fext
u
1 u1
u1
This option is not available for gravity simulation.

Displacement control value (buckling risk)
In some cases, the line search method is not sufficient to solve the Newton divergence
problems. This happens usually when there is a buckling behavior during springback.
This option uses the initial stress matrix.
The input parameter is the maximum displacement in one Newton iteration. This option
is still an alpha option, to be used with some care.
Damping scale factor
The Implicit damping scale factor controls the blank average nodal displacement of one
increment. When this parameter is increased, the average displacement will be
decreased, and this is usually useful to solve some divergence problems related to
blank/die contact stability.
When the damping scale factor is increased, the total number of increments is also
increased and so is the CPU time.
Default values:
The Line Search option is active by default with a value of 2 for QUIKSTAMP PLUS
holding and forming simulation and a value of 10 for springback simulation.
The Displacement control option is not active by default.
If activated, the advised
value is 10.
The Damping scale factor option is available for Gravity stage only. Default value
is 1.

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Advanced Implicit
Purpose
Advanced implicit algorithm improves current Implicit algorithm. Generally the basics
are the same as for Implicit algorithm. In this chapter the differences and improvements
will be described.
S : E
d0 ...
d n1 ...
n1
S : E
d n ...
n+
n
Current configuration
Initial configuration
(integration volume)
Final configuration of
previous increment
Total Lagrange
(or integration
volume)
Updated Lagrange
Quasi-Euler
Advanced Implicit
Implicit
In advanced implicit calculation, the mechanical equation is solved on final

configuration of the previous increment, which is known (Update Lagrange method),
while in implicit calculation it is solved on current configuration, which is unknown
(Quasi-Euler method). Updated Lagrange is usually more stable than Quasi-Eulerian
method because it is easier to compute a tangent matrix which is fully consistent with
Residual Forces.
Calculation of each increment

In advanced implicit simulation a set of non linear equations is solved by using either
Newton-Raphson method (as in Implicit) or Arc-length method, both used to
convergence criteria on Force and Displacment.
Newton-Raphson method:
Tangent Matrix (Total Stiffness matrix) :
Kt = KL + KDu + Ks
KL
: Linear Stiffness Matrix
KDu
: Initial displacement Matrix (Updated lag. Form.)
Ks
: (Initial) Stress stiffness matrix or Geometrical stiffness matrix

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New Options
Force convergence tolerance
|Fn|/Max(|Fi|)<TolF
Geometric stiffness matrix
Update Geom_Stiffness Matrix at each iteration. In case of compressive stress, this term
can introduced singularity in problems and leads to divergence. If removed,
convergence rate is reduced; and increases slightly CPU in some cases
Automatic stabilization
Add artificial damping to model in order to suppress singularity introduced by

geometric stiffness matrix. This damping is based onto artificial mass. Damping
coefficient is computed automatically by using the value defined by user. This value is
the maximum ratio expected between Internal Energy and Viscous Energy dissipated by
damping.
Progressive unloading
In this method, one considers that at the end of the previous stage (usually stamping
stage), blank is in mechanical equilibrium. It means that Contact Forces are equal to
internal forces generated by stress into blank. At beginning of implicit computation,
internal forces are recomputed and stored into Fcontact vector like an external force.
This external force is progressively (linearly) released from initial Fcontact to zero.
Notes:
Progressive unloading is not available for volume elements. In a computation

with volume elements, stress is released within 1 increment.
Arc-length method
Standard Newton-Raphson method freaks out when approaching limit point

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Objective Load
Limit Point
Post-Collapse
d
is load step ratio (between 0 and 1) and d the mean value of displacement.
Objective of method is to find solution into cylinder : 2 + d2 = L02 with L0 imposed
arc length defined by user
Kd
( 0)
F int d (i )
K d (i )
F int d (0)
L0
d (0)
d (i )d (i 1)
The maximum number of non-linear iterations is a parameter that is defined in an

Advanced Implicit page of the global objects Advanced Parameters attribute.
Arc-Length method is efficient when instability affects global load-displacement
response. If instability is localized and has no impact onto global response, Arc-length
is not efficient.

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With respect to optimal accuracy and CPU performance there have been validated
values for Displacement convergence tolerance, Force convergence tolerance,
Maximum number of non-linear iterations, Maximum iterations of Line search and
Load control; For each type of process advanced implicit gravity, advanced implicit
springback and advanced implicit springback with contact (and gravity). These
parameters are set to default (optimal) values if Automatic tolerance option, Automatic
maximum number of non-linear iterations option, Auto.max.search. option of Line
search and Automatic option of Load control are checked in the Advanced implicit
page of the global objects Advanced parameters attribute.
Default values advanced implicit gravity
Displacement convergence tolerance: 0.1
Force convergence tolerance: 0.1

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Solver type: MUMPS direct
Maximum number of non-linear iteration: 50
Resolution method: Newton-Raphson
Line search: active; max iteration: 50; energy tolerance: 0.1
Automatic stabilization: inactive
Geometric stiffness matrix: inactive
Load control: Regular
Load per increment: 100%
Progressive unloading: inactive
Damping scale factor:
Default values advanced implicit springback without contact
Load control: Regular
Load per increment: 100%
Progressive unloading: active
Default values advanced implicit springback with contact (and gravity) with
standard contact

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Load control: Automatic
Load per increment: 1%; Min: 0.1%; Max: 10%
Iteration criterion: active; Min: 3; Max: 15
Increase factor: 2; Reduction factor: 0.5
Min number of increments: 2
Cutback Reduction factor: 0.5
Progressive unloading: active (if inactive, gravity computation only)
Use advanced contact for springback: inactive
Default values advanced implicit springback with advanced contact (and

gravity) with advanced contact
Load control: Automatic
Load per increment: 10%; Min: 1%; Max: 100%
Iteration criterion: active; Min: 3; Max: 15
Increase factor: 2; Reduction factor: 0.5
Min number of increments: 2
Cutback Reduction factor: 0.5
Progressive unloading: active (if inactive, gravity computation only)
Use advanced contact for springback: active
Default values advanced implicit arc-length

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Resolution method: Arc length
Geometric stiffness matrix: active
Initial load: 1
Arc step min: 0.001; max 1
Iteration criterion target:3
Cutback: inactive
Progressive unloading: active
Buckling analysis
Stability Theory:
Tangent matrix is no more definite positive (or singular):
duT.Kt.du 0 for all du (small perturbation)
LINEAR BUCKLING (Euler method)

-
Main assumptions: behavior of structure prior to buckling remains linear. Stress are
linearly dependent of load magnitude (l)
Usually Applied to stiff structures (long strut, stiff arc)
Based on Eigen mode analysis

Definition of problem
Kt singular <=> det Kt = 0
Eigen value problem : det (KL+ .K)=0
where KL is linear stiffness matrix computed onto initial geometry with Elastic
Material, K being stress stiffness matrix due to reference force F0

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Critical Load or buckling point : Fcrit = 0 x F0

where 0 is the first Eigen value of the Eigen problem
Associated to is the buckling mode shape defined as (KL+ .K) =0
For Springback application : in SPBK is a percentage of unload at which buckling
is triggered, Ds should be increment of stress due to springback by considering
structure as Elastic and with small displacement.
Alternative use of Linear Buckling

If instability is too far from initial geometry, assumption of small displacement prior
to buckling is no more satisfied; solution is to combine LINEAR Buckling with
Picking to approach limit or bifurcation point.
Eigen value problem becomes

det (KL + K + .K)=0
where KL is linear stiffness matrix, K being stress stiffness matrix due to reference
force F0 , K being stress stiffness matrix due to increment of force F
Critical Load becomes : Fcrit = F0 + 0 x F
where 0 is the first Eigen value of the Eigen problem

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TIME STEP & INCREMENTS

From the previous chapter it has become clear that two types of solvers are supported,
i.e. implicit and explicit integration scheme. Implicit and explicit algorithms (see
Algorithm) work step by step in order to find dynamic or static equilibrium at each step.
While the explicit integration scheme makes use of time-steps, the implicit solver uses
increments to discretize the calculation.
Implicit Increments
For implicit calculation, the equation is not solved using the whole imposed
displacement or load; displacement and load conditions are broken up into several steps,
called increments. Each step is called Load Increment.
I1
I2
In
Displacement
& Loading
For each increment, the solution of the sets of non linear equations requires iterations,
called Newton iterations. A convergence criterion is needed to stop iteration loop.
Springback
Usually one increment could be sufficient for a springback simulation in case of small
deformations or if material exhibits linear behavior.
Sometimes springback exhibits high geometrical non linearity due high displacements.
Many increments are needed to increase the accuracy of the solution. In this case the
increments are not useful to divide on loads or displacements but only used to decrease
the non-linearity of the problem.
Gravity
In implicit gravity simulation, the increments are used to manage the blank nodes
average displacement using an implicit damping method.
The default implicit damping scale factor is 1. When this parameter is increased, the
average displacement will be decreased. This is usually useful to solve some divergence
problems related to blank/die contact stability. By limiting displacement of nodes, too
high penetration in tools is avoided.
When the damping scale factor is increased, the total number of increments is also
increased and so is the CPU time.

Time Step & Increments
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Advanced Implicit Increments

There are two options for defining advanced implicit increment according to the method
used: classical Newton-Raphson or Arc-length method.
Load control-Newton-Raphson method
Regular method
If no automatic method used, step size keeps a constant value tuser along non linear
analysis.
Automatic method
If automatic increment is enabled calculation starts with initial load step value. Then
load step is determined automatically for following increments. Load step is bounded
by min, max values.
-
If only automatic load step is defined, then the load step could only decrease with
cutback but never increase.
Cutback option : in case of divergence in increment. Increment is restarted by using
a new load step which is computed by multiplying old load step by factor in
Cutabck option If dtnew is lower than dtmini, computation stops.
-
Iteration criterion allows to increase or decrease the load step using the number of
equilibrium iterations Niter that was needed in last increment.

If Niter > itmax, load step is reduced from dtired parameter:
dtnew = dtired . dtold
If Niter < itmin, during nitmin consecutive increments, load step is increased from dtiinc
parameter:
dtnew = dtiinc . dtold
Default options:
There have been identified default values for different process simulations
Advanced implicit Gravity, Advanced implicit Springback with contact and
Advanced implicit Springback without contact. See paragraph Advanced implicit
default values.
Load control-Arc-length method
In this method, piloting value is no more load step but Arc Length. Load step becomes
a variable which is computed by algorithm.
Default options:
The Initial load value of 5, min arc step 0.005 and max arc step 10 is set as default.

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Explicit Time-Steps
For explicit calculation, the state of the simulation is not continuously calculated; the
time is broken up into a large number of steps called cycles and the state of the
simulation is calculated for each cycle. The interval between two cycles is called time
step:
Tn-1
Tn
Tn+1
Time step must be small enough to satisfy the stability condition of explicit integration
scheme and to assume small displacement approximations.
A local time step is associated with each element. This element time step Tel is equal
to the time taken by an elastic wave to pass through the element. Hence it depends on
the size, density and elastic modulus of the element. A global time step T, used for the
calculation, is computed from these element time steps. Only the time step of
deformable elements is being used for the calculation of the global time step.
Time Step Calculation for a Shell Element
Bending Options
There are two ways to calculate the time step for a shell element, one taking into
account the bending of the element (Large bend option), the other ignoring this bending
(No bend option).
No bend option
T
el
characteristic size
E

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Large bend option
characteristic size characteristic size characteristic size 3 1

T min
,
el
thickness
2
E
E
Default option:
The default option is Large bend. Using No bend option may lead to a large
increase of the time step when the mesh contains small and thick elements.
This parameter can be modified in the Advanced parameters attribute of the

global object for each stage of calculation.
Characteristic Length
There are two criteria to define the characteristic length of a shell element, the Large
criterion and the Small one. The small criterion is more stringent. It should ensure
solution stability in severe cases (distorted meshes for example), where the large
criterion may become inadequate. The use of the small criterion may sometimes
considerably reduce the time step and so increase the CPU time.
Default option:
The default option is Small.

Time Step Calculation for a Volume Element

T
el
characteristic size
2
where:
characteristic size
volume
max (facets area)
E
E
and
2 1
1 1 2
E: Youngs modulus.
: Poissons coefficient.
: density.

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Time Step Calculation for a Bar Element

M
T
el
slope
M: bar mass.
slope: the slope of the force-elongation curve for the current elongation.
Calculation of Global Time Step T

Stability of the explicit method is ensured if the global time step is lower than the
smallest element time step. The following equation is used to ensure the stability of the
algorithm:
2
T min
TSSFAC
T = TSSFAC
[ Tel 1
] min el
where TSSFAC scale factor (stability protection) is a safety coefficient and is a

damping ratio calculated by the solver.
The time step is automatically calculated at each cycle.
Default value:
The default value for the scale factor is 0.9.
The default value for the damping ratio is 0.1.

Notes:
If the size of the smallest element is doubled (for the same number of elements),
the time step is multiplied by two and the calculation time is divided by two.
Only deformable elements with defined material attribute (surface blank, volume
blank, rigid bar ) affect the time step.
The time step can be increased (this reduces the calculation time), by increasing
the mass of the elements whose time step is smaller than a defined value: this is
called mass scaling (see paragraph Mass Scaling below).
Time step can also be modified by using adaptive meshing (see paragraph Time
Step Reduction Factor below).

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Mass Scaling
Purpose
The purpose of mass scaling is to reduce CPU time by increasing the time step. This
increase of the time step leads to a reduction of the number of cycles, hence to a
reduction of the CPU time, since the latter is proportional to the number of cycles. To
do this, the mass of some elements is artificially increased, thus the element time steps
are increased too.
Data Set-up
In the CPU Control attribute of the global object, define the Mass scaling by activating
the Characteristic length toggle and entering the value required (expressed in the unit of
length used during the project). A wizard can help the user to define a value well
adapted to the simulation. It is also possible to select Automatic mass scaling. The
calculation will be done automatically when launching the solver respecting the rule
described here after.
Mass scaling wizard or automatic calculation
The wizard, or the automatic mass scaling, computes the characteristic length the
following way:
-
The minimal element size is computed: one of the smallest initial element after
maximal refinement, but using only the 90% larger elements of the blank. The main
purpose is to avoid taking small elements of the border into account.
The minimal element size is calculated on the blank object selected by the user,
taking into account all the refinement attributes that can be defined directly on that
object but also on other sub-objects.
The stage type is checked:
If it is a holding stage: the minimal element size is multiplied by 2
If it is a stamping stage: the minimal element size is used as Characteristic

length
If it is an explicit Springback stage: the minimal element size is multiplied by 2

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Note:
If there is no refinement defined on the selected object for all the stages, the
minimal element size will not be multiplied by 2 for the holding stage.
If the surface of deformable elements with a size smaller than 2 x Characteristic

length is larger than 5% of the total surface of deformable elements, the minimal
element size will not be multiplied by 2 for the stage. This will avoid inertia
effect and mainly occurs when doing a holding on an already refined blank (due
to a previous stamping stage for instance).
Operation
Mass scaling makes it possible to impose a minimum time step. The value entered by
the user corresponds to a characteristic length of element; the corresponding element
time step is automatically calculated and given to the solver.
All the elements with a characteristic length smaller than this value will have their mass
increased so that their element time step corresponds to that of an element which has a
characteristic length equal to the value input by the user.
This increase of mass and modification of element time step is done if necessary at the
beginning of the computation and after refinement of the element.
Utilization
When adaptive meshing is activated in a holding project, it is recommended to enter the

smallest size of the elements of the blank, multiplied by two. In as much as, during a
holding, the velocities are low and as only few elements are refined, the mass scaling
will act on a small number of elements and will introduce little effect of inertia.
In a stamping project, it is recommended to enter the smallest possible size of the
elements of the blank. Thus, only the elements with maximum refinement, whose size
has been reduced, will be affected by the mass scaling and this will have little effect on
inertia.
In a springback project, with explicit algorithm, it is recommended to enter the smallest
size of the elements of the blank, multiplied by two.
If there are few elements smaller than the other ones, situated on the border of the
blanks, they can be ignored. The increase of their mass will have no effect since they
are situated under the blank holder, and they should not impose the time step for the
whole blank. The wizard automatically ignores these elements, when searching for the
smallest size of elements.
Caution:
Increasing the mass of the elements increases the inertia of the blank, and this
can lead to erroneous results. The mass scaling is to be used cautiously.

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Time step options
Minimum time step
The user may impose the maximal solution time step, tuser. Note that if the stability
time step (tstab) computed by the solver becomes lower than tuser, then t = tstab.
Otherwise, the solver will use t = tuser.
Automatic for Rollhemming
In this mode, we compute a variable time step t = f(t) so that the time step is always
smaller or equal to the time spent by the Robot between two discretisation points of the
path. The time step depends on the paths and robots involved in the analysis. This
automatic time step is used only in a Kinematic check calculation of Rollhemming (See
Rollhemming chapter)
Time Step Reduction Factor

Purpose
The purpose of time step reduction factor is to reduce CPU time by increasing the time
step. This increase of the time step leads to a reduction of the number of cycles, hence
to a reduction of the CPU time, since the latter is proportional to the number of cycles.
To do this, the mass of some elements is artificially increased, thus the element time
steps are increased too.
Data Set-up
In the CPU Control attribute of the global object, define the Reduction factor by
activating the toggle and entering the value required (no unit).

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Operation
When an element is refined, and its time step is only geometry dependent, the child
element time step is equal to the parent element time step divided by two. Thus, during
a simulation, a fairly important time step decrease can be observed when a new
refinement level is reached. This time step reduction can be limited by giving a time
step reduction factor between 1 and 2. This value represents the coefficient by which
the time step is divided during mesh refinement. So, if a value r is given, the refined
elements density is modified, in order to have a time step divided by r during the
refinement, instead of 2.
This option works in a similar manner to the mass scaling option, and should also be
used with caution.
With a value of 1.33, this option enables to significantly reduce the simulation time,
particularly when it is coupled with an adaptive meshing without the curvature radius
criterion.
Default value:
By default the time step reduction factor is not used.
Notes:
A value of 2 does not mean that no modification is applied to the element

density. When an element is refined, the time step can become thickness
dependent (see paragraph Time Step Calculation for a Shell Element, Large bend
option), and can be divided by a value higher than 2. In this case the element
density is modified in order to respect the imposed condition.
This decrease of the simulation time is obtained to the detriment of the stress
field quality. Thus, it is not possible to expect springback results.
This time step reduction factor is only useful for elements that are refined.

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ELEMENTS
The characteristics of the elements presented here depend on their geometry (volume, 3node, 4-node, bar elements) and on the mechanical properties subsequently assigned to
them (material attributes, behavior).
Elasto-Plastic Shell Elements (for AUTOSTAMP)

Properties of 3-node and 4-node Elements
-
Midlin-Reissners Theory: The transverse shear strain, constant in the thickness, is

taken into account.
Each node has three degrees of freedom in translation and three degrees of freedom
in rotation.
Sub-integration: There is only one integration point on the surface of the element
and in its thickness.
No transverse shear locking.
Thickness integration rule and number of integration points (in Global advanced
parameters).
Shell anti-drilling (in Advanced parameters).
Strain order (in Advanced parameters).
Excellent CPU time.
3-node Element
This element has the following

characteristics:
-
Element C0: degree one

interpolation polynomials.

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4-node Element

characteristics:
-
Element C0: bi-linear

interpolation polynomials.
Shell Hourglass control (in

Advanced parameters) (stiffening
of parasitic strain modes caused
by the sub-integration).
Shell Elements Options
All the following options of shell elements are available from the Advanced parameter
or from the Global Advanced parameters attributes.
Thickness integration
The non linear stress distributions across the thickness resulting from plastification
require numerical integration in the thickness direction. Two parameters can be defined:
-
Thickness integration rule:
Defines the distribution of the integration points across

the thickness, and the weight of each point. There are two integration rules:
Uniform
Gauss
rule distributes evenly the integration points with an equal weight.
rule: the weight is different and the distribution is done to improve the
quality of the results.
Number of integration points
through the thickness: five points are needed for a
good quality of results.

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Default value:
Number of integration points
Thickness integration rule
is set to 5 by default.
is set to the Gauss rule by default.
Shell Element Type

Several element formulations are available. The default one is Belytschlo-Tsay, that is
well qualified for stamping.
-
BELYTSCHKO-TSAY (by default):
HUGHES-TEZDUYAR:
BELYTSCHKO-WONG-CHIANG:
BWC FULLY INTEGRATED:
the Belytschko-Tsay element is a simple and

efficient element. It is based on the concept of uniform reduced integration.
this element has a correct rank (i.e. no hourglass modes). It
gives good results for vibration and shock-dominated problems and is a substitute
for the Belytschko-Tsay element when excessive hourglassing is observed.
the formulation of this element is based on a better
kinematic field (also the shear strains are calculated by a nodal projection). The
same hourglass control method of the Belytschko-Tsay shell element is used. The
addition of a projection scheme makes it use as a six degrees-of-freedom shell
element very accurate in warped configurations.
the fully integrated BWC element is a shell element
based on the formulation of Belytschko and al. The main differences are the
following:
Instead of using one point integration in the plane to evaluate the forces and
moments, four Gauss integration points are used to obtain an exact integration of
the internal forces. This results in a full rank element, i.e. no zero energy modes
(hourglass modes) are present in the element. This removes the need for
hourglass control used in both the classical BT and BWC elements, but results in
more CPU time to evaluate the internal forces of the element since four
integration points are used.
An assumed shear field based used to avoid shear locking in the element due to
full integration.
An assumed membrane field is used to avoid membrane locking due to full

integration.
BATOZ Q4 gamma: This
is the default element used for advanced implicit

computation. Previously described elements use plate formulation with various
improvements to overcome problems of warping. This BATOZ Q4 Gamma element
uses a shell formulation in which the non-uniform normal in element improves the
accuracy of the element in case of warping. Four integration points are needed; and
the shear assumed strain is used to overcome transverse shear locking problems.
This element gives more accurate results with higher CPU cost than BelytschkoTsay element, but implicit CPU cost is not sensitive to the choice of element
formulation.

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Note:
Element type must be changed cautiously, since it requires a good knowledge of

the Finite Element simulation.
Shell Hourglass Control

In very rare cases, the mesh may degenerate as shown below. In this case the user must
enter a value equal to the default value (0.001) multiplied by 10. The Hourglass
algorithm enables the user to stiffen the strain modes with nil energy.
There are three possibilities of Shell Hourglass control attribute definition:

-
Stiffness using elastic modulus:
Hourglass control is based on the elastic modulus.

It adds stiffness to elements, which in some cases may be considered too stiff for a
structure.
Stiffness using plastic modulus:
Viscosity:
Hourglass control is based on the plastic tangent

modulus for elements, which have plastified, rather than on the elastic modulus of
the material. This results in a less severe damping of the hourglass modes.
The anti-hourglass stresses are calculated proportional to the generalized
hourglass strain velocities and do not have the cumulated effect as in the stiffness
formulation.
Default option:
Shell Hourglass control
is set by default to Stiffness using elastic modulus.
Shell anti-drilling
It is used for improved results in case of strongly warped shells. There are two possible
definitions:
Anti-drill by adding penalty on z-rotation.
Penalty:
Projection:
The projection method removes any parasitic straining due to drill
rotation.
Default option:
Shell anti-drilling
is set to Penalty by default.

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Strain Order
When used, the second order term in the strain and thickness calculation is taken into
account or not. Its value can be 1 or 2; value 2 is used for the best quality of results but
consumes more CPU time.
Default value:
Strain order
is 2 by default.
Accurate total strain

When this option is selected a Total Lagrangian method is used to calculate the total
strain. The Lagrangian method gives an exact value of the total true strain since it uses
the deformation gradient.
This total Lagrangian formulation is only used for strain output contour, the finite
element integration remains updated Lagrangian.
When it is not selected an incremental method is used. The incremental method adds the
incremental strain to the Almansi strain at the previous time step. It is an approximation
since high order terms are neglected. These high order terms are accumulated for large
deformations.
Elasto-Plastic Shell Elements (for QUIKSTAMP PLUS)

In QUIKSTAMP PLUS, the decoupled bending stretched element formulation (where
the rotational mode is determined by the geometry) is mixed with the full coupled
standard formulation. It makes QUIKSTAMP PLUS more accurate with good CPU
efficiency.
Common Properties of 3-node and 4-node Elements

-
Midlin-Reissners Theory: The transverse shear strain, constant in the thickness, is

taken into account.
Each node has three degrees of freedom in translation and three degrees of freedom
in rotation. Rotational degrees of freedom can be fully coupled or decoupled from
translational degrees of freedom.
Sub-integration: There is only one integration point on the surface of the element.
No transverse shear locking.
Thickness integration rule and number of integration points (by default).

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3-node Element
4-node Element

characteristics:

characteristics:
Element C0: degree one interpolation

polynomials.
Element C0: bi-linear interpolation

polynomials.
Elasto-Plastic Volume Elements (for AUTOSTAMP)

This element has the following characteristics:
-
Four to eight nodes per element:
Element C0: tri-linear interpolation polynomials.
Each node has three degrees of freedom in translation and no degree of freedom in
rotation.
Sub-integration: there is only one integration point in the element.
Anti-hourglass (stiffening of parasitic strain modes caused by the sub-integration).
Excellent CPU time.
Integration rule
Two integration rules are available for solid elements:
-
Uniform
(by default): uniform underintegration which uses one integration point.

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Selective reduced:
solids using the selective reduced integration rule have eight

integration points for the deviatoric strain part and one integration point for the
volumetric strain to avoid the so-called volumetric "locking" in case of
incompressible material behavior. Generally, this element is four times as expensive
as the uniformly underintegrated solid element.
Hourglass
When solid elements are used, Hourglas is activated. The parameters for Hourglass are
accessible in the Element page of the Advanced Parameters attribute.
Three Hourglass types are available:

-
Viscous (by default): viscous method using hourglass base vectors.
Flanagan-Belytschko viscous: viscous method using hourglass shape vectors.
Flanagan-Belytschko stiffness: stiffness method using hourglass shape vectors.
Three viscosity coefficients manage the hourglass options. They are all pre-defined:
Quadratic and Linear bulk viscosity coefficient: an artificial bulk viscosity
is computed whenever a solid element is undergoing compression and is added to the
pressure. This viscosity permits the formation of shock waves and damps out numerical
oscillations. The calculation uses a quadratic (1.2 by default) and linear (0.06 by
default) coefficient.
Hourglass viscosity coefficient: the solid hourglass viscosity coefficient
prevents vibrations in zero energy (hourglass) modes (0.1 by default).
Non Elasto-Plastic Elements

Non elasto-plastic elements represent 3-node, 4-node or volume elements with the
following characteristics:
3-node, 4-node Element

-
Each node has three degrees of freedom in translation.
No stiffness.

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Volume Element (for AUTOSTAMP)

-
Four to eight nodes per element:
No stiffness.
Bar elements
Bar elements can be employed to discretize cables, springs, and truss-like members that
are unable to transmit bending and torsion moments. In the case of cables, these
elements cannot transmit compression forces.
-
No moment applied to the nodes by the element.
Drawbeads are defined with bar elements, but only for the geometric aspect of these
elements (position of the node), not for the mechanical properties.
Bar elements can also be used to model gas-springs within a die. In order to do this, the
compressive behavior of the spring is defined using a force vs. displacement curve.

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MATERIAL PROPERTIES
Characteristics
The behavior of orthotropic elements is isotropic in elasticity and orthotropic in
plasticity. Several plasticity criteria (material laws) are available:
-
The HILL 48 criterion coupled to an isotropic hardening law is the most commonly
used criterion. Besides that, the software supports the use of the HILL 48 criterion
coupled to isotropic-kinematic hardening laws.
The HILL 90 criterion type is based on a non-quadratic yield function as opposed to

a quadratic yield function (HILL 48). This criterion is able to take into account
different behaviors during the bending/unbending phase and seems to be well
adapted to aluminum. The HILL 90 criterion models plasticity convexes in a more
general manner than the HILL 48 model but the simulation time is increased. Also
this model supports both isotropic hardening and combined isotropic-kinematic
hardening laws.
The BARLAT91s criterion makes it possible to represent more general plasticity

convexes than HILLs criterion, but increases significantly CPU time. Hence, it
should be used with caution. Also BARLAT91s model supports both isotropic
hardening and combined isotropic-kinematic hardening laws.
The BARLAT89s criterion is a three-component yield criterion, less sophisticated

then BARLAT91 (six components), but has the advantage of being much more
stable and faster. Also this model supports both isotropic hardening and combined
isotropic-kinematic hardening laws.
The BARLAT2000s criterion is an eight-component yield criterion, more

sophisticated than BARLAT89 (three components) and Barlat91 (six components).
Also this model supports both isotropic hardening and combined isotropickinematic hardening laws.
The Corus-Vegter criterion provides the possibility to describe more accurately the
Yield locus from a series of physically tested points. Bezier interpolation is
performed between points to construct the ellipse(s).
The Corus-Vegter model was developed by Dr. Vegter at the Corus R&D facility in
Ijmuiden, the Netherlands, the international metals company, and first published in
the Benchmarks of the NUMISHEET-1996 Conference. Corus R&D supported ESI
in the implementation of this model in its products.
The Corus-Vegter light criterion is a simplified model; it is based on 8 Parameters

instead of 17 parameters of the standard Corus-Vegter model, by skipping plane
strain and pure shear information. This skipped information is approximated from
uni-axial and bi-axial information using Nurbs interpolation. The 8th parameter (biaxial r-value) is optional and approximated by the Hill48 value.

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Material laws Hill 48, Hill 90 or Barlat91 are compatible with Matfem failure
criterion.
A non-linear visco-elastic law is available.
The Mooney Rivlin law makes it possible to represent volume tools.
Anisotropic, Von Mises, elastic plastic material law is available for volume blank.
A user-defined material law is available.
Material type
There are several Material types (standard steel, special steel, aluminum ) that help
the user to choose the material law. The option of the Material law corresponds to each
of these material types:
Material type
Material law
Standard steel
Hill 48
Available for
object type:
Hill 48
Special steel
or
Aluminum
Super plastic
Rubber
User-defined
Hill 90
Barlat89
Barlat91
Barlat2000
Corus-Vegter
Non linear visco-elastic law
Mooney-Rivlin
-
Surface blank
Volume blank
Surface blank
Volume blank
Surface blank
Surface blank
Surface blank
Volume blank
Surface blank
Surface blank
Surface blank
Volume tool
Surface blank
The User-defined material law is described in a specific separate documentation. Please

consult with the local ESI subsidiary for more information.

Material Properties
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Options
Material law
Ito-Goya
plasticity
L. Chaboche
Kinematic
hardening
Yoshida
Kinematic
hardening
Strain
Rate
Thermal
option
EWK
rupture
model
Matfem
Failure
criterion
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Hill 48
Hill 90
Barlat89
Barlat91
Barlat2000
Corus-Vegter
Non linear viscoelastic
Mooney-Rivlin
x
x
The combined isotropic and kinematic hardening, as well as the strain rate hardening
option are described in the material hardening laws chapter. The Ito Goya plasticity is
described in the Hill 48 material law chapter. For the thermal option the user can refer to
the Thermal material option chapter and the description of the EWK rupture model is
done in the EWK rupture model chapter. Matfem failure criterion is described in the
Matfem failure criterion chapter.
Common Data
The following data necessary for process definition do not depend on the material law:
-
Thickness
(does not apply to volume elements): The thickness is not defined in the
property, but only in the project. This enables a single material property for sheets
of different thicknesses to be used.
Youngs modulus E.
Poissons coefficient
Density
Rolling direction:
Thickness direction:
The rolling direction is projected onto each element that belongs

to the material. This vector represents the local rolling direction of the material. It is
not defined in the property, but only in the project.
The thickness direction is used for the definition of the rolling
plan in case of volume blank..

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Material encryption
It is possible to encrypt material data and to protect them by a password. It is thus
possible to give simulation (set-up and results) to partners keeping the confidentiality of
a material. The partners can do other simulations without having access to the material.
With the required password any user can decrypt the material data.
Encryption access
Encryption or decryption of material data is done from the material data base.
It is not possible to encrypt or decrypt materials inside a project, but the material can be
imported as an entry in the database and then be decrypted.

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HILL 48 MATERIAL LAW

The HILL 48 criterion coupled to an isotropic hardening law is the most commonly
used criterion. The data of this law are easy to obtain, and it is well adapted for standard
steels.
The common data and general information about this law are described in the Material
properties chapter.
Anisotropy
Lankfords coefficient
Lankfords coefficients r0, r45 and r90 (or anisotropy coefficients) along directions 0,
45 and 90 with respect to the rolling direction have to be defined.
w
traction
Rolling direction
sample
blank
A traction test is performed on the test sample, then w() and t() are measured:
w: width strain.
t: thickness strain.
( )
Lankfords coefficient along direction is equal to: r w
t ( )
Wizard option
If Hills coefficients are known and not Lankfords coefficients, a wizard enables to
define them and to transform them into Lankfords coefficients.
Hills coefficients are F, G and N:
Hill48
1
2
2
2
2
H 11 22 F 22 33 G 33 11 2N12
2

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Notes:
When F=G=1 et N=3, the yield surface is equivalent to von Mises one
H+G = 2
Anisotropy type
The need for Lankfords coefficients depends on Anisotropic type option:
-
Orthotropic:
The anisotropy in three directions is taken into account so three values

r0, r45, r90 are needed.
Normal:
Isotropic:
Only the anisotropy through the thickness is taken into account, so only
one average value r independent of the direction is needed.
There is no anisotropy so there is no need for Lankfords coefficient.
Solid element
Lankford theory does not exist for 3D, but 2D Hill coefficients are the same like 3D
Hill coefficients F G L M N. So Lankford 2D coefficients from user input are
automatically converted to Hill 2D ones (P Q R G F N) and there is assumed
isotropy for in 13 and 23 directions (L=M=3).
Ito-Goya plasticity
This option is only available with Hill 48 law.
This material is based on the Hill 48 plasticity but the elastic-plastic flow rule is
incorporating the stress rate dependence.
If H is the work hardening rate in the loading direction (tangent to the hardening curve),
the Ito-Goya flow rule can be expressed as follow:
N
d
dp
H dp = () { Kd d + Kf (d : n).n}
where:
dp is the plastic strain tensor increment

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Kd = sin/sin,
Kf = sin(-)/(cossin),
= Kc,
Kc is a material parameter indicating the degree of dependency of the direction of
plastic strain increment on the direction of the stress increment.
() = cos
n = (ep-Kc lp) / |ep-Kc lp|
ep = dp / |dp|
lp = d / |d|
d is the deviatoric stress increment.
is the angle of the stress increment direction measured from the natural direction n:
cos = d.n / |d|
If Kc=0 the flow rule formulation becomes: H dp = (d : n).n which is the standard
normality rule.
Non-associated plasticity
This option is only available with the Hill 48 law.
In associated plasticity the plastic strain rates are presented as vectors perpendicular to
the yield surface. To improve the model and better take into account the anisotropy of
the material, in addition to the yield function a plastic flow rule is introduced.
The plastic flow rule is defined by the anisotropic coefficients, Lankford or Hill
coefficients (F, G, N).
The yield surface is defined either by the yield stresses in 0, 45 and 90 (experimental
option) or by the Hill coefficients f, g, n (general option). The yield stress in rolling
direction is not defined by the user in the main menu but in the definition of the
hardening curve.
Default
By default the non-associated plasticity is inactivated.

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Notes:
If the hardening curve is defined by the Hollomon law the value Re0 is reported,
otherwise the Re0 is estimated and reported in the material dialog box.
If the Hill coefficients f, g, and n are the same as F, G, and N, the plasticity is
associated
If Ito-Goya option is selected, the only possibility of non-associated plasticity is

the General one.
Available options
Please refer to Material properties chapter.

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HILLS 90 MATERIAL LAW

The HILL 90 criterion type is based on a non-quadratic yield function as opposed to a
quadratic yield function (HILL 48). This criterion is able to take into account different
behaviors during the bending/unbending phase and seems to be well adapted to
aluminum. The HILL 90 criterion models plasticity convexes in a more general manner
than the HILL 48 model but the simulation time is increased.
The common data and general information about this law are described in the Material
properties chapter.
Yield description
For plane stress conditions and in the orthotropic axes, the yield function is written as
x
m ( x
y)
m
2 2
x2 2y 2 xy
m
2 2
4 xy
( x2 2y ) ( x y )2 1 m 1y
(2 by )m ,
1y : yield stress under uni-axial tension on rolling direction.

by : yield stress under equi-biaxial tension.
, , and m: data to enter (material dependent).
In terms of principal stress components for which,

x y 1 2 , x y (1 2 )cos2 and xy ( 1 2 )
sin 2
2
the yield function becomes

m
1 2
1 2
12 22 2

HILLs 90 Material Law
(12 22 )cos 2 (1 2 )2 cos2 2 (2 )m.

b
y
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Hill 90 parameters computation
A wizard enables to calculate the , , and m coefficients of Hill 90's law.

This calculation is based on an iterative method that minimizes a function whose
variables are the yield stresses and the anisotropy coefficients (least square method).
The user must define uniaxial yield values (u) for each Lankford coefficients (r) and
either Hill 90 coefficient (m) either equi-biaxial yield stress (y). In the last case the user
must set a minimum and a maximum value for m.
Available options

HILLs 90 Material Law
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BARLAT89 MATERIAL LAW

The BARLAT89s criterion is a three-component yield criterion, less sophisticated than
BARLAT91 (six components), but has the advantage of being much more stable and
faster.
This criterion is mainly used for aluminum.
BARLAT89s criterion coefficient: a,h,c,p and m.
Yield function of Barlat89 describing planar anisotropy for full plane stress state:
2Y m a K1 K 2
a K1 K 2
c 2K 2
K1 x h y / 2, K 2 x h y / 2 p 2 xy
2
2 1/ 2
Notes:
m is a strictly positive real.
optimal m exponent for aluminum is 8.
Default is c = 2 a. (HC expressed at a rolling direction).
If user defines a c value different from 2-a, he has to express his hardening
curves in the appropriate direction corresponding to the c value.
Available options

BARLAT89 Material Law
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The BARLAT91s criterion makes it possible to represent more general plasticity
convexes than HILLs criterion, but increases significantly CPU time. Hence, it should
be used with caution.
BARLAT91s criterion coefficient: A, B, C, F, G, H and m.
g | S1 S2 |m | S2 S3 |m | S3 S1 |m 2Y m
Si are of the natural values of following matrix:

h12
g 13
[(b c)11 c22 b33 ]/ 3
h12
[(a c)22 c11 a33 ]/ 3
f 23
g 13
f 23
[(a b)33 b11 a22 ]/ 3
with a b c 3
In order to identify coefficients A, B, C, F, G,
H, and m from traction tests, a wizard is
available in the application. Enter several test
results as displayed:
-
Angle
is the angle (in degrees) between

the traction direction and the rolling
direction.
Re is
r is
The weights make it possible to affect

more or less significance to each test.
the yield stress along the traction

direction.
Lankfords coefficient along the
traction direction.

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The wizard selects the A, B, C, F, G, H and m coefficients in a range specified by the

user, in order to better respect the traction tests.
Notes:
It is recommended to choose m as an integer. The choice of m as a real still

increases the calculation time. A good method, the default one, consists in
setting m equal to 8 and restraining the variation interval to [8,8].
The weights are positive or negative values. Thanks to them, the calculation can
be based on measures of Re above all or on measures of r. The higher the
weight, the more significant the measure. The user must specify a non-zero
weight for Re at 0 degrees, even if he wants the calculation to be based on
measures of r only.
Solid element
Barlat91 2D coefficients and Barlat91 3D coefficients are not the same according
following equations:
Where
3a
3b
, b
,
a b c
a b c
3g
3h
, h
,
a b c
a b c
3f
,
a b c
m m.
a , b , c , f , g , h , m are the Barlat91 2D coefficients.
Available options

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The BARLAT2000s criterion is an eight-component yield criterion, more sophisticated
than BARLAT89 (three components) and Barlat91 (six components).
This criterion is mainly used for aluminum.
BARLAT2000s criterion coefficient: A1, A2, A3, A4, A5, A6, A7,
A8 and m.
Yield function of Barlat2000 describing planar anisotropy for full plane stress state:

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Ym
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1
' "
2
' X 1' X 2'
" 2 X 1" X 2"
X 1" 2 X 2"
1 '
'
X 11 X 22
2
1
'
X 2' X 11' X 22
2
1
"
"
X 1" X 11
X 22
2
1
"
"
X 2" X 11
X 22
2
'
'
X 11' L11
L12
' '
'
X 22 L21 L22
' 0
0
X 12
"
X 11
L"11 L"12
" "
"
X 22 L21 L22
" 0
0
X 12
'
L11
2 0
'
1 0
L12
' 1
L21 0 1
' 3 0
2
L22
0 0
L'33

X 1'
'
11
'
X 22
2
4 X 12'
'
11
'
X 22
2
4 X 12'
"
11
"
X 22
" 2
4 X 12
"
11
"
X 22
" 2
4 X 12
0 11

0 22
L'33 12
0 11

0 22
L"33 12
0
0a 1

0a 2
0a 7
L"11
8 2
2 2
"
1 4 4 4
L12
" 1
L21 4 4 4 1
" 9 2 8
2 2
L22
0
0
0
0
L"33


0a 3

0a 4

0a 5
0a 6

9a 8
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Notes:
optimal m exponent for aluminum is 8.
Available options

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VEGTER MATERIAL LAW

The Vegter criterion provides the possibility to describe more accurately the Yield locus
from a series of physically tested points. Bezier interpolation is performed between
points to construct the ellipse(s).
The Vegter model was developed by Dr. Vegter at the Tata Steel (former Corus) R&D
facility in Ijmuiden, the Netherlands, the international metals company, and first
published in the Benchmarks of the NUMISHEET-1996 Conference
Data Specific to Vegter Law

The data to be entered describes the yield
surface in stress space. The stress data should
be normalized with respect to the uniaxial yield
stress in the 0 degree direction (this is always
set to 1).
The data to be entered is:
-
-uniaxial: the uniaxial yield stress at 0, 45,

and 90 degrees (pre-set to value 1 at 0
degrees).
r-value uniaxial: the uniaxial Lankford

coefficient at 0, 45, and 90 degrees.
-plane strain: the yield stress in a plane

strain state at 0, 45, and 90 degrees.
plane strain: this is a factor that can be

used to fine tune the fitting of the yield
surface, by default it is set to 0.5. It is
required for 0, 45 ,and 90 degrees.
-pure shear: the yield stress in a pure

shear state at 0, 45, and 90 degrees.
r-biaxial: Lankford coefficient in the biaxial

stress state.
-biaxial: the yield stress in a biaxial state.
An important part of this model is a planar anisotropic yield criterion, which includes
the information of other than uni-axial stress states. The basis of this yield criterion is
the measured information of mechanical tests under the following conditions: pure
shear-state, uni-axial stress-state, plane strain state and the equi-biaxial stress state. All
these tests (except the equi-biaxial stress test) can be made at different angles to the

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rolling direction. In this way a planar anisotropic yield criterion can be constructed by
means of interpolation.
The Vegter yield criterion

A new yield criterion has been formulated, that is able to incorporate more measurable
data than any other yield criterion. This criterion is defined in the principal axes of
stress instead of the axes of anisotropy. When a stress is described in principal axes, it
only consists of normal components called principal stresses, and shear components
vanish. These principal stresses follow from the general (plane) stress components by
the following relations:
1
2
xx yy
2
xx yy
2
xx yy

2
xx yy
xy 2
y
2
xy 2
xx yy
cos 2
(Usually rolling
direction)
2
xx yy
xy 2
Principal axes
The angle denotes the angle between the principal 1,2-axes and the x,y-axes, as
indicated above.
1 = 2
2
UN
PS
BI
SH
PS
UN
UN
PS
SH
BI
PS
UN
1 =-2
Vegter yield locus

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The choice to use principal stresses cancels out the shear stress, so that the yield surface
can be represented as a curve in a 1-2-plane. To describe the yield locus, the Vegter
criterion makes use of Bezier curves that connect certain reference points related to
measurements. The diagram above shows a yield locus passing through these reference
points, and the measurements they relate to.
To define the course of the yield locus between adjacent reference points the yield
criterion utilizes quadratic Bezier curves. The strain vectors define the tangent slopes of
the yield surface in the reference points. The hinge-point for the Bezier curve is defined
as the point where these tangents intersect. The diagram below shows a Bezier curve
described by parameter passing through reference points A and C. It also illustrates
the way the tangents in the reference points and the location of hinge-point B relate to
each other.
2
=1
C (C1, C2)
B (B1, B2)
=0
A (A1, A2)
Figure 1: Bezier curve
Bezier interpolation enables the construction of a smooth surface, with continuous

gradients. This enables the description of smooth yield.
Each reference point defines a location in the principal stress space, and a strain vector,
related to the normal on the yield surface. The required measurements are listed in the
table below. A denotes that this value can be measured, a denotes that a parameter
is not practically measurable.
Measurement
Equibiaxial stress test (compressive test) (BI)
Plane strain test (PS)

Uniaxial tensile test (UN)
Shear test: pure shear stress (SH)
= 1
=0
1-2=sh
Measurements required for the Vegter yield criterion

VEGTER Material Law
Strain vector
( = 2/1)
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It turns out that the yield locus is so versatile that not all data to define all reference
points and accompanying strain vectors can be found by currently available
measurements. This is true for the plane strain and the pure shear points. Therefore
assumptions have to be made to estimate these missing parameters. However, when new
measurement techniques become available that enable these parameters to be measured,
these measurements should be used instead of the assumptions.
For the plane strain test, the transverse stress cannot be determined with the present
test. The solution is shown in the figure below. Points a and b are defined as the points
of intersection of tangent lines through the uniaxial and biaxial point with the line 1 =
PS, respectively. By means of an extra input-parameter -plane strain, the user can specify
the location of the actual plane strain point between these limits. This parameter should
have a value between 0 and 1. If the transverse stress is known then that value can be
used to determine -plane strain. However, current measurement techniques are unable to
determine the transverse stress and therefore usually a value of -plane strain = 0.5 is
assumed.
BI (BI, BI)
b()
PS (PS(), PS2())
2
1
()(b() - a())
a()
UN (UN(), 0)
0
Figure 2: Locating the plane strain point
With shear tests one does not really know whether we have a pure shear state (strain
vector 2/1 =-1, stresses are unknown) or the maximum shear stress state has been
met in the force direction (2=-1, strain vector is unknown). We assume we have a
state of pure shear and that we can derive the maximum shear stress of the measured
force. This way, we know the difference between the two principal stresses but not the
values. If additional information is available then it can be used to locate the shear
point. Otherwise the assumption that 2=-1=-1/2 sh is recommended.

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Mechanical testing procedures for the Vegter model

Uniaxial tensile test EN10002
Tensile test were carried out according to EN10002. Mechanical properties were
determined from the stress strain curves.
Plane strain tensile test

To obtain a plane strain state, a specimen as shown in the figure below may be used.
The axial force is measured as a function of the axial strain. The strain in the axial
direction is measured using an extenso-meter attached to the sheet. The plane strain
stress can be determined in a sufficiently accurate way by dividing the force to the area
of the cross section, derived from the measured strain. In preliminary tests, a variation
of the width, W, of the specimen did not demonstrate a clear influence on the stress
strain curves. As a consequence, no additional edge correction is required; in most cases
a fixed width of 60 mm is used. In the case of a high strength steels, the width can be
reduced until a minimum of 40 mm. In this way a good clamping of the specimens is
maintained.
70 mm
R2 mm
10 mm
W varies between 40 and 80 mm
Figure 3: Plane strain tensile test and specimen
Compression tests on the sheet plane

To obtain data under equi-biaxial stress compression tests on the sheet plane are carried
out using a specimen of stacked sheets. The deformation is the same as in case of equibiaxial stretching, but the stress is shifted by a hydrostatic component to the
compressive side. This hydrostatic component does not influence the plastic material
behavior. The procedure is prescribed in Figure 4; friction between the compression
tools and the specimen has to be avoided as much as possible using lubrication and foil.
In the present test procedure the friction contribution in the force is estimated to be
about of 1-2%. The advantage of the compression test is that a more direct force
measurement is used and that the r-value for the equi-biaxial point is obtained.

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Figure 4: Compression test on the sheet plane and specimen
Sheet shear test

The fourth mechanical test to be performed is the sheet shear test.
Undeform
ed
Deform
ed
Figure 5: The sheet shear test-specimen
The shape of the test specimen was originally proposed by Miyauchi [Miyauchi 1985].
This test is of particular interest for the description of the plastic material behavior in
the flange part during a deep drawing process. At present, the shear strain is measured
optically using grid lines on the specimen.
Light mode

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The Vegter-Lite option allows the user to define 7 Parameters instead of 17 parameters
by skipping plane strain and pure shear information.
-
uniaxial(45), uniaxial(90), biaxial
runiaxial(0), runiaxial(45), runiaxial(90), rbiaxial
rbiaxial definition is optional. If it is not defined, it is calculated by an approximation

method.
plane
strain
Making use of the uni-axial

information and bi-axial information,
hinge points are built between these
points.
2/f
Hingepoints
Nurbs
interpolation
Basic points
Vegter Lite
Vegter Lite
shear
1/f
Second order Nurbs interpolation is used with fixed estimated weight factors for steel
and aluminium for the calculation of the plane strain points and the pure shear points.

(1 - ) 1 + w 2 (1 - ) 1 + 2 1
1
2 i
2 i
2 i 1
=
2
2
(1 - ) w 2 (1 - ) +
2
r
The values for the weight factors are based on experience of measured yield loci until
now:
-
Steel:
Shear w = 2/3, Plane strain w = 2/3,
Aluminium:
Shear w = 0.75, Plane strain w = 0.4125,
They can be defined by the user, selecting user-defined as interpolation type and
defining the Shear weight and Plane weight.
Using the complete Nurbs interpolation is not feasible due to the more complex
formulation: Plane strain points and shear points are calculated providing the remaining
information for the Vegter yield criterion (using 2nd order Bezier interpolation).

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Example Data
A range of example data is provided by Tata Steel. Further data may be available
directly from Tata Steel, by following the web links from the data input page.
Disclaimer
Data is taken from a coil sample test according to Tata Steel internal standard, but is
not guaranteed to mirror all Tata Steel manufactured material of the same grade.Tata
Steel endeavors to select coil samples which are representative of everyday production
at the time of testing although these data may be subject to change without prior notice.
Tata Steel, including its subsidiaries, does not accept responsibility or liability for errors
or information which is found to be misleading.
Available options
-

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MATFEM FAILURE CRITERION

Matfem failure criterion is available for material laws Hill48, Hill90 or Barlat91
Failure Criteria
The MATFEM Program calculates risks for three different failure modes:
-
Unstable necking (plastic instability).
Ductile failure associated with void formation.
Shear failure associated with shear banding.
Note that plastic instability is not equivalent to fracture, but is a useful tearing criterion
in practical applications since unstable necks usually continue to grow into cracks.
When the local neighborhood in the sheet hinders further localization of the neck, the
criterion is too pessimistic.
These risks are available in specific contours and history curves:
-
Instability risk.
Ductile fracture risk: maximum between lower and upper fiber results.
Shear fracture risk: in the middle fiber.
Maximum instability risk.
Overall Failure risk.
Warning:
The equivalent stress in output is always calculated with a Hill48 criterion.

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Failure parameters
The parameters for failure criterion are:
-
os, ns, ms, od, nd, md, r:
parameters for Isotropic Hardening.

-
r0, r45, r90, KH1, KH2, KH3,

d: parameters for anisotropy,
kinematic hardening,
inhomogeneity.
-
FLDS1, FLDS2, FLDS3,

FLDS4, FLDD1, FLDD2,
FLDD3, FLDD4: parameters for
FLD approximation.
-
DFS1, DFS2, DFS3, DFD1,

DFD2, DFD3, DFA1, DFA2:
ductile fracture criterion parameters.

-
SFS1, SFS2, SFS3, SFD1,

SFD2, SFD3, SFK: shear fracture
criterion parameters.
Plastic Instability
The plastic instability model may be regarded as refinement of the MarciniakKuczynski Theory with:
-
Better geometric modelling of localized necking.
Refined material description including orthotropic and kinematic hardening effects

as well as strain rate dependencies.
Optional consideration of interstage annealing.
The instability analysis is based on the response of necked specimens at various

orientations subject to the sheet strain history as indicated below.

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Necked Specimen
22
Strain History
Instability Limit with
Linear Continuation
of Strain Path
Current
State
12
11
11
11
Eq. strain
Orthotropic Axis 1
12
22
22
Eq. strain
hm
12
Initial neck of relative size

d=(h-hm)/h at orientation
(exaggerated representation)
Eq. strain
Calculation of instability Limits.
For the plastic flow up to the current equivalent plastic strain and additionally
determines the plastic strain i() at which instability first starts when the strain path is
continued linearly. Instability is considered to occur when material outside the neck
stops flowing. The likelihood of necking is described by an instability risk:
,
min i ()
whereby values smaller than 1 indicate failure. Note that i may behave
discontinuously when the strain path changes direction suddenly and can jump
instantaneously from non-critical to critical values (i.e. from above to below one).
The initial neck size d represents all sources of variation in the material (including
thickness, grain size and micro-damage changes) and is termed the inhomogeneity
parameter. It is usually calibrated from fracture strains measured in uniaxial tests.
Key features of the material model used for the instability analysis are noted below:
-
Hill 1948 yield criterion.
Flow stress: Y K m( ) ( o )n ( ) .
Backhaus kinematic hardening law.

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The kinematic hardening model introduces a strong dependence of the stability limit on
the most recent strain path history. Interstage annealing is described by sudden material
parameter changes over the strain history.
Ductile and Shear Failure

Ductile and shear failure are described by the tensorial integral criteria summarised
below.
Ductile Failure
Shear Failure
d max dl , du 1
1
1
2 ijdl ijdl
2
4
p
2 1
dl d ij
d ijdl

l
32
gd ( )
dl
du
s 1
1
2 ijdu ijdu
4
p
2 1
du d ij

u
32
gd ( )
d ijdu
d dl d dl
d du d du
/Y
u iiu / Y
l
ii
g d ( )
d s d s
T sinh c( 2) T sinh c(2 )

sinh 4c
c k0 k1 cos 2 k2 cos 4
1 k ii Y
max
sinh f (4k 2 ) s sinh f (4k 2 )

g s ( ) s
sinh 8 fk
ductile failure risk

ductile failure risk on lower/upper surface
ductile damage tensor on lower/upper surface
,
l , u
gd ( )
accumulated ductile damage on lower/upper surface

triaxiality factor on lower/upper surface
ductile damage function
du
1
2 ijs ijs
4
p
2 1
s d ij

32
g
(
d )
d ijs
d
dl , du
ijdl , ijdu
dl
s
ijs
shear failure risk

ductile damage tensor
accumulated shear damage
gd ( )
shear stress factor

shear damage function
( k , S , S , f ) material parameters
angle between principal anisotropic and strain rate axes

( T , T , k0 , k1 , k2 ) material parameters
gd ()
g s ()
1.8
1.6
1.8
1.6
1.4
1.4
1.2
1.2
0.8
0.8
0.6
0.6
0.4
0.4
0.2
0.2
0
0.6
0.8
1.2
1.4
1.6
1.8
Triaxiality factor
2.2
2.4
2.6
0.6
0.8
1.2
1.4
1.6
1.8
Shear stress factor
2.2
2.4
Fracture criteria
Note that the ductile criterion is directionally dependent while shear failure is
considered to be isotropic. The following material parameters are strain rate dependent:
T , T , k0 , S , S , f . Both safety risks may decrease during the calculation (a
consequence of the chosen tensorial formulation).

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Element
The plasticity algorithm and the element formulation used for the Matfem materials are
slightly different from the ones used for the other materials:
-
Matfem plasticity algorithm is designed by a third party company (MATFEM), and

implemented as it is in PAMSTAMP2G.
In the standard Hill 48, Hill 90 and Barlat91, plasticity without failure criteria;
improvements have been done on Shear Stress (Transverse shear stress and Shear
strain factor) that are not available for Matfem materials.
Warning:
It is advised to use a UNIFORM integration scheme instead of GAUSS.
Mapping and Picking

The Failure criteria variables and the Isotropic damage parameter are included in the
mapping file if they are asked in the Mapping export or Mapping import attributes.

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It is also possible when starting a new computation:

-
to continue the previous process, or not to take into account the failure criteria
applied in the previous simulation,
to apply a heat treatment coefficient for failure criteria
These options are available when importing a Mapping file, when importing a computed
model or with the Picking attribute.
Imported computed model
MATFEM HILL 48 plasticity

see HILL 48 Material Law chapter
Notes:
Lankford coefficients are used in the Failure criteria. It is advised to enter the
corresponding Hills coefficient for the material calculation and Lankford
coefficients for the failure criteria.
MATFEM HILLs 90 plasticity

see HILL 90 Material Law chapter
MATFEM BARLAT 91s plasticity

see Barlat 91 Material Law chapter
Remark:
In the Matfem Barlat 91 material law the F and G coefficients are imposed to 1,
and the parameter C is equal to 3-B-A

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SUPERPLASTIC MATERIAL LAW

The superplastic material law defines a nonlinear viscoelastic shell element of Maxwell
type used for superplastic forming applications. Under uniaxial loading it is equivalent
to the mass-damper system shown below.
Definition
The constitutive equations are as follows:
This model uses:

-
Elastic-plastic decomposition
Isotropic elasticity law
Orthotropic equivalent yield stress function (Hill 1948)
Flow rule (associative).

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Flow stress definition

Four types of flow stress definition are available:
- Simplified : K m
n m
Krupkowsky : K 0
g ,
- Lookup table function
- user function

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Lookup table definition:
It is possible to combine both dependencies to plastic strain and strain rate, by using
Lookup table.
The user must define first the abscissa values of P (first argument) and the abscissa
values of strain rate (second argument). He defines then for each couple of values (P,
strain rate) the value of hardening curve.
If the user wants to use the flow stress only dependent to strain rate, he blocks the
hardening curve at a plastic strain value, using the deactivate axis at value. In that
case he must put a value of a predefined plastic strain value.
Several types of interpolation between points, and extrapolation before the lower
abscissa value and after the upper abscissa value are proposed:
-
Linear
Logarithmic
Exponential
closest value (for interpolation only)
horizontal (for extrapolation only)

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User function:
In this case, the user has the possibility to program his own function: g ,
21 real parameters are available in the data setup:
Please consult with the local ESI subsidiary for more information.
Strain Rate Control Option

Superplastic metals exhibit maximum ductility over a particular strain rate range. For
best results and the shortest cycle time it is generally desirable to design the process so
that the maximum strain rate in the sheet is equal to a particular value
during
forming. The strain rate control option allows the calculation of an optimal pressure or
displacement cycle leading to this condition.
When the option is active, the program automatically varies the rate scale factor during
the simulation so that the highest element strain rate is approximately equal to max
strain rate. The ratio between the simulation time t and 'real' time T is then no longer
constant and the following supplementary global variables are recorded on the history
file:
-
Rate scale factor
Time scale factor (inverse of rate scale factor)
Maximum element strain rate measure
Maximum normalized element strain rate measure
Mean element strain rate measure.
The user has four choices for the Element strain rate measure with differing emphasis
on bending deformation as indicated below.

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Different sheet regions can be assigned individual strain rate measures and/or maximum
strain rate values by forming separate material groups with differing parameters. The
normalized strain rate measure represents the ratio of the element strain rate measure to
its specified max strain rate value.
The following modelling technique is recommended for strain rate control in pressure
forming processes:
-
Assign appropriate strain rate measures and max strain rate values to sheet regions
where rate control is required.
Activate strain rate filtering, so that the calculated loading cycle is unaffected by
localized transient strain rates associated with impact (tfil=0.02 ms).
Specify a fluid-cell over the whole sheet with an imposed velocity of 3 m/s with a
starting ramp of width 2. In complicated geometries with a large range of forming
radii, specify a value of 3 for the velocity standard deviation factor (to avoid large
peak velocities)
Variable Rate Scale Factor

The user may specify the velocity scale factor as a tabulated function of the simulation
time in the element control cards. Applied abscissa values must increase
monotonically, the ordinates must be positive.
Calculation time can be saved with this option in simulations without strain rate control
by specifying high factors at the start of forming when the initially flat sheet is
particularly susceptible to inertia effects. In the course of forming the factor can be
reduced as the sheet curvature increases and the lowest natural frequency increases.

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Velocity correction parameter
It is necessary to define the velocity correction in Advanced parameter attributes of the

global object. The velocity correction describes the relationship between the simulation time t
and the physical time T: vvc=dT/dt
Example: if the punch velocity is multiplied by ten in the simulation model with respect
to reality, then vvc = 0.1
The velocity scale factor can be either a constant or a curve.
Note:
Real time notion has been introduced as progression type. The feature is
particularly useful for models with variable rate scale factors (no conversion of
loading curves into simulation time is required).

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MOONEY-RIVLIN MATERIAL LAW

The Mooney Rivlin law makes it possible to represent volume tools and is used for
rubber pad simulation.
W = W(I1, I2, I3) = A(I1-3) + B(I2-3) + W(I3): strain energy density
where: A and B are material parameters and W(I3) is a penalty function for
incompressibility (using = 0,499: Poissons ratio).
I1=3+2J1
I2=3+4J1-4J2
Right Cauchy-Green strain invariants
I3=1+2J1-4J2+8J3
J1=Tr(ij)
J2=1/2 ij ij -1/2 J12
Green-Lagrange strain invariants
J3=Det(ij)
Sij
w
ij
Sij is the 2nd Piola-Kirchhoff stress tensor.
This wizard enables to calculate the A and B coefficients of Mooney-Rivlin's law

starting from the list of points of an experimental tension / compression curve.
The Mooney-Rivlin coefficients computation dialog box

Mooney-Rivlin Material Law
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MATERIAL HARDENING LAWS

Isotropic hardening law
The hardening curve (stress-plastic strain curve) along the rolling direction can be
defined in several ways:
-
Point list:
Enter the values of the experimental hardening curve (usually known for
P between 0 and 20%).
Hollomon prolongation:
Use the program to calculate the Hollomons law

coefficients (=K ) on the interval (10< <20%) and extend the curve up to =
100% using Hollomons law. Re is defined in the hardening curve definition.
n
If coefficients K and n are known, define the whole hardening curve

using Hollomons law =Kn ( is total strain, the program transforms it in a list of
points depending on plastic strain). This method is less precise than the previous
one.
Hollomon:
Power law:
Krupkowsky:
Kinematic:
Hardening curve is defined as =YS + KPn .

Hardening curve is defined as = K (p+n .
Hardening curve is defined as = 0Rsat (1-exp(-Crp
Remarks:
l
l
Strains are 'true strain': ln 1 ln
l0
l0
with l0: initial length, l: current length.
F
S
with S: current cross section, F: traction force.
Stresses are 'true stresses':
The hardening curve is described as a function of plastic strain and not total
strain.
The hardening curve slope must be positive.
The yield stress (YS) defined in the hardening curve is the first point of this
curve.
Use
It is used for:
Hill 48 law.
Matfem Hill 48 law.
Hill 90 law.
Matfem Hill 90 law.

Material Hardening Laws
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Barlat 89 law.
Matfem Barlat 91 law.
Barlat91 law
Corus-Vegter law.
Lemaitre and Chaboche Isotropic - Kinematic hardening law

This is a mixed hardening model. The plastification will occur when eq - (R + Re0) >=
0 (eq=equivalent stress, R=isotropic hardening variable).
Hardening curve
It can be defined only with Kinematic option:
= 0Rsat (1-exp(-Crp
Rsat
0
p
C r , R sat : kinematic parameters to enter, also used into:
dR = Cr R sat -R d p .
dR, R: represent the isotropic hardening variable.
d p : effective plastic strain rate.

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Kinematic hardening law coefficients:
dXij
dR
Yield surface at time t
Yield surface at time t+dt
dXij Cx Xsatdijp Cx Xijd p .

Cx, Xsat:
material-dependent data
dXij , Xij : kinematic hardening variables (tensor)
d p : effective plastic strain rate.
d ijp : plastic strain rate tensor.

X11, X22, X12:
initial position of the center of the yield surface in the orthotropic system
(1=rolling direction).

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Use
It can be used for:

-
Hill 48 law.
Matfem Hill 48 law.
Hill 90 law.
Matfem Hill 90 law.
Barlat 89 law.
Barlat 91 law.
Corus-Vegter law.
Yoshida-Uemori Isotropic-Kinematic hardening law

This is an advanced mixed hardening model of Yoshida-Uemori [1]-[3].
Yoshida-Uemori proposed a model of large-strain cyclic plasticity that well describes
the stress-strain responses in reverse deformation (see Figure 1), as well as cyclic
hardening characteristics, such as:
-
Two stages of the Bauschinger effect:
the transient Bauschinger deformation characterized by early re-yielding and

smooth elastic-plastic transition with a rapid change of workhardening rate
the permanent softening characterized by stress offset observed in a region after

the transient period;
Plastic strain-dependent Youngs modulus
The workhardening stagnation appearing at a certain range of reverse deformation
Strain-range and mean-strain dependency of cyclic hardening, e.g., the larger the
cyclic strain range the larger the saturated stress amplitudes.

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Figure 1. An example of stress-strain response in a forward-reverse deformation

(experimental data of in-plane tension-compression of SPCC) [3]
Formulation
Hardening curve
As described above with Lemaitre-Chaboche model. Also for Yoshida-Uemori model,
the hardening curve can be defined only with Kinematic option:
= 0Rsat (1-exp(-Crp
Kinematics law:
The rate of deformation D is decomposed into its elastic part De and plastic part D p ,
as
D = De + D
(1)
In this model, the yield surface moves kinematically within a bounding surface as
schematically illustrated in Figure 2.

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Figure 2. Yoshida-Uemori model.
For the yield surface only the kinematic hardening is assumed, whereas for the
bounding surface, mixed isotropic-kinematic hardening. When the yield function at the
initial (non-deformed) state, f 0 , has a general form:
f0 ( ) Y 0 ,
(2)
where denotes a function of the Cauchy stress , and Y are the initial yield stress
(note that Y is the elastic limit, which is not the same as the yield strength usually
defined by 0.2% plastic-strain poof stress), the subsequent yield function f is given by
the equation:
f ( ) Y 0 ,
(3)
where denotes the backstress. The associated flow rule is written as

Dp
f
,
(4)
The bounding surface F is expressed by the equation:

F ( ) ( B R) 0 ,
(5)
where denotes the center of the bounding surface, B and R are its initial size and
isotropic hardening (IH) component.
The kinematic hardening of the yield surface describes the transient Bauschinger
deformation characterized by early re-yielding and the subsequent rapid change of
workhardening rate. The relative kinematic motion of the yield surface with respect to
the bounding surface is expressed by

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* ,
(6)
The evolution equation of * is given by
a
a
* C ( )
* ,
Y
(7a)
2 3 D p : D p , * (* ) , a B R Y
(7b)
where is the effective plastic strain rate, defined as the second invariant of D p ,
and C is a material parameter that controls the rate of the kinematic hardening.
For some materials, the shapes of stress-strain curves near the initial yielding in forward
deformation and one in the vicinity of re-yielding in reverse deformation are quite
different. To describe such a difference in stress-strain behavior, one may assume that
the material parameter C takes the value of C C1 only in the vicinity of the initial
yielding ( refp small plastic strain), then it switches to C C2 in the subsequent
deformation.
To describe the global workhardening, for the bounding surface, the following
evolution equation of the isotropic hardening is assumed:
R m( Rsat R) ,
(8)
where Rsat is the saturated value of the isotropic hardening stress R at infinitely large
plastic strain, and m is a material parameter that controls the rate of isotropic hardening.
In order to describe the permanent softening and workhardening stagnation stress
reversals, the kinematic hardening and non-IH region during stress reversals are
assumed for the bounding surface. For the kinematic hardening of the bounding surface,
the following evolution equation of Armstrong-Frederick type is assumed:
2
m bsat D p ,
3
(9)
where and are the deviatoric component of and its objective rate, respectively
(hereafter, the prime ( ' ) denotes the deviatoric stress component), and bsat is a material
parameter.
To describe the workhardening stagnation, the non-isotropic-hardening (non-IH) of the
bounding surface at a certain range of reverse deformation is assumed. Let us define the
non-IH surface g , in the deviatoric stress space, as schematically illustrated in Figures
3(a) and (b), as
g ( , q, r )
3
q : q r 2 0 ,
2
(10)
where q and r denote the center and the radius of the non-IH surface, respectively. We
assume that the center of the bounding surface, , exists either on or inside of the

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surface g . The isotropic hardening of the bounding surface takes place only when the
center point of the bounding surface, , stays on the surface g
(see Figure 3(b)),
namely
R 0 when g , q, r 0 and
g , q, r
: 0 ,

R 0, otherwise.
(13a)
(13b)
Figure 3. Schematic illustration of non-IH surface defined in stress space,

when (a) non-IH; and (b) IH takes place.
From some experimental data of stress-strain curves under a large-strain reverse

deformation, it is found that the plastic strain region of workhardening stagnation
increases with the accumulated plastic strain. Such a phenomenon is expressed by the
expansion of the surface g with increasing plastic strain. Here, we assume the
kinematic motion of the surface g such that the center of g moves in the direction of
q , as
q q

(14)
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From the consistency condition that the center point of the bounding surface, , should
be either on or inside of g , we have
3 q : r
.
2r 2
r
(15)
Here, we assume the following evolution equation for r :

r h ,
3 q :
2r
when R 0 ,
(16a)
r 0 when R 0 ,
(16b)
where h ( 0 h 1 ) is a material parameter that determines the rate of expansion of

surface g Then , Eq. (15) is rewritten by the equation:
1 h
(17)
The larger value of h gives a rapid expansion of the non-IH surface, and as a result, it
leads to the prediction of smaller cyclic hardening. Since the non-IH (workhardening
stagnation) appears during reverse deformation after pre-strain, the initial value of r ro
may be assumed to be very small.
The elastic-plastic constitutive equation is expressed by the following equation:
o
C
C:
2
H kin
3
f
f
:C

f
f
f
:C :
:D
(18a)
where C denote the elastic modulus tensor, and

Ca mbsat
f
a
H kin
C * m :
Y
*
(18b)
In the present model, the size of yield surface is kept constant. However, if we carefully
observe the stress-strain response during unloading after plastic deformation, we can
find out that the stress-strain curve is no longer linear but slightly curved due to very
early re-yielding and the Bauschinger effect. In order to describe this, the following
equation of plastic-strain dependent Youngs modulus [2] is assumed
E Eo ( Eo Ea ) 1 exp( ) ,
(19)
where Eo and Ea stand for Youngs modulus for virgin and infinitely large prestrained
materials, respectively, and is a material constant.
As an example, the comparison of cyclic stress-strain responses under a cyclic
deformation between the calculated and experimental results on a high strength steel

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sheet (SPFC590) is illustrated in Figure 4. The present model can describe the realistic
stress-strain response of the Bauschinger effect. Owing to the non-IH surface modeling,
the strain-range and mean-strain dependencies of cyclic hardening characteristics are
well reproduced.
Figure 4. Cyclic stress-strain responses, on high strength steel sheet of SPFC590,

calculated by Yoshida-Uemori model, together with the experimental data [1].
Some of steel sheets have clear yield plateau in their stress-strain curves. If we assume a
certain size of non-IH surface ro initially, the present model simulates the stress-strain
curve with yield plateau (see Figure 5).

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Figure 5. Cyclic stress-strain responses, on mild steel sheet, calculated by Yoshida-Uemori

model, together with the experimental data.
Special emphasize is placed on the description of the yield plateau [1].

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Material Parameters in PAM STAMP 2G
E= E0
Xsati = B - Y
(mostly 0.1Y Xsati 0.5Y )
Bsat = bsat
(mostly 0.1Y Bsat 0.5Y )
Rsatx = Rsat
Cx1 = C1
(200 Cx1 2000)
Cx2 = C2
(100 Cx2 800)
EpRef = refp
(default value = 0.005)
Hnih = h
(0 Hnih 1.0, mostly Hnih 0.5)
Rnih0 = r0
(default value r0 = 0.01 MPa)
AM = m
(2 AM 30)
Xi
Younga = Ea
References
[1] Yoshida, F. and Uemori, T.: Int. J. Plasticity, 18, 2002, 661-686.
[2] Yoshida, F., Uemori, T. and Fujiwara, K.: Int. J. Plasticity, 18, 2002, 633-660.
[3] Yoshida, F. and Uemori, T.: Int. J. Mechanical Sciences, 45, 2003, 1687-1702.

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Use
Yoshida-Uemori law can be used for:

-
Hill 48 law.
Hill 90 law.
Barlat 89 law.
Barlat 91 law.
Corus-Vegter law.
Strain rate model

It is only available in AUTOSTAMP.
In some materials the rate of deformation affects the yielding behavior. The values SRC
and EP0 define the viscoplasticity (when it is active). The viscoplasticity modifies the
hardening curve as a function of the plastic strain velocity:
y ( p , p ) h( p ) g( p )
h: usual hardening curve definition (Hollomon, Krupkowsky, Power, ).

g: laws depending on the velocity of deformation (Cowper Symonds, Johnson-Cook
).
p : plastic strain rate.
This phenomenon is represented in the program by means of different laws:

-
Johnson-Cooks law:
1

n = y 1 + ln max ,1
p
D
D, p: material constants.
-
Modified Jones' law:

1
A
+ B
u - y
n = y 1
Du - y + D y u -
y, u, A, B: material constants.
Dy, Du: time constants having the unit of time-1.

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Cowper-Symonds' law:
1
n = y 1 +
D, p: material constants.
-
Left Shifted Laws:
0ref
ref
(, ) (, ref )
0ref
n ref
0ref , nref, b: material constants.
ref : reference strain rate.

-
Modified Krupkowsky's law :
(, ) k ref a 0ref b
where
n ref c
ref
0ref , nref, a, b, c: material constants.
ref : reference strain rate.

Warning:
It is necessary to define the velocity scale factor since strain rate is a variable
rate. Velocity scale factor is set it in CPU control attribute under Global object.
Example: If the punch velocity is multiplied by ten in the simulation model with
respect to reality, then Velocity scale factor = 0.1

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Multi-curve strain rate

In case of multiple strain rate:
hi+1
y ( p , p ) 1 h i ( p ) h i 1 ( p )
for ip p ip1
h
hi
where:
hi is the hardening curve of ip
hi+1 is the hardening curve of ip1
p ip
i 1
p
or
i
p
, linear interpolation
Log p Log ip
Log ip1 Log ip
, log interpolation.
Remark:
For all materials, except MATFEM, Multiple strain rate curves are defined by
using the Lookup table (see below).
Note:
All of the curves must have their points at the same abscissa value, interpolation
is only done for ordinate values
Use
It can be used for:

-
Hill 48 law.
Matfem Hill 48 law.
Hill 90 law.
Matfem Hill 90 law.
Barlat 89 law.
Barlat 91 law.
Corus-Vegter law.

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Strain rate and thermal dependant Hardening: Look up table

It is only available in AUTOSTAMP.
The Look-up table is an extension of the old multi-curve option to a multidimensional
abscissa axis. Actually, three abscissa axis are supported: P, p , T .
Strain-rate dependent hardening can be defined from users measurement points in the
look-up table format.
Some materials display a strong influence of their ductility according to the forming
temperature. This behavior is exploited in processes of Hot Forming typically for
Boron Steels, and Warm Forming typically for Aluminum. The material hardening
curve can be defined as temperature-dependent using the look-up table option.
It is possible to combine both dependencies to strain rate and temperature in the Lookup
table definition.
The user must define first the abscissa values of the plastic strain P (first argument),
then the abscissa values of strain rate p (second argument) and finally the abscissa
values of temperature T (third argument). He defines then for each set of values (P, p ,
T ), the value of hardening curve.
Several types of interpolation between points, and extrapolation before the lower
abscissa value and after the upper abscissa value are proposed:
-
Linear
Logarithmic
Exponential
closest value (for interpolation only)
horizontal (for extrapolation only)

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Warning:
It is necessary to define the velocity scale factor since heat equations depend on
heat flux. Velocity scale factor is set it in CPU control attribute under Global object.
Use
It can be used for:

-
Hill 48 law.
Hill 90 law.
Barlat 89 law.
Barlat 91 law
Corus-Vegter law.

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THERMAL MATERIAL OPTION

Thermal Material for Blank
Some materials display a strong influence of their ductility according to the forming
temperature. This behavior is exploited in the processes of Hot Forming typically for
Boron Steels and Warm Forming typically for Aluminum. Thermal influence on
materials can be considered (in PAM-AUTOSTAMP only). This will require the user to
specify a number of additional parameters in order to describe the temperature influence
and metallurgy.
Strain rate and temperature Dependent Hardening

It is possible to define temperature dependent hardening by using the Lookup table. The
user must define first the abscissa values of the plastic strain P (first argument), and the
abscissa values of temperature T (second argument). He defines then for each set of
values (P, T), the value of hardening curve.

Thermal Material Option
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These hardening curves will describe the hardening at temperatures that cover the range
likely to be encountered during the simulation, this does not necessarily mean that the
starting temperature is the maximum, as thermal increase caused by plastification /
internal energy can also be accounted for. The material model will interpolate for values
in between two points. However it is important to have sufficient temperature argument
values, as (particularly for Hot Forming of steels) phase changes inside materials results
in this being a very strongly nonlinear effect. For further information see Material
hardening curve chapter.
It is also possible to combine both dependencies to strain rate and temperature, by using
theLookup table. The user must first define the abscissa values of the plastic strain P
(first argument), then the abscissa values of strain rate p (second argument) and finally
the abscissa values of temperature T (third argument). He then defines for each set of
values (P , p , T), the value of hardening curve.
Warning:
It is necessary to define the velocity scale factor since heat equations depend on
heat flux. Velocity scale factor is set it in CPU control attribute under Global
object.
Thermal parameters
Thermal hardening is only part of the data required to capture the effects of temperature
within the material model. Additionally the user needs to supply data to describe the
temperature dependent material properties and metallurgy effect.
Material dialog is split into three pages:
-
Mechanics. See Material properties chapter for details.
Thermal
Metallurgy. See Metallurgical material option chapter for details.
In the Thermal page, some optional parameters, independent on phase fractions, can be
defined:
Dissipation factor:
This is the dissipation factor which describes the percentage of

internal work which will be converted to temperature (no units). The default value is
0.9.

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Youngs modulus can be temperature dependent
E(T):
Nu(T):
Expansion: during heating of blank, blank expansion phenomenon occurs. On contrary,

during cooling of blank, shrinking phenomenon can occur . This can be simulated within
Poissons coefficient can be temperature dependent
PamStamp by defining one of the options described below.
Thermal expansion may be characterized by:

-
Dilatation coefficient:
It is the mean dilatation coefficient between Tref and
current T values, function of temperature (T , Tref )

-
Thermal strain:
it is the thermal strain function of temperature th (T , Tref )
is the initial temperature in a physical

expansion test leading to the measured strain curve th (T,Tref)
Temperature reference: Tref
(T , Tref ) is the slope of the secant line between Tref and T ( points A and B) on
the curve th (T , Tref ) . It is also the mean dilatation coefficient between Tref and
T values, indeed:
(T )
d th
dT
th (T , Tref )
Tref

(T ) dT
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Therefore:
(T , Tref )
1
T Tref
T
Tref
(T ) dT
Consider a material submitted to a temperature rise T-T0 then thermal expansion

can be expressed as:
th ( T 0 T )
T
T0
Tref
T0
(T ) dT
dT
T
Tref
dT
( T 0, Tref ) . (T 0 Tref ) ( T , Tref ) . (T Tref )
or
th (T 0, Tref ) th ( T ,Tref )
depending on the characterization way.
Some other thermal parameters which are mandatory and dependent on phase fractions
must be set:
If metallurgy is activated, then the four

pages corresponding to each phase
fractions (for STEEL) will be filled.
If metallurgy is not activated, then only

the All phases page will be filled.
Thermal density (T): is the density of the material, can be defined by a constant or a
function of temperature (curve)
Conductivity (T):
Enthalpy H(T):
Specific heat Cp(T):
is the thermal conductivity of the material, can be defined by a

constant or a function of temperature (curve)
Enthalpy as a function of temperature. A different function for each
phase allows simulating the latent heat during phase change.
Specific heat as function of temperature
In this case, the enthalpy curve is determined by solver from specific heat as follow:
H (T ) Href Cp(T ).dT

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Href is the Enthalpy Reference; constant to be defined for each phase. A different
value for each phase allows simulating the latent heat during phase change.
Notes:
The user must take care with units for thermal calculations.
Thermal behavior is not considered during implicit calculation stages (eg

Gravity) the initial temperature will be used and considered to be constant.
The mechanical data E, Rho and Nu available in Mechanics page are still
mandatory because used as default values.
Thermal Material for Tools

At validation stage, in order to be as much accurate as possible, it is recommended to
define an initial temperature on tools which will vary during the process. This can be
done by applying a thermal material for tools. This material attribute is to be defined in
allstages for each object tool.
This dialog gathers both the initial conditions of the tool and the thermal properties.
Thermal thickness
is the thickness through which we assume there is a gradient

of temperature. The default value is 6mm.
Initial temperature
is the temperature of the tool when starting the calculation;

after the temperature is updated by the solver from the heat exchange with blank
and free convection with inner tool (as shown here after).
Tool surface
Tool volume
Free convection
Some thermal properties have to be defined for these thermal tools. The material can be
loaded from the public material database by pushing the button Get from material
database or created directly in the dialog.

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Thermal density (T)
is the density of the material tool, can be constant or

temperature-dependent (curve)
Conductivity (T)
Planar conductivity factor
is the conductivity of the material tool, can be constant or

temperature-dependent (curve)
corresponds to the factor between the planar
conductivity and conductivity through thickness. The default value is 0.1 which
means that the conductivity through thickness is ten times higher than the
conductivity into the membrane.
Km = 0.1*Kt
Enthalpy H(T):
Enthalpy as a function of temperature.
Specific heat Cp(T):
Specific heat as function of temperature
In this case, the enthalpy curve is determined by the solver from specific heat as
follow:
H (T ) Href Cp(T ).dT
since no phase change is applied on tools,

reference enthalpy is optional and will be used, if defined, only for enthalpy output
contour.
Href is the Enthalpy Reference;
The material file format for tools is the same as the material file format for blank.

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Notes :
A tool material created inside the project cannot be uploaded into the database.
If material definition is the same for all the thermal tools, then it is better to use
the copy/paste action.
Use
It can be used for:
-
Hill 48 law.
Hill 90 law.
Vegter law
Barlat 89 law
Barlat 91 law
It is only available in AUTOSTAMP with Accurate contact.

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METALLURGICAL MATERIAL OPTION

The metallurgical structure of a steel evolves according to the thermal path followed
locally in a part (phase change phenomena). In turn, this evolution has an impact on
temperature (thermal properties depend on metallurgical structure). This paragraph
describes a thermo-metallurgical model, which makes it possible to integrate this
interaction between steel structure and thermal path.
Computation module was developed for calculation of metallurgical transformations at
GAUSS points using the temperature and the metallurgical transformation properties.
The heat conduction equation takes into account the transformation latent heat. The
thermal properties can be defined in input as temperature and phases dependent. They
are then weighted according to the latter.
The metallurgical transformation properties can be defined with Johnson-Mehl-Avrami
model or Koistinen-Marburger law.
Metallurgical Transformations
In metallurgical terms, a material is defined by proportions Pi of the various phases (in
PS2G 4 phases are taken into account: ferritic, bainitic, martensitic and austenitic).
Modes for describing metallurgical history, in other words to compute changes in the Pi
proportions, is generalized to include Johnson-Mehl-Avrami type transformation
kinetics. This approach requires determination from a Continuous Cooling
Transformation (CCT) diagram, or dilatometric test used to create the latter. However,
in the case of the Johnson-Mehl-Avrami law, which gives phase proportion according to
time at constant temperature, direct determination of the parameters can be achieved by
using an Isothermal Transformation diagram.
CCT diagram of 22MnB5

MetallurgIcal Material Option
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A distinction is generally made with steels, between martensitic type and diffusion type
phase transformations. The thermal paths are neither isothermal nor have they a
constant cooling rate. This is why differential formulation is frequently used for phase
transformation kinetic.
Diffusion Type Transformations (Johnson-Mehl-Avrami

Kinetic Law)
In case of a diffusion type transformation, which occurs by nucleation and growth of a
new phase inside the previous phase, a number of formulations are possible. The most
frequently used is that developed by Johnson, Mehl and Avrami, for isothermal kinetics.
The equation is generally written as follows:
dP P P
dt
TR
P: metallurgical phase proportion,

t: time,
P : interpreted as the equilibrium value,
TR: equivalent to a time delay. If is varied in time, the above equation
describes the fact that P follows P after time delay TR.
In practice, a number of transformations can occur in the material. This signifies that the
transformation rate for phase i depends on the other metallurgical phases:
dP
Aij ( j 1,2,...., n)
dt
j i
where Aij represents the quantity of phase i transformed to phase j per time unit. The
expression of term Aij is assumed to be independent of phases k (ki and k j), and is
given by the equation:
Aij ( K i j .Pi ) ( K 'i j .Pj )
where Ki->j and K'i->j are constants of reaction i->j, which can depend on and
under:
K i j K ( ).F ()
K i j K ( ).F ()
Two variables Peq( ) and Tau( ) can also be used, which identify with a proportion
at equilibrium and time delay, both independent from rate, such that:

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1 Peq
Peq
Peq.F
and TR
Peq.F (1 Peq ) F
Peq.F (1 Peq ) F
and
so that:
Knowledge of functions Peq( ), ( ), F( ) and F'( ) is therefore required for

characterization of a metallurgical transformation. The user can apply these functions
directly, or functions:
K ( )
Peq ( )
( )
; K ( )
1 Peq ( )
( )
; F( ) and F( )
In practice, an adjustment, involving comparison of the results of the CCT diagram (for
example) with the predictions provided by the model, is required to obtain Peq( ),
( ), F( ) and F'( ).
The martensitic transformation is an instantaneous transformation. It is treated in
priority compared to the others transformations. If we need to treat it at the same level
as the others, the parameters K, K and f( ) must be used.
The model described above has been generalized to reproduce Johnson-Mehl-Avrami
type kinetics, to give current proportion Pi of phase i according to time, for a given
temperature :
Pi ( , t ) P.(1 e
t n
)
TR
When the temperature varies, we consider the Pi derivative with respect to time at
constant temperature, with temperature-dependant transformation parameters Peq, and
n:
dPi
P P
P
n.(
).(ln(
)) ( n1) / n
dt
TR
P Pi
Where
P proportion obtained after an infinite time,
TR delay time associated with the reaction,
n()
It should be noted that when n = 1 , the last equation is generally identical with the
equation mentioned above.

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P(t)
time log
Diffusion controlled transformation - fraction proportion during time
Martensitic Transformations (Koistinen-Marburger Kinetics

Law)
In the case of a martensitic type transformation, formed phase proportion p depends
only on current temperature in the form:
p( ) P 1 e b( M s )
for M s
where P is the proportion obtained at an infinitely low temperature, frequently

assimilated to 1. Parameters Ms and b characterize transformation start temperature and
transformation rate respectively. They are generally relatively well-defined
experimentally (dilatometric curve records and residual austenite measurements). KMequation reflects actual transformation kinetics accurately. However, in a case where
other transformations have already occurred, parameter Ms can vary sharply, as it
depends in particular on the carbon content of the austenite which is transformed
(austenite stabilization phenomenon).
P(T)
temperature
Diffusionless transformation temperature dep. fraction proportion
Differential formulation of KM-equation is obtained if we assume that P and b are

temperature-independent. We have:

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p( , t )
b ( P p ) __ for _ M s
0 __________for _ M s
The temperature-dependence of P and b can now be introduced bearing in mind that

conformity with KM-equation can only be maintained if P and b are constant.
Utilisation of metallurgy in PS2G

PS2G GUI provides simple interface for definition of transformation parameters for
both reaction types listed above. Parameter can be defined as constant or curves in this
case curves in the curve editor are linked to object with material. Heating and Cooling
processes can be considered.
Transformation parameter definition for reactions of diffusion type (JMA - left) and
martensitic reaction (KM - right).
The thermal properties can be defined in input as temperature and phases dependent.
Currently phase fraction does not have influence on mechanical properties.
Table: Units of parameters used in phase transformation models
Ms
Temperature
Temperature-1
Peq
None
Time
F, F
None
K, K
None
None

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Hardness determination
It can be more useful for the user to know the hardness at a point rather than the
proportions of the various phases. A module for analysis has been developed and can be
used to determine the hardnesses from the chemical composition of the materials on one
hand and the results of the thermal and metallurgical calculations on the other, in
conformity with the empiric formulas drawn up by metallurgists.
Knowledge of the thermal and metallurgical history of a part enables to predict its
hardness at all points of the heat-affected area depending on:
The chemical composition of the material.
The structure at the end of the thermal cycle for quenched and
tempered structures.
The cooling cycle to which the part was subjected (cooling rate).
The grain size.
An experimental forecast of the hardness of carbon and low-alloy steels, according to
their structure, chemical composition and heat treatments was performed in 1975 by
Blondeau, Maynier, Dollet and Veieillard-Baron for the three as-quenched phases
martensite, bainite and ferrite. In 1982, Leslie has proposed formulas for the case of
steels containing more than 0.5% of carbon. In the studies the parameter grain size was
not involved.
Hardness at a point is actually determined starting from the hardness of various
structures (martensite, bainite, ferrite, austenite). Knowing the elementary hardness of
the phases and their proportions, hardness of the material point will be calculated
considering the addition rule. Structure and cooling rate will be provided by the
numerical tool and the chemical composition must be known.
From these studies an automatic analysis code to determine the hardness has been built
in Sysweld and adopted in Pamstamp. The implemented TTT-CCT model provides an
estimation of the hardness of a steel as a function of
chemical composition of the material,
cooling rate VR at 400C (C /h) and
phase proportions.
It takes into account as-quenched structures as well as the effect of tempering, while
neglecting the grain size. The model is based on Maynier's formulae and an empirical
equation for the tempering kinetics.
As-quenched elementary hardness

The following equations have been implemented to calculate the hardness of
martensitic, bainitic and ferritic structures in the as-quenched state:
Martensitic structure
The Vickers hardness of martensite is given by:

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Hvmartensite = 127 + 949 C + 27 Si + 11 Mn + 8 Ni + 16 Cr + 21 Log10 Vr

Hvmartensite = 150 + 166 C + 926 C2
for C<0.5%
for C>0.5%
where C, Si, Mn, Ni, Cr, Mo, V are concentraitions of a solute element in % and Vr is
the cooling rate (by default at 400oC) in [K/hour]. We can note the preponderant
influence of C in the hardness of martensite.
Bainitic structure
The Vickers hardness of bainite is given by:
Hvbainite = - 323 + 185 C + 330 Si + 153 Mn + 65 Ni + 144 Cr + 191 Mo + (89 + 53 C 55 Si - 22 Mn - 10 Ni - 20 Cr - 33 Mo) log10 VR
A warning is produced if C > 0.5%, because no bainite is expected in that case.
Ferritic structure
The Vickers hardness of ferrite (pearlite included) is given by:
Hvferrite = 62 + 223 C + 53 Si + 30 Mn + 12.6 Ni + 7 Cr + 1 Mo + (10 - 19 Si + 4 Ni + 8
Cr + 130 V) log10 VR
for C<0.5%
Hvferrite = 150
for C>0.5%
Austenitic structure
The Vickers hardness of Austenite is given by:
Hvaustenite = 100
Drawn up from the results obtained by a series of tests, the formulae give a dispersion
for a standard deviation of about 10 Vickers.
The formulae delivers valid results for as quenched structures within the following
chemical composition ranges:
0.1 < C < 0.5
Si < 1 %
Mn < 2 %
Ni 4 %
Cr 3 %
Mo 1 %
V < 0.2
Cu < 0.5 %
0.01 % < Al < 0.05 %
Tempering hardness
The tempering kinetics of martensite, bainite and ferrite is calculated with the following
empirical expression:

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t n
HV (t,T ) HV HVAsQ HV exp
,
(T )
where HVAsQ is the as-quenched hardness calculated as described above, n=0.2 is an

exponent, and (T ) 0 exp H / RT ( H 418000 J/mol , 0 2.0 10-21s ) is a tempering
characteristic time.
HV is the fully tempered hardness, which is calculated with the following expression:
HV 62 223wC 15wSi 30wMn 21wNi 23wCr 19 wMo 260 wV ;
Since the temperature is not necessarily constant, the calculation is made by numerical
integration of the tempering rate:
HVAsQ HV
dHV (t )
n
HVAsQ HV Ln
dt
(T (t ))
HV (t ) HV
n 1
n
A Runge-Kutta integration method is used if the time-step is large.

Equations for computation of tempering kinetics were modified in order to reach a
tendency to the as-quenched value for a vanishing tempering time and to the fully
tempered value for a tempering time tending to infinity.
Input parameters and setup

The chemical composition for hardness computation will be stored in the material card.
Content of carbon, silicon, manganese, nickel, chromium, molybdenum and vanadium
is mandatory and has to be set in dialog Metallurgy of Material definition (in the
standard material database average values for hotforming material 22MnB5 will be
used).
In real process, cooling rate VR changes during quenching. To enable computation of
hardness, a representative constant value has to be set in the equations above; which is,
in hotforming processes with boron steels, the cooling rate at the beginning of
martensitic transformation. By default cooling rate at 400 oC will be taken into account,
but the temperature can be set in Advanced parameters by changing the parameter Cross
temperature for cooling rate output.

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Metallurgy dialog in the material card with chemical composition input
The user can set initial elementary hardness values. This can be done in the attribute
Values initialisation by defining the Vickers hardness for each phase: austenite,
martensite, bainite and ferrite.
Initialization of elementary hardness values

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Output definition
Knowledge of the thermal and metallurgical history allows to predict hardness in the
heat-altered zone. Starting from initial values, the program calculates elementary
hardnesses of present phases for each element. Final average hardness value will be
computed in an incremental manner according to phase proportions and elementary
hardness reached during the thermal proces.
Resulting scalar contour represents the average hardness on element. Elements without
active metallurgy get Not Valid Value. For elements with activated metallurgy but
without chemical composition, the hardness contour delivers Not Valid Value.
Solver uses initial hardness values picked from previous stages or in first stage, when
no picking is available, hardness values for each element will be calculated from phases
portions and initial elementary hardness defined in input using the equations above. If
no initial hardness is defined, hardness contour returns Not Valid Value until cooling
rate value VR becomes valid.
In results contour dialog of Metallurgy, the user can display average hardness contour on
blank. If element history was stored for blank elements during the thermal process,
hardness progress on such elements can be displayed in the diagram.
Average hardness values distribution after quenching process

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Average hardness on element in dependency of temperature during

quenching process

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EWK RUPTURE MODEL

Model description
The EWK model of ductile fracture correctly predicts fracture initiation and
propagation. Fracture occurs in the model when the time-integrated product between the
equivalent of the plastic-strain rate and two functions (one of the mean tensile stress
and the other of the asymmetric stress distribution) exceeds a critical value over a
critical dimension.
This cumulative-strain-damage model assumes that fracture is the result history of strain
damage to the material. It is well known that ductility increases when hydrostatic
tension decreases. This behavior can be interpreted in terms of hole growth by using the
theoretical models of Mc Clintock and Rice and Tracey. Their models suggest a rapidly
increasing ductility with decreasing hydrostatic tension. This result is simply built into
the EWK fracture model by the hydrostatic tension term (mean tensile stress) which
accounts for the growth of holes during loadings that consist of large triaxial stress and
small strain. The asymmetric strain term accounts for the observation that, after
initiation, the holes can link up as a band if subsequent loading is shear.
Because the spacing and size of the inclusions control the cracking, it is not enough for
this critical value to be reached at a single point; it must occur over some length rc that is
characteristic of the microstructure of the material.
A fundamental assumption behind the EWK model is that the initiation or the extension
of a crack can be treated as a constitutive property of materials. Fracture will then
depend explicitly on the current mechanical state and past history of a local region, and
will be independent of geometry and boundary conditions except as they affect the local
state. Thus crack extension and crack initiation are treated alike.
The EWK model is based on the fracture model suggested by Wilkins (see References)
which in turn is based on the ductile-fracture theory of Prof McClintock. The EWK
model contains material-dependent parameters that are linked semi-empirically to other
physical properties and they are adjusted by trial and error until a single set of values is
obtained that fit experimental fracture initiations in several different small size
specimen geometries.

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EWK damage function

The EWK rupture model uses a damage function DEWK which, when exceeding a critical
value Dc over a critical material volume Rc, leads to discontinuous macro crack creation
and stepwise growth.
The cumulative strain damage function of the model is as below:
DEWK W 1.W 2. p
Where W1 is the hydrostatic pressure weight
1
W1
p
1
Plim
And W2 is the asymmetric strain weight
S S
W 2 (2 Max 2 , 2 )
S3 S1
S p
S1 S2 S3
Fracture starts when
eigen .values
DP > DC over a distance r > rC

It can be shown theoretically that the coefficient Plim is linked to the plastic flow
around the crack tip and the exponents and are linked to the plastic instability of the
material. It can be shown that Plim, and are interrelated through Dc, hence it is not
recommended to attempt to adjust each parameter individually in order to fit them to a
particular material.

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Damage attribute
The rupture criterion can be activated from the Damage attribute.
Dc : Reference damage. Damage starts when Dp>Dc
Unit: No
Usual value: 1
Rc : Reference damage distance. Damage starts when Dp>Dc over a distance R>Rc.
Unit: Length
Usual value: 0,15 mm for Aluminum and 0.05 mm for HSS
Plim: hydrostatic pressure limit
, : exponents
Unit: Stress
Unit: No
En: Necking plastic strain
Unit=No
Note :
During the implicit stages (gravity or springback), the EWK damage factor is
taken into account in implicit internal forces calculation (it is picked from
previous stages), but it remains constant.

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Example
Here is an example of damage parameters for a Steel DP 450:
Forming limit curve:
Dc = 1.0
True [MPa]
Rc = 0.04 mm
325
Plim = 780 MPa
0.025
400
Alpha = 0.18
0.045
450
Beta = 0
0.08
500
0.235
620
0.92
800
600
Damage Contour and history curve

If Damage attribute has been used in the
definition of the material and EWK damage
selected in Contour settings of Control attribute, a
EWK damage contour is available in postprocessing. It displays the damage as a parameter
between 0 (no rupture DEWK < Dc) and 1, based
on the DEWK value.

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If rupture criterion has been used in the definition

of the material, EWK damage has been selected
in Contour settings of Control attribute and
element history have been stored with PostAnalyze attribute, a EWK damage history curve is
available in post-processing for these elements. It
displays, for the selected element, the evolution
during the simulation of the same results as the
contour.

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Mapping
The Isotropic damage parameter is
included in the mapping file if they are
asked in the Mapping export or Mapping
import attributes.

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Element elimination
The EWK damage criterion can be used to
eliminate during the simulation the
elements having rupture. Element
elimination attribute must be defined on
the blank with a limit to the Damage
parameter (between 0 and 1, see damage
contour paragraph).
See Solver analysis tools chapter for more
information about element elimination.
References
[1] Computer Simulation of Dynamic Phenomena Mark L. Wilkins, Springer
publication.

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MATERIAL FILE FORMAT (.PSM)

The material files are ASCII format files, which can be edited manually if required. The
structure of such file is:
a one line header identifying the file type and version
an optional block for definition of lookup tables
the main block containing the material parameters
The following pages describe the file format of v2012.0 in detail:
An example of .psm file content

1.
PAM-COMMON
V1.8.A
ASCII PS-MATERIAL
2.
3.
DEF_MATERIAL
4.
REFERENCE = example
5.
ORIGIN = ESI-GROUP
6.
CREATION_DATE = 'Tuesday 11 January 2011'
7.
CREATED_BY = 'ESI GROUP'
8.
LAST_MODIFICATION_DATE = 'Wednesday 18 July 2012'
9.
MODIFIER_NAME = 'xyz'
10.
UNIT_SYSTEM = MM.KG.MS.C
11.
COMMENTS = ' '
12.
NAME = 'Box'
13.
TYPE = STANDARD_STEEL
14.
LAW = HILL_48
15.
HARDENING = ISOTROPIC
16.
ANISOTROPIC_TYPE = NORMAL
17.
E = 210
18.
NU = 0.3
19.
RO = 7.8e-006
20.
R0 = 1.7
21.
ACTIVE_THERMAL = NO
22.
ACTIVE_METALLURGY = NO
23.
HARDENING_CURVE = 'Box Hardening curve'
24.
TYPE = POINTS_LIST
25.
EPSILON_SIGMA = 0 0.162
26.
EPSILON_SIGMA = 0.048719 0.269015
27.
EPSILON_SIGMA = 0.0985079 0.313331
28.
EPSILON_SIGMA = 0.148369 0.342565
29.
EPSILON_SIGMA = 0.198262 0.364947

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30.
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FORMING_LIMIT_CURVE = 'FLC DB Blank'
31.
TYPE = KEELER_LAW
32.
THK_IN_MM = 0.5
33.
N = 0.22
Material file header

This header is the first line of file and it is mandatory. It is composed of 5 fixed length
strings:
[Software][Context][File version][File encoding][File type]
Example: PAM-COMMON
V1.8.A
ASCII PS-MATERIAL
[Software]: 12 character string defining the application the file is reserved to. It is
always PAM-COMMON for material files, which means they can be imported into any
application supporting this material file format.
[Context]: 4 character string defining the application context the file is reserved to. It is
always blank for material files, which means they can be imported for any selected
context in the application.
[File version]: 20 character string defining the file version, which makes backward
compatibility possible. V1.8.A is supported by Pam-Stamp 2G v2012.0, V1.7.A by
Pam-Stamp 2G v2011.0 and V1.7.B by v2011.1.1 resp., V1.6.A by Pam-Stamp 2G
v2009.0 and above, V1.5.A by Pam-Stamp 2G v2008.0 and above and so on
[File encoding]: 8 character string defining the file encoding type. It is always ASCII
for material files.
[File type]: 16 character string defining the file contents type. It is always PSMATERIAL for material files, which is the .psm file format documented here.
Material block format (DEF_MATERIAL)

This block is composed of several sections in any order. These block sections are:
Header: material history, file references, author
General parameters: material type and law, general mechanical parameters
Parameters for selected material law
Hardening parameters
Forming limit and thermal curves
Failure criterion options
Strain rate model options
Thermal and metallurgy parameters

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Rules for parameters:
If a parameter does not appear in the file, it is not set for the material (useful for
optional parameters)
Each parameter that needs a value must be followed by = and the value.
For parameters that need several values, the values must be set after the = and
separated by a space.
Empty lines are not necessary!
The order of parameters does not matter.
Only one parameter per line is accepted!
Header
Keyword
Type
REFERENCE
String
ORIGIN
String
CREATION_DATE
String
CREATED_BY
String
LAST_MODIFICATION_DATE
String
MODIFIER_NAME
String
COMMENTS
String
FILE_NAME
String
NAME
String
Notes

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General parameters
Keyword
Type
Notes
TYPE
Keyword
Possible values:
STANDARD_STEEL
SPECIAL_STEEL_OR_ALUMINIUM
SUPER_PLASTIC
RUBBER
USER-DEFINED
MULTIPLIES
LAW
Keyword
Possible values:
STANDARD_STEEL
HILL_48
SPECIAL_STEEL_OR_ALUMINIUM
HILL48
HILL_90
BARLAT_89
BARLAT_91
BARLAT_2000
CORUS-VEGTER_YIELD_LOCUS
SUPER_PLASTIC
NON-LINEAR_VISCOELASTIC
RUBBER
MOONEY-RIVLIN
USER-DEFINED
MATERIAL_184
MULTIPLIES
HILL48
HILL_90
MOONEY-RIVLIN
UNIT_SYSTEM
Keyword
Possible values:
MM.KG.MS.C
M.KG.S.C
CM.G.S.C
CM.100KG.S.C
MM.T.S.C
MM.DAT.S.C
CM.G.MICROS.C
MM.G.MS.C
MM.KG.MS.K
M.KG.S.K
CM.G.S.K
CM.100KG.S.K
MM.T.S.K
MM.DAT.S.K
CM.G.MICROS.K
MM.G.MS.K
Real
Except for MATERIAL_184
NU
Real
Except for MATERIAL_184
RO
Real

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Hill 48 law
Keyword
KC
Type
Real
ANISOTROPIC_TYPE
Keyword
Notes
Optional
Possible values:
ISOTROPIC
NORMAL
ORTHOTROPIC
R0
Real
Only if ORTHOTROPIC/NORMAL
R45
Real
Only if ORTHOTROPIC
R90
Real
Only if ORTHOTROPIC
NON-ASSOCIATED_PLASTICITY_TYPE
Keyword
Optional
Only if ORTHOTROPIC
Possible values:
EXPERIMENTAL
GENERAL
NON-ASSOCIATED_PLASTICITY_RE0
Real
Only if EXPERIMENTAL
Real
Real
NON-ASSOCIATED_PLASTICITY_F
Real
Only if GENERAL
NON-ASSOCIATED_PLASTICITY_G
Real
Only if GENERAL
NON-ASSOCIATED_PLASTICITY_N
Real
Only if GENERAL
Hill 90 law
Keyword
Type
ALPHA
Real
BETA
Real
GAMMA
Real
Real
Notes
Barlat 89 law
Keyword
Type
Real
Real
Real
Real
Real
Notes
Optional

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Barlat 91 law
Keyword
Type
Real
Real
Real
Real
Real
Real
Real
Notes
Barlat 2000 law

Keyword
Type
Real
A1
Real
A2
Real
A3
Real
A4
Real
A5
Real
A6
Real
A7
Real
A7
Real
Notes
Mooney-Rivlin law
Keyword
Type
Notes
NU_FOR_LOADING
Real
LAW_COEFFICIENT_A_FOR_LOAD
Real
LAW_COEFFICIENT_B_FOR_LOAD
Real
NU_FOR_UNLOADING
Real
Optional
LAW_COEFFICIENT_A_FOR_UNLOAD
Real
Only if NU_FOR_UNLOADING is
set
LAW_COEFFICIENT_B_FOR_UNLOAD
Real
Only if NU_FOR_UNLOADING is
set
NUMBER_OF_CYCLES_BETWEEN_SEARCH_FOR_LOADI
NG/UNLOADING
Integer
NUMBER_OF_CYCLES_FOR_TRANSITION_BETWEEN_L
OADING/UNLOADING
Integer

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Non-linear viscoelastic law

Keyword
ANISOTROPIC_TYPE
Type
Keyword
Notes
Possible values:
ISOTROPIC
NORMAL
ORTHOTROPIC
R0
Real
Only if ORTHOTROPIC/NORMAL
R45
Real
Only if ORTHOTROPIC
R90
Real
Only if ORTHOTROPIC
FLOW/YIELD_STRESS_FUNCTION_DEFINED_MODE
Keyword
Possible values:
SIMPLIFIED
KRUPKOWSKY
LOOKUP_TABLE
USER_FUNCTION
STRAIN_RATE_HARDENING_COEFFICIENT
Real
Only if SIMPLIFIED/KRUPKOWSKY
STRAIN_RATE_HARDENING_EXPONENT
Real
Only if SIMPLIFIED/KRUPKOWSKY
EPS0
Real
Only if KRUPKOWSKY
Real
Only if KRUPKOWSKY
VISCO_LOOKUP_TABLE
String
Only if LOOKUP_TABLE
Reference to a lookup table
defined in DEF_LOOKUPTABLE
USER_VALUES
List of real
values
Only if USER_FUNCTION
TRANVERSE_SHEAR_CORRESTION_FACTOR
Real
STIFFNESS_PROPORTIONAL_DAMPING_RETION
Real
DAMPING_TARGET_FREQUENCY
Real
SPECIFIED_STRAIN_RATE
Real
Optional
RESPONSE_TIME_OF_LOW_PASS_FILTER
Real
Optional
ELEMENT_STRAIN_RATE_MEASURE
Keyword
Possible values:
MEAN_VALUE_OVER_THICKNESS
MAX_VALUE_OVER_THICKNESS
MIN_VALUE_OVER_THICKNESS
MEMBRANE_VALUE
Material 184 law (user-defined material)

Keyword
ANISOTROPIC_TYPE
USER-DEFINED_FLOAT_LIST
USER-DEFINED_INTEGER_LIST
Type
Keyword
Notes
Possible values:
ISOTROPIC
ORTHOTROPIC
List of real
values
List of
integer
values

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Corus-Vegter yield locus law

Keyword
Type
Notes
VEGTER_LIGHT_MODE
Boolean
Possible values:
YES
NO
VEGTER_LIGHT_INTERPOLATION
Keyword
Only if VEGTER_LIGHT_MODE=YES
Possible values:
USER_DEFINED
ALUMINIUM
STEEL
VEGTER_LIGHT_SHEAR_WEIGHT
Real
Only if USER_DEFINED
VEGTER_LIGHT_PLANE_WEIGHT
Real
Only if USER_DEFINED
VEGTER_UNIAXIAL_0
Real
VEGTER_UNIAXIAL_45
Real
VEGTER_UNIAXIAL_90
Real
VEGTER_PLANE_STRAIN_0
Real
Only if VEGTER_LIGHT_MODE=NO
Real
Real
VEGTER_R_0
Real
VEGTER_R_45
Real
VEGTER_R_90
Real
VEGTER_ALPHA_0
Real
VEGTER_ALPHA_45
Real
VEGTER_ALPHA_90
Real
VEGTER_PURE_SHEAR_0
Real
VEGTER_PURE_SHEAR_45
Real
VEGTER_PURE_SHEAR_90
Real
VEGTER_BIAXIAL
Real
VEGTER_R-BIAXIAL
Real

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Hardening by points list

Keyword
HARDENING_CURVE
Type
String
TYPE
EPSILON_SIGMA
Free curve name
Keyword
Must be POINTS_LIST
2D point
Example: 0.05 0.312
EPSILON_SIGMA
Notes
2D point
Hardening by Hollomon law

Keyword
HARDENING_CURVE
Type
String
TYPE
Keyword
Real
Real
RE
Real
STEP
Real
SIGMA_MAX
Real
Notes
Free curve name
Must be HOLLOMON_LAW
Hardening by Power law

Keyword
HARDENING_CURVE
Type
String
TYPE
Keyword
Real
Real
Real
SIGMA_MAX
Real
Notes
Free curve name
Must be POWER_LAW

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Hardening by Krupkowsky law

Keyword
Type
HARDENING_CURVE
String
TYPE
Keyword
Real
Real
SIGMA_MAX
Real
EPSILON0
Real
Notes
Free curve name
Must be KRUPKOWSKY_LAW
Hardening by Kinematic law

Keyword
HARDENING_CURVE
Type
String
TYPE
Keyword
SIGMA0
Real
CR
Real
RSAT
Real
SIGMA_MAX
Real
Notes
Free curve name
Must be KINEMATIC_LAW
Hardening by Kinematic law (Yoshida model)

Keyword
KINEMATIC_HARDENING_MODEL
Type
Keyword
X11
Real
X22
Real
X12
Real
XSATI
Real
BSAT
Real
RSATX
Real
AM
Real
CX1
Real
CX2
Real
EPREF
Real
HNIH
Real
RNIH0
Real
YOUNGA
Real
XI
Real

Notes
Must be YOSHIDA
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Hardening by Kinematic law (Chaboche model)

Keyword
Type
KINEMATIC_HARDENING_MODEL
Keyword
CX
Real
XSAT
Real
X11
Real
X22
Real
X12
Real
Notes
Must be CHABOCHE
Hardening by lookup table

Keyword
Type
Notes
STRAIN_RATE_HARDENING
String

TEMPERATURE_HARDENING
String

STRAIN_RATE_AND_TEMPERATURE_HARDENING
String

Forming Limit Curve(s) by points list

Keyword
FORMING_LIMIT_CURVE
TYPE
MIN_MAX
Type
String
Free curve name
Keyword
Must be POINTS_LIST
2D point
Example: 0.05 0.312
MIN_MAX
Notes
2D point
MIN_THICKNESS
Real
Optional
MAX_THICKNESS
Real
Optional

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Forming Limit Curve(s) by Keeler law

Keyword
Type
FORMING_LIMIT_CURVE
String
TYPE
Notes
Free curve name
Keyword
Must be KEELER_LAW
THK_IN_MM
Real
Example: 0.05 0.312
Real
MIN_THICKNESS
Real
Optional
MAX_THICKNESS
Real
Optional
Thermal curves(s) by points list

Keyword
Type
MATERIAL_CHARACTERIZATION_CURVE
String
TYPE
ABS_ORD
Free curve name
Keyword
Must be POINTS_LIST
2D point
Example: 0.05 0.312
ABS_ORD
Notes
2D point
Matfem options
(only for Hill48, Hill90 and Barlat91 laws)
Keyword
ACTIVE_MATFEM
Type
Boolean
EOS_FOR_FAILURE_CRITERIA
Real
NS_FOR_FAILURE_CRITERIA
Real
MS_FOR_FAILURE_CRITERIA
Real
EOD_FOR_FAILURE_CRITERIA
Real
ND_FOR_FAILURE_CRITERIA
Real
MD_FOR_FAILURE_CRITERIA
Real
ER_FOR_FAILURE_CRITERIA
Real
R0_FOR_FAILURE_CRITERIA
Real
Real
Real
KH1_FOR_FAILURE_CRITERIA
Real
Real

Notes
Must be YES
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Real
D_FOR_FAILURE_CRITERIA
Real
FLDS1_FOR_FAILURE_CRITERIA
Real
Real
Real
Real
FLDD1_FOR_FAILURE_CRITERIA
Real
Real
Real
Real
DFS1_FOR_FAILURE_CRITERIA
Real
Real
Real
DFD1_FOR_FAILURE_CRITERIA
Real
Real
Real
DFA1_FOR_FAILURE_CRITERIA
Real
DFA2_FOR_FAILURE_CRITERIA
Real
SFS1_FOR_FAILURE_CRITERIA
Real
Real
Real
SFD1_FOR_FAILURE_CRITERIA
Real
Real
Real
SFK_FOR_FAILURE_CRITERIA
Real
NFIL_FOR_FAILURE_CRITERIA
Integer
DEPS_FOR_FAILURE_CRITERIA
Real
Strain rate model options

Keyword
STRAIN_RATE
Type
Keyword
Notes
Possible values:
COWPER-SYMONDS
JOHNSON-COOK
MODIFIED_JONES
LEFT_SHIFTED_LAWS
MODIFIED_KRUPKOWSKY
STRAIN_RATE_D
Real
Only if COWPER-SYMONDS/
JOHNSON-COOK
STRAIN_RATE_P
Real
Only if COWPER-SYMONDS/
JOHNSON-COOK

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STRAIN_RATE_DY
Real
Only if MODIFIED_JONES
STRAIN_RATE_B_JONES
Real
STRAIN_RATE_DU
Real
STRAIN_RATE_A_JONES
Real
STRAIN_RATE_EPSILON
Real
Only if MODIFIED_KRUPKOWSKY/
LEFT_SHIFTED_LAWS
STRAIN_RATE_EPSILON_U
Real
STRAIN_RATE_EPSILON_Y
Real
STRAIN_RATE_NREF
Real
LEFT_SHIFTED_LAWS
STRAIN_RATE_EPSILON0
Real
LEFT_SHIFTED_LAWS
STRAIN_RATE_A
Real
Only if MODIFIED_KRUPKOWSKY
STRAIN_RATE_B
Real
LEFT_SHIFTED_LAWS
STRAIN_RATE_C
Real
Only if MODIFIED_KRUPKOWSKY
Thermal options without metallurgy

Keyword
ACTIVE_THERMAL
DISSIPATION_FACTOR
Type
Boolean
Notes
Must be YES
Real
THERMAL_E(T)
Real or
curve name
Optional
THERMAL_NU(T)
Real or
curve name
Optional
DEF_THERMAL_EXPANSION
EXPANSION_TYPE
CURVE
TEMPERATURE_REFERENCE
Optional
Keyword
Possible values:
DILATATION_COEFFICIENT
THERMAL_STRAIN
Real or
curve name
Real
DEF_AUSTENITE
DENSITY
Real or
curve name
CONDUCTIVITY
Real or
curve name
SPECIFIC_HEAT
Real or
curve name
ENTHALPY_REFERENCE
ENTHALPY

Real
Real or
curve name
Only if SPECIFIC_HEAT is set

Exclusive with SPECIFIC_HEAT/
ENTHALPY_REFERENCE
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Thermal options with metallurgy

Keyword
Type
Notes
ACTIVE_THERMAL
Boolean
Must be YES
ACTIVE_METALLURGY
Boolean
Must be YES
DISSIPATION_FACTOR
Real
THERMAL_E(T)
Real or
curve name
Optional
THERMAL_NU(T)
Real or
curve name
Optional
DEF_THERMAL_EXPANSION
TYPE
CURVE
TEMPERATURE_REFERENCE
Optional
Keyword
Possible values:
DILATATION_COEFFICIENT
THERMAL_STRAIN
Real or
curve name
Real
DEF_AUSTENITE
DENSITY
Real or
curve name
CONDUCTIVITY
Real or
curve name
SPECIFIC_HEAT
Real or
curve name
ENTHALPY_REFERENCE
ENTHALPY
Real
Real or
curve name

ENTHALPY_REFERENCE
DEF_FERRITE
DENSITY
Real or
curve name
CONDUCTIVITY
Real or
curve name
SPECIFIC_HEAT
Real or
curve name
ENTHALPY_REFERENCE
ENTHALPY
Real
Real or
curve name

ENTHALPY_REFERENCE
DEF_BAINITE
DENSITY
Real or
curve name
CONDUCTIVITY
Real or
curve name
SPECIFIC_HEAT
Real or
curve name

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ENTHALPY
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Real
Real or
curve name

ENTHALPY_REFERENCE
DEF_MARTENSITE
DENSITY
Real or
curve name
CONDUCTIVITY
Real or
curve name
SPECIFIC_HEAT
Real or
curve name
ENTHALPY_REFERENCE
ENTHALPY
REACTION
Real
Real or
curve name
String

ENTHALPY_REFERENCE
Free reaction label
Repeat block for each
reaction
PHASE_SOURCE
Keyword
Possible values:
AUSTENITE
FERRITE
BAINITE
MARTENSITE
PHASE_TARGET
Keyword
Possible values:
AUSTENITE
FERRITE
BAINITE
MARTENSITE
DIRECTION
Keyword
Possible values:
HEATING_+_COOLING
COOLING
HEATING
MODEL
Keyword
Possible values:
JOHNSON-MEHL-AVRAMI
KOISTINEN-MARBRUGER
DEFINITION_TYPE
Keyword
Only if JOHNSON-MEHL-AVRAMI
Possible values:
BY_EQUILIBRIUM_&_TIME_DELAY
BY_K_&_K'_PARAMETERS
PARAMETER_1
Real or
curve name
Is equilibrium value if
Is K value if
PARAMETER_2
Real or
curve name
Is time delay value if
Is K value if

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Real or
curve name
F'
Real or
curve name
Real or
curve name
TEMPERATURE_AT_START_OF_MARTENSIT
Real
Only if KOISTINEN-MARBRUGER
MARTENSITIC_LAW_COEFFICIENT
Real
Only if KOISTINEN-MARBRUGER
COMPOSITION_IN_CARBON
Real
Content in %
COMPOSITION_IN_SILICIUM
Real
Content in %
COMPOSITION_IN_MANGANESE
Real
Content in %
COMPOSITION_IN_NICKEL
Real
Content in %
COMPOSITION_IN_CHROMIUM
Real
Content in %
COMPOSITION_IN_MOLYBDENUM
Real
Content in %
COMPOSITION_IN_VANADIUM
Real
Content in %
Lookup table format (DEF_LOOKUPTABLE)

The DEF_LOOKUPTABLE block allows defining lookup tables that can be referenced
within DEF_MATERIAL block for parameters supporting lookup tables.
DEF_LOOKUPTABLE block must be placed before DEF_MATERIAL block.
Lookup table
Keyword
NAME
Type
String
Notes
Free lookup table name
DEF_DEFINITION
DEF_ARGUMENT
Repeat block for each

argument
NAME
Free argument name
INTERPOLATION_MODE
Keyword
Possible values:
LINEAR
LOGARITHMIC
EXPONENTIAL
CLOSEST_VALUE
LOWER_EXTRAPOLATION_MODE
Keyword
Possible values:
LINEAR
LOGARITHMIC
EXPONENTIAL
HORIZONTAL
UPPER_EXTRAPOLATION_MODE
Keyword
Possible values:
LINEAR

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LOGARITHMIC
EXPONENTIAL
HORIZONTAL
VALUES
List of
real values
Example : 0 0.1 0.15 0.2
List of
real values
Example : 0 0.1 0.15 0.2
DEF_FUNCTIONS
VALUES
List of
real values
VALUES
Example of lookup table for strain rate dependency:

DEF_LOOKUPTABLE
NAME = 'HT(Eps,Eps p)'
DEF_DEFINITION
DEF_ARGUMENT
NAME = 'Plastic strain'
INTERPOLATION_MODE = LINEAR
LOWER_EXTRAPOLATION_MODE = LINEAR
UPPER_EXTRAPOLATION_MODE = LINEAR
VALUES = 0 0.1 0.15 0.2
DEF_ARGUMENT
NAME = 'Strain rate'
INTERPOLATION_MODE = LINEAR
LOWER_EXTRAPOLATION_MODE = LINEAR
UPPER_EXTRAPOLATION_MODE = LINEAR
VALUES = 0 0.1 0.01
DEF_FUNCTIONS
VALUES = 1 2 3 4
VALUES = 5 6 7 8
VALUES = 4 5 6 7

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Multiplies material
Multiplies material definition (still within DEF_MATERIAL block) is composed of a
list of sub-materials and a list of plies, each ply being attached to one of the submaterials.
Definition format for sub-materials is similar to standard material.
Sub-materials
Keyword
Type
SUB_MATERIAL
Notes
Repeat block for each submaterial
NAME
String
TYPE
Keyword
Free sub-material name

Must be MULTIPLIES
Sub-material parameter (see

standard material format)


Plies
Keyword
PLY
Type
String
Notes
Free ply name
Repeat block for each ply
TARGET_GROUP
String
ROLLING_ANGLE
Real
THICKNESS
Real
Reference to a sub-material

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SIMULATION CONCEPTS
CONTACT AND FRICTION
Contact
The contact and friction are defined simultaneously for each pair of objects by declaring
that one of the objects (the master) is impenetrable by the other (the slave). The contact
then permanently prohibits the nodes of the slave object, generally the blank, from
penetrating the master object elements, generally the tool.
For the contact attribute of the master, the following main parameters have to be
defined:
-
The Contact type.
The list of slave objects with the

friction value: Impenetrable by (slave)
option.
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Contact and Friction
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Contact types
Different contact types are available,
depending on the project type and on the
kinematics and loading conditions:
-
Penalty
Accurate
Lagrangian
Implicit
Self Contact
For QUIKSTAMP PLUS holding and forming simulation there is no choice of contact,
it is automatically defined by the solver.
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Conditions of use
Each contact type can be used only under some kinematics and loading conditions.
Implicit (for
Advanced
implicit)
Self
Contact
AS
AS
AS
No Cartesian
kinematics
AS
AS
AS
Rotational
kinematics
AS
Cartesian
kinematics
Penalty
Accurate
AS
Fluid Cell +
Cartesian
kinematics
Lagrangian
Implicit
AS
AS
Imposed
1
movement
Fluid Cell +
Cartesian
kinematics
AS
Non imposed
2
movement
Implicit gravity
Advanced
implicit gravity
(and
springback)
AS,
QSP
AS
Imposed movement: it means that Tx, Ty, Tz have either an imposed

velocity, or a lock condition and Rx, Ry and Rz are locked
2
Non imposed movement: it means that Tx, or Ty or Tz are free or

with initial velocity.
Moreover the Accurate contact is incompatible with the other contacts inside the same
project, but a stage can be calculated with the Accurate contact and the stage after with
the Penalty contact.
The Self Contact is an extension of the Accurate contact, and follows all of the rules for
Accurate.
Selection of contact type

The user can select manually the contact type he wants to use. In that case he must
check that all the conditions for using it are fulfilled, as described before.
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The user can also select the Automatic option for contact type, and the contact
corresponding to the conditions of calculation will be selected automatically when the
solver is launched. The user can then see in the message the contact type defined for
each contact attribute. He can also check it with the Attribute check.
As Penalty and Accurate contacts can be used in the same attributes condition, the
selected contact corresponds to the one defined in the Advanced Parameter / Default
contact attribute.
The choice between Penalty and Accurate contact must be done according to the quality
of tool mesh (see next paragraphs Penalty Contact and Accurate Contact). If the tool
mesh is of bad quality the Penalty contact must be selected. The Accurate contact must
be used with a tool having good quality of mesh.
Self contact is to be used in cases where it is likely or possible to encounter contact
between the blank (sheet or tube) and itself. This can typically be cases where strong
wrinkling or buckling is expected.
Contact activation
It is possible for the user to choose when he wants the contact to be activated and
deactivated using the sensor definition available in the contact attribute. A simply start
and stop values can be defined or a more complex function of time.
Accurate Contact
This contact permanently prohibits the nodes of the blank sheet from penetrating the
volume of the element of the tool during a calculation.
The nodes are kept exactly at the surface of the element
owing to the contact forces being precisely calculated;
they cannot go to the other side of the master element.
For this reason:
-
There is no need for mesh orientation.
This contact respects the tool geometry.
The stress calculation is good.
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There is a possibility of ironing.
A rigid body with a deformation height should be used for tool without imposed
movement.
A node is considered as a ball with a diameter equal to the mean of the thicknesses of
the elements it belongs to. There is penetration when the node ball penetrates the
volume of an element declared impenetrable for the node.
When the diameter of the ball is nil (slave is defined by solid elements or shell elements
with a nil thickness) and the master element is a shell element with a nil thickness or a
solid element, penetration is no longer possible. For the algorithm to operate, a Contact
thickness is added to the element (contact advanced parameter). This Contact thickness
is automatically calculated but can also be given by the user.
The problem mentioned above occurs when there is a contact between a die with nil
thickness and a blank holder with nil thickness or the volume blank holder, or between a
tool with nil thickness and a volume blank.
This problem also occurs, during the automatic positioning of tools. In such a case, the
program calculates a Contact thickness. This Contact thickness will be communicated
to the solver at start-up. Similarly, during a picking, if the solver runs into such a case
during the picked calculation, it will communicate to the interface the value of this
Contact thickness.
Normals Orientation
There is no need for consistent orientation for tool elements normals. Since the side of
each tool is not recognized by normal orientation, the nodes of the blank should always
be kept on the right side of the elements.
For this reason:
-
There should be a good initial positioning.
It is better to create blank holder walls.
When a calculation starts, an initial penetration test can be activated; it detects whether,
if at the initial instant, for each contact pair of objects, a node penetrates an
impenetrable element or if a node potentially created by the adaptive meshing would
then penetrate an impenetrable object. These initial penetrations can result from a bad
positioning of the tools and should be avoided especially with the Accurate contact.
The initial penetrations depend on the maximum refinement level. Indeed, the initial
penetrations test algorithm checks whether these potential nodes, whose number and
position depend on the maximum level, will penetrate. Thus, two picked objects can end
up in strong initial penetration assuming the maximum level is changed. In such a case
they would need to be repositioned since the maximum level is taken into account in the
positioning.
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Situation at the end of

the previous calculation
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Situation at the start of a calculation

where the maximum level was increased
with respect to the previous calculation
Tool
Blank
Potential node created

by the adaptive meshing
Two objects in contact always slightly penetrate each other, because of the local
stiffness or because of the numerical rounding errors. Therefore, two objects that are
picked and that were in contact, will always give initial penetrations. These penetrations
are normal and it is recommended not to position automatically the objects.
In all the other cases, if the maximum value of the initial penetrations is less than 0.01
mm, the user can start the calculation as such, after having removed the initial
penetration test. Otherwise, it is advisable to change the position of the objects.
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Note:
It is useless to re-position objects that have been picked and that were
previously in contact, unless refinement levels are increased.
With an Accurate contact, vertical walls should be created on the blankholder to prevent
a node of the blank from passing over the blankholder.
Blankholder without
vertical walls
Blankholder
Blank
Blankholder with
vertical walls
This node cannot pass

above the blank holder
Respect of Tool Geometry

contact respects tool geometry. That is why only tools with a high mesh quality
can be used. Therefore, the tool radius and friction coefficient value have a big
influence on results.
Accurate
Rigid Body
A simplified rigid body with deformation height, which is slightly deformable, should
be used for a tool without imposed movement, like the blank holder with a loading
attribute, during the stamping stage for example (see Rigid Body chapter).
Pinch Test
The pinch test, between two objects,
enables a calculation to be stopped when a
node of the blank is pinched between those
two objects.
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Check during calculation
This option enables detection of ironing:
The pinch test has detected

that the node is pinched
between the die and the
punch, there is ironing.
A calculation stopped because of the presence of ironing can be restarted by deactivating the pinch test. Nevertheless, the results will not be satisfactory, as the ironing
is not correctly taken into account by the solver (the transverse stresses produced by the
ironing are not taken into account and therefore the friction forces generated at the point
of ironing are not representative of reality). However, on large parts, it could be useful
to continue the calculation, as it can be assumed that the results in the zones remote
from the ironing zone are not affected by the latter.
We strongly advise not to do this for springback calculation.
If the user does not define a pinch test, the solver writes a warning message if it detects
that a node is pinched between two elements with an imposed movement, and it will
continue the calculation by trying to compress this node. The user must identify where
the pinch occurred and determine if the calculation was completed or if there is ironing.
If the calculation was completed, this means that the final value of the progression
variable was too high. It is then necessary to restart the calculation from the restart file
that preceded the warning, modifying the final value of the progression variable or
defining a pinch test.
Warning:
To allow a calculation to continue after a pinch test can seriously compromise

the validity of the results. As indicated above, the ironing of the shells is not
taken into account. Moreover, the user could end up with an extreme situation
where the punch, whose movement is imposed, passes through the die. The
solver will not be able to identify where to place the blank. Consequently, any
calculation without a pinch test must be carefully analyzed.
To avoid ironing when thickening appears, a gap between the die and the punch is used
(5 per cent of the blank thickness) during tool meshing (see Meshing of the Other Tools
chapter).
Stop criterion
The pinch test allows the automatic termination of a holding or stamping calculation. In
a holding project, the pinch test is activated between the die and the blankholder, when
a node of the blank is pinched between these two objects, this means that the blank
holder surface is closed and therefore the calculation is completed. In a stamping
project, the pinch test is activated between the die and the punch.
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When a node of the blank is pinched

between these two objects, it means that
the punch is at the bottom of the die (in
such a case, the calculation is completed).
The pinch test has detected that

this node is pinched between
the die and the punch, the
calculation is completed.
Good Stress Calculation

The Accurate contact enables the user to have a good stress calculation if it is used
correctly:
-
No initial penetration. There should be a correct tool positioning.
High mesh quality for tools.
Gap between die and punch. It is necessary in order to avoid the calculation to be
stopped by a pinch test.
Use of pinch test.
Blankholder walls.
Advanced rigid body for blankholder when loading is applied.
Data (advanced parameters)

-
Contact thickness:
Automatic calculation (the solver takes the thickness of the

blank, updated at each increment) or value entered by the user, see the explanation
above.
Default option:
Contact default thickness
is automatically calculated by default.
Self Contact
This contact type is in fact a derivative of the Accurate contact type, and as such all the
text above will apply. The self-contact requires the user to observe the rules and
guidelines for Accurate contact, and to additionally specify the number of rows of
elements which will be ignored for the self-contact search. The parameter Count for
ignored rows of elements simply literally describes the number of rows of elements
from any node which will not be considered during the treatment of the self-contact;
this is essential in order to allow the user to use very small elements (eg during flanging
or hemming studies) and for elements too close to be discounted for contact treatment,
the default value is 3. The value should be adjusted according to the ratio of material
thickness to mesh size.
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Note:
Self-contact treatment is not compatible with Adaptive meshing.
Penalty Contact
This contact type allows small penetrations between slave and master objects. The tool
geometry is less respected than in the previous contact type. Stress calculation with this
contact is not so accurate, that is why it is not recommended to apply Penalty contact
when springback calculation is performed afterwards.
The penalty forces are generated in response to existing or potential penetrations
between two objects. The forces are applied on the nodes of slave objects penetrating
the master. An efficient searching method is used to localize slave nodes in a domain
surrounding the master element. At every time step, and for a given master element,
only its slave nodes are checked for penetrations.
When the sheet is compressed between two rigid tools, the normal elasticity provided
by the penalty spring ensures that contact pressure is distributed over a finite area rather
than being concentrated at a single slave node. The effective stiffness of contact is a
function of the original slave mesh size, increasing with the fineness of the slave mesh.
Best modeling results are obtained when this stiffness is equivalent to the normal
elasticity of the physical tools.
It is not possible to define a real thickness for a tool with the Penalty contact (Thickness
attribute). Even if a thickness attribute is defined beforehand, when the Penalty contact
type is chosen this thickness value is automatically used for the Contact thickness (with
a warning message) in the Contact attribute.
Normals Orientation
Normals of the tool elements have to be oriented consistently such that they define the
contact surfaces of the tools. They must point towards the blank.
Parameters
-
Contact default thickness:
Automatic calculation or value entered by the user. See
description before.
Note:
If the thickness value is defined in the Thickness attribute of surface tool and the
Penalty contact is used, the defined thickness value is automatically removed
from the Thickness attribute and defined in the Contact thickness attribute.
Contact acceleration: Represents the number of time steps between contact slave
searches.
Scale factor:
Scale factor for sliding interface penalty. This factor directly modifies
the spring stiffness. The default setting is usually satisfactory. With a very coarse
sheet mesh, higher values may be required to eliminate large penetrations.
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However, values larger than 0.3 may lead to integration instabilities and should be
avoided.
-
Contact damping default values are suitable for most applications. Higher
values can be tried, should vibration levels be unrealistically high.
Damping:
Mass proportional factor: This parameter can efficiently damp out low
frequency vibrations. It is recommended for damping out residual oscillations in
quasi-static situations, such as in springback, where the residual deformed shape
is wanted.
Stiffness proportional ratio: Nodal damping is added to the normal contact
penalty spring forces acting between the slave nodes and the master surface.
When the node is penetrating the tool, the contact force is increased with this
parameter, and when the node is going out of the tools, the contact force is
decreased with this parameter.
-
Sharp edges:
Activates the contact force normal flag useful for coarse slave
meshes.
Default options and values:
Contact default thickness
is automatically calculated by default.
Contact acceleration
Scale factor
Mass proportional factor
Stiffness proportional ratio
is set to 0.03 by default.

is set to 0.1 by default.
Use
This contact type is simple to use but the results are not so accurate. It is not
recommended to apply this contact if springback calculations are planned. On the other
hand, when quality of CAD data of the tool is not very good, then Penalty contact
should be used.
Lagrangian Contact
The Lagrangian contact is very similar to the Penalty contact, the difference is only in the
contact formulation. No penalty scale factor and no damping parameters are needed in
the input.
The contact force of the Lagrangian contact is a kinematics force, this force is the result
of the equilibrium condition which satisfies the zero relative motion between slave
nodes and master elements.
Hydroforming application
This contact force formulation is necessary in case of very high contact pressure, which
is usually the case in hydroforming applications. All Penalty contact force formulations
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can fail in these kinds of applications, this is why the Lagrangian contact is oriented
towards hydroforming simulations.
An integrated fluid cell can be defined in the input (as aquadraw attribute on the blank)
when Lagrangian contact is used. This fluid cell has a behavior which is coupled to the
contact between blank and die.
The pressure of the fluid located between the blank and the binder part of the die can
be reduced using the fluid pressure scale factor to make the simulation more realistic
if needed.
If the pressure scale factor is equal to zero, the fluid pressure depends only on the
classic fluid cell parameters, in particular the volume and the fluid bulk modulus and
the fluid flow rate.
If the pressure scale factor is greater than zero, the fluid cell pressure value will depend
also on the equilibrium condition of the blank under the action of the blankholder force,
the die force and the fluid pressure.
Note :
A very small value (1.e-5) of the pressure scale factor is recommended as

default for aquadraw simulations.
Implicit Contact for Implicit Gravity

This contact is based on a penalty method that does not support friction.
The contact search method used in the Implicit contact for Implicit Gravity is made very
efficient in case of high displacement problems; this is needed because in Implicit
gravity the blank nodes have big displacements by increment.
A global contact orientation (usually equal to stamping direction) is to be defined as
input parameter and is needed especially for the high displacement oriented contact
search method.
This contact can also be used for other applications like binder wrap (in QUIKSTAMP).
In this case, the contact increments number (=1 in case of gravity) must be defined, this
parameter is needed to solve the initial high perforations between blank and blankholder in an incremental way.
Implicit Contact for QUIKSTAMP PLUS

The contact used in Pam-Quikstamp Plus enables the use of mix of decoupled
bending/stretching and full coupled contact solution.
A decoupled bending-stretching calculation is performed at each Newton iteration,
which means that in the course of forming, two deformation modes can be identified,
i.e.:
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Bending solution:
Find the intermediate geometry of blank

through the action of tools, as this is only
an out-of-plane equilibrium, only
stretching forces are used. A bending of
the sheet occurs over the die and punch
geometry
-
Stretching solution:
Find the in-plane blank equilibrium in this

intermediate geometry; use normal-to-node
rotations for bending effect. The stretching
of the sheet will define the plastic material
flow
These two deformation modes are separated into two different sub-calculations for a
simpler and quicker computation, each having its own particular contact behavior. The
contact treatment as such can be considered as the previously described Penalty contact.
Due to the decoupled calculation, wrinkling phenomena cannot be simulated accurately.
During the stretching sub-calculation, nodes are only allowed to slide on the already
computed intermediate blank shape, and therefore buckling effect will not be taken into
account.
Implicit Contact for Advanced implicit Gravity (and

Springback)
Standard contact for Advanced implicit Gravity (and Springback)
Standard contact is used for Advanced implicit Gravity (and Springback) only and
it is available for any contact pair blank-blank, tool-blank.
Standard contact is based on a penalty method and it supports friction.
Initial penetration removal
At advanced implicit calculation start, an initial penetration test is activated; it detects,

for each contact pair of objects, if a node penetrates an impenetrable element, coming
from explicit contact treatment in a previous stage. Initial penetrations are removed by
adjusting tools thickness in appropriate areas (not physical blank thickness).
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Normals Orientation
There is no need for consistent orientation for tools elements normals. Since the side of
each tool is not recognized by normal orientation, the nodes of the blank should always
be kept on the right side of the elements.
Advanced contact for Advanced implicit Gravity (and Springback)

An optional contact is available for Advanced implicit Gravity (and Springback)
which reduces the CPU time of the simulation.
Advanced contact is available for contact pairs toolblank only. If there are both
contact pairs (blank-blank and tool-blank) defined in simulation and Advanced contact
selected, Standard contact is automatically used for blank-blank contact pairs and
Advanced contact for tool-blank contact pairs.
Advanced contact is set in Advanced implicit card of Advanced parameters of
appropriate Gravity or Springback stage.
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Initial penetration removal
There is the same Initial penetration removal as for Standard contact for Advanced
implicit Gravity (and Springback).
Normals Orientation
This is an oriented contact; normals of tools elements have to be oriented consistently

such that they define the contact surfaces of the tools. They must point towards the
blank.
Tools mesh quality control
There is an automatic control of mesh quality at the solver start with Advanced
contact. T-branches, totally warped elements and normal orientation are checked and
stated in out file of computation in error or warning message.
Automatic walls removal
For Advanced contact, walls on blankholder(s) are undesirable because they are
perpendicular to the contact shape and may lead to wrong orientation and issues in
contact management. Walls of any tool, consisting of 1 element in height, are
automatically suppressed for computation at solver start. Information about such
suppression is stated in out file of computation in an info message.
Note:
Advanced contact is CPU optimized and provides shorter computation time of

advanced implicit gravity and springback simulations compared to Standard
contact.
Small sliding contact for Advanced implicit Gravity and Springback

Small sliding contact is a special contact for advanced implicit clamping simulation,
where small sliding of blank between clamps is observed. It is not a penalty contact, no
penetrations are allowed during computation, which is imposed by Lagrangian
multipliers.
For Small sliding contact are valid all properties as for Advanced contact for
Advanced implicit Gravity (and Springback).
Small sliding contact is defined per each slide-line in Contact definition dialog.
This contact provides more accurate and exact results but there is a strict limitation on
the sliding length of the blank which must be about the size of the contacted elements
locally.
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Note:
Small sliding contact is a prototype contact available for advanced implicit

clamping simulations.
Friction
Coulombs law
When an element of an impenetrable object applies a force normal to a node, it also
applies a tangential force along the direction opposite that of the sliding, whose norm is
equal to *N if there is sliding and lower than *N if there is no sliding (Coulombs
law: N is norm of the normal force, is Coulomb friction coefficient).
Examples of Coulombs coefficient:
- 0.05
excellent sliding
- 0.1 to 0.15
conventional values (0.12 for Accurate contact and 0.15 for Penalty
contact )
- 0.2
rough surface
Due to the closer respect of tooling geometry with Accurate contact, a slightly lower
Coulomb friction value is normally used.
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Parameters
The user has a number of options which can be used to define the friction, ranging from
a very simple constant Coulomb definition, up to a User sub routine in which the user
can program his own friction relationship. The more commonly used options are:
-
Constant:
a single value for coulomb friction
Function of Pressure:
Function of Velocity:
Function of Pressure & Velocity:
Function of Pressure & Velocity & Temperature:
User Defined: the user can enter in the GUI the parameters used in a user friction
subroutine which he can program & link with the solver as a library.
a curve which defines the variation of coulomb friction

against contact pressure
a curve which defines the variation of coulomb friction
against the sliding velocity
uses two independent curves, the product of
which will define the coulomb friction varying with both pressure and velocity
friction coefficient dependency
on normal pressure, sliding velocity and blank temperature is defined via lookup
table
The User-defined friction is described in a specific separate documentation. Please

consult with the local ESI subsidiary for more information.
Gluing
This contact is advised for an implicit calculation when there are 2 blanks in contact.
After hemming in example, there is some glue in the hemming area of the inner or outer
blanks. Then, during the springback stage, there is no relative displacement in this area
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between the two panels, but in the center part relative, displacement of these two panels
are still possible.
Consequently the outer blank is divided in 2 sub-objects. The user defines a gluing
contact between the inner blank and the sub-object.
The user has to put the Search distance parameter used for finding the nodes and
elements that are in contact. This parameter can be equal to 2.
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OBJECTS & ATTRIBUTES

The use of the interface is object-based; an object is a set of entities to which
attributes are assigned. Each entity can belong to several objects and the attributes of
these objects should be coherent.
Characteristics
An object can be a set of 3D curves, CAD surfaces, elements, edges and nodes. There
are hierarchies in the entities that form the objects. Assuming that symbol > means
"hierarchically higher", then:
volumes > volume elements > edges > nodes
surfaces > surface elements > edges > nodes
and:
3D curves > 2-node elements > nodes
The advantage offered by the notion of object is that very different operations can be
performed on a single object: translation, assignment of material properties, definition
of kinematics, definition of a level of refinement... Hence, the user can use this program
in a much more direct and intuitive way.
When the user applies an attribute to an object, the attribute is applied not only to the
entities, which form the object, but also to all of the entities of lower hierarchical level
included in the initial entities.
Examples:
-
The material properties assigned to an object are transmitted to the elements that
belong to that object.
When a force is applied to an object, this force is applied to all the nodes contained
in that object.
When the user fixes the three translations to the external edges of a sheet, these
boundary conditions are automatically applied to the nodes that belong to these
edges, including the nodes that will be created by the adaptive meshing (see
Kinematics Chapter).
Moreover, when the adaptive meshing is used, the new elements belong to the object of
their parent-element, the new faces belong to the object of their parent-face, and the
new edges belong to the object of their parent-edge.
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AutoStamp Object Types

There are several Object types, which help the user do the data set-up more easily and
avoid mistakes. Pre-defined information is automatically given to the solver, and the
attributes are filtered to help the user with the data set-up:
The following Object types can be defined:

-
Undefined:
The user should avoid using this type because the data set-up control is
not done and the user can commit some errors defining non-consistent attributes.
The use of this type is recommended only in case of an object containing some
entities from the die and some from the blank, or an object with 3D curves.
Volume Blank:
Surface Tool:
Volume Tool:
Drawbead:
Spotweld:
Coordinate System:
Plane:
Guiding:
Bar:
RollPath:
Surface Blank:
To define the objects containing entities of volume blanks.

To define the objects containing entities of tool.
To define the objects containing entities of volume deformable tools,

like rubber. It is not available for Tube projects.
To define the objects containing entities of drawbead. It is not available
for Tube projects.
To define the objects containing entities of spotweld. It is not available
for Tube projects.
Can be defined by several methods or imported from a CAD
file. The user has to enter an objects name and choose the definition type.
Enables to define a plane to introduce symmetry conditions or to use as stop
plane. The user has to enter an object name and a Definition mode for creation of the
plane.
To define the objects containing entities of guide. It is not available for
Tube projects.
To define gas-springs for more accurate blankholder force definition, or for
tube bending.
To define the objects containing entities of roll path. It is not available for
Tube projects.
SIMULATION CONCEPTS
To define the objects containing shell elements of the blank sheet.
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Global object:
It is not really an object, only a presentation of all the attributes

common to several objects.
Note:
The With material button in Surface tool and Drawbeads options assigns a
material constitutive law according to the selected type of elements.
Object Attributes
AUTOSTAMP
Surface
Tool
Volume
Tool
Drawbead
Spotweld
Guiding
Bar
RollPath
Undefined
Stamp
Undefined
Tube
Global
Object
+
+
+
+
-
+
+
+
+
-
+
+
+
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
+
+
+
+
-
+
+
+
+
+
-
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-
+
-
+
+
+
+
+
+
-
+
+
+
+
+
+
+
+
+
+
+
+
+
Plane
Volume
Blank
Attributes
All Stages:
Object Type
Material
Thickness
Behavior
Spotweld definition
Blank definition
Drawbead definition
Path Definition
Robot Components
Definition
Multi body system
Damage
Global advanced
parameters
Unit system
License options
Runtime data check
By Stage:
Aquadraw
Automatic feeding
Boundary condition
on points
Contact
Drawbead Activation
Dynamic Freeze
Element elimination
Fluid Cell
Follower force
Surface
Blank
Object Type
Coordinate
System
Here is the list of all the attributes available for each type of object:
SIMULATION CONCEPTS
SIMULATION CONCEPTS
Available
+
+
-
Not available
+
-
Global
Object
+
+
+
+
+
+
-
Undefined
Tube
+
+
-
Plane
+
+
+
-
Undefined
Stamp
RollPath
+
+
+
+
+
-
Bar
+
+
+
+
+
+
+
+
+
-
Guiding
Volume
Tool
+
+
+
+
+
+
+
+
Spotweld
Surface
Tool
+
+
+
+
+
+
+
+
+
+
+
+
+
-
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Drawbead
Volume
Blank
Attributes
Force
Freeze
Gravity
Ironing
Kinematic Path
Mapping Import
Post Analyze
Pressure
Refinement
Rigid Body
Spotweld Action
Springback
Substructure cut tool
Substructure export
Symmetry Plane
Thermal behavior
Values initialization
Advanced Parameters
Control
CPU Control
DMP decomposition
Global refinement
Mapping export
Mesh Transformation
Picking
Quenching parameters
Stage Information
Substructure import
User-Defined
Surface
Blank
Object Type
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Coordinate
System
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+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-
+
+
+
+
+
+
+
+
+
+
+
+
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QUIKSTAMP PLUS
Plane
+
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
+
+
-
+
+
+
+
+
+
+
+
+
-
+
+
+
+
-
+
+
+
-
+
+
+
+
-
+
-
+
+
+
+
+
+
+
+
-
+
+
+
+
+
+
+Available
Global
Object
Guiding
Undefined
Drawbead
All Stages:
Object type
Material
Thickness
Blank definition
Drawbead definition
Definition
Global advanced
parameters
License options
Runtime data check
By Stage:
Cartesian Kinematics
Contact
Drawbead activation
Force
Gravity
Mapping Import
Post analyze
Refinement
Symmetry plane
Advanced Parameters
Control
Mapping export
Mesh transformation
Picking
Stage Information
Surface
Tool
Attributes
Surface
Blank
Object Type
Coordinate
system
-Not available
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INVERSE
All Stages:
Object type
Material
Definition
Unit system
By Stage:
Cartesian Kinematics
Inverse object
Inverse condition
Symmetry plane
Advanced Parameters
Control
Mapping export
Stage Information
Undefined
+
-
+
+
-
+
+
-
+
+
-
+
+
-
+
-
+
-
+
+
-
+
+
+
+
+Available
Global
Object
+
+
-
Plane
Surface
Tool
Attributes
Surface
Blank
Object Type
Coordinate
system
-Not available
Object Content
The Objects content management is a functionality that helps the user to modify easily
the content of an object without modifying the data set-up. If a user for instance imports
a new die mesh or new drawbead shapes, he only has to replace the content of the die or
drawbead objects, the object attributes will remain the same.
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It is possible to directly activate this functionality when importing a mesh with the Add
to existing objects option.
Object Group
Each object can be identified as a group. The group enables to identify the object and to
fulfill automatically the macros and some attributes so that the user does not have to
identify twice the objects. This information is kept among modules (Meshing, Design
and Set-up).
One group corresponds to one tool. If there are two different blank holders in the
process, each of them is identified as a separate group, Blankholder_1 and
Blankholder_2. The user can define the number.
Groups are automatically defined in the Design module after operations like tipping,
create simulation model, as well as in the Set-up module when using the ToolEditor, the
accessory, the blank meshing or the filleting
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KINEMATICS
The kinematics conditions are attributes applied to an object to determine its movement
conditions (fixing, imposed velocity or displacement).
When kinematics or loadings are applied to an object, they are applied to all the entities
of lower hierarchical level included in the initial entities.
Therefore, the user should adopt a physical approach rather than a numerical one
when choosing the objects to which kinematics will be applied. A metal sheet side is a
set of edges and not a set of nodes. A tool is a set of elements and not a set of nodes.
When the adaptive meshing splits an element or an edge, the new elements or edges
belong to the object of their parent. Thus, if the user analyzes the selection of the object
correctly, the kinematics will remain correct despite the refinement of the adaptive
meshing.
Example:
If the user wishes to fix the side of a surface blank, he must create an object that
contains the edges of the blank that forms that side. Thus, all the nodes of these
edges, including those created by the adaptive meshing, will be fixed. If, instead
of selecting the edges, he chooses the side nodes, the nodes created by the
adaptive meshing on the side will not be fixed.
There are different types of kinematics and for each of them a coordinate system may
be used:
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Kinematics
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For PAM-QUIKSTAMP, the boundary conditions are defined by locking

translation/rotation along/about X, Y, or Z or by applying an imposed Displacement
along X, Y or Z.
For PAM-AUTOSTAMP, several kinematics can be defined:
-
Lock: Boundary conditions
are defined by locking translation/rotation along/about
X, Y, or Z
-
Initial velocity:
A translational or rotational velocity is defined at the start of the

simulation. From then on, the velocity of the nodes is no longer imposed.
Imposed velocity:
A translational or rotational velocity is applied to the nodes
(constant or as a function of time) during the simulation. The button

the user to gain access to the 2D curve plotter to define a velocity curve
allows
Lock & velocity: lock and velocity will be successively applied, depending on the sensor
definition (see Sensor paragraph, here below)
Imposed displacement:
The user defines the displacement he wants to be applied

(constant or as a function of time) during the simulation. Node accelerations will be
automatically updated during the simulation to reach the requested displacement.
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3D boundary (min or max): A minimal or maximal displacement can be defined by the user
along X, Y or Z. The object can be moved freely along this axis (the displacement is
managed by contact, force or pressure), but the displacement is controlled by the 3D
boundary.
Automatic feeding:
This option is available only if Automatic feeding and Fluid cell

attributes are defined. The displacement of the object will be automatically
calculated from the fluid cell parameters (see the Loading chapter for further
information on Automatic feeding and fluid cell).
Notes:
The rotation velocities are expressed in radians per unit of time.
The solver checks the coherence of the motions. Example: the user cannot define
a motion for a set of nodes which includes node N about an axis which passes
through node N.
For defining symmetry condition, it is advised to use symmetry plane rather than
nodes locking. See the Symmetry plane chapter for further information).
Rotational kinematics attribute enables
to impose angular velocities for an
object. It is used for example to model
the rotation of the 'bend die' object in a
tube forming process. This velocity can
be a value or a curve that can be defined
as pre-process function in the 2D curve
plotter.
Kinematic path
This kinematic is used in Rollhemming simulation to move a robot along a 3D curve.
See the Simulation methodology for tube section for further information.
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Kinematics
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Boundary condition on points

Boundary conditions during simulation
For more information on the use of Boundary condition during simulation, see the
Springback measurement chapter in the Simulation Methodology for Specific Processes
section.
By setting Boundary conditions on points attribute, the user defines positions instead of
nodes and locks conditions. Before starting the simulation PamStamp 2G will find the
nodes closest to the defined positions and apply lock on them. This attribute is used for
locking blank nodes during springback simulation.
Freeze
For some simulation (for multi-bending of tube or
flanging of sheet), a big area of the tube or blank
is not deformed. . In order to speed up the
calculation, certain areas of the tube can be
defined as frozen objects, using the Freeze
attribute.
The Freeze option consists of ignoring all internal forces in the freeze area. As a
consequence; the area is locked.
Note :
An object with Freeze attribute can have only Post-analyze and Substructure
export attributes.
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Kinematics
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Freeze and Rigid body

It is possible to define the object with freeze attribute as a rigid body. In that case,
kinematics, loading (force or pressure) and contact can also be applied to define the
movement on the object.
Tube bending
See the Simulation methodology for tube section for further information on tube
bending.
In order to speed up the calculation, certain areas of the tube can be defined as frozen
objects, with rigid body attribute. This area will then be treated as a rigid body, and
kinematics must be applied to move these objects together with the tube Cartesian
kinematics for feeding parts and rotational kinematics for parts are already bent and are
rotating with the tube during the next bending operation.
Freeze object in non-deformable zone is rotating with the bend die and clamp die.
Freeze and Rollhemming

See the Rollhemming section for further information on use of Freeze option during
Rollhemming simulation.
Dynamic Freeze
Dynamic Freeze option is available. This option is used to freeze the whole model,
except in a bowl of a given radius and centered on a selected. See the Rollhemming
section for further information.
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Rigid Body
For a rigid body, loading and kinematics are automatically applied to the center of
gravity of the rigid body.
If an entity (element, node) belongs to several objects one of which is a rigid body,
the kinematics must be applied to the object with the rigid body attribute; otherwise
the rigid body will have loading or kinematics conditions applied to one of its nodes
instead of its center of gravity, which is not possible.
Sensors
Sensors are defined by a 2D function or by definition of the progression when the

attribute started or/and stopped is applied. The 2D function enables to activate and
deactivate the attribute depending on the progression. The attribute is activated as soon
as the ordinate value is different from zero.
For the Cartesian kinematics attribute five sensors are available. If the user wants to
apply alternatively locking then an imposed velocity, it should use the Lock and
imposed velocity kinematics. That way, the lock will be imposed depending on the
Lockings sensor, and the imposed velocity depending on the Translational kinematics
sensor.
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FORCE AND PRESSURE

Force and Pressure can be defined with a constant value or as a function of time (PAMAUTOSTAMP).
More particularly for PAM-AUTOSTAMP, when loading is applied to a surface tool
object, this object must be defined as a rigid body.
When kinematics or loadings are applied to an object, it is applied to all the entities of
lower hierarchical level included in the initial entities.
When the adaptive meshing splits an element or an edge; the new elements or edges
belong to the object of their parent. Thus, if the user correctly analyzes the selection of
the object, the kinematics will remain correct despite the refinement of the adaptive
meshing.
Force
If a rigid body is defined, the value of the force is
automatically applied to the center of gravity of the
rigid body.
If there is no rigid body attribute (e.g. in PAMQUIKSTAMP), the total force is applied to the
object; each node receives a force equal to the
defined value divided by the number of nodes of the
object.
A local coordinate system can be used to define the
force.
Note
Force can be applied in Z direction of any

local system the user defines.
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Force and Pressure
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Follower force
The follower force is a special case of the force
loading. Here also a force component being a
constant value or a curve is applied in a given
direction of a local coordinate system.
What is special about this, is the ability to
change the direction of the force component
during computation depending on the rotational
kinematics of a given object.
This gives the user the possibility (for example.
the clamp die in tube bending simulation) to let
the force applied rotate together with the bend
die.
The local frame is updated during the simulation
by the solver. Using the Updated direction
option will update the frame at the beginning of
the next simulation stage.
Pressure
Pressure is applied using the normals of the
elements. Therefore the orientation of the normals
should be consistent. A positive value of pressure is
applied in the opposite direction of the normals.
Note:
To apply pressure the user should first

orient consistently the normals.
Rigid Body
the kinematics must be applied to the object with the rigid body attribute. Otherwise
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Sensors
Sensors are defined by a 2D function or by
definition of the progression when the attribute
started or/and stopped is applied. The 2D function
enables to activate and deactivate the attribute
depending on the progression. The attribute is
activated as soon as the ordinate value is different
from zero.
Note:
For reading the projects coming from PamStamp 2K, sensors are available for
the following attributes: Explicit gravity, Explicit springback, Forces, Rigid
body, Pressure, Contact (except for Accurate contact that was not used in
PamStamp 2K), Pinch tests.
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Force and Pressure
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FLUID CELL AND AQUADRAW

For PAM-AUTOSTAMP, when loading is applied to a surface tool object, this object
must be defined as a rigid body.
When kinematics or loadings are applied to an object, it is applied to all the entities of
lower hierarchical level included in the initial entities.
When the adaptive meshing splits an element or an edge; the new elements or edges
belong to the object of their parent. Thus, if the user correctly analyzes the selection of
the object, the kinematics will remain correct despite the refinement of the adaptive
meshing.
Fluid Cell
The fluid cell option represents a computationally convenient way to model a fluid
volume, where a pressure buildup, through the action of a pump or through tool motion
is used, to deform a part without the need to discretize the fluid domain.
HYDROFORMING PROCESS
F1
Pressure build up
in enclosed fluid
Die
Piston
F2
F3
Piston
Tube
Piston
FLEXFORMING PROCESS
Pressure build up
caused by pump
Press housing
Pump
Rubber
membrane
Sheet
Die
Ideally, the fluid cell should be defined as a closed volume with shell or membrane
elements and the orientation of the elements should be such that their normals point
inwards.
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Fluid Cell and Aquadraw
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The fluid cell is an attribute of the tube

or the blank. It is defined by the fluid
bulk modulus, the volume of the fluid
cell and several options to control the
fluid cell (pressure or volume).
Fluid bulk modulus

The bulk modulus of the fluid is used for calculation of pressure variation.
Cell volume
The cell volume is calculated from the volumes between the element surfaces and the
projection of element surfaces onto a plane given by the Axis for volume calculation.
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Segment j
Axis for volume calculation:

Direction Z
Shell mesh defining

boundary of fluid cell
Vi
VCELL=
i
Z=O Plane
Prism of volume
Vi
Warning:
To apply fluid cell, tools must be oriented towards blank and blank must be
oriented towards fluid.
Fluid cell control

Boundary of fluid cell delimited by blank
or tube mesh (and eventually a plane)
Inflow:
Volume
flow rate
(dV/dt)
Fluid cell
Outflow:
Maximum
fluid
pressure
(Pmax)
Maximum velocity
of blank nodes
The variation of the internal volume during the run and the definition of a given flow
rate induce the creation of a pressure load applied on the elements forming the fluid
cell. Each of this parameter can be controlled and have impact on the other parameters.
Imposed Velocity in Fluid Cell
Pressure is calculated so that the average free sheet velocity (Vav) matches a user
specified Target value (Vimp) for the fluid cell option:
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The average sheet normal velocity Vav represents the mean velocity weighted by a factor
dependent on the width of the velocity distribution and input parameter deviation factor
(SIGV). This additional parameter provides additional control over the peak velocity
when the sheet velocity distribution is wide, as may occur in industrial cases with a
large range of forming radii.
Sheet nodes are classified as 'free' or 'constrained' in the contact routines depending on
their proximity to tool surfaces:
Free Sheet Nodes: Proximity to tools > 1.5 * Contact Thickness
Constrained Sheet Nodes: Proximity to tools < 1.5 * Contact Thickness
Die
Sheet
Notes :
For zero values of deviation factor, the average sheet normal velocity reduces to
the mean value.
Deviation factor
values between three and four provide effective control of the

maximum sheet velocity in cases with non-uniform sheet velocities. Values
greater than six may increase pressure fluctuations and are not recommended.
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Autostop in Fluid Cell

Two automatic termination criteria are available:
The computation is automatically terminated when one of the following conditions is

reached:
The proportion of sheet area in contact with

the tools is above a user specified limit
(contact ratio)
The pressure limit is maintained over a

continuous time interval of user specified
duration (Time interval)
Note that the contact area based criterion can be based on the total fluid-cell bounding
surface or on a partial selection. In this case, a new history output will be available in
the post-process which is the proportion of sheet area in contact.
The corresponding stop criterion has to be activated in the control attribute.
Automatic Feeding
Punch1
U1
Punch2
Fluid cell object
U2
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The automatic feeding option enables to

optimize the displacement of the
punches depending on the fluid cell
parameters. This attribute is defined on
the tube object, which already has a
fluid cell attribute.
All the punches listed in this attribute
must have automatic feeding option as
Cartesian kinematics in one direction
(X, Y or Z), while the other directions
are locked (see Kinematics chapter for
further information).
Punches are listed with a weight
coefficient.
The velocity of the punches is optimized
either to keep a constant surface of fluid
cell or to respect the Imposed velocity of
the fluid cell nodes. The velocity of each
punch comes from the optimized
velocity multiplied by the weighted
factor.
Note
It is also possible to define

instead of the punch an object
containing some tube nodes
Three options can be used for the calculation of the optimized velocity:
-
Folding surface ratio max.:
If punch velocities are too high, some folds defects may

appear during the forming. Fold defects are automatically detected (from the normal
variation of the fluid cell elements) and a surface with folding is calculated. When
the ratio between the surface with fold and the global fluid cell surface is higher
than the value entered by the user, the velocity of the fluid cell nodes is imposed to
zero. The corresponding punch velocity is then calculated.
Velocity coefficient:
Maximal velocity:
After optimization of the punches velocity keeping a constant

surface of the fluid cell or respecting the velocity of the fluid cell nodes, the predefined coefficient is applied to the punch velocity.
the user can define a maximal velocity (constant or function of
time) of the punches. The weight of the punches is respected. This parameter is
available only for constant surface objective.
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Aquadraw
The Aquadraw attribute enables to model a fluid cell
volume between the die, the blank sheet and the binder;
and to control the outflow of fluid under binder. The
parameters are the same as for the fluid cell, but the
binder must be identified and the fluid pressure scale
factor has to be defined.
In order to get an accurate value of the fluid cavity volume, the model must be
positioned along the axis for volume calculation in such a way that the center of
gravity of the binder part of the die has a 0 abscissa (after auto-positioning).
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Rigid Body
the kinematics must be applied to the object with the rigid body attribute. Otherwise
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RIGID BODY
Definition
A rigid body is a set of elements to which no strain is applied and the movement of
which can be described by the six degrees of freedom of its center of gravity: three
translations and three rotations.
The elements that constitute a rigid body must be non elasto-plastic elements or bar
elements.
A middle node must not belong to a rigid body.
Note:
A middle node is a node created by the adaptive meshing during refinement,

located in the middle of an edge of a neighboring element.
middle
node
Rigid body are available only in PAM-AUTOSTAMP projects
To define a rigid body, add a Rigid Body attribute.
Kinematics of Rigid Body

The kinematics of a rigid body are applied to the center of gravity of the rigid body.
Boundary conditions, initial or imposed velocities cannot be applied to an object with
nodes that also belong to a rigid body.
When a node of a rigid body with deformation height (blank holder) belongs to a
symmetry plane, this rigid body is assumed to be symmetrical to this plane.
Consequently, the center of gravity is projected onto the plane and boundary conditions
needed for the definition of this symmetry are automatically applied.
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Rigid Body
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Rigid Body Types
There are three types of a rigid body: Regular, User-defined and Simplified. As there are
some limitations to the use of the rigid body in combination with the contact types, the
Cartesian kinematics and loading, the table below should be considered.
Contact type
Penalty
Accurate
Lagrangian
Attributes
User defined
Simplified
Fluid cell + Cartesian kinematics

with imposed movement
Fluid cell + Cartesian kinematics
with non-imposed movement
Simplified
Cartesian kinematics with imposed

movement
Simplified
Simplified
Cartesian kinematics with nonimposed movement
Simplified
Simplified
deformation
height
Cartesian kinematics: FREE
Regular
For simplicity, rigid body type can be automatically defined when starting the
calculation. The type of rigid body used is written in the messages, and it can also be
visualized with the attribute check.
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Rigid Body
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Simplified rigid body

The simplified rigid body has no rotation, rotational degrees of freedom are locked. It is
the rigid body type usually used for the standard stamping tools (die, punch, blank
holder).
For tools with imposed movement, the use of the simplified rigid body enables to save
CPU time. It can be defined with both contact types (penalty and accurate contacts).
It is necessary to use this rigid body for tools without imposed movement, particularly
with a loading attribute.
Automatics parameters
If the user defines the parameters as automatic, the rigid body will be calculated with:
-
the mass of the blank,
no deformation height (for tools without imposed movement with Accurate contact
a deformation height is used with factor 1),
no inertia since the rotations are locked.
If tools have non imposed movement with the Accurate contact; the deformation height
will enable to make the tool slightly deformable. Without it a blank holder would only
be in contact with a few nodes of the blank because of its non deformability and the non
penetration of the nodes inside the tools.
Regular rigid body

The regular rigid body has its mass, moments of inertia and center of gravity
automatically calculated by the solver from the mass distribution of the given rigid body
nodes.
This rigid body type is only used in combination with Accurate contact if there are no
imposed boundary conditions.
Automatics parameters
-
no deformation height.
User-defined rigid body

For the user-defined rigid body, the center of gravity, moments of inertia and mass can
be defined by the user and be given to the solver.
It is used in combination with Accurate contact if there are imposed rotational boundary
conditions, since then the center of gravity is then defined by the center of the rotational
movement.
It can be used with Accurate or with Penalty contacts when you want to apply a force
on the blank holder with free rotations. In that case it is advised to define:
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Rigid Body
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An Inertia factor of 1, so that the gravity center and the inertia axis are correctly
calculated,
a deformation height factor of 1 if an Accurate contact is used.
Automatic parameters
-
the mass of the blank,
no deformation height,
the center of gravity equal to the center of rotation defined in the rotational
kinematics attribute. If no rotational kinematics attribute is defined, it will then be
set as (0 0 0).
Moments of inertia equal to 1.
Parameters
Mass
The default mass factor is 1. A mass proportional to that of the blank is applied. It is
possible to define a factor to modify this value.
Deformation height
In Accurate contact, stiffnesses are optimized to avoid penetration of the blank into
tools. There is only one exception: Deformation Height. This parameter is used to
impose stiffness of slave nodes which impact master rather than use the automatically
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computed high stiffness. It is used to decrease the stiffness of nodes in contact with
object with this attribute. This is very important for nodes between die and blankholder:
-
to avoid too important localization of contact forces because of high stiffness,
to decrease vibration of nodes in contact with 2 surfaces. These spurious vibrations

decrease the quality of the results for springback.
A value suitable for the conventional stamping problems is calculated (the calculated
value corresponds to a tenth of the largest dimension along X, Y or Z axis of the
object). (See Contact and Friction section). It is possible to define a factor to modify this
value.
Warning:
It is extremely inadvisable to increase the default value of this parameter, as

stiffness could become too low to maintain node on the right side of the tools.
Inertia
The inertia is defined by the Center of gravity and the Inertia in the three main axes. In
an automatic mode the center of gravity is defined as the position of the rotational
center if a rotational kinematics attribute is applied to the rigid body.
The inertia factor enables to calculate automatically the inertia as follow
-
The center of gravity is the center of gravity of the rigid body,
The inertia are the same in the three direction: factor * mass of the blank * ( max
length of blank).
Multi body system

A special type of object group is the Multi body system. This allows linking together
one or several objects by links. The link can be:
-
Spherical
Translational
Rotational
Translational + Rotational
Lock
User defined
The initial direction of the link and the point on which the link goes through must be
defined.
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Kinematics are only defined on the main object, and the other objects follow the objects
with whoses there are linked. All the objects linked with Multi body system must have
rigid body attributes.
For tube bending simulations, this is used for the clamp die (translational) and for the
mandrel balls (spherical).
The multi body system is used in Tube bending and Rollhemming simulation. See
Rolllhemming section for further information.
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ADAPTIVE MESHING
Definition
The adaptive meshing automatically refines a mesh (that of the blank), where and when
it is required. The program performs a one-level refinement when this element is cut
into four other elements (each edge is cut in two):
The adaptive meshing is defined as an object attribute. It is activated when a surface

blank - type object has a refinement attribute. A maximum refinement level must then
be defined for all the isotropic or orthotropic shells in keeping with the following rule:
-
Objects with a maximal refinement level can only contain isotropic or orthotropic
plates and they cannot share common elements.
A level 1 element has not been

refined whereas a level n element
was refined n-1 times:
Level 1
Level 2
Level 4
Level 3
Refinement Criteria
Two criteria are used to determine whether or not there should be refinement: the first
one is an angle criterion, the second a geometrical criterion.
Angle Criterion
The solver refines an element when the
variation of the angle between its normal and
that of one of its neighbors exceeds a limit
angle whose default value is 10.
> limit angle
This criterion is useful for the detection of

wrinkles.
Warning:
If the size of the blank element exceeds the size of the wrinkles (distance between
two peaks) to be detected, these wrinkles might not be visible.
This criterion must always be defined when the adaptive meshing is used.
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Adaptive Meshing
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Geometrical Criterion
The program adapts the density of the mesh to the local curvature of the tools close to
the blank.
Example:
(a)
(b)
(c)
(a) Detects that a tool with a marked curvature comes close to the blank.
(b) Refines the blank in the region close to the tool.
(c) Then the blank can fit with the form of the tool.
This criterion triggers blank refinement before errors due to a too coarse mesh appear. It
enables a more accurate calculation of the stress field. On the contrary, the angle
criterion only acts once the error is detected.
Note:
This criterion is optional. The following paragraphs explain that when this
criterion is deactivated, it is possible to substantially decrease the simulation
time for some cases. Nevertheless, it must be activated when springback results
are required.
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Adaptive Meshing Control Parameters for AUTOSTAMP

Criteria
Uniform Level
This parameter is used to define a uniform refinement and enables the user to force the
refinement manually. It is defined in the refinement attribute of the object on which it is
applied:
-
The default value is 1 which means that there will
not be any global refinement during

the calculation. For instance, if it is equal to two, all level 1 elements (i.e. all nonrefined elements) belonging to the object for which this parameter is defined, will be
refined once.
The option Set uniform level at, defined in the Global refinement attribute of Global
object: defines the instant at which the uniform refinement will take place. For
AUTOSTAMP, this instant is time or stroke - depending on the selected progression
type. The default value is Begin that means at the beginning of the calculation.
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Default values:
Set uniform level at
Uniform level
is set to Begin by default.
Maximal Level
This parameter is used to define the maximal refinement level that the elements can
reach. It is defined in the refinement attribute of the object on which it is applied:
The value depends on the final mesh size that the user wants to reach. For penalty contact, it is
advised not to use a value higher than 3. For Accurate contact, there is no limit for this value.
The option Start maximal level at, defined in Global refinement attribute of Global object
allows the user to define the instant at which to start refinement during the calculation. For
AUTOSTAMP, this instant is time or stroke - depending on the selected progression type.
Note:
If the maximal level is lower than the current level, then the element refinement
is blocked. This is a way to locally prevent the refinement. It is therefore
possible to stop the refinement in an object by defining the maximal level of
refinement attribute equal to 1.
Default value:
Start maximal level at
is set to Begin by default for PAM-AUTOSTAMP
Maximal Angle
This parameter is defined in the Global refinement attribute of the Global object. It is
the limit angle used by the adaptive meshing angle criterion. It must be defined
whenever the adaptive meshing is activated.
Default value:
Maximal angle
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Adaptive Meshing
is 10 by default for PAM-AUTOSTAMP.
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Local initial level
This option enables to refine initially the part of the blank that is close to another object.
It is particularly useful for the lockbead to refine the blank mesh near it in order to
capture better the deformation of the blank near this lockbead.
All the elements of the object with this refinement option that are at a smaller distance
of the target object will be refined initially to the local initial level.
To calculate the distance, only 3D curves, bars and edges will be used. This distance is
calculated after the autopositioning, so this option works well with multistage and
autopositioning.
Warning:
The Local initial level cannot be higher than the maximal level.
Geometrical Criterion (curvature radius criterion)
The curvature radius criterion is optional. If it is not activated, the elements are only
refined when the angle criterion is reached. In that case the tool geometry is not
necessarily respected. It is then impossible to continue the simulation with a springback
calculation, the stress field calculated during the stamping simulation not being accurate
enough.
The CPU time can be considerably decreased with this option.
Default option:
Curvature radius criterion
is activated by default.
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Bending Criterion
This option enables to refine the elements of the blank when the maximal transverse
shear strain is higher than the value given by the user.
Options
Respect curvature
The respect curvature is an option which can be defined in the Global refinement
attribute of Global object. By default it is not activated. The elements are refined in the
beginning of the stage with the minimum imposed level by taking care of the curvature
of the blank. The nodes are pushed outside of the curved shape in order to obtain a
smooth curvature area.
Example:
(a)
(b)
(c)
(a) The blank before refinement.
(b) The blank after refinement without option.
(c) The blank after refinement with the respect curvature option.
Note:
This option is useful for improving the surface defect results described in the
Cosmetic Defects Analysis chapter.
Interruption
Memory Size
This optional parameter is defined in the Global refinement attribute of the Global object.
Its function is to stop the refinement without stopping the calculation when the memory
allocated by the program reaches the given value (in Mb). Once this limit is reached, the
calculation continues without refinement.
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Default value:
Memory size
is set to 4000 Mb by default.
Number of elements
This optional parameter is defined in the Global refinement attribute of the Global
object. Its function is to stop the refinement without stopping the calculation when the
total number of elements of the project reaches the given value. Once this limit is
reached, the calculation continues without refinement.
Default value:
Number of elements
Minimal Element Size
Sometimes, when the blank mesh is heterogeneous, the simulation time is increasing
because of the refinement of a tiny element compared to the average characteristic size
of the other elements.
The refinement of this element at the same level as the others is perhaps not necessary
and could be avoided by defining different levels of refinement in different objects in
order to determine several refinement zones. To avoid this tedious operation, the
minimal characteristic length of the elements after refinement can be defined. During a
refinement, when the characteristic length of an element is less than the Minimal element
size, the element is not refined.
Notes:
In order to properly use this option, the inverse problem should be considered:
which minimal size is allowed for the model.
The chosen value for this parameter should be coherent with the Maximal level
of refinement value.
Default value:
Minimal element size
is 0 by default.
Automatic refinement / Refinement wizard
The optimal refinement levels are computed automatically or by the wizard respecting
the rules described in the Blank meshing chapter:
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The Initial mesh size of the object is computed, by eliminating the 10% smallest
elements and the 10% largest elements. The initial mesh size is then the average of
the size of the 80% elements.
Based on sliding radius, Blank thickness and High Quality information, the
maximum final size is computed (see next paragraph).
Then, the initial size is divided by a factor two step by step until reaching the
maximal level and the real final mesh size. Then in case of Accurate contact, the
uniform level is set to 1. In case of Penalty contact, it is set to the maximum
refinement level -2.
When open, the wizard is fulfilled from the attributes values of the stage (for contact
type and thickness) and from the already defined values (for springback and radius).
The user can modify these parameters if needed.
Final mesh size

The final mesh size is calculated the following way.
-
For high quality stamping simulation, like springback or surface defect, the size (d)
of the deformed elements of the blank that slides on a fillet must be smaller than
25% of the curvature radius of the blank at its neutral fiber when it passes over a
sliding fillet, i.e. 25% of the sum of curvature radius of the fillet and the halfthickness of the blank. See the chapter blank meshing in the Simulation
methodology for high quality stamping section.
For feasibility calculation without springback the final mesh size is half of the sum
of curvature radius of the fillet and the half-thickness of the blank. See the chapter
Autostamp of the Simulation methodology for design and stamping feasibility
section.
Refinement automatically applied by solver

The adaptive meshing is used for surface blank objects only. If the user wishes to define
the same maximal level for the whole blank, it is sufficient to define the maximal level
for the blank object. On the contrary, if the user wishes to define different maximal
levels along the zones of the blank, the adaptive meshing should not be defined on the
blank object but on objects which contain elements of the different refinement level
zones. These objects should not include common elements and must cover the whole
blank.
The difference between the respective refinement levels of two neighbor elements
cannot exceed 1. Therefore, if this occurs, the program will automatically reduce certain
maximal levels.
For instance, on the following blank meshed with sixteen 4-node elements, two
refinement zones will be defined, one composed of only one element with a maximal
level equal to 2, the other composed of all the other elements and with a maximal level
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equal to 4. The program automatically modifies the maximum refinement levels, so that
the difference between the maximal levels of neighboring elements does not exceed 1.
4
Refinement levels proposed by the user
Refinement levels corrected
Adaptive Meshing Parameters for QUIKSTAMP Plus

PAM-QUIKSTAMP Plus has a simplified method of defining the adaptive meshing
criteria, where the refinement levels are imposed automatically as a result of the
geometry properties. The user is required to enter:
-
Die entry radius
Minimal Sliding radius
Final mesh quality (fine / rough)
From these parameters, the solver will automatically adjust the refinement levels to
suitable values.
The maximal angle can still be set in the global object advanced parameters, though the
default value of 7 degrees is strongly recommended.
Additionally in the global object advanced parameters there is the possibility to define a
maximum number of elements in the model, this is generally not to be used, but in rare
cases on 32 bit computers it may happen that the solver could stop due to memory
exhaustion, limiting the number of elements in this parameter will prevent the memory
exhaustion, though of course this will limit the level of detail which can be captured, as
some required refinement will not take place.
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DRAWBEAD
Characteristics
Purpose
This property enables the action of the drawbead on the blank and on the blank holder
to be represented without representing the geometry of the drawbead on the mesh. Thus
it is much easier to represent and modify the drawbead.
Blank holder
Blank holder
Die
Equivalent
drawbead
Die
Reality
Equivalent Model
Drawbead action applies to 2-node elements.

The drawbead applies two types of forces: a restraining force and an opening force. The
restraining force represents the restraining action exerted by the drawbead onto the
blank. The opening force represents the force applied by the blank on the blank holder
when the blank slides in the drawbead.
The object content on which a restraining force can be applied is:
-
4-node shells (with an orthotropic or an isotropic behavior)
The object content on which an opening force can be applied is:

-
solid elements
Notes :
If the blankholder is described with solid elements, the drawbeads should not be
close to the blankholder walls.
Elements with a drawbead type do not affect the time step.
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Data
-
Restraining force
per drawbead length unit together with the object onto which this
force will be exerted.
Opening force
per drawbead length unit together with the object onto which this
force will be exerted and the direction in which this opening force is applied on the
blank holder. The opening force will always be normal to the faces of the object you
want to open, but the direction will give you the sign.
Notes:
It is not necessary to subtract the drawbead opening force from the force of the
blank holder, assuming, of course, that the opening force applied to the
drawbead is specified. This method offers the advantage of applying the opening
force at the correct location and to no longer apply an opening force when the
blank comes out of the drawbead.
The holding force should be greater than the total opening force of the
drawbeads, otherwise the simulation will not be correct.
of the tube that represents the drawbead. It is advisable to choose an

action radius equal to five times the blank thickness - this radius value is calculated
automatically by the wizard option. The radius must be large enough to enable the
blank and the blank holder to intersect with the tube and small enough to stop
imposing an opening force when the blank is no more in contact with the blank
holder. If this condition is fulfilled, the value of the action radius does not influence
the results.
Action radius
Notes:
The drawbead should be projected on the die and not on the blankholder,
because everything is working with action and reaction principle. When Fo is
imposed to the blankholder, -Fo is imposed to the drawbead. If drawbeads and
blank holder belong to the same rigid body the global force applied on this rigid
body will be F=Fo-Fo+Fblankholder=Fblankholder, the opening force will be
cancelled out.
Application of restraining and opening forces

The restraining force only acts on isotropic or orthotropic plates that intersect with the
tube that represents the drawbead. If there is a relative velocity of these elements with
respect to the drawbead, the force applied is normal to the axis of the drawbead, in the
plane of the element, and opposes the sliding of the element in the drawbead.
Let VR be the relative velocity of the blank element with respect to the drawbead and F
be the force applied by the drawbead to the element. F is normal to the drawbead line,
in the plane of the element, and opposite to the relative velocity:
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VR
Blank element
Drawbead
Note:
The action radius does not affect the value of the forces applied. It simply allows
the user to detect the faces onto which the forces are to be applied and to
visualize the drawbead better.
The opening force acts on all the elements that intersect with the tube representing the
drawbead, except the 2-node elements. When there is no blank element passing through
the drawbead, no opening force is applied.
The user specifies the objects onto which these forces will be applied: the blank for the
restraining force, the blank holder for the opening force.
The opening force is
applied to this element
Fope
The restraining force is

applied to this element
Blank holder
Blank
Blank movement
Frest
Drawbead radius
Drawbead element
(not necessary node)
Calculation of restraining and opening forces

A drawbead can impose an opening force, only if a restraining force was imposed.
When only a part of a drawbead is used to calculate the restraining force, it is only this
part that can be used to calculate the opening force. So at each step of the calculation,
when the restraining forces are known, an active zone for each drawbead is
calculated.
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The drawbead forces are estimated as follow:

-
Frestraining = L x Frestraining force / unit length
Fopening = L x Fopening force / unit length
Where L represents the intersection of the drawbead and the element face.
J2
4
3
L
2
J1
The restraining force can be less than the formula given below. As for the friction in the
contact algorithm, a restraining force can slow down a node movement but not reverse
it. A first estimation of the restraining force is calculated for each node of the blank, and
then the relative movement of the node (compared to the drawbead) is estimated for the
next step. If the movement is reversed, the restraining force is limited to a value, which
stops the node movement.
Note:
As the drawbead force is calculated taking into account only the intersection of
the drawbead and the elements, it is not necessary to have small elements to
describe the drawbead. Small elements will affect the CPU Time especially with
DMP
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Drawbead definition
The Drawbead editor,accessible from the Data setup page, provides functionalities to
build Drawbead curves.
Note:
button is available only in standard stamping process. It is not

available in hot forming or roll hemming context.
Drawbeads
Drawbead editor
The Drawbead editor contains four important areas. Name area and three pages for
Drawbead definition: Location, Tools and Blank.
Drawbead editor - Name option

In the Name area, it is possible to see the name of the selected drawbead object, we
actually work with.
Add new drawbead object.
Delete selected drawbead object.
Selecting of drawbead object by picking.
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Drawbead editor - Location page
This page allows definition of drawbead object geometry in the User Interface. There
are two possibilities for defining: 3D Curves and 1D-bar elements (bars).
For drawbead forces definition on prepared geometry, it is recommended to use directly
imported 3D curves or 3D curves done inside the curve editor. No need to transform
into bars (which are used by the solver): 3D curves will be automatically transformed in
1D bar elements when launching the simulation.
Curves can be easily edited during iterations. Moreover, when using curves, it is
possible to define forces zones and pins anywhere (see zones and pins in Blank page
chapter), but in the case of bars is possible to define pins (zones) to existing nodes of
bars only.
For 3D drawbead curves definition it is possible to use following options:
New curve offers creating of new 3D curves
with 3D curve editor.
Edit curve enables editing of selected curve.
Import curve - 3D curves can be directly
imported from a CAD file, or mesh file.
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Set curve lists allows selecting of curve from a

list of 3D curves. Pins and zones (see Drawbead
editor - Blank page) are re-projected on the new
set of curves (to redefine forces on the new set of
curves) if required by the user
Project all curves: projects all drawbead curves
on Die object.
Defined drawbead curves will be put in the current Drawbead object, after that, the
definition should be confirmed by Apply.
Notes :
It is possible to use several Drawbead objects in a simulation.
One drawbead object can contain several curves. It is recommended to have a

curve per object. Especially, if you have parallel non uniform drawbead curves,
it is better to put them in different drawbead objects.
Drawbead editor - Tools page

This page is used for setting all properties connected with tools.
Drawbead object have to be linked to Die and Blankholder. A drawbead is linked to a
die, means that it will have exactly the same behavior as the die during simulation: it is
attached to it! So no specific attributes have to be provided to the drawbead for its
movement: it will be automatically activated if the die object is present in a stage and it
will have the same boundary conditions as the die.
The blankholder object corresponds to the objects on which the drawbead will apply the
uplift force.
The second parameter on this page is Opening direction (direction of opening force
from die to blankholder). The next parameter is Action radius (see in Characteristic
chapter). It is possible to obtain the value of this parameter; automatically, use wizard,
or set the value directly. The final option on this page is the button to Estimate total
opening force. This can be helpful for the blankholder force determination.
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Drawbead editor - Blank page
It is possible to define the drawbeads in two different ways in the Drawbead editor:
-
Uniform mode
Non Uniform mode
Uniform
When using the uniform drawbead definition, the user creates one object per drawbead
section. For each object only one restraining value per blank and one opening force can
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be defined. It is very easy to manipulate but can lead to a high number of drawbead
objects.
For uniform drawbead definition check the Uniform option on Blank page in the
Drawbead editor. First possibility of definition is to set values for restraining and
opening force directly. Second possibility is to use Drawbead Calibration (see
homonymous chapter).
Non uniform
The non uniform drawbead definition allows the user to keep a single drawbead object,
but to specify variations in the drawbead forces (and thickness variation / plastic strain)
as required. This non uniform method offers a great advantage to the user: on one given
curve (in one object), the user can specify variable restraining forces without splitting
into different objects. Moreover, it offers great flexibility for modifying drawbead
values, to make new simulation iterations.
The user selects on the 3D curves pins or zones on which drawbead forces, sections and
options are defined.
A zone is a segment of a drawbead line (curves or bars) along which the drawbead
forces are constant. Between two neighbor zones, a transition is applied (see Transition
length chapter) to smooth the drawbead force variation.
To set linear drawbead variation, the user can define locations (called pins) of specific
drawbead forces. Between two pins (or between a pin and the limit of a zone, or
between two zones), the drawbead forces are linearly interpolated.
At the end of a drawbead line, an end-pin can be added and a parameter d is available
which will put the point at the distance d of the end of the drawbead as the solver. Force
will go to zero from this point until the end.
Here below is an example on drawbead curve with 2 end points and 2 zones. You can
see the transition area between the zones and the final transition to 0. at the end of curve
along 30 mm. Moreover between the zones and the end points, the restraining force is
linear.
Notice that all arrows correspond to nodes which will be automatically created at solver
launch.
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It is still possible to have a constant value drawbead object by simply defining only one
point or one zone.When a curve is modified or replaced inside a drawbead object by
another curve (by a new import for instance), the pins and zones are projected on the
new drawbead curve.If on a given drawbead curve, the user wants to finally eliminate
drawbead on an area, the best way is to set a zone with restraining force set to 0. When
iterating, it is easier than splitting curves and removing some afterwards.
Duplication of drawbead object
Drawbeads groups can be duplicated using the icon
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It will add a new drawbead group. This object will have the same attributes as the first
one and same restraining and opening forces.
3D View pick tools:
Add zone - New zone crating selecting of area

on the 3D curve.
Add point - Pick point on 3D curve.
Add end point The closest end point of the
curve is automatically selected after picking a
point on the 3D curve.
Move the closest point to the clicked location
Delete a segment - Delete of point or zone.
Edit a segment - Property editing of selected pin
or zone.
Import values - Importing sets of drawbead
values from an external file (plain text). The file
reading format is flexible and simple for the user
to adapt to his needs.
After segment the definition, is necessary to apply forces by direct values insertion to
segment table, or through the Drawbead force edition dialog by double clicking on the
segment name in the table (for this possibility see Drawbead Calibration chapter).
Functions on pin or zone are accessible through popup menu in the pin list:
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Paste
geometry
Assign geometry of one segment to

another.
Insert zone
Select two pins in the table and

through this option insert zone
between them.
Expand zone
Expand select zone to next zone (not

pin).
Move to
extremity
Move pin (or zone) to curve extremity.
Current coordination of all pins and zones including drawbead forces are listed in the
text view through the Segments Cords button.
For drawbeads, where geometry is defined, all forces will be recomputed using the
Staughton method through the Update all forces button.
Possibilities of segments labels display in 3D:
Notice that when displaying restraining forces, forces are computed at the position of
nodes which will be provided to the solver at the launching of the simulation.
Drawbead setting for multiple blanks

It is possible to define drawbeads for multiple blanks (tailored blanks as well as
patchwork blanks) like shown below.
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Drawbeads that cross over 2 different blank thicknesses are now supported
In this case, there are two configurations of drawbeads in connection with multiple
blanks. The first one is: drawbead curve lies on one of multiple blanks (picture above
vertical curves). And the second one is: drawbead curve lies on both blanks (picture
above horizontal curves).
In reality, drawbead physically represents a part of the tools, so it is common for all
blanks of one OP. However his action (restraining and opening forces) depends on the
blanks (friction, material, thickness). So there must be one drawbead object with one set
of forces definition per blank. Such process is handled in PamStamp2G v2012.
Drawbead definition must be done in this way:
-
Create an object drawbead which contains all the drawbead curves
Fill in the pages Location and Tools as described before
In Blank page, there is a new button

which enables to add as many restrained
blanks as needed. Here in this case, only 2 blanks are welded, so we add only one
blank card. Then, 2 pages Blank 1 and Blank 2 appear.
In each page, select the type of drawbead and select the right restrained blank in the
drop list
Define the drawbead forces as usual for each sub-blank
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Here is an example of such definition:
In the solver when reading the drawbeads, their nodes and bars (after conversion from
3D curves) are duplicated so that for each restrained blank, a standalone interface
drawbead/blank is sent to solver. So, solver will apply the correct force for each
restrained blank. Duplicated nodes and bars don't appear in results files.
Notes :
User can define null force in blank1 page for the drawbead zone which will
never cross over blank1 because it wont be used by solver. Same for blank2.
Described methodology is same for patchwork blanks. In patch area, solver will
apply both drawbead forces defined in the 2 blank pages.
Only one set of drawbead forces can be displayed at once
Drawbead options
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The Drawbead options described below are available only for AUTOSTAMP. This
dialog is available per button Options in the Drawbead editor
Lockbead
The lockbead is a specific drawbead that should prevent the global sliding of the blank.
It can be defined either by selecting the Lockbead option, or by using a high restraining
force. When using the Activated Lockbead option, a local equilibrium is used in order
to find which Restraining force will give Vr = 0
This option is available per button Options in the Drawbead editor. This means that if a
drawbead is locked, it is lockbead for all the restrained blanks.
Note :
It is not recommended to use the Activated Lockbead option for new models,
instead, it is better to use a high restraining force, which is more consistent and
easier to iterate.
Edge line effect
This option enables the user to take into the blank width, and the decrease of the
restraining force when the blanks border is sliding through the drawbead. This means
that if a drawbead is locked, it is lockbead for all the restrained blanks. The equivalent
drawbead mesh represents the middle of the real drawbead. This option is available via
the Options button in the Drawbead editor.
First configuration
Ft
width
flow
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width
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Second configuration
Ft
width
flow
width
Third configuration
Ft
width
flow
width
Thickness variation and plastic strain increase
This option is available via the Options button in the Drawbead editor, for each couple
of drawbead and restrained blank.
When the blank goes through the drawbead it induces local thinning that is taken into
account with this option.
Plastic strain or thickness variation is added progressively to the elements which are
crossed by a drawbead, with a function depending on the relative velocity of the blank
through the drawbead and the characteristic length of the element.
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p= p + i pdrawbead
where = i = 1, i is the part of the blank element that crosses the drawbead.
Notes:
These options are applied by the drawbead object. That means that the thickness
decrease or the plastic strain increase is defined once per restrained object.
The i variable is picked between the stages.
Drawing angle option
When the draw-in is no more perpendicular to the drawbead element, the restraining
force norm decreases, and its direction is modified. This option enables to take into
account this effect, for all drawbeads. This option is available via the Options button in
the Drawbead editor.
Without drawing angle option
With drawing angle option
Fri =i*L*Fr
Fri =i*L*Fr*cos()
Transition length
The transition length option provides Smoothing forces between two neighbor zones.
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If the length of the transition zone between two zones is higher, than set value for
transition length, there is no change in transition zone.
The solver extends the length of transition zone, if the length of the transition zone
between two zones is smaller, than set value for transition length.
Drawbead Calibration
PAM-STAMP2G offers two methods for the calculation of the drawbead parameters;
that is an empirical method from Tom Stoughton (Analytic calculation)
, and a
simulation-based method (Calibrator calculation)

. The simulation-based method is
recommended when the user wishes to use any of the advanced options.. The Stoughton
model will only calibrate for Restraining and opening forces, whereas the simulation
method will also provide values for Plastic strain and thickness variation. The
Simulation method uses the AUTOSTAMP solver, and as such, cannot be used by users
having only a QUIKSTAMP Plus license.
It is possible to import sets of drawbead values from an external file (plain text), as well
. The file reading format is flexible and simple for the user to adapt to his needs.
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Analytical Calculation
The STOUGHTONs model is used. Five
types of drawbeads are available:
This option has two different modes:

-
Calculation of the restraining and opening forces as a function of the drawbead

geometry and of the blank material properties.
Determination of the geometry of the drawbead and the opening force from the
restraining force and from blank material properties.
Data for calculation of the restraining and opening forces:

-
Thickness of the blank.
Youngs modulus of the blank.
Yield stress of the blank.
K: Hollomons law coefficient ( = Kn) for the blank.
n: Hollomons law coefficient ( = Kn) for the blank.
Mean Lankfords coefficient: r = 0.25 (r0 + 2r45 + r90) for the blank.
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Friction coefficient.
Geometrical data (R1, R2, G, D or R1, R2, L2, D or R1, R2, L1, L2, D depending
on the geometry).
In order to determine the geometry of the drawbead from the restraining force, it is
necessary to enter the restraining force and the geometrical data except one geometrical
parameter that will be calculated by the program. This will also give the user the
opening force. This so-called "inversion" method is very useful for the toolmaker who,
after having found the ideal restraining to achieve a good stamping, must choose the
geometry of the drawbeads that enables such restraining.
Calibrator calculation
The Drawbead calibrator is accessible through Drawbead editor and can be used to
define the drawbead forces and options from a simulation of a blank strip drawing
inside a real geometric drawbead.
The tools and blanks will be automatically meshed from the input data and put in the
objects. A separate project (project_DbCal.pre) containing these meshes and
corresponding attributes is automatically created and launched.
The user can load this project and analyze it, but he can also directly load the drawbead
results from the Analyze results button without opening the drawbead calibrator project.
Input data
The input parameters for the calibrator are the

same as for Stoughtons model, however there
is a requirement to specify a Relative gap (as a
percentage of nominal blank thickness), and to
define / select the solver host machine on
which the calibration model will be solved.
There is the possibility to write input file only
and then to launch the solver manually on
another machine if required (or submit to
Queuing system).
Drawbead project
The following meshes and objects are automatically created with two symmetry planes
normal to Y. The blank is meshed with squared element having the following size:
(min (R1, R2) + thickness) which defined the width of the blank strip.
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The following setup is applied:

-
The Blank has the material and thickness defined by the user
Two symmetry planes are activated
Bead and Groove have friction with the blank (value defined by the user)
A velocity is first applied on the Bead in -Z direction (1 m/s)
Then Blank end nodes have a velocity of 1m/s applied on X
Blank start and Blank end nodes are locked in Z direction to avoid oscillations of
the blank strip
Section force is defined between Blank end nodes and Section force element.
Accurate contact is used.
Results analyze
In the standard case, when the calibration run is launched directly from the user
interface, the results will appear in a pop up window automatically on completion of
the calculation.
An Analyze results button is provided in order to retrieve these results again at a later
stage.
The results are calculated the in following way:
-
Drawbead forces:
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At the end of the Drawbead calibration project (Project_DBcal) two history curves are
automatically created:
Contact force on Bead object, in the Z direction for Opening force
Section force on Blank_end object in the X direction for Restraining force
A moving average filter (MVA) with a window width of 25 is applied on these curves
and the maximum of the last 10% values is selected. This value is then divided by the
blank width to obtain Fo and Fr.
-
Drawbead options
The Thickness variation is calculated from the difference between the maximal and
minimal thickness value of the blank. The Plastic strain increase is calculated from the
difference between the minimal and maximal plastic strain value of the blank.
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General drawbeads definition information

The positioning and projection of drawbead on die is automatic in the defined direction
at the beginning of each stage. The drawbead object has automatically the same
kinematic as the die object (any stage type) if the appropriate die object is active in that
stage. They can be also be put different kinematic attributes if necessary (if an attribute
of kinematics is added, it is taken into account instead of the die kinematic).
In the stamping stage type, forces corresponding to the blank are automatically applied
if the die object is active. If the die is deactivated, these forces are not applied.
In other stage types (undefined, holding) forces are applied if new attributes called
Drawbead activation is activated only. See the table for the usage of this attribute.
If the die object is active in some stage here is an example of different situations.
Drawbead forces
activation attribute
status is:
Stage type =
stamping
Stage type =
other than stamping
activated
Drawbead forces
applied by solver
Drawbead forces applied by

solver
deactivated
Drawbead forces not

applied by solver
Drawbead forces not applied by

solver
no attribute
Drawbead forces
applied by solver
Drawbead forces not applied by

solver
SIMULATION CONCEPTS
Drawbead
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Upgrade of PS2G v2009 (or older) project

In the old projects the following methodologies were used for drawbead proces
definiton:
1. All drawbeads in project are in local objects. On each local object
are applied drawbead forces. Each local object is defined in All
stages like Drawbead with material object type.
Global object with movement, containing all local drawbeads

objects, is defined. This object is undefined in All stages.
2. All drawbeads in project are in local objects. Drawbead forces are

applied.on every local object. Each local object is undefined in All
stages.
SIMULATION CONCEPTS
Drawbead
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Global object with movement, containing all local drawbeads

objects, is defined. This object is defined like Drawbead with
material object type in All stages.
3. Sometimes 3Dcurves or bars are needed in results for post

processing. False drawbead object is defined like Drawbead with
material object type in All stages and is not passed to the solver
(there are no process atributes in atribute tree).
Upgrade procedure:
1. Open project in a new version

2. Use Upgrade option in Project menu.
3. Delete Global drawbead (or undefined)
object used for movement
SIMULATION CONCEPTS
Drawbead
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Objects linking after old project upgrade
After the upgrade of the old project it may happen, that the die and blankholder are not
linked.
Automatic link of the die and blankholder is done only if both of the following
conditions are satisfied:
1. Die object in old (2009 and older) db definition dialog was linked.
2. Blankholder object was put to be opened by opening force.
Linking of the die and blankholder in v2011 is mandatory. If not defined, the solver will
stopwith an error.
Always open the drawbead editor and check (or set) links to die and blankholder after old
project upgrade.
Click on APPLY in case of each drawbead object, if link was set!
Shared nodes duplicating of different drawbead objects
It is recommended to avoid neighbour curves (curves with extremities at the same

point).
If there were local drawbead objects with extremities at the same point in the old
project, after upgrading the procedure duplicated nodes are shared and curve is
transformed to neighbour curves.
General upgrade project information
fictive drawbead objects without drawbead force attributes are transformed

into undefined objects.
If pins are not set at extremities in the previous version, it is no longer

necessary to add pins at extremities.
If you need to delete an inner part of a curve because a drawbead is removed

locally use a zone with 0.0 as forces, instead of splitting the curve (it is then
easier to change).
SIMULATION CONCEPTS
Drawbead
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SYMMETRY PLANE
Purpose
The purpose of the symmetry plane is to restrain the model when the part to be stamped
includes symmetry planes, in order to shorten the CPU time. Only part of the model will
be modeled.
Data Set-up
In order to define a symmetry plane, the user must create a plane-type object, define its
position in the Definition attribute, activate the Symmetry attribute and define a
tolerance.
Default value:
The Tolerance is set to 0.1 by default.
To check that all required entities are within this tolerance, one can use
selection by plane.
Operation
All the entities (elements, faces, edges or nodes) whose distance to the plane is shorter
than the tolerance at the start of the calculation, will get applied symmetry conditions.
An entity lying on the symmetry plane, cannot have an imposed velocity that is not in
the plane. This is not compatible with the symmetry plane.
If at least one node of a rigid body belongs to the symmetry plane, symmetry conditions
are applied to the center of gravity of the rigid body.
SIMULATION CONCEPTS
Symmetry Plane
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Influence of a Symmetry Plane on an Offset

If a symmetry plane has been defined, when an offset is performed, the nodes created
from the nodes belonging to the symmetry plane will remain in the symmetry plane.
Offset mesh
Offset mesh
Symmetry plane
The boundary remains in
the symmetry plane
Therefore, the symmetry planes must be generated before any offset.
SIMULATION CONCEPTS
Symmetry Plane
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PICKING
Purpose
The purpose of picking (Picking of / Computed model option) is to retrieve the results of
a previous calculation to build a new one. These results are recovered from the restart
file of the previous calculation, which contains all the information required (meshes,
thicknesses, stresses, strains), at a given time.
Operation
The Picking dialog box (accessed through Picking of / Computed model) allows the
picked objects to be selected:
Choice of the restart file from which the data will be retrieved. The program gives
information about the value of the progression when the restart file has been written.
Choice of the objects that the user wishes to pick. Then, the material properties,
stresses, strains, thicknesses will be recovered.
SIMULATION CONCEPTS
Picking
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Picked Information
-
The material attributes (including the thickness and the rolling direction), are
systematically recovered, moreover, they can no longer be modified.
The drawbead forces attributes may be modified: the list of objects, the restraining
and opening forces may be edited, but not the value of the action radius.
Any element of a picked object must belong to a picked object that has a material
property.
Example:
If the die is separated into several zones, but only the "die" object has the with
material option in the object type attribute, the user cannot pick one of the zones
of the die alone but has to pick the whole die.
When a picking is being performed, the nodal coordinates, element connectivities

and the material properties are imported into the gn.pre file (which contains all of
the project data); the values per element (stresses, plastic strains, etc.), are only
loaded when the calculation is started.
Several pickings from several different calculations can be performed within a

single project.
When an object containing an adaptive mesh attribute is picked and when these
elements are not deleted, an adaptive mesh attribute must also be defined in the new
calculation. It is possible to stop refinement by using a maximum level of
refinement equal to one.
Options
Options available when picking the object (Picking dialog box):
-
Pick nodes velocities:
If this option is selected a Picking attribute with the selected

option is created (see next paragraph) in the first stage.
Perform annealing:
If this option is selected, all the strains and stresses are set to
zero.
-
Multiply stress by factor:
If this option is selected a Picking attribute with the

selected option is created (see next paragraph) in the first stage.
Pick temperature:
Pick attributes: This
This option allows the picking of nodal temperatures between

stages of thermal based calculations.
option put automatically in the existing stages all of the
attributes of the selected objects and the global object. These attributes may be
modified subsequently. If there was already attributes defined for global objects,
there are completed or replaced.
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Picking
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Pick progression and time: This
Special treatment for failure criteria:
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option is available only if the Pick attributes option

is selected. When the progression variable is the stroke, the time which corresponds
to the stroke value of the picked restart file is automatically put for the parameter
Time origin of the Control menu. It enables the user to define the origin of the times
to use time-dependent curves (imposed velocities, forces, ) (see Control
Parameters).
This dialog appears only if a Matfem material is
available in the restart file. It enables to apply a Heat treatment coefficient for the
failure criteria of the Matfem materials; and to choose if the user wishes to continue
the failure estimation of the previous stage or to start from beginning.
Options available during data set-up (Picking attribute):
Pick nodes velocities:
By default when picking, the velocities are cancelled out

during the next operation. Especially for lancing operations or complex multi-action
forming, one wants to keep the velocities of the nodes in order not to disturb inertia
of the blank sheet. If, however, an initial velocity is defined on an object, the
picking velocities are erased. This option can be added to any stage and is applied
for all objects.
SIMULATION CONCEPTS
Picking
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Perform annealing:
Multiply stress by factor:
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If this option is selected, all the strains will be set to zero and
Multiply stress by factor 0 will be activated by default. This option can be added
to any stage and is applied for all deformable objects.
This option allows the user to modify the stress values
during picking in order to model annealing processes (stress factor between 0 and 1)
or spring-forward (stress factor 1). This option can be added to any stage and is
applied for all deformable objects.
Note:
There is another possibility to multiply stress and strains on an object when

starting a simulation of any process stage. This is independent from picking and
is done using the Values initialization attribute on blank object (see also chapters
Objects and Attributes and Hotforming ). This attribute allows the user to modify
the initial stress and strain values of any deformable object at the beginning of
any stage with factor between 0 and 1 for performing special initial conditions
(eg. for warmforming simulation). Stress factor allows values between 1 and 1
(negative factor may be used for spring-forward calculation).
Pick time origin: When
the progression variable is the stroke, the time which

corresponds to the stroke value of the picked restart file is automatically set for the
parameter Time origin of the Control menu. It enables the user to define the origin of
the times to use time-dependent curves (imposed velocities, forces ) (see Control
Parameters). This option cannot be added to the first stage, for the first stage you
have to select it in the picking of computed model menu.
Pick progression: This
Pick Temperature:
Special treatment for failure criteria: This option allows the user to apply a Heat
treatment coefficient for the failure criteria of the Matfem materials; and to choose if
option allows the user to keep the progression type and

values: in such case, the calculation does not restart from zero but from the value of
progression of the picked restart file, and this value is automatically put for the
parameter Start at of the Control menu. This option cannot be added to the first
stage. Instead, you have to select it in the picking of computed model menu.
This allows the picking of nodal temperature between stages for
thermal calculations.
the user want to continue the failure estimation of the previous stage or to start from
beginning. This option is available only with Matfem materials.
SIMULATION CONCEPTS
Picking
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Warning:
The program records in the project, the name and the directory of the restart
file, if it is different from the project directory. Consequently, if the picked
restart file is moved in a directory different from the project directory, it is
necessary to define the new path of the restart file in the project (Project /
Restart files option).
SIMULATION CONCEPTS
Picking
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DISTRIBUTED MEMORY PROCESS (DMP)

DMP is available only for PAM-AUTOSTAMP.
Definition
DMP is a method of computation on several processors that greatly reduces CPU time,
it is therefore very well adapted to large model simulations.
With DMP, the computation is distributed over n processors.
With SMP (shared memory process), n processors share the computation, each
processor accessing the same data, so some operations in the code remain sequential.
The model is shared on all processors, one is the master processor, it collects and
merges results from all processors.
SMP version
DPM version
Definitions
SMP relies on shared memory for

communication.
Processes running in parallel exchange data

via messages. No shared memory is
required, as each process addresses its own
memory space.
Standards
OpenMP directives and variables.
MPI message passing library.
What is done
in parallel
Loops and sub-programs are parallelized.
The model is decomposed into subdomains acting as local models for each
process executing the same program.
Simple
Scheme
Initialization
Sequential parts
Parallel loops
The SMP version can only be run onto a single computer, which has to be contrasted
with the possibility of running on computer clusters for the DMP version (see DMP
Version section hereafter).
Characteristics
The DMP solver version can be used on two hardware architecture types:
-
a single node computer,
a cluster of computer nodes.
SIMULATION CONCEPTS
Distributed Memory Process (DMP)
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A cluster is a collection of interconnected stand-alone computers that are used as a

single computing resource. Each stand-alone computer in a cluster is called a node.
Available options
DMP is available for:
-
All contact types.
All materials (except user material)
Shell and solid elements
All the rigid body types
Multistage calculations.
Trimming and positioning operations.
Explicit gravity.
Explicit springback.
The following conditions can be used with DMP:

-
Cartesian and rotational kinematics
Boundary conditions on points
Force and pressure
Fluid cells and aquadraw
The following options are available:

-
Adaptive meshing use.
Symmetry plane.
Drawbeads use.
Multi body system definitions
Freeze
Thermal properties
Element elimination
EWK rupture model
Substructure
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After a DMP simulation, the following post-processing options are available:

-
Historic Output
Contact marks
Drawbead marks
Repeatability
The results of a simulation do not depend on:
-
The number of processors used to run the computation.
The mode of parallel simulation, SMP or DMP.
The decomposition of the model during the DMP simulation.
Interoperability
The restarts are compatible:
-
between all platforms,
between SMP/SP, SMP/DP, DMP/SP and DMP/DP.
Restarts of DMP on n1 processors are compatible with restarts of DMP on n2

processors.
Scalability
Performance depends on:
-
Hardware: the calculation time is controlled by the slowest calculation or processor

but also by communication between processors.
Model size: the performance is better on large models.
Besides the initialization, there are very few sequential operations. The limiting factor
of the DMP version is message passing between processors. Domain decomposition
techniques and solver programming aim at minimizing communication time.
Files
Some files are common to all processors (*.pre, *.out, *.his, *.res), but there is
one restart file (*.rst) per processor. There is also one listing file (*.lis) per
processor but they are merged at the end of the calculation
SIMULATION CONCEPTS
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DMP Decomposition
The model is distributed on the processors using a DMP decomposition attribute of the
global object. Two methods are available, the LCB and the CCB. The decomposition is
based on the number of deformable elements, and it is performed at each stage.
With a specific contour it is possible to visualize the decomposition in the postprocessor.
The decomposition takes into account adaptive mesh.
If there is no DMP decomposition attribute defined, then LCB will be used.
SIMULATION CONCEPTS
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Linear coordinate bisection (LCB)
PROC 1
PROC 2
PROC 3 PROC 4
LCB Direction
The model is divided in a linear fashion. The axis can be defined by the user or
automatically defined. In the latter case the selected axis is the largest direction of the
model.
Cylindrical coordinate bisection (CCB)
PROC 1
PROC 2
Point + axis
PROC 4
PROC 3
The model is divided in a cylindrical fashion around a point and axis.
Utilization of DMP
A multi-processors machine or a cluster machine is needed and the MPI libraries must
be installed for the communication between processors.
Prerequisites
In all cases, the Message Passing Interface library (MPI) must be installed on the
system.
For running the DMP version on single node hardware, there is no other particular
prerequisite.
For running the DMP version on a cluster of UNIX system nodes, all the computers
participating in the cluster must be configured as Trusted hosts. This requires
having the same user account and the ability to remotely login to each of the nodes
participating in the cluster, without prompting for a password.
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In order to meet this requirement, make sure that the remote hosts security policy is
correctly set up. This can be achieved by setting up security files authorizing access by
remote hosts and users on local host: hosts.equiv, .rhosts.
For example, in the users home directory, the .rhosts file must contain one line for
each participating host. If the user account is doe, in order to use machines a.our.org
and b.our.org, the .rhosts file should contain the following entries:
-
a.our.org
doe,
b.our.org
doe.
Specific data set-up

To optimize performance, which is the purpose of DMP, all tools defined as rigid
bodies and the elements of the drawbeads must be part of a rigid body on which the
kinematics are applied.
Start a DMP calculation
To start a DMP calculation the Start menu is used, and information on DMP nodes are
defined in the DMP node dialog box available from the Start menu.
It is also possible to run it without the GUI, using the following command line:
pamstampdmp np NPROC *.pre > *.out
or
pamstampdmp cf clusterfile_name *.pre > *.out
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PROCESS SETUP
Purpose
The process macro enables the user to automatically perform several successive
operations during the setup. With a set of process macros at his disposal, the user is
significantly more efficient in building the simulation setup.
Standard public macros are available in the installation directory, but the user should
create his own macros, adapted to his process, way of working and language in order to
have very easy of use set-up.
Several types of process macros are available:
-
AutoStamp standard forming
macros, including volume blank, hotforming, roll

hemming and use of fluid cell (*.ksa)
AutoStamp tube forming
macros (*.ktf)
AutoStamp tube bending
macros (*.ktb)
QuikStamp Plus
Inverse standard forming
macros (*.ksp)
macros (*.ksi)
The concept of a process macro is divided into two steps:

-
Creation of the End user macro with the help of a Stamp Tool Kit according to the
process requirement by the so-called Advanced user.
SIMULATION CONCEPTS
Process Setup
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The use of the created macro by the End user in the standard software environment.
The End user enters a reduced number of parameters to set-up his project.
Stamp Tool Kit
To access the Stamp Tool Kit the user must activate the Advanced mode in the
Customization menu (it can be done by default, in the Customization / macro menu).
After creation, a new macro is saved as an independent file into a directory, which can
either be created especially for all available macros or be the default project directory.
All predefined macros are presented to the user from the Process / Data set-up wizard
option directly. The user easily opens the chosen macro and applies it to the process
setup.
If modification of the macro is necessary, the macro has to be opened from the Project /
Open menu and all the required modifications are conducted from there
See the Customization chapter of the Simulation Methodology for Design and Stamping
feasibility section to have other information about the Stamp Tool Kit use.
SIMULATION CONCEPTS
Process Setup
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Stage
Each stage is defined as a period of time during which each object has only one type of
kinematic effect applied to it, i.e. static, dynamic or applied force. When creating a new
macro, different process stages can be chained one after another. These stages can be
added, renamed or deleted.
The type of stage is selected. The user
determines the location of the new stage
relative to the stages already defined.
The first stage is defined as empty, all
following stages can be added with one
of two data loading possibilities:
-
Empty:
The new stage does not

contain any initial data, it is empty.
Keep tools:
Only tool geometries are

imported from a previous stage to the
new one.
Each stage contains the necessary tools. A stage is designed in a diagrammatic format
on the left hand side of the Stages panel. The Advanced user drags the tools in the
diagram and draws the schematic of the stage. If a tool is not active in one stage, its
entities (nodes, elements, 3D curves) will not be taken into account by the solver during
the computation.
Blank
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Process Setup
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When a stage is created, blank or tube is automatically shown.

The following options are available for blank:
-
Add
blank: A new blank will be automatically created.
Volume
With Offseted tool:
blank: It can be activated in the blank panel for AutoStamp standard

forming macros only
It can be activated in the blank panel for Quikstamp plus forming
macros only. This option manages the contact attributes that will be all defined with
offseted tool option for contact thickness.
Diagram and Preview Panel

The schematic in the Stages panel is a 2D representation of the process. The user can
visualize the process during the macro creation. The Preview panel shows the user what
the macro will look like in the GUI. A separate bar at the bottom of the schematic grid
enables utilization of process tools, which cannot be represented in a 2D view, like a
feature line or a free tool.
The user can pre-define a color to be used for the blank object (right click in the
diagram, Edit/Color menu)
Tool
A tool is a specific type of object, e.g. die, punch, drawbead,

guide, clamp, bend die etc. A tool is defined by its
representation in the schematic grid of the Stage panel and
specific type of attributes. A tool, as seen by the advanced
user, will correspond to an object, as seen by the end user.
The tool shapes are simplified and represented by buttons
either in the Tools menu or in the Macro editor toolbar.
Other specific tools enable the advanced user to define post
process attributes on some objects:
-
Feature line:
It is used to define some node marks.
Element history:
Node history:
Free tool:
This tool represents an object

containing elements and nodes. With this it is possible to
plot history curves for post processing.
This tool represents an object containing
nodes. With this it is possible to plot history curves for
post processing.
SIMULATION CONCEPTS
Process Setup
It is used for all the attributes the advanced
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user wants to define in a process, for example, mesh

refinement for the blank or end of gas spring
(automatically set).
The available tools are the following:
-
Standard Tool, rotating tool and mandrel:
Standard tools are defined by fictitious

material attributes. They have automatically a rigid body and a contact attribute with
the blank or tube. Transformation attribute is automatically defined for autopositioning with blank (standard forming macros type).
Guiding:
Drawbead: A
Spacer: A
Spotweld: Spotwelds
Trimming: It
Symmetry plane:
Gaz spring:
Ball:
It can be a guide or a locator pin. A guiding tool can only be applied lock
or imposed velocity. It has automatically a contact attribute with the blank or tube.
drawbead will be applied restraining and opening forces via the
drawbead forces menu. It can only be located on a standard tool and has the same
kinematics.
spacer is a tool that has contact with other tools.
are specific tools which represent the constraint between

double-sheet blanks. It can only be associated with the blank onto the schematic
grid, when double blanks are available.
represents the trimming curve. Transformation/Trimming attributes is
automatically defined in the global object
It represents the symmetry plane, with a symmetry attribute.
It can be located only on standard tool and has the same kinematics. End
of spring free tool is automatically created with a behavior definition (accessible
with right click menu on the tool name).
are defined inside the tube. Automatically Multibody system attribute is
opened. It has rigid body and contact attributes.
All tool names are written into the Tools panel along
with a comment that specifies if they are used or not in
the stage.
Several options are available in the right click menu,
depending on the tools type:
-
Add position:
The user can add position in the

diagram to have a realistic process drawing
Edit:
The user can also modify the tools type for

standard tool
Delete
The user can edit and pre-define the color to

be used for the tool object or rename it.
the tool
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Process Setup
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Thickness:
Thermal material:
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Thickness can be added on tools for

simulation with volume blank for instance (see
Contact and friction chapter)
user can add a thermal material
attribute to a tool
-
Volume:
user can specify if a tool is a volume tool
Multi body system:
Behavior:
The user can access to the

multi body system definition
it is used to define behavior common to
all stages, for gaz spring for instance.
The right click menu usually enables the access to the

all stages attributes of the tools.
Behavior
Behaviors can be applied to the tools or blank from the Tool menu, the Toolbar or with a
right mouse-click in the diagram. The user can apply gravity, velocity, force, locking of
movement , by positioning the chosen option onto the tool in the diagram; the
attributes corresponding to the behavior will automatically be defined in the attributes
tree.
The available behaviors are the following:
-
Lock:
It put automatically Cartesian Kinematics attribute with everything locked.
Velocity:
Imposed displacement:
It brings up the Cartesian Kinematics dialog, partially fulfilled.

It brings up the Cartesian Kinematics dialog, partially
fulfilled.
-
Rotation:
It brings up the Rotational kinematics dialog. It can be located only on

rotating tool.
Force:
Follower Force:
Pressure:
Gravity:
Springback:
It brings up the Forces dialog.

It brings up the Follower forces dialog.
It brings up the pressure dialog
It brings up the gravity dialog. It can be defined only on blank.

It brings up the springback dialog. It can be defined only on blank or
tube.
-
Fluid cell:
SIMULATION CONCEPTS
Process Setup
It brings up the fluid cell dialog. It can be defined only on blank or tube.
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Note:
All the attributes and behaviors, defined in the Stamp Tool Kit, will be
automatically created in the attributes tree of the project when the process
macro is applied by the-end user.
Attributes
The process attributes have to be defined for all tools drawn schematically in the Stages
panel, and also for the blank(s). These attributes are shown in the right hand part of the
Stages panel. Specific attributes assigned to each tool characterize its function during
the stamping process. These permitted attributes can be setup by means of the attribute
tree.
Click on the defined tool in the diagram,
and the corresponding tool name appears
in the Attributes panel. Here the user can
add new attributes (rigid body, contact,
Cartesian kinematics, force, pressure,
CPU control, etc.) with a right mouseclick into the Attributes panel for the
corresponding tool. Available options
from which the user can choose new
attributes depend on the tool type. The
program automatically offers the
corresponding options.
Parameters
The Parameters window (in the right part of graphical window) shows the existing
parameters and allows specifying new ones.
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Process Setup
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Several options have to be defined:

-
The Type of parameter: One from four options must be chosen (integer, real,
coordinate system, 2D function).
Modification level:
Advanced user:
End user:
The kind of level chosen is very important:
All the parameters defined in this level are not available for
some changes by the End user. The parameter values are fixed and taken into
account during the process. They are hidden and the user does not see them in a
macro. The main advantage is that the Advanced user can create the parameter
"Friction", use it everywhere for contact definition and only at the end define the
imposed friction value. If the Advanced user wants to modify this value, it needs
only be modified in the parameter definition and not in each attribute.
The parameters created in this level are variable. The user has to
define them in the PamStamp Macro-command.
Value:
For a parameter at the Advanced user level, this value is the fixed value of
the parameter. For a parameter at end-user level, this value is a default one, which
is proposed to the end-user when he uses the macro-command. The end-user can
then modify it.
These parameters are defined during the Attributes setup. They can be added or deleted
by using the right mouse-button.
The created macro is then saved and can be used for subsequent work by the End user.
Unit system
The provided macros are defined in mm.kg.ms.C unit system.
But user can create his own macro with another unit system.
Macro files
The macro files from v2012 onwards use an ASCII format which is identical to the
attribute file (.att), but with an additional paragraph for the definition of the
parameters. These files can be edited by hand if required.
Note
If modification of the macros is done in Ascii file, there is no check of the data.
The user is then responsible of doing a correct data set-up.
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Process Setup
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End User Macro
To access the macro, the user has to open the Process / Data set-up wizard
and to choose the required macro. This macro is subdivided into
several parts in which the user defines the parameters.
When the end user uses the Save button, all data already defined in a macro is saved to
memory. After re-opening this macro, the data will again be available.
Multiple operations
The macro management buttons
successive operations.
enables to load several macros and to define
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When applying the macros, the stages of each macro will be added one after each other
in the attribute tree. The user can later check the data by opening the different used
macros that appear in the drop list at the top level of the macro.
This can be also useful for more complex process with several holding stages or
stamping stages, and should answer most of the processes.
It is possible to replace all processes in one click by using the
Customize
After loading a macro, the corresponding
operation (defined previously in Tool editor) has
to be selected. The tools and the stages that are
necessary for the process must be selected also
and renamed if the name is liable to lead to
confusion (for example when loading several
macros).
SIMULATION CONCEPTS
Process Setup
button.
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Blank Material
The user can choose an existing material
in the database or create a new one. He
can also keep the one already defined in
the Blank editor.
Diagram
When the corresponding object(s) and the parameters of a group are defined in a stage,
a straight line in the 2D diagram represents the group.
Group
A group represents a tool or the blank, as defined by
the Advanced user. It is selected from the group
drop-down list . The corresponding object is then
chosen from the object drop-down list or by clicking
on it in the 3D view.
If a group is not used in a process, the-end user can
easily delete it by deactivating it in the customize
menu. At the same time this group will be removed
from the 2D diagram together with all its parameters.
Duplication
Some object groups like the mandrel balls in Tube process can be duplicated using the
icon
The same functionality is still available for blanks that can be duplicated for tailored
blanks simulation. But this procedure is now useless since tailored blanks properties are
now defined through Blank and Tool editors (see Tailored blanks chapter for further
information).
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Automatic fulfill
The groups are automatically fulfilled if the previous steps (blank editor / tool editor /
drawbead editor) of workflow have been done.
It can also be done using the group management menu whenever the user wants.
The group number can be defined using the Set button and its associate value filed.
Macro update
The purpose of this option is to modify the content of the macro process from the
existing attributes tree of the project. This is useful for iterations, when the user wants
to modify one parameter of the process (friction, thickness, blank holder force) from the
macro. The modifications that he may have done previously in the attributes tree will be
kept.
The macro button
SIMULATION CONCEPTS
Process Setup
enables to open the following dialog:
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It is used to indicate the correspondence between each macros stage and each projects
analysis.
After pressing this button
the system will update the macros stages with
the content of the attributes tree. Then it is possible to accept or to reject each change
that has been made to the macro, and a dialog automatically opens:
Previous macro content
Updated macro content
The left side is the previous content of the macro; the right side is the new content of the
macro. By default all changes have been already made (selection in red). However if the
user wants to cancel a modification, he just have to click on the lines of the left side he
wants to revert, and then press the
button to validate.
Macro complete
Sometimes the end user wants to partially apply the macro, thats to say he wants to
keep some projects stages and apply some other macro stages. This is done by clicking
on the complete button
.
A dialog opens to ask the user which macro stages must be applied, and which project
stages must be kept or not:
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In this example, the gravity and holding macro stages will replace the corresponding
project stages, the stamping macro stage will be inserted in 3rd position, and then the
original stamping analysis will be kept.
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Process Setup
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OFFSET
The offset is done to build tools based on the mesh of an initial CAD geometry
representing the complete die geometry modeled either on die or punch side. It can be
performed through the Tool editor or outside the dialog by using the transformation
menu.
The Initial CAD Corresponds to the Die

Two successive offsets will be performed to generate the punch and the blank holder
using different selections of the initial mesh:
blank holder
punch
blank holder offset
punch offset
initial CAD (die)
The Initial CAD Corresponds to the Punch and Run-offs:

The mesh corresponding to the initial CAD should be used for offsetting in order to
create the die. Then the original mesh of the CAD on the punch side should be
separated into two non connected meshes: punch and blank holder.
Penalty Contact
blank holder
punch
blank thickness
source CAD
die
blank thickness
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Accurate Contact
There are two methods for die creation:

-
Gap on die side:

The offset value to generate the die is the sum of the blank thickness and gap.
blank holder
punch
blank thickness
source CAD
blank thickness + gap
die
Gap on punch side:

The offset value to generate the die is the blank thickness.
An offset with the gap value is performed from a selection of the initial mesh to
create the punch. The blankholder is created from a selection of the initial mesh.
The initial mesh not used for the blankholder is deleted.
source CAD
blank holder
punch
gap
blank thickness
die
QuikStamp Tool Editor Macro without offset

When a feasibility simulation is performed with QuikStamp Plus without offset, the
tools are created by an offset of 0 mm. In that case, there are no offset parameters, no
gap information and no blank thickness to set up.
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Offset
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Offset Types
The offset creates a second mesh parallel to a mesh of shell elements (3 or 4-node
elements):
Offset mesh
Offset
Initial mesh
Two algorithms are available for offsetting; one is for Accurate contact, the other for
Penalty contact.
The offset for Accurate contact is very precise, but does not deal with low mesh quality
(overlaps, free edges ).
The offset for Penalty contact deals with local defaults:
Non Linear Penalty offset
Penalty offset
x
Offset value x
The offset is saturated to l
The offset is saturated when is higher than a Trigger angle. Then the length l is equal
to the offset value x, multiply by a factor, Transfer level. By default, the angle is 50 and
the offset is saturated to x (Transfer level is then zero). But these values can be
managed from the Offset parameters dialog:
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Non Connected mesh

Non connected mesh can be offset.
If the gap between two free edges is small, it is considered as a mesh defect and it is
treated so that the offset does not increase the mesh defect:
Gap
Treatment of the gap:
Gap
The maximal distance of the non connected meshes can be managed from the Offset
parameters dialog:
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Offset
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Symmetry Plane
The offset takes into account the presence of a symmetry plane:
Offset mesh
Offset mesh
Symmetry plane
(no
symmetry
plane)
The boundary
remains in the
symmetry plane
For this reason, symmetry planes must be defined before applying Tool editor.
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Offset
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MESH CHECK AND CLEANUP

Purpose
The simulation of stamping requires getting a mesh of the tool surface. This mesh must
have precise characteristics in order to get a correct simulation. Moreover, the mesh of a
tool is usually offset in the setup in order to create the mesh of the other tools (like a
punch create by offset of a part of the die).
The tool Mesh check and cleanup has the following objectives:
-
Analyzes the displayed mesh and identify bad quality area, based on some
criteria
Repairs the mesh where the quality is not sufficient.
Mesh check and cleanup

The dialog is available from the menu Geometry Check/Repair Mesh check and
or directly from the tool editor through the
selected).
cleanup
button (with the Clean item
When pushing the Check button, the displayed mesh is analyzed following some
criteria. These criteria are defined through the
SIMULATION CONCEPTS
Mesh Check and Cleanup
button close to Check.
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Mesh check criteria
The most critical issues are checked. They are all optional:
-
Too small elements: if elements are very small, they can be an issue in contact
algorithm and they would likely produce waves at the offset. Smaller elements than
0.1 by default are detected. It is highly recommended to detect and repair these
elements. Note that if the mesh has been produced by Deltamesh Stamping, it is
recommended to use here a value equal or smaller to the minimal size set to
DeltaMESH.
Element warping angle: in order to avoid issues in contact algorithm, warped

elements must be avoided. It is highly recommended to detect and repair these
elements.
Angle between elements: to obtain a correct contact and sliding during the
simulation, this angle should be as small as possible. This is important to analyze
these areas. Note that repairing the mesh is not always possible, especially if the
model has not been filleted and contains sharp edges. In that case the user should
neither select this criterion nor clean all the mesh automatically but only locally (see
the mesh clean paragraph hereafter).
Offset results: the very interesting functionality is the analysis of what would be the
resulting offset of the mesh. The offset is defined by a direction and a distance ; this
distance should be the thickness of the blank (or thickness and a gap). The direction
is displayed by an arrow on the screen, showing on which side of the mesh the
offset will be done. This offset analysis requires that the mesh has been oriented
beforehand. The defect elements are the one which produce:
Reversal of elements: if the orientation of the offset element is inverse, it means

that the offset has been inverted. It occurs often in very small areas where the
local radius of curvature is small compared to the offset distance.
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Angle between elements after offset: if the resulting offset produces sharp
edges, the initial elements are considered as critical.
Note :
The offset analysis requires that the mesh has been oriented before.
Mesh check
When the user pushes the Check button, the analysis is performed using the preset
criteria. If criteria have not yet been used for the model during the session, a dialog is
prompted asking the user to enter the distance of offset to use and the direction.
Once this is done, the number of critical elements is displayed in the dialog. Elements
are grouped into zones which are highlighted in the 3D view: a zone contains neighbor
critical elements (using a distance called zone radius).
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Note that the zone radius can be changed in the advanced area of the dialog using the
button.
In the advanced area of the dialog (obtained by clicking on
), details
about defects are listed for the current zone. The current zone is set by clicking on the
corresponding arrow in the 3D view when the
button is down. With a double
click, a local zoom is performed and only elements close to the zone are displayed, in
order to see the mesh easily. Clicking the
button will undo or redo this focus.
Mesh clean
Full and automatic cleaning
Once the defect elements have been detected, the user can ask to simply clean all these
elements by clicking the Clean button. A progress bar is displayed and automatically
stops only once all elements have been corrected.
Once it is finished, zones are displayed with a green arrow, and in order to validate the
changes, the distance between initial and final mesh is computed. If a new element is
further than a given distance (set by pushing the
button in the text) to the initial
mesh, it is displayed in red. If it is closer, it is displayed in green. Moreover the
maximal distance is displayed as results in the dialog.
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If the mesh is too far from the initial one, the user can undo the correction locally: See
the Undo paragraph hereafter.
The user can stop the cleaning at any moment by pushing the Stop button. It is possible
to keep on cleaning after pushing the Clean button again.
It will then display elements in their current state:
-
Initial zones fully cleaned are displayed with a green arrow
Not fully cleaned zones are displayed with a red arrow.
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Likewise, the number of still critical elements and zones are displayed.
Local cleaning
If the user stops the cleaning (or even from the beginning), he has the possibility to
either clean zone by zone, or entity per entity. This is available in the advanced area of
the dialog:
-
select a zone by the
button.
The list of critical entities with a description of their defects is displayed.
The user can clean the zone or only the selected entity in the list through the
Clean entity and Clean zone(s) buttons.
Undo
It is always possible to undo cleaning carried out as long as the dialog is not closed. A
full Undo is available through the Undo button. Local undos are also available:
-
By pushing down the

button and clicking an element: this element and
all the connected ones inside the same zone will go back to their initial state.
In the advanced area, per entity or per zone through the Undo last entity and
Undo last zone(s) buttons.
Cleaning principles:
The mesh cleaning algorithm does not have access to the CAD surfaces. It only uses
initial nodes and elements. In order to be sure that nodes rely on the initial surface, no
node is added by the algorithm. Nodes are merged, edges are swapped, and connections
are transformed in order to get the best elements according to the criteria.
Recommended strategy:
It is recommended to try first the full and automatic cleaning. If it takes time (note that
the percentage of correction sometimes decreases due to propagation of errors), the user
can stop and check the results: it is useful to focus on zones not yet corrected and check
especially if the cleaning is too intensive and not going right.
If this is ok, you can keep on cleaning by pushing Clean again.
If it is not good, you can undo locally the cleaning of the zone (using the
button
and clicking an element in the 3D view). In that case the algorithm cannot clean the
model locally but you can select entities and clean them one by one.
If it is still not good (undo is always possible), you may have to quit this dialog and edit
nodes or elements.
Another result to check ( even if the model was fully cleaned in one shot) is the
distance to the initial mesh: check the maximal distance displayed in the dialog and
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zoom on elements in red in the model. If this is not okay, you can undo locally by
clicking an element with the button
down.
Limitations:
There are some defects in the initial mesh which are not detected and cleaned by this
method:
-
Overlapping elements
Holes
These defects rarely occur when using DeltaMESH Stamping for getting the mesh on a
relative clean CAD model.
The cleaning algorithm cannot be used for filleting. It can detect and solve local sharp
edges with efficiency. But if a fillet is missing do not expect the cleaning algorithm to
locally correct the situation.
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FILLETING
Purpose
In order to obtain realistic results, the tools used in the stamping simulation, which are
represented by meshes, must be completely filleted as they are in reality. A sharp edge
leads to a likely rupture of the blank, just as in the reality. However, all fillets do not
need to be created in the CAD, since the filleting can be performed directly on the mesh
using DeltaMESH Fillet.
From the definition of radius values on edges in PAM-STAMP2G, DeltaMESH Fillet

builds a CAD model. It is not visible by the user. This temporary geometrical model
will be meshed by DeltaMESH Fillet and the new mesh will be imported and merged
into the initial sharp edges model. Using few parameters, DeltaMESH Fillet can set an
optimal distribution of nodes on the surface. The user has the possibility to go back to
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the sharp model, or to apply a new radius value to edges that have already been
filleted.
A list of fillets are created and stored. These fillets contain all the information of the
sharp models, they are used to unfillet and refillet.
Set-up, Design
Filleting is available both in Design and Set-up modules.
In Design modules, unfilletting is available only when sharp edges that are filleted, are
located inside the part. No elements of the addendum must be modified by the filleting
action if the user wants to do unfillet later.
Fillets done in design modules can be modified only inside this module, but not in the
set-up. The user only has to go back in the design module, unfillet and refillet them and
update the set-up.
Filleting
Filleting is done on the fillets selected by the user (see next paragraph), however there
are some constraints:
-
When asking for filleting a specific selected fillet, it is possible that another non
selected fillet is automatically filleted in the same time. Fillets that share edges or
that are very closed to each other (one fillet is in the influence area of another one)
are filleted in one shot. This ensures the consistency of the mesh and the possibility
of unfillet.
The meshing parameters (that are not in Fillet parameter) are the ones of the last
DeltaMESH session.
If a fillet length is smaller than the radius value (for instance, fillet containing only
one sharp edge) it could be not filleted.
Note :
It is possible to change the meshing strategy and remesh all fillets (Project ->
Change mesh strategy )
Object content
Automatic fillet object can be created during filleting, depending on the following rule:
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Filleting
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When a fillet belongs to a border of several objects, like the die entry line that limits the
binder source and in the punch source objects, a Fillet object will be automatically
created containing the elements of this fillet. When fillets are completely contained in
existing objects, the created elements after filleting will be kept inside them.
Re-filleting
It is possible to unfillet and re-fillet existing fillets done in PamStamp 2G, however
there are some constraints to keep the re-filleting possibility:
-
Fillets described in the fillet list must not be deleted.
Mesh of fillets should not be modified.
Fillets in the design module must be done inside the part and not on the borders with
addendum (see previous paragraph).
When asking for unfilleting a specific selected fillet, it is possible that another non
selected fillet is automatically unfilleted in the same time.
Procedure
Fillet definition
There are several ways of defining the fillets:
-
Autobuild: fillets are created using an

Max angle for sharp edge detection
optimal distribution of edges (defined with the

parameter, in the Fillet parameters menu). If
fillets already exist, they can be replaced or completed with the new ones.
Pick 2 nodes, Pick edge:
by picking 2 nodes on sharp edges or one sharp edge (by

propagation), the user will create a new fillet.
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Split, Merge, Delete:
these functionalities enable the user to split, merge (The second

fillet receives the edges of the first one) or delete selected fillets of the list.
When fillets are created they are displayed in the fillet list with Default radius value
assigned on them. It is possible to change the Name of existing fillet.
Note
A sharp edge can not belong to several fillets.
Radii definition
When being created, fillets have a Default radius value, but it is possible to modify them
with:
-
A constant value on the selection, using the Set radius to selection
A constant value on one fillet, using the Constant definition
Interpolated values, defining Radius 1 and Radius 2 on the two extreme nodes of a
fillet.
Actions
It is possible to fillet or unfillet selected fillets of the list or to Fillet all, Unfillet all. At the
end of the filleting session, groups of fillets are built (the user does not see them). Fillets
of the same groups might be filleted or unfilleted even if they are not selected in the list.
The status of a fillet is written in the list.
Fillet parameters
This Fillet parameters menu allows the user to configure DeltaMESH Fillet meshing
parameters. The other meshing parameters for fillets are the ones of the last DeltaMESH
session.
The most important fillet parameter is the Max. Angle Criteria, that must be set to 7.5
when doing High Quality simulation and must be kept to 15 for feasibility. See the
Simulation methodology for design and stamping feasibility and Simulation methodology
for high quality stamping sections.
The other parameters are:
-
Minimum radius:
DeltaMESH Fillet creates a CAD model according to radius

settings on the sharp edges but also according to geometrical criteria. In some cases,
it is not possible to build a surface that fulfills the radius settings. Consequently,
DeltaMESH Fillet gradually decreases the radius value until it is able to build the
proper geometry. Minimum radius is the limit for that decrease.
(Default value: 1.0)
Geometric precision:
During the CAD model creation, DeltaMESH Fillet will not

generate any surface which size is lower than this value. (Default value: 1.0)
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Filleting
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SUBSTRUCTURING
Purpose
The substructuring technique is provided to allow the user to make efficient simulations
when working with large models. The objective of substructuring is to provide a
mechanism whereby some areas of a large model can be reduced to local models or so
called substructures, these small models however will retain the global behavior coming
from the global model. This is achieved by recording the displacements through time
of all of the nodes on the substructure boundary, and then imposing these same
displacements in time during the substructure calculation (subrun).
Substructuring is a very useful technique for a number of different purposes:
-
More detailed / fine mesh study in local zone.
Surface defect analysis in local zones (see Simulation methodology for high quality
stamping/ Further analysis: Surface defect)
Localized geometry modifications.
The fundamental principle of substructuring is that any changes in the local model will
not influence the global behaviour at the subrun boundary; this rule must be respected
for results to remain valid.
The mechanism for substructuring provided in AUTOSTAMP is compatible with all the
standard options of AUTOSTAMP, including adaptive meshing, and multi-stage
simulations.
A mechanism is provided to take only partial tools (automatically) for the subruns. This
is simply to reduce the overall model size to the minimum and make it CPU cost
effective.
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During the first global simulation, the user will defined the border of the local zones on
which he wants to iterate. A local stamping simulation, defined only on this local blank
zone is then performed, the border nodes having a constrained displacement imported
from the substructure file.
Note :
Substructuring is not compatible with the following options: Fluid cell,

Spotwelds, Gravity, Springback, Quikstamp plus, and volume blanks
Global simulation
The stamping simulation is first done with a reasonable coarse blank mesh and specific
objects (part of the initial blank) are created to define local zones (Substructure export
attribute will be defined on this zone).
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Substructuring
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The elements of the local zone border are automatically refined with a uniform
refinement level equal to the maximum refinement level. The time step of the global
simulation is then not modified. All the nodes of the border which were created during
this operation are considered as the border nodes and their displacements are stored in a
substructure file (.S0i).
Local simulation
A local stamping simulation, defined only on a local blank zone can be performed. All
the border nodes will have a constrained displacement imported from the substructure
file.
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Refinement during local simulation

The local zone (in local simulation project) can be defined with whatever the level of
refinement the user wants, but the elements of the border nodes keep the same level of
refinement as in the global simulation. That is why, it is strongly recommended to select
a zone larger than the local zone the user wants to study.
Example:
If the maximum refinement level is 2 in global run, the border elements of the
local zone will be forced to uniform level 2 during the global run.
If a maximum refinement level of 4 is defined for the local run, the border
elements of the local zone will not be more refined and keep a 2 refinement level
while adaptive meshing with a maximum refinement level of 4 will be used for
the rest of the zone.
Displacement storage
For each stage, an independent substructure file is created during global simulation. The
progression interval corresponds to the interval that the solver uses to write the
information in this substructure file. During local simulation, information are coming
from picking (not specific to substructure) and also from the global simulation of this
stage, using the substructure files (, .S0i, .ini and *_ids.bf).
Displacements of blank border nodes and COG of tools with a simplified type rigid
body attribute are stored. This ensures exactly the same displacement of the tool, in
particular when there are piloted with force. For the local simulation all the boundary
conditions (velocities, fixed d.o.f) are duplicated from the global one except the
imposed force attribute.
Note
Time interval storage should not be too high to avoid contact problems
Accelerations (deduced from Displacement) at time t are supposed to be linear

compared to accelerations at time t1 and t2 when t1<t<t2. Therefore, nodes
belonging to border will be piloted only by the global run, not by contact.
.psp, .pre,.S0i, .ini, _ids.bf files of global run are needed for the local run.
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Positioning and stroke

In order to manage auto-positioning which could be different between global and local
simulation progression of stroke must be used in the Control attribute.
If there is a delay due to different positionings between global and local simulations, the
kinematics will be applied but the border node of the blank will be considered as fixed
by the solver. The solver will wait until reaching the same stroke to apply the stored
displacement of the border nodes of the blank.
On the contrary, if tools are closer in the local simulation, the first values of thesub-run
file will not be used.
Modification of the tool geometry

Substructure can be used when the tools geometry is locally modified.
-
The user replaces the content of the existing die object by the new one, using the
import tools CAD or import tools mesh option and replacing the content of the object
(transfer rules).
Punches and blank holder are generating applying the toolbuilder.
Tools must be in the same position than in the global simulation (before positioning) in
order to have the same progression values between global and local run. The Best-fit
option can be used.
The changes in the local zone must not change the global behaviour of the blank, and
the zone must be large enough so that border nodes displacement remains the same.
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Procedure
The following procedure must be applied to have a successful substructure simulation.
-
Global project
A project containing the global simulation model must be created, following

standard rules.
In this global project, local zone(s) of the initial blank will be defined and put in
separate objects (there may be any number of local zones). It is advised to define
the area larger than the studied area.
A Substructure export attribute has to be defined for each local zone.
The progression interval corresponds to the interval that the solver uses to write the
blank nodes in this substructure file.
The global project can be computed.
SIMULATION CONCEPTS
Substructuring
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307
USERS GUIDE
(released: Oct-12)
Local projects
In the global project setup, the subrun project creation menu enables the
automatic creation of the local project, with the same data setup as the global
project. It is opened with the following button
The combo box lists all the objects of the project which have the substructure
export attribute.
If the user changes the value of maximal refinement level, the mass scaling is
automatically recomputed and updated. The pinch test defined in the stage is
already listed in this dialog, so that the user can add or remove them for the local
computation.
option can be used to reduce automatically the geometry of
tools (reduced to the local area) in the local subrun project.
Use part of the tools
In each subrun project:

import substructure attribute is automatically added with the right
parameters (the export substructure attribute is removed).
Refinement attribute is updated
Pinch test and mass scaling attributes are updated.
If the user has checked the option Use part of the tools in subrun project
creation menu, an attribute Partial tool is added for each rigid body with the
type Automatic in the subrun project.
SIMULATION CONCEPTS
Substructuring
USERS GUIDE
(released: Oct-12)
308
PAM-STAMP 2G 2012
2012 ESI Group
Notes :
Partial tool attribute is not available for volume tools.
Partial tool can not be used if rotational kinematics / Transformations are

defined.
SIMULATION CONCEPTS
Substructuring
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309
USERS GUIDE
(released: Oct-12)
MAPPING
The mapping technique is provided to allow the user to make a simple transfer of result
data from PAM-STAMP to another software system or vice versa, for further
simulation. It is similar in concept to picking which is used in between two stages of
PAM-STAMP calculation, but with some differences which make it more generic.
A major function of mapping is that it allows the transfer of shell element variables
between dissimilar meshes.
Typically the most common usage is to enable the PAM-STAMP forming history to be
included into PAM-CRASH simulations, giving better prediction of the crash behavior.
Other uses can be to consider the material thickness change from stamping in structural,
fatigue or NVH simulations, or even to consider welding history effects as the starting
point for a stamping simulation.
Procedure for Mapping Export

-
The stamping simulation setup is as

normal, simply with the addition of the
mapping export attribute in global object
of the stage.
The user chooses which parameters

should be exported to the mapping file.
By default the mapping file will be in

PAM-STAMP 2G / PAM-CRASH 2G
format, but it can be forced to PAM 2000
format by selecting the corresponding
toggle.
Unit system is exported in the mapping file.
Mapping files will have the file type extension gn.M01, gn.M02, gn.M0x.
In case of synchronize with states option, the file extension of the intermediate mapping
files is gn.kkk.M01, gn.kkk.M02, gn.kkk.M0x. where kkk is the state number,
but the last exported mapping file keeps the usual extension gn.M01, gn.M02,
gn.M0x.
SIMULATION CONCEPTS
Mapping
USERS GUIDE
(released: Oct-12)
310
PAM-STAMP 2G 2012
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Stress and strain export for shells:

The tensors (stresses or strains) are exported in the local frame of the element:
-
For the strain tensor, the 3 values (xx, yy and xy) are written for both upper and
lower fibers
For the stress tensor, the values for all the integration points over the thickness are
exported.
The local frame of the element is calculated the following way:
For Quad :
For triangles :
calculate medians, through the midst of

the 4 edges.
x is on edge 1-2
x is on the first median
z is on the vector product of edges 12 and 1-3
z is on the vector product of medians
y is on the vector product of z and x
y is on the vector product of z and x
Note :
It is not possible to import upper and lower strain tensors when the accurate
total strain option is activated in the Global advanced parameter. Only export is
possible.
Plastic strain export for solids:

-
Only plastic strain export is possible with solid elements
SIMULATION CONCEPTS
Mapping
PAM-STAMP 2G 2012
2012 ESI Group
311
USERS GUIDE
(released: Oct-12)
Mesh Transformation
It is possible to define a transformation to the blank mesh. The transformation will be

applied on the exported mesh to fit with the position of the mesh of the blank object in
the new project. This is useful if the blank mesh in the project is not expressed in the
same system than the exported mesh, or if the part has to move to be in a new position.
By default, no transformation is applied (no translation, identity matrix for the rotation).
SIMULATION CONCEPTS
Mapping
USERS GUIDE
(released: Oct-12)
312
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Procedure for Mapping Import

-
The stamping simulation setup is as normal,

simply with the addition of the mapping
import attribute in blank object in the first
stage.
The user chooses which file to import.
The user chooses which variables to import.
The user can specify a transformation matrix

if required
Note
Only the exported data can be imported,

therefore if there is any doubt about the
variables needed in the subsequent
simulation, it is better to export all, this
will result in a bigger file size, but all
data will be available
It is not possible to import upper and

lower strain tensor when the accurate
total strain option is activated in the
Global advanced parameter.
Only plastic strain import is possible

with solid elements
Mesh Transformation
A transformation is applied on the imported mesh to fit with the position of the mesh of
the blank object before mapping. This is useful if the blank mesh in the project is not
expressed in the same system than the imported mesh, or if the part has to move to be in
a new position. This transformation is defined by a translation vector (first column) and
a rotation around the origin (defined by its matrix in the global system). It can also be
defined by coordinates transformation where user has to specify the initial and target
frames.
By default, no transformation is applied (no translation, identity matrix for the rotation).
Note :
: the mapping, if any, is performed after picking operation.
SIMULATION CONCEPTS
Mapping
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
313
Mapping file format

See the Mapping file general format for detailed format description.
Parameters blocks:
File format:
Control parameters Block
Title
Date
Nb of nodes, elements
Version
Transformation of export
Rotation matrix
(only used to reset export

transformation during
import)
Translation
Exported Mesh Block
Nodal Coordinates
Shell connectivities
Nb of IP and GP
Exported variables list

block
Variable name=THIC,PLAS,STRS,STRN,ORTH,KINH
Dependency flag on IP
Dependency flag on GP
SIMULATION CONCEPTS
Mapping
USERS GUIDE
(released: Oct-12)
SIMULATION CONCEPTS
Mapping
314
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(released: Oct-12)
315
Mapping file example:

This is a case with 3 integration points through thickness and one gauss point in plane.
AMAP
6
11
2
TITL
results
NAME
blank
TJOB
standard
DATE
DATE
08/06/19
VERS
PSOL
2008
COM1
HOUR
6094
6403
17/41/54
COM2
COM3
COM4
COM5
COM6
MATR
4
0.100000E+01
0.000000E+00
0.000000E+00
0.000000E+00
UNIT
1
0.100000E-02
NODE /
107925
NODE /
107927
NODE /
107928
NODE /
107929
NODE /
107931
NODE /
107933
NODE /
107936
NODE /
107937
NODE /
107938
.
.
.
3
0.000000E+00
0.100000E+01
0.000000E+00
0.000000E+00
3
0.100000E+01
0.26026860E+04
0.25928909E+04
0.26340300E+04
0.26222744E+04
0.26203169E+04
0.26163989E+04
0.26105220E+04
0.26085627E+04
0.26066021E+04
0.000000E+00
0.000000E+00
0.100000E+01
0.000000E+00
0.100000E-02
0.58668555E+03
0.58782104E+03
0.58305115E+03
0.58441455E+03
0.58464154E+03
0.58509589E+03
0.58577710E+03
0.58600409E+03
0.58623120E+03
0.21162048E+04
0.21159895E+04
0.21168889E+04
0.21166318E+04
0.21165891E+04
0.21165037E+04
0.21163757E+04
0.21163333E+04
0.21162908E+04
integration
points on
thickness
SIMULATION CONCEPTS
Mapping
USERS GUIDE
(released: Oct-12)
SHELL
SHELL
SHELL
SHELL
SHELL
SHELL
/
/
/
/
/
/
316
122419
122420
122421
122422
122423
122424
.
.
.
THIC
PAM-STAMP 2G 2012
2012 ESI Group
1
1
1
1
1
1
107983
107979
107982
107984
107985
107986
107982
107983
107984
107985
107986
107973
107974
107974
107974
107974
107974
107974
-1
-2
0
0
0
0
0
0
3
1
3
1
3
1
3
1
3
1
3
1
gauss points
6
1
PLAS
6
1
STRS
6
5
STRN
6
0
0
0
0
0
0.500021E+01 0.318013E-03 0.318013E-03 0.318013E-03-0.401391E-01 0.225439E-01
-0.218759E-01 0.000000E+00 0.000000E+00-0.401391E-01 0.225439E-01-0.218759E-01
0.000000E+00 0.000000E+00-0.401391E-01 0.225439E-01-0.218759E-01 0.000000E+00
0.000000E+00-0.244814E-03 0.202921E-03-0.312513E-03-0.244814E-03 0.202921E-03
-0.312513E-03
0.499984E+01 0.433082E-03 0.433082E-03 0.433082E-03-0.733997E-02 0.211043E-01
-0.503893E-01 0.000000E+00 0.000000E+00-0.733997E-02 0.211043E-01-0.503893E-01
0.000000E+00 0.000000E+00-0.733997E-02 0.211043E-01-0.503893E-01 0.000000E+00
0.000000E+00-0.852007E-04 0.117973E-03-0.719847E-03-0.852007E-04 0.117973E-03
-0.719847E-03
.
.
.
.
case of EXPORT/STRS defined:

thic
plas1(lower) plas2
plas3(upper) sxx1(lower) syy1(lower)
0.499794E+01 0.495450E-03 0.495450E-03 0.495450E-03 0.115600E+00 0.573983E-01
sxy1(lower) syz1(lower) sxz1(lower) sxx2
syy2
sxy2
0.163558E-01 0.000000E+00 0.000000E+00 0.115600E+00 0.573983E-01 0.163558E-01
syz2
sxz2
sxx3(upper) syy3(upper) sxy3(upper) syz3(upper)
0.000000E+00 0.000000E+00 0.115600E+00 0.573983E-01 0.163558E-01 0.000000E+00
sxz3(upper) exx(upper)
eyy(upper)
exy(upper)
exx(lower)
eyy(lower)
0.000000E+00 0.413814E-03-0.191335E-05 0.233655E-03 0.413814E-03-0.191335E-05
exy(lower)
0.233655E-03
.
.
.
case of EXPORT/STRS not defined

thic
plas1(lower) plas2
plas3(upper)
0.499794E+01 0.495450E-03 0.495450E-03 0.495450E-03
eyy(upper)
exy(upper)
exx(lower)
eyy(lower)
-0.191335E-05 0.233655E-03 0.413814E-03-0.191335E-05
Remark:
exy is the Gamma value of strain
SIMULATION CONCEPTS
Mapping
exx(upper)
0.413814E-03
exy(lower)
0.233655E-03
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
317
MAPPING FILES
The following sections describe the content of PAM-SOLID mapping files and the
ASCII format. Mapping files are processed by the Export and Import options.
File Content
Mapping files contain deformed geometry and element variables for selected shells and
volume elements together with an associated part name. Optional reflections and
geometric transformation which may have been applied to the structure are also
recorded.
The tables below list the supported shell and volume element variables:
Supported Shell Variables
Element Variable
Keyword
THIC
PLAS
STRS
STRN
ORTH
FIB1
FIB2
STF1
STF2
KINH
CRAC
DAMG
xxxx
Description
Thickness
Effective plastic strain
Stress tensor
Upper and lower strain tensor
Major orthotropic direction
Fiber direction 1
Fiber direction 2
Fiber strain 1
Fiber strain 2
Back stress tensor
CRACH variable block
Isotropic damage parameter
User variable (arbitrary four character string)
Supported Volume Element Variables

Element Variable
Keyword
PLAS
PORO
Description
Effective plastic strain

Porosity
A series of FORTRAN interfaces allow user-variables to be processed by the Export

and Import options. (For details see the User Mapping section of the Solver Notes
Manual). The following tables summarize which variables are supported by each
material type. Note that for the user materials 180-4, unsupported standard variables
can be activated using the User Mapping option.
SIMULATION CONCEPTS
Mapping Files
USERS GUIDE
(released: Oct-12)
318
PAM-STAMP 2G 2012
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Available Shell Variables per Material Type

Variable
Keyword
THIC
PLAS
STRS
STRN
ORTH
FIB1
FIB2
STF1
STF2
KINH
CRAC
DAMG
xxxx
101
x
o
o
o
o
o
o
o
o
o
o
o
o
102
x
x
x
o
o
o
o
o
o
o
o
o
o
103
x
x
x
o
o
o
o
o
o
o
o
o
o
105
x
x
x
o
o
o
o
o
o
o
o
o
o
106
x
x
x
o
o
o
o
o
o
o
o
o
o
107
x
x
x
x
x
o
o
o
o
x
o
o
o
Shell material type

108 109 115 117
x
x
x
x
x
x
x
x
x
x
x
x
o
x
o
x
o
x
o
x
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
x
o
x
o
o
o
o
o
o
o
o
o
o
o
o
118
x
x
x
o
o
o
o
o
o
o
o
o
o
128
x
x
x
x
x
o
o
o
o
x
x
x
o
140
x
o
o
o
o
x
x
x
x
o
o
o
o
143 180-4
x
x
x
o
x
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
x
Available Volume Element Variables per Material Type

Variable
Keyword
PLAS
PORO
Material type
1
x
52
x
x
ASCII Mapping File Format

Complete input steps 1-12 for each required mapping file.
Step 1: Control Data

Supply card sequence {1a, 1b, 1c} once.
Card 1a: File header
Columns Item
1-4
Keyword AMAP (file header)
Format
Name
version/option
version/option
A4
Card 1b: Number of control variables

Columns Item
Format
Name
1-8
I8
NCCAR
Number of control variables

=6:
for shells alone
=10: for shells, solids and tetrahedra
SIMULATION CONCEPTS
Mapping Files
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
319
Card 1c: Control variables

Columns Item
Format
Name
1-8
9-16
17-24
25-32
33-40
41-48
49-56
57-64
65-72
73-80
I8
I8
I8
I8
I8
I8
I8
I8
I8
I8
NABLO
NRBLO
NRMAT
NNODE
NSHELL
NVAR
NSOLID
NTETRA
NTETR4
NVARV
Number of descriptive data blocks

Number of transformation/unit data blocks
Number of materials
Number of nodes
Number of shells
Number of variables per shell
Number of solid elements
Number of ten node tetrahedra
Number of four node tetrahedra
Number of variables per solid/tetrahedron
version/option
Step 2: Descriptive Data

Repeat card sequence {2a, 2b} NABLO times, where NABLO is the number of
descriptive data blocks defined in card 1c.
Card 2a: Descriptive data keyword
Columns Item
Format
1-4
A4
Keyword selected from list below:

NAME: Specify part identifier in card 2b
(required)
TITL: Specify title in card 2b
TJOB: Specify job title in card 2b
DATE: Specify job date and time in card 2b
VERS: Specify solver name and version
COM1: Specify comment 1 in card 2b
Name
version/option
Name
version/option
Card 2b: Parameter string

Columns Item
Format
1-80
A80
Parameter string
Step 3: Transformation/Unit Data

Repeat card sequence {3a, 3b(1), , 3b(NLIN)} NRBLO times, where NRBLO is the
number of transformation/unit data blocks defined in card 1c and NLIN is specified in
card 3a.
SIMULATION CONCEPTS
Mapping Files
USERS GUIDE
(released: Oct-12)
320
PAM-STAMP 2G 2012
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Card 3a: Transformation keyword

Columns Item
Format
Name
1-5
A4,X
KEY1
I8
NLIN
I8
NCOL
Format
Name
E16.0
E16.0
E16.0
PAR1
PAR2
PAR3
6-13
14-21
Keyword selected from list below:

MATR: Specify geometric transformation in
cards 3b(1), , 3b(NLIN)
UNIT: Specify unit factors in
cards 3b(1), , 3b(NLIN)
Number of additional lines to be read
(see table below)
Number of parameters read per line
(Specify 3)
version/option
Card 3b(i): Transformation parameters

Columns Item
1-16
17-32
33-48
Parameter 1 as defined below

KEY1
in card 3a
NLIN
in card 3a
PAR1
PAR2
PAR3
MATR
A11
A12
A13
A21
A22
A23
A31
A32
A33
T1
T2
T3
U length
U mass
U time
UNIT
with
A , i, j 1, 2, 3
ij
Ti , i 1, 2, 3
SIMULATION CONCEPTS
Mapping Files
Transformation matrix
U length
Translation vector
Length unit in m
U mass
U time
Mass unit in kg
Time unit in s
version/option
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
321
Step 4: Nodal Data

Repeat card 4 NNODE times, where NNODE is the number of nodes specified in card 1c.
Card 4: Nodal data
Columns Item
1-8
9-16
17-32
33-48
49-64
Keyword NODE__/_
Node number
X-coordinate
Y-coordinate
Z-coordinate
Format
Name
A8
E16.0
E16.0
E16.0
E16.0
NUMNO
XNO
YNO
ZNO
version/option
Step 5: Shell Data

Repeat card 5 NSHELL times, where NSHELL is the number of shells specified in
card 1c.
Card 5: Shell data
Columns Item
1-8
9-16
17-24
25-32
33-40
41-48
49-56
57-64
65-72
Keyword SHELL_/_
Shell number
Material number
Node 1
Node 2
Node 3
Node 4
Number of integration points over thickness
Number of Gauss points
=1: Belytschko-Tsai
=4: Hughes-Tezduyar
Format
Name
A8
I8
I8
I8
I8
I8
I8
I8
I8
NUMNO
NUMMAT
N1
N2
N3
N4
NP
NGAUSS
version/option
SIMULATION CONCEPTS
Mapping Files
USERS GUIDE
(released: Oct-12)
322
PAM-STAMP 2G 2012
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Step 6: Shell Variable Descriptions

Repeat card sequence {6a, 6b} NVAR times, where NVAR is the number of variables per
shell defined in card 1c.
Card 6a: Shell variable keyword
Columns Item
Format
1-5
A4,X
6-13
Keyword selected from following list:

THIC: Thickness
PLAS: Effective plastic strain
STRS: Stress tensor
STRN: Upper and lower strain tensors
ORTH: Major orthotropic direction
FIB1: Fiber direction 1
FIB2: Fiber direction 2
STF1: Fiber strain 1
STF2: Fiber strain 2
KINH: Back stress tensor
CRAC: CRACH variable block
DAMG: Isotropic damage parameter
xxxx: User variable
Number of additional parameters to be read
(Specify 6)
Name
I8
NPAR
Format
Name
I8
I8
KVAR
KNP
I8
KMTY
I8
I8
I8
IPLN
IPMS
IPTM
version/option
Card 6b: Shell variable description parameters

Columns Item
1-8
9-16
17-24
25-32
33-40
41-48
Number of values read per variable

Flag for dependency on number of integration
points over thickness
=0: independent
=1: dependent
Flag for dependency on number of Gauss
points
=0: independent
=1: dependent
Length unit exponent
Mass unit exponent
Time unit exponent
SIMULATION CONCEPTS
Mapping Files
version/option
PAM-STAMP 2G 2012
2012 ESI Group
USERS GUIDE
(released: Oct-12)
323
Step 7: Shell Variable Data

Supply NSHELL variable data blocks for each shell element in turn as specified in
section 5. Data for each block are written in the format specified by card 7 (i.e.
FORTRAN format 6E13.0).
Card 7: Shell variable data
Columns Item
Format
Name
1-13
14-26
27-39
40-52
53-65
66-78
E13.0
E13.0
E13.0
E13.0
E13.0
E13.0
PAR1
PAR2
PAR3
PAR4
PAR5
PAR6
Parameter 1
Parameter 2
Parameter 3
Parameter 4
Parameter 5
Parameter 6
version/option
Step 8: Solid Element Data

Repeat card sequence {8a,8b} NSOLID times, where NSOLID is the number of solids
specified in card 1c.
Card 8a: Solid element data
Columns Item
Format
Name
A8
I8
I8
I8
NUMSO
NUMMAT
NGAUSV
Columns Item
Format
Name
1-16
17-24
25-32
33-40
41-48
49-56
57-64
65-72
73-80
16X
I8
I8
I8
I8
I8
I8
I8
I8
N1
N2
N3
N4
N5
N6
N7
N8
1-8
9-16
17-24
25-32
Keyword SOLID_/_
Element number
Material number
=1: Uniform
=8: SRI
version/option
Card 8b: Solid element data
Blank
Node 1
Node 2
Node 3
Node 4
Node 5
Node 6
Node 7
Node 8
version/option
SIMULATION CONCEPTS
Mapping Files
USERS GUIDE
(released: Oct-12)
324
PAM-STAMP 2G 2012
2012 ESI Group
Step 9: Ten Node Tetrahedron Data

Repeat card sequence {9a,9b,9c} NTETRA times, where NTETRA is the number of ten
node tetrahedra specified in card 1c.
Card 9a: Ten node tetrahedron data
Columns Item
Format
Name
A8
I8
I8
I8
NUMTE
NUMMAT
NGAUSV
Columns Item
Format
Name
1-16
17-24
25-32
33-40
41-48
49-56
57-64
65-72
73-80
16X
I8
I8
I8
I8
I8
I8
I8
I8
N1
N2
N3
N4
N5
N6
N7
N8
Columns Item
Format
Name
1-16
17-24
25-32
16X
I8
I8
N9
N10
1-8
9-16
17-24
25-32
Keyword TETRA_/_
Element number
Material number
Specify 4
version/option
Card 9b: Ten node tetrahedron data
Blank
Node 1
Node 2
Node 3
Node 4
Node 5
Node 6
Node 7
Node 8
version/option
Card 9c: Ten node tetrahedron data
Blank
Node 9
Node 10
version/option
Step 10: Four Node Tetrahedron Data

Repeat card 10 NTETR4 times, where NTETR4 is the number of four node tetrahedra
specified in card 1c.
Card 10: Four node tetrahedron data
Columns Item
1-8
9-16
17-24
25-32
33-40
41-48
49-56
57-64
Keyword TETR4_/_
Element number
Material number
Node 1
Node 2
Node 3
Node 4
Number of Gauss points.
Specify 1
SIMULATION CONCEPTS
Mapping Files
Format
Name
A8
I8
I8
I8
I8
I8
I8
I8
NUMT4
NUMMAT
N1
N2
N3
N4
NGAUSV
version/option
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Step 11: Solid/Tetrahedron Variable Descriptions

Repeat card sequence {11a, 11b} NVARV times, where NVARV is the number of
variables per solid/tetrahedron defined in card 1c.
Card 11a: Solid/tetrahedron variable keyword
Columns Item
Format
1-5
A4,X
Keyword selected from following list:

PLAS: Effective plastic strain
PORO: Porosity
Number of additional parameters to be read
(Specify 5)
Name
I8
NPAR
Columns Item
Format
Name
1-8
9-16
I8
I8
KVARV
KMTYV
I8
I8
I8
IPLNV
IPMSV
IPTMV
6-13
version/option
Card 11b: Solid/tetrahedron variable description
17-24
25-32
33-40
Number of values read per variable

Flag for dependency on number of Gauss
points
=0: independent
=1: dependent
Length unit exponent
Mass unit exponent
Time unit exponent
version/option
Step 12: Solid/Tetrahedron Variable Data

Supply NVOL=NSOLID+NTETRA+NTETR4 variable data blocks for each
solid/tetrahedron element in turn as specified in sections 8, 9 and 10. Data for each
block are written in the format specified by card 12 (i.e. FORTRAN format 6E13.0).
Card 12: Solid/tetrahedron variable data
Columns Item
Format
Name
1-13
14-26
27-39
40-52
53-65
66-78
E13.0
E13.0
E13.0
E13.0
E13.0
E13.0
PAR1
PAR2
PAR3
PAR4
PAR5
PAR6
Parameter 1
Parameter 2
Parameter 3
Parameter 4
Parameter 5
Parameter 6
version/option
SIMULATION CONCEPTS
Mapping Files
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Notes:
Values for each shell variable data block in card 7 are specified in a series of
nested loops as indicated below.
num 0
for i 1, 2, , NVAR
Loop 1 in shell variables
for j 1, 2, , ( NGAUSS 1) * KMTY 1

for k 1, 2 , ( NP 1) * KNP 1
Loop 2 in Gauss points
Loop 3 in integration points

through thickness
num num 1
Specify value num
end
end
end
The number of values read for variable i is:

LVAR(i ) {KVAR *[( NP -1) * KNP 1]}*[( NGAUSS -1) * KMTY 1]
and the total of values per block is:

LVAR
NVAR
LVAR(i ).
i 1
Values for each volume element variable block are specified in a series of nested
loops as indicated below.
num 0
for i 1, 2, , NVARV
Loop 1 in solid/tetra variables
for j 1, 2, , ( NGAUSV 1) * KMTYV 1

num num 1
Specify value num
end
Loop 2 in Gauss points
end
The number of values read for variable i is:

LVARV (i ) KVARV *[( NGAUSV -1) * KMTYV 1]
and the total of values per block is:

LVARV
NVARV
i 1
SIMULATION CONCEPTS
Mapping Files
LVARV (i ).
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Shell variable description parameters for the standard shell variables (card 6b) are
listed below.
Variable
Shell variable description parameters
Keyword KVAR KNP KMTY IPLN IPMS IPTM
THIC
1
0
1
1
0
0
PLAS
1
1
1
0
0
0
STRS
5
1
1
-1
1
-2
STRN
6
0
0
0
0
0
ORTH
2
0
0
0
0
0
FIB1
2
0
0
0
0
0
FIB2
2
0
0
0
0
0
STF1
1
0
0
0
0
0
STF2
1
0
0
0
0
0
KINH
3
1
1
-1
1
-2
CRAC
186
0
0
0
0
0
DAMG
1
1
1
0
0
0
Shell description parameters can assume arbitrary values for user variables but must
match values specified by the USR_MAP_INIT_VAR FORTRAN interface for
compatibility with the Export and Import options (see User Mapping section of the
Solver Notes Manual).
Standard values of the volume element variable description parameters (card 6b) are
listed below.
Variable
Keyword
PLAS
PORO
Volume variable description parameters

KVARV KMTYV IPLNV
IPMSV
1
1
0
0
1
1
0
0
IPTMV
0
0
Element local frame used for strain and stress calculation:
SIMULATION CONCEPTS
Mapping Files
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328
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3
y
x
y
1 x
For quadrangles :
For triangles :
-calculate medians, through the mids of

the 4 edges.
-x is on edge 1-2
-x is on the first median
-z is on the vector product of edges 1-2 and 13
-z is on the vector product of medians
-y is on the vector product of z and x
-y is on the vector product of z and x
Mapping file examples

1 - Example ASCII mapping file is given below for a part consisting of two elements.
PLAS
0.5
NP
PLAS
STRS (1) STRS (2) STRS (3) STRS (4) STRS (5)
0.1
0.41
0.01
0.01
0.01
0.01
0.2
0.42
0.02
0.02
0.02
0.02
0.3
0.43
0.03
0.03
0.03
0.03
PORO
0.6
18
15
17
16
Units:
Mass
kg
Time
ms
SIMULATION CONCEPTS
Mapping Files
Length mm
2
BT Element
14
11
13
12
Uniform Integration Element
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AMAP
10
2
NAME
simple part
VERS
PSOL
2005
MATR
4
12
0.
0.
0.
0.
0.
0.
0.
0.
10.
10.
10.
10.
3
1.
0.
0.
100.
UNIT
1
0.001
NODE /
1
NODE /
2
NODE /
3
NODE /
4
NODE /
11
NODE /
12
NODE /
13
NODE /
14
NODE /
15
NODE /
16
NODE /
17
NODE /
18
SHELL /
1
PLAS
6
1
1
STRS
6
5
1
0.1
0.01
0.02
SOLID /
1
PLAS
0.
1.
0.
0.
0.
0.
1.
0.
1.
0.
10.
0.
10.
20.
30.
20.
30.
20.
30.
20.
30.
1
0.001
0.
0.
10.
10.
0.
0.
10.
10.
0.
0.
10.
10.
3
1
0.2
0.01
0.43
2
11
-1
1
0.3
0.42
0.03
1
12
13
-2
0.41
0.02
0.03
14
0.01
0.02
0.03
15
16
0.01
0.02
0.03
17
18
5
1
PORO
0
0.6
5
1
0.5
2 - Example ASCII mapping file is given below with and without STRS export: (case of 3 integration points
through thickness and one gauss point in plane)
AMAP
6
11
2
TITL
results
NAME
blank
TJOB
standard
DATE
DATE
08/06/19
VERS
PSOL
2008
HOUR
6094
6403
17/41/54
SIMULATION CONCEPTS
Mapping Files
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COM1
COM2
COM3
COM4
COM5
COM6
MATR
4
0.100000E+01
0.000000E+00
0.000000E+00
0.000000E+00
UNIT
1
0.100000E-02
NODE /
107925
NODE /
107927
NODE /
107928
NODE /
107929
NODE /
107931
NODE /
107933
NODE /
107936
NODE /
107937
NODE /
107938
.
.
.
SHELL
SHELL
SHELL
SHELL
SHELL
SHELL
/
/
/
/
/
/
122419
122420
122421
122422
122423
122424
.
.
.
THIC
0.000000E+00
0.000000E+00
0.100000E+01
0.000000E+00
0.100000E-02
0.58668555E+03
0.58782104E+03
0.58305115E+03
0.58441455E+03
0.58464154E+03
0.58509589E+03
0.58577710E+03
0.58600409E+03
0.58623120E+03
1
1
1
1
1
1
107983
107979
107982
107984
107985
107986
107982
107983
107984
107985
107986
107973
107974
107974
107974
107974
107974
107974
-1
-2
0.21162048E+04
0.21159895E+04
0.21168889E+04
0.21166318E+04
0.21165891E+04
0.21165037E+04
0.21163757E+04
0.21163333E+04
0.21162908E+04
0
0
0
0
0
0
integration
points on
thickness
3
3
3
3
3
3
1
1
1
1
1
1
gauss points
6
1
PLAS
6
1
STRS
6
5
STRN
3
0.000000E+00
0.100000E+01
0.000000E+00
0.000000E+00
3
0.100000E+01
0.26026860E+04
0.25928909E+04
0.26340300E+04
0.26222744E+04
0.26203169E+04
0.26163989E+04
0.26105220E+04
0.26085627E+04
0.26066021E+04
6
0
0
0
0
0
0.500021E+01 0.318013E-03 0.318013E-03 0.318013E-03-0.401391E-01 0.225439E-01
-0.218759E-01 0.000000E+00 0.000000E+00-0.401391E-01 0.225439E-01-0.218759E-01
SIMULATION CONCEPTS
Mapping Files
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0.000000E+00 0.000000E+00-0.401391E-01 0.225439E-01-0.218759E-01 0.000000E+00

0.000000E+00-0.244814E-03 0.202921E-03-0.312513E-03-0.244814E-03 0.202921E-03
-0.312513E-03
0.499984E+01 0.433082E-03 0.433082E-03 0.433082E-03-0.733997E-02 0.211043E-01
-0.503893E-01 0.000000E+00 0.000000E+00-0.733997E-02 0.211043E-01-0.503893E-01
0.000000E+00 0.000000E+00-0.733997E-02 0.211043E-01-0.503893E-01 0.000000E+00
0.000000E+00-0.852007E-04 0.117973E-03-0.719847E-03-0.852007E-04 0.117973E-03
-0.719847E-03
.
.
.
.
case of EXPORT/STRS defined:

thic
plas1(lower) plas2
0.499794E+01 0.495450E-03 0.495450E-03
sxy1(lower) syz1(lower) sxz1(lower)
0.163558E-01 0.000000E+00 0.000000E+00
syz2
sxz2
sxx3(upper)
0.000000E+00 0.000000E+00 0.115600E+00
sxz3(upper) exx(upper)
eyy(upper)
0.000000E+00 0.413814E-03-0.191335E-05
exy(lower)
0.233655E-03
.
.
.
plas3(upper)
0.495450E-03
sxx2
0.115600E+00
syy3(upper)
0.573983E-01
exy(upper)
0.233655E-03
case of EXPORT/STRS not defined

thic
plas1(lower) plas2
plas3(upper)
0.499794E+01 0.495450E-03 0.495450E-03 0.495450E-03
eyy(upper)
exy(upper)
exx(lower)
eyy(lower)
-0.191335E-05 0.233655E-03 0.413814E-03-0.191335E-05
sxx1(lower) syy1(lower)
0.115600E+00 0.573983E-01
syy2
sxy2
0.573983E-01 0.163558E-01
sxy3(upper) syz3(upper)
0.163558E-01 0.000000E+00
exx(lower)
eyy(lower)
0.413814E-03-0.191335E-05
exx(upper)
0.413814E-03
exy(lower)
0.233655E-03
Remark:
exy is the Gamma value of strain.
SIMULATION CONCEPTS
Mapping Files
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USER-DEFINED ATTRIBUTE
Purpose
The purpose of the User-defined attribute is to allow the user to access solver functions
which are not available in the graphical user environment. This may be to access solver
functions which are part of the PAM-SYSTEM Solid Core Library (which is the
shared part of ESI-Groups Computational Structural Mechanics solver family), but
normally associated with another product e.g. PAM-CRASH 2G.
This also allows ESI to develop and deliver updated solver functionality without the
need for a matching new graphical interface.
The User-defined attribute is considered an advanced option, and should only be used
with a thorough understanding of the option and its limitations.
As this function allows the user to access all CSM solver functions, it is the users
responsibility to ensure that the input remains consistent. For example only stamping
materials and contacts will have been developed to be compatible with Adaptive
meshing, and as such, the use of un-tested combinations of functions cannot be
guaranteed.
Data Set-up
In order to define a User-defined attribute, the user should add this as a global attribute
in each stage of a calculation.
This section is used to enter the PAM-SCL

keywords, in PAM-SCL 2004 (2G) format.
This section is for ID range reservation.

This section is for Object ID assignments.
In the first section, the first four (4) cards are automatically written and must not be
altered. After this block, the user can add cards as required, following the PAM-
SIMULATION CONCEPTS
User-Defined Attribute
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CSM 80 column format. If you require card format descriptions, please contact your
local ESI Group technical support.
-
The ID reservation allows the user to block a range of unique identifiers which will
be assigned by the user attributes, this is in order to prevent conflicts with ID
assigned automatically by the solver for conventional objects and attributes. For
simplicity, we recommend to reserve the IDs from 1 to 1000 for user attributes.
Finally the user must associate the objects in the model with the PART IDs used
in the user attributes.
Operation
The solver will simply use the function exactly as it has been entered, there will not be
any compatibility checking done by the attribute check in the graphical environment.
Any Cartesian kinematics or forces input via the user attribute will not be recognized by
the kinematics check.
The solver will read the PAM-CSM keywords, and the reserved ID range. Any Userdefined attribute will over-ride a standard input if assigned to the same object ID.
If the user calls a solver function that is not a default part of the used product, a specific
license for such a function may be required.
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User-Defined Attribute
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ANALYSIS TOOLS
CONTOURS
Available contours
Contours list
Contours are one way of analyzing the results of simulation. Several types of contours
are available, here are the main ones:
-
Thickness
Strains:
and thinning: for shell elements of the deformable part (blank or tube)
The principal major and minor strains are observed in order to determine the
zones with maximum traction or compression strains. Visualizing the
associated vectors can be very useful to determine the principal directions.
The strain mode makes it possible to know the type of stress (simple
traction, bi-axial traction, restrained) to which a zone is submitted.
The plastic strains enable the sheet hardening hence the consolidation of
the blank to be assessed.
Stresses:
stresses are essential to analyze the stretching of the part as well as the
risk of waves formation. They usually indicate what will happen with the
springback, especially when analyzing them on fibers.
FLD:
Kinematics
Mesh Quality & Undercut:
Draw depth:
Distance:
see FLD chapter
& Position: these contours give information on the velocity,

displacement or positions of the nodes. These contours must be analyzed on nodes,
with smooth display. It can be used for tools (like the blank holder) or for analyzing
the springback of the blank.
all the contours about mesh quality are useful to analyze
the quality of the tool mesh, especially for the use of advanced contact or for doing
an offset.
this contour is used for checking the die design and optimized it.
this contour is calculated on node, and is used to check the distance

between blank and tools or between two blanks. The second blank can be imported,
or displayed with the multistate mode. The distance is calculated from the node of
the 1st set to the element of the 2nd set. The signed distance option enables to have
positive and negative values given by the scalar product between the vector
(node/element) to the elements oriented normal.
ANALYSIS TOOLS
Contours
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Numerical:
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these contours give information on the used attributes or on refinement
level.
-
all these contours help analyzing the contact between blank and tools or a
specific zone of tools. This is used for external parts that should not be marked by
the radii of the tool to avoid shape defect. It can also be interesting information for
the tools wear.
Contact:
Pressure:
gives numerical information on the normal and tangential nodal

contact between blank and tool. The pressure is a nodal pressure, calculated by
dividing the contact force (applied by all the elements that are in contact) at each
node by the average surface of all the elements to which the node belongs.
Using the mark contour (see below) the user can know with which tool the blank
is in contact.
Marks:
Detachment:
gives instantaneous or cumulated information on blank nodes in contact

with a tools (binary information) See Solver analysis tools chapter for further
information.
can be used for analyzing surface defects, by checking the loss of
contact between blank and tools during simulation. (for more details see Further
analysis: surface defect section, in the Simulation methodology for high quality
stamping part)
Energy:
this group of contours gives the different energies of the blank (internal,
hourglass, membrane ). It can be used for very specific processes.
Other specific contours like Die compensation or Thermic are available when these
options are activated. See the chapters linked to these options to have information on
the corresponding contour.
Detailed contour description is available in the reference manual.
Options
Variables or vectors may be displayed in 5 different ways according to their type:
-
Normal (scalar):
displays one value per element. For nodal contour like node
velocity or distance, the element value is the middle value of all nodes defining the
element. This visualization is advised for element contour.
Smoothed (scalar):
Banded (scalar):
Isolines
displays one value per node. The hardware Gouraud algorithm

for interpolating colors between the nodes defining the elements. This visualization
is advised for node contour.
displays one value per node using a texture mapping between the
nodes defining the elements.
(scalar): displays isolines on the model. Each of these lines marks the
positions where the contour value is constant. This option is also an addition to the
Normal, Smoothed and Banded display modes described below, with the
ANALYSIS TOOLS
Contours
icon.
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USERS GUIDE
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(vector): the length of the vector depends on the result
value.
-
Fit in element
(vector): the size of the element delimits the size of the vector.
For each contour, options are available for defining the way the contours will be
calculated. For example with:
-
Location:
to define the fiber on which the contour is calculated
Value type:
to define the way of calculation (true or engineer for the strain)
Object link:
to define the object linked to the contours (tools object for the marks)
Specific options: like the direction
The display of isovalues can be modified in the Legend Configuration dialog box.
Stress and strain

Stresses and strains contours calculation must be activated in the setup using the
contour settings option of the control attribute. Several contours are activated by
default.
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Contours
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Stress
Stresses are calculated by element, and should be displayed by elements (Normal
option).
From plane stress tensor values (xx, yy, xy) in top and bottom integration points, the
main values and directions are calculated.
-
They can be visualized with Tensor/Major, Tensor/minor or Tensor/Major and minor

options. The user selects the fiber.
The same values (without the direction) can be visualized with the option
Values/Major or Values/minor.
Values/Equivalent
stresses correspond to the stresses calculated with:
Von Mises's law for isotropic entities,
Hill 48's law for orthotropic entities as per HILL 48's law with isotropic
hardening,
Lemaitre/Chaboche's law for orthotropic entities as per HILL 48's law with
kinematic hardening,
The equivalent stress on min/max plastic strain fibers correspond to equivalent

stress of the layer on which there is the minimum or maximal plastic strains.
For the membrane fiber, the main values and directions are calculated from the
following tensor: (xx top+ xx bot )/2 ; (xy top+ xy bot )/2, (yy top+ yy bot )/2. top and
bot correspond to the values in the top and bottom integration points.
Top and bottom fibers depend of the normal orientation of the element.
Strain
Strains are calculated by element, and should be displayed by elements (Normal option).
-
Strains can be displayed as True or Engineer values:

The value of the True strain is: ln (1+((L-L0)/L0)).
The value of the Engineer strain is: (L/L0)-1
with
L: current length in major direction,
Lo: initial length in major direction.
From plane strain tensor values (xx, yy, xy) in top and bottom integration points, the
main values and directions are calculated.
-
They can be visualized with Tensor/Major, Tensor/minor or Tensor/Major and minor

options. The user selects the fiber.
The same values (without the direction) can be visualized with the option
Values/Major or Values/minor.
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The Values/Mode is calculated the following way: each element corresponds to a P

point in the space of the main strains (minor strain in abscissa, major in ordinate).
The strain mode represents the angle (in degrees) between the axis of the abscissa
and the line that joins the center to the P point, measured clockwise.
The strain mode enables the type of constraint to which the element is submitted to
be known (simple traction, bi-axial traction, restrained).
-
The equivalent plastic strain can be visualized with
The Values/Plastic Membrane. It corresponds to the hardening rate of the

membrane fiber of the element.
The Plastic Max./Min. over thickness. It corresponds to the maximum or

minimum equivalent plastic strain, between upper, membrane and lower fibers
of the shell element.
For the membrane fiber, the main values and directions are calculated from the top and
the bottom values.
Top and bottom fibers depend of the normal orientation of the element.
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User Defined Contour
Purpose
The user can define his own contour. The user-defined contour is saved in the
configuration file, and is available for all the projects. It can be shared also by all the
users if it is saved in the configuration file of the installation.
The user contour is based on existing contours, on which functions are applied. A user
defined contour can be a combination of several contours. It can also be based on
contour values at different states (absolute number of state or relative, using for
example current state and previous one).
Zone contour
This type of user contour displays zones defined by combination of contours values
compared with fixed limit. It can be used for analyzing complex behavior like surface
defect area that need multiple analysis of contours.
Zone contour are created using the Zone functions in the User contour editor. The user
defines each zone he wants to analyze with the following parameters:
-
Name of the zone
1st contour
Limit of the 1st contour
2nd contour
Limit of the 2nd contour
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The second zone can then be defined in the same way.

The elements belonging to no defined zone are automatically displayed with the Other
zone.
The limit of the contour can be fixed values or values defined in the attribute (mainly
material data). The user uses the Attribute contours to select the available value in the
displayed list.
Example:
Zone ("zone1",[THINNING]>0.02 & [STRAIN_MINOR /FIBER = "MEMBRANE"
/VALUE_TYPE="TRUE"] < 0 )
+
Zone ("zone2",[THINNING]>0.02 & [STRAIN_MINOR /FIBER = "MEMBRANE"
/VALUE_TYPE="TRUE"] > 0 )
Split function
This function allows splitting a contour automatically in zones from the limit values
defined by the user.
Example:
Split (" thinning", [THINNING /VALUE_TYPE="TRUE"],-0.05, 0.2)
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Legend
Legend Options
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Double clicking on the legend or use the Legend options access, the Scalar contour
legend menu is displayed. Lots of options are available to configure the legend and the
contour display. It is possible for the user to:
-
Define the maximum and minimum value of the contour display and to select
the color above and below these limits.
Configure the color range of the contour
Define the number of color graduation for the contour and the number of
decimal written in the legend
Define the display of the Isolines
The configuration is defined for the displayed contour and it is not saved in the project
or in the configuration file. When displaying another contour, the default parameters are
again used. If the user wants to save the configuration of the contours he should used
the preset option.
Following options can be customized and saved in the configuration file:
-
Display the minimal and maximal values for the active state
Display the minimal and maximal values for all the loaded states
Display the labels of the entities corresponding to these minimal and maximal
values.
Highlight the entities that delimit the range. This can be used for finding easily
mesh quality problem.
They are available for all projects and can be shared by all the users (if they are saved in
the configuration file of the installation).
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Legend customization: preset
With the Preset functionality it is possible to associate to a contour specific legend

configurations. The preset is then saved in the configuration file and can be used for any
project to display a contour.
To define a preset, the user has to:
-
Display the contour
Select the displayed option, with the legend contour dialog
Save the preset with the Contour display parameter presets menu, using
To display a contour with a preset, the user has to:

-
Display the contour
Select the preset he wants to be displayed from the Apply preset access. The
name of the preset is written below the name of the contour in the Legend.
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Keep objects color

With the Keep objects color for not valid values option, the objects having a non valid
contour, like the refinement level for the tools, are not displayed in white but they keep
their objects color.
Histogram
For each displayed contour, it is possible to have the histogram of the contours,
activated from the Legend.
Several Histogram Options are available:
-
The zones can be defined, either link to the legend, by ratios or by values defined by
the user.
The ratio or the sum can be computed with different ways: by surface, by Mass, by
Length, by values or by entities numbers.
Several graph types are available.
Display options are also available, like the Background color, the size .
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Quick multiple display of contours
With the Multiple contours display it is possible to display in one click several 3D view
with different contour in each 3D view. It can be used for analyzing complex behavior
like surface defect area that need multiple analysis of contours or for analyzing rupture
using in the same time the FLD and the thinning criteria.
The Multiple contours displays are saved in the configuration file and can be used for
any project to analyze a phenomenon.
The 3D view that are created are automatically customized to have the same visibility
(object display, positioning of the model), and are linked together for the 3D
movements.
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To create a Multiple contour display, the user has to:

-
Open the Multiple contours display in the Customize menu
Define a group of contours
Add or remove contours in the group. The contours can be saved with preset.
To display a Multiple contour display, the user opens the menu and click on the group of
contours
Post-processing tools shortcut
is a functionality that created shortcut for the functionality used for

analyzing the results, like the contours with preset, or the Multiple contours display.
The shortcuts are put in the Custom Command dialog, and can be sorted by page. It
helps the user by putting together all the contours, or tools that he needs for analyzing
one phenomenon.
Custom Command
The Custom Commands are saved in the configuration file and can be used for all the
projects, or can be shared between users.
To put contours in Custom command, the user has to:
-
To create a new button, defining its display, the tool tip, and the action linked to
the button. An easy action is the display of the contour as it is defined (with the
preset).
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To affect the button to a page of the custom command
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FORMING LIMIT DIAGRAM (FLD)
Definition
A point in a bi-dimensional space is associated to each element. The abscissa is the
minor strain of the element; the ordinate is the major strain of the element. All these
points constitute the strain forming limit diagram. The FLD diagram is displayed in a
2D window and is juxtaposed to the 3D window where the same results are displayed
onto the structure.
majorPlan Strain
Deep drawing
Stretching
minor
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This diagram enables the user to evaluate the risks of rupture or necking by comparing
the position of these points to one or several limit curves (which correspond to necking,
rupture or to other curves taking into account a safety coefficient).
For volume blank the abscissa is the minor in plane strain and the ordinate the major in
plane strain.
Options
The FLD can be displayed with strains or with stresses. Usually strains are used since
it is easier to define experimentally the Forming Limit Curve for strain than for stress.
But the FLD by stresses is useful because the analysis depends less on the path (see
next paragraph). The FLD Diagram is based on True Strains (not engineering Strains)
The FLD can be analyzed for each fiber (membrane, lower and upper), that can be
displayed separately (Zones by FLC or Zones by Quality) or simultaneously (Rupture
risk). If several fibers are displayed simultaneously, the value of the element in the 3D
view is the maximum risk of the fibers displayed (i.e. the fiber located most above the
curve).
For a given material it is possible to use a Forming Limit Curve (FLC) which separates
the diagram into two zones: above the curve, the points correspond to elements in
rupture. From this diagram and using the FLD, several options are available:
-
Zones by FLC:
the elements are displayed per "zones" of diagram, a zone

corresponding to a part of the diagram delimited by FLCs.
Zones by quality:
the elements are displayed per "zones" of quality (strains diagram
only).
Zone 1: cracks. Points located above the forming limit curve.
Zone 2: excessive thinning. Points located between the forming limit curve and
the same curve decreased of 10% of the curve value at x=0. The percentage can
be modified by the user
Zone 3: safe zone.
Zone 4: insufficient stretching. Points located inside the circle with its center as
the origin and with a radius value of 0.002. It can be modified by the user
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Zone 5: wrinkling tendency. Points located above the y=-x straight line and
under the y=((-1-Rm)/Rm)*x straight line (Rm = Average Lankford coefficient).
Zone 6: strong wrinkling tendency. Points located under the y=-x straight line.
The contour quantifies the "risk of rupture" per element. There are
several possibilities for this contour display:
Rupture risk:
Absolute: (as v2005 and earlier) works by measuring the distance d of the point
associated to the element to the FLC selected as reference. A negative value
corresponds to a point below the curve, positive to a point above. The Rupture
risk can be displayed as absolute or relative value for the strain diagram.
Relative: Shows the same information but is displayed as a percentage. Where

zero is no strain, 100% means the point lies on the FLC, and anything over
100% is above the FLC.
Orthogonal distance: The distance is calculated orthogonally to the FLC and

not vertically.
Note:
If the point is out of the definition domain of the FLC, the associated element
will have a No Value.
FLC
The FLC is usually an experimental curve defined for each material and thickness
range. It is possible to use an approximate FLC calculated with Keeler model, but in
that case the results are less precise and must be cautiously analyzed.
Keeler law
This Forming Limit Curve has been used for about twenty years and has yielded
numerous successful results. It must be noted, however, that this empiric formula was
obtained from experimental trials on standard steel test specimens and that the
thicknesses never exceeded 5mm. As for new steels, the Keeler FLC seems to be below
the experimental curves and is therefore rather restrictive.
Important:
-
The validity of the Keeler law is not verified for steel with a thickness in excess of
5mm.
Do not draw hasty conclusions when applying the law to new steels (deep drawing
steels, high tensile steels, high strength steels, Dual-Phase steels...). It might
underestimate or overestimate the forming capabilities of these new materials.
The generalization of the Keeler law to materials with a hardening coefficient in

excess of 0.21 is not conclusive.
Do not use the Keeler law with aluminum.
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Notes:
If the point is on the left of the FLC, the curve is continued in the direction of the
first segment. If the point is on the right of the FLC, the curve is continued by
the line Y=X.
The Create a FLC button brings up the Curve Plotter dialog where a Forming
Limit Curve can be created. On a more general basis, the curve plotter can be
used independently to edit all types of curves (modified, destroyed, imported,
and exported).
Configuration
The FLD can be customized with several options available from the right-click menu of
the 2D graphic window:
-
Customize the display of the FLD:
Fit Display:
Zoom Out:
Create a FLC:
fits the diagram in its window.

zooms-out the FLD diagram.
create a forming limit curve (FLC) which can afterwards be used in
the diagram.
-
Define Strain path: see next paragraph
Display options:
Customize the display of the FLD
Draw the legend:
Display or not the legend in the case of the rupture risk
Draw the marginal zone limit:
Display or not the marginal zone limit in the case

of zones by quality or rupture risk analysis (FLC curve decreased of 10% of the
curve value at x=0).
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Draw Y=X:
displays the y = x straight line
Draw constant thinning lines:
Color of curves:
Color of points:
Background color, Line width, Shape of points, Axes style: these options configure
the display of the diagram.
display of the straight lines y = -x + y0. All the

points located on this straight line have a thickness strain equal to -y0. These
lines help to analyze the rupture, checking in the same time the elements above
the FLD and the elements having a thinning superior to y0.
define the color of all the curves used in the diagram.
define the color when several fibers are displayed or when

several blanks are displayed (tailored or double blanks)
It is also possible to use the Camera toolbar to perform zooms in the diagram
Notes:
The total interactivity between the diagram and the tri-dimensional model
enables at any time to link the points of the diagram with a zones of the blank
and vice versa.
The single selection and the screen area selection of elements are possible
directly in the diagram. This makes it possible, namely, to isolate risk points in
by selection and also inside an object.
Strain path
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Strain path displays as a curve the values reached by the major strain / stress and minor
strain / stress of an element during all the computation states
FLC analysis as described before is exact for straight strain paths. Non linear path are
qualitative effect on rupture or necking. So it is interesting to check this linearity
Options
-
Linearity check:
after the path is computed, a check is done on the growth of the

points ordinates (with a tolerance) state after state. If this check is satisfied, the
displayed path can be considered as valid and a green marker appears in the dialog.
If it is not satisfied, a red marker appears. The check tolerance can be defined in this
Linearity check dialog.
FLD window:
the way the path is displayed in the FLD window is selected. The user
can either disable this display or enable it with or without clearing any previous
paths before adding a new one.
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Curve plotter: the
way the path is displayed in the curve plotter window is selected.

The user can either disable this display or enable 2D curve creation (the same for all
paths or one curve per path).
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DRAW-IN TOOLS
A draw-in analysis can be done for analyzing the flow of material on the border of the
blank.
Draw-in Analysis
The aim of the draw-in functionality is to analyze some specific profiles. In top view,
the profiles are straight lines, limited by a reference contour (usually the initial blank
contour) and the blank sheet contour (free edges). The top view is defined by a
reference normal (which is usually Z). The planes in which profiles are built are defined
by a point (also called measure point), a measuring vector, and the reference
normal. These lines are projected on the die surface to obtain 2D geodesic lines and
we compute their length. This functionality is available in any post-process state.
This function is available in post processing through the menu Analysis and Reports as
shown below. It opens the Draw-in dialog box.
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Global parameters
The reference:
The drop down menu allows the user to select from Blank contour in post (default) 3D
curve, Drawbead, or Die entry line as the reference object from which the draw in will be
computed.
The intersection of the measure plane and this contour gives the first extremity of the
geodesic line. This contour is a 3D curve (built generally from the contour of the blank
in another state of the analysis). By default the contour can be the first 3D curve found
in the model. When switching reference contour the computed profiles are removed. All
measure planes remain unchanged. The user can click Compute to update the geodesic
lines.
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Notice that the 3D curve is automatically created when the reference contour is the
Blank contour in post. It is put in a new object Reference Contour.
To use the contour of the blank from another project (or from the setup), the 3D curve
must be exported from the original project and imported into the post-processing
module where the draw-in values will be plot.
The blank object:
The user can select from the drop-down menu the blank object in the state from which
the measurement should be made. If a different state is selected, the new outline (free
edge) is displayed, and the user should click the calculate button to make new
measurements of this state & display them.
The free edges of that object are the contour to analyze. The measure points are on that
contour. A point on that line is the 2nd point of the geodesic line. When switching blank
objects, the computed profiles are removed. All measure planes remain unchanged but
measure points are recomputed by intersection of the plane with new free edges. The
user can click Compute to update the geodesic lines.
The reference normal:
This vector is the normal of the reference plane (top view). This plane is used to set the
measuring vectors. A measure plane is defined by the measuring vector, the reference
normal and the measure point (on the blank contour). The standard vector custom
control provides all capabilities needed.
The die object:
All segments joining the reference contour to measure points are projected on that
object in the direction of the reference normal. Consequently, all geodesic lines are on
the die objects surface. When switching blank object, the computed profiles are
removed. The user can click Compute to update the geodesic lines.
Planes definition
The user can select from the drop-down menu, the method to be used for defining the
measurement planes, this can be done by Number of planes, Interval between planes,
maximum angle and by Pick points.
Planes are built using the reference normal (set as global parameter), the measuring
vector and a point on the blank border.
Measure vector:
By default the planes will be calculated as orthogonal to reference, but they can be
switched to Orthogonal to blank, or Directional. In case of directional, the user must
define the directions as below
This vector gives the direction of the sample. It is used to build the measure plane at the
next point definition.
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Measure points/planes:
These points are on the blank contour. There are four ways for setting the points. One
mode is manual (pick points), the other three are automatic:
-
Pick points:
The user can pick a 3D point on the blank contour to delete or create a measure point.
The standard position-picking tool is available (points, nodes, center of edge, etc ..). At
the picking, the measure point is created only if the reference normal and the measuring
vectors are correct (not null). You should pick on the blank, close to the contour. The
direction of the measure vector is used for localizing the point or node on the border.
To delete a plane in 3D, use the standard picking of point. The plane attached to the
closest point is erased.
-
Automatic:
There are three automatic modes to generate measure planes:
The first mode is Set planes number. The default is using the All around toggle
on, this will distribute the planes evenly around the outline, alternatively, the
user can set the number of planes he wants to create between 2 planes he has
previously built. The 2 planes must be selected in the 3D window (or in the drop
list) and have the same measuring vector.
The second mode is Set interval. The default is setting the All around toggle on,
this will distribute the planes evenly around the outline, alternatively, the user
sets the maximal distance between planes that will be built between 2 planes he
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has previously built. The 2 planes must be selected in the 3D window (or in the
drop list) and have the same measuring vector.
The third mode is Set angle. The default is setting the All around toggle on, this
will distribute the planes evenly around the outline, alternatively, the user sets
the maximal angle between blank contours segments (in the plane normal to the
reference direction). A plane is built if the angle between blank contours
segments is higher than the maximal value.
To start the automatic generation click on

The image below shows how planes are built.
Remark:
ANALYSIS TOOLS
Draw-In Tools
Both point coordinates and vector coordinates can be edited, deleted (<Del>
key, TAB) directly in the list. If any graphical information is linked to the
current edited line, it must be updated (modified, deleted etc).
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Functionalities
Compute draw-in:
This is the main action button. If at least one measure plane is defined, it will build and
project the line (between the measure point and the reference point) on the die object.
The projection is done in the direction of the reference normal. To compute the
projection we can use the section capabilities available for options profiles and check
die sections. The 3D geodesic lines are then displayed with 3D text mentioning their
length etc
Remark:
The die must be visible for computing the draw-in.
Top view:
Click this button to change the camera position and view the objects in the reference
normal direction. Once draw-in is reported in the 3D it is a shortcut to 2D
representation.
Print an image:
The goal of the draw-in functionality is to print out a view with annotations. Images
can be saved using the standard Export / Images available in the Project menu.
Display labels:
A toggle is provided to display or not display the blank and reference contour labels in
the 3D view
Display values:
A toggle is provided to display or not display the values in the 3D view

Number of decimals:
Depending on the unit system in use, and size of part, the user may wish to adjust the
number of decimals which are displayed in the 3D view.
Highlight Reference:
A toggle is provided to highlight the reference contour for better visibility

Close:
When closing the dialog, all planes and annotations are lost.
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BLANK SHIFTING
Purpose
This option enables creating automatically several projects containing blank definitions
that are variations of an original blank mesh from the current project.
The new projects that are created with the modified blank have the same attributes as
the original one.
Data Setup
Conditions
You must be in the setup module of the reference project. It must correspond to the
setup of the forming stage. The closing is already done and the blank is closed between
die and binder.
Autopositionning attribute must be defined and the recomputed toggle must be set in the
control attribute of the global object, because the tools may move before the beginning
of the computation (due to the blank movement) and the final stroke will have to be
recomputed.
Definition of variation projects

In the Save variation menu, the initial blank object must be specified. Then it will be
projected on a tool (die or binder), on which it will be moved or resized to create other
blank meshes. The direction of projection used is the stamping direction.
A list of variations is then defined, with the parameters necessary to define the new
blank mesh of each variation.
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Once variations are defined the corresponding projects are created when clicking on
A directory path is requested for storing the new projects. For each variation, a project
is built containing the new blank. The names of the projects are
referenceprojectname_var_i where referenceprojetname is the name of the
current project and i is the variation number (starting at 1).
The variations are stored in the reference project in which they are defined. Then these
variations can be run again if attributes are modified in the reference project. Variations
can also be modified and applied again.
Blank Variations Definition
There are two ways of defining the variations:

-
Location
Size
for shifting the blank.
for resizing the blank size.
Note:
The Preview button allows the user to see the blank outline which is not
projected on the projection object but only translated as specified in the
variation.
Two special options are compatible with the variation:
Picking properties are kept.
Adaptive meshing may be used in the blank.
Location variation
The displacement is defined by a vector in a specified coordinate system. The global
blank is shifted based on the vector direction and magnitude.
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The direction is projected on the blankholder surface or die surface (projection object)
outside the blank, taking into account the thickness of the blank. This action is done
incrementally so that the length of variation is the geodesic length on the blank and
projection surface. Internal free edges are computed and do not move.
Size variation
Four nodes have to be specified and for the border between these nodes, a value of
translation is given.
The blank outline is divided into 4 segments (limits are the nodes specified as corners in
the properties).
For each segment, a main translation is computed based on the distance given by the
user and the global normal direction of the segment.
For each corner, the translation is the sum of the main translation of its two segments.
Along the segments the translation is smoothed, based on translations of the corners.
Inside the blank, a translation vector is computed locally based on translation values and
distance to segments.
Similarly to location-type variations, this direction is projected on the blankholder
surface or die surface outside the blank, taking into account the thickness of the blank.
This action is done incrementally so that the length of variation is the geodesic length
on the blank and projection surface.
Limitations and Restrictions

-
There must be no internal free edges for size variation. For location variation,
internal free edges are accepted when they are close to the blank border (within
about 4 times the blank variation) but problems may occur due to element distortion.
Variation is limited to 20 times blank thickness and 5% of overall blank dimension.
Some shapes like U shape cannot be used: the angle between normals to the blank
and direction of shifting must be more than 45.
If the element size is reduced (due to internal free edges) so that the minimal time
step decreases by more than 35%, the project based on this variation is discarded.
Note that variations are done on the closed blank. Outside its initial contour, the blank is
projected on the projection object so that, if there is a distance between tools and blank
(tools not closed) an abnormal angle may appear.
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SOLVER ANALYSIS TOOLS

Solver Messages
are accessible both during a calculation, and after completion. In the
case of multistage calculations, the user can select to view the listing for the opened
stage, or for the multistage run.
Solver messages
It is possible to filter the information levels, to see only Errors, Warnings, or all
Information
It is advisable to check the solver output messages at the end of each calculation,
NORMAL TERMINATION at the end of the listing should always appear; if it does not,
there is an indication that the calculation is either incomplete, or has some error.
A search facility is provided to assist in finding specific characters in the listing file.
History Curves
In addition to the contour display of results, other
result data is read as History Curves. Typically
history curves are used for specific results where
the history of evolution is important. The evolution
can be plotted against Time or Progression.
The usual results a user may wish to examine in
this way are:
-
Contact Force curves
Energies (Total, internal)
Thickness, Stresses or strains in specific

locations
The advantage of examining shell thickness or strain in a curve is that generally

speaking the frequency of monitoring this information is much higher for History than it
is for output result states. See the contours chapter to have more detailed information on
the stresses and strains available data.
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In order to have these results, the user

must specify them in the History curves
settings of the Control attribute.
If the curve to analyze is created by
elements (element page), an object
containing those elements must be created
in the set-up with the Element history
option activated in the Post analyze
attribute.
Marks
Contact marks
Marks enable the user to identify the blank
nodes which are or were in contact with a set
of elements during the calculation. This set of
element (for example tools fillet) must be
defined beforehand in the set-up, putting them
in an object with the Node marks option
activated in the Post analyze attribute.
Marks are available only with Accurate
contact.
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Die entry fillet current marks
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Die entry fillet previous marks
Drawbead marks
Drawbead marks enable the user to identify
the blank elements which are or were in
contact with drawbeads during the
calculation. These drawbeads must be
identified beforehand in the set-up, activating
the Node marks option in the Post analyze
attribute.
Drawbead
Marked Blank
Drawing direction
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Drawbead previous marks
Element elimination
It is possible to have in post-processing
elimination of elements, to show the rupture.
This element elimination is based on criteria
defined by the user is the set-up. The user
defines the element elimination attribute on the
blank (or part of the blank) and activates the
criterion.
The elements that are eliminated are put in the
Others visibilities in post-processing, but are no
more picked by the solver for the following
stages simulation.
Notes
The eliminated elements put in Others should not be removed. There are used
for flattening, follower lines or other user interface analysis options.
The eliminated elements put in Others should not be picked in the following
stages, since they can no more be calculated by the solver.
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Section forces
Section forces (and moments) give the sum of forces (or moments), applied by elements
of an object (object E) on nodes of another object (object N), having the Post
analyze/Section forces attribute. Because these forces are internal forces, the nodes of
object N must belong to the elements of object E to obtain a non nil resultant force.
It is also possible to have the section forces applied on nodes having kinematics
definition (Boundary conditions on points or Cartesian kinematic attributes), such as
locking nodes of blank during implicit springback for instance. In that case the forces
will be calculated on these nodes only.
Definition in the setup

attribute must
be defined on the node object, with
definition of the elements objects; or on the
object having kinematics defined on some
node using Kinematics BC reaction option.
Post analyze/Section forces
In order to have these results, the user must

specify them in the History curves settings
of the Control attribute.
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Node object
Post-processing
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USER INTERFACE ANALYSIS TOOLS

Measurement Tools
Toolbar
A measurement toolbar is provided for the user to quickly check key measurements in
the simulation model. The toolbar contains the tools for measuring lengths, path
lengths, angles & radii in the 3D view. The measurements are displayed as annotations
in the 3D, and also printed in plain text in the console window measurements tab.
There are also additional tools to make quick radius and angle checks in 2D section
windows.
More detailed measurement tools are also provided in the Analysis Dockable menus,
these are:
Distance
The user can select the entity type, to select node or position and also the co-ordinate
system in which to measure. The use of the analysis functions does not display the
measure in the 3D window, it is reported in both the console & the menu page.
Angle
The user can select to measure Radius & Angles from 3 points, or Angle between 2
vectors. Again there is a choice of entity to select, either Node or Position, and the coordinate system in which to perform the analysis.
Entities
The user can select an entity for analysis. The data given will depend on the entity
selected. Valid choices are Node, Edge, Element, 3D curve, Object, Surface
Info Pointer
The Info Pointer can be toggled on and off via the view menu, with the shortcut key
F10. When activated, the info pointer will give an information display in the lower
status bar about the highlighted entity in the 3D view. It will display entity identifier,
and active contour value.
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Kinematic Check
Check of the attribute definition in the 3D view can be done using the Kinematic Check
option available from the Attribute tree menu and from the Analysis page:
It will display in the 3D view the displacement of the tools from the Autopositioning
and Cartesian kinematics definition.
Animation
Animation of results can be made from the Analysis dockable dialog box, or from the
Multistate & Animation toolbar.
Standard animation
The standard animation is used for viewing an animation of model results, with or
without contours. This type of animation is compatible with all options, and must be
used for flattening and follower line analysis.
Fast animation
The Fast animation offers a faster way to load the results files for animation of very
large models, or standard models on computers with limited memory. It is a less
memory intensive animation type, but has a few limitations, as a result it cannot be used
for flattening and follower lines.
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Multistage animation
It is possible to make a continuous animation
of a complete multistage simulation. By right
clicking on the results label, it is possible to
Include Multistage results from such a
project, or to include project for example if
import computed model has been used rather
than Multistage.
Movie creation
Whilst an animation type is playing, it is possible to export the animation directly to a
movie file (AVI format), using the Project, export, animation, menus. The user can
select to resize the movie frames, change the background colour to white, use raw or
compressed format, and select the colour depth. This allows the use to tailor the movie
file size & quality to his needs.
Flattening
The functionality is provided to perform a Flattening analysis. The purpose of this is
to project a curve; typically a trimline, or a limit of visible surface line on to the
deformed blank shape in the final state, after projection, the user can go backwards
through an animation (not Fast animation) in order to see where the material had started
from on the flattened or initial blank shape. This will help develop blank shapes, and
cost estimating.
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Follower Lines
The Follower line functionality is similar to that

of Flattening, but in the opposite sense. It allows
the user to select points, lines or curves, and
project them onto the blank at any stage during
the forming stroke, and then Follow them, to see
where they end up on the final finished part.
This is very useful for tracking slip lines, and
understanding material flow.
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Sections
Plane management
There are several tools for managing the plane
section (creation, copy, deletion, deletion of all, and
selection). New planes are created from the
button and displayed in the planes list.
Plane creation
Several options are available for defining a plane.

Parallel plans can also be automatically created.
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Plane modification
Sections plans already created can be then modified interactively using the virtual
thumbwheel, or positioned at precise locations & orientations depending on the
requirement.
The default behavior for modifying sections plane is the quick 2 point method, in which
the section is always cut through the two points and in the die line
.
Model Cutting
The user can cut sections in the model at any time and in any module. These sections
can be standard 2D sections, or 3D sections. If a contour is displayed it will also be seen
in the 2D section
The user must:
-
Select the plane in the list to use for cutting the model, by putting it as Model cutting
plane. This has to be done only if there are several existing section planes. The
section plane activated for cutting is displayed in red in the list.
Cut the model in 2D or 3D, activating with the following button:
It is then possible to select the preferred display type for section planes; box,
transparent, grid or with name. Several options allow the user to change the line
weighting to improve visibility of sections in large models, or to adjust the thickness of
the section according to active contour value.
Section line
It is possible to see section lines. These graphics lines represent the intersection of the
objects (all objects or selected objects) by the selected section planes. There are
interactive and link to the objects and section planes.
A small sign before the section plane indicates if a section line is available. The
option Set/unset as section lines plane enables to display or not section line for each
plane.
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From the section line button

curves or as 2D functions.
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, the user can then export all the section line as 3D
Section as 3D curve
Section can be exported as 3D curves object suitable for exporting to CAD via iges
export menu. When being saved as 3D curves, 3D curves become independent to the
section plane and are not automatically updated when section plane are modified.
3D curve can be exported from:
-
Selected section plane: the user selects a plane in the list and use the export sections
to from the
button
Cutting plane (red plane in the list) using the Export to from
All the sections lines using the Export to from
button
button
Contour cut (section as 2D function)

A contour cut is a combination of a 2D model cutting and a result contour. It displays in
the curve plotter, the value of the contour against the length along the contour cut
(Cartesian or curvilinear abscissa). It can also be used to save the X,Y coordinates of a
section.
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Contour cut can be exported from:

-
Selected section plane: the user selects a plane in the list and use the export sections
to from the
button
Cutting plane (red plane in the list) using the Export to from
All the sections lines using the Export to from
button
button
Advanced option for the contour cut are available only from the Cutting plane
Symmetry Creation
If a model has been running using a symmetry
plane (in order to speed up the calculation time)
it is still possible to re-create the other half of
the model during post processing using the
Symmetry option. Animations and contours can
then be displayed on the entire model
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User Diagram
User Diagrams are available from the following button

of the Analysis page. The
user can define his user diagram by selecting a contour in the X axis and another
contour in the his user diagram by selecting a contour in the X axis and another contour
in the Y axis. See the Contour chapter for further information on the available contours,
including the user contours.
Several User Diagram Options are available:
-
Domain
can be defined, with the minimum and maximum axis values
Curves can
Display options are also available, like the Background color, the size .
be used. It must be FLC type 2D curve defined in the 2D curve editor.
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Strain Measurement Data

An import filter is provided for reading the data coming from Strain Measurement
systems, to allow direct comparison of the results from measurement with simulation
inside the PamStamp2G graphical user interface. Currently the same file format can be
exported from Corus PHAST TM, GOM ARGUS TM, and VIALUX AutoGridTM optical strain
measurement systems, the data file should have a .txt file extension. To read the data,
procedure is as follow:
-
Import mesh, choose the STRAIN_MEASUREMENT filter and select the file to be
imported, taking care to check the keep identifiers toggle on.
The mesh is then displayed on the screen.
To display the major or minor strain contours, the imported, scalar value contour
must be used. From the drop down list the user selects either
MEASURED_MajorStrain or MEASURED_MinorStrain. The strains must be imported
from the same file as the mesh itself.
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Display Options and Show Toolbar

Many of the display options can be tailored to suit personal preference.
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Node options:
Bar options:
Wireframe, Background, Selection and Not valid color:
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choose the display shape for nodes, and impose a uniform color
adjust the visibility thickness

impose the color of these
options
-
Vector length:
choose the vector length display, to fit in shells or scale to magnitude
Lighting:
3D curve options:
adjust the visibility thickness and color
Entities highlight:
toggle the highlighting of potential mesh and geometry errors
Special markers:
choose from preset options, or adjust manually to suit
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toggle the visibility of the origin & the element normals
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SCRIPTING
Purpose
The purpose of scripting is to record actions executed in the graphical user interface,
and to play them automatically. It can be used for creating reports automatically from
data set-up and results of simulation, and for running automatic analyses.
The script file is an ASCII file that can be modified manually.
Script Use
There are two ways of recording and playing script, either using the Scripting toolbar
from PamStamp 2G user interface either by specific launching option of PamStamp 2G
(outside PamStamp 2G user interface).
Record
Launched option
To record a script file PAM-STAMP 2G must be launched with the option save=<filename>. Please note that <filename> must be enclosed in double quotes
( ).
The following shortcut is available in the Start menu on PC/Windows:
Using this shortcut, the file name of the script to save is asked by the launcher dialog.
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Toolbar use
To record a script, the

button must be pressed and the script file name as the stored
directory is then defined by the user. While record is activated the user can break or
stop it.
A breaking dialog is available if the user wants that the script displays messages during
the script play
Play
Launched option
To play an existing script file, PAM-STAMP 2G must be launched with the play=<filename> option. Here again <filename> must be enclosed in double quotes
( ).
It is possible to monitor the execution of a script file 'step by step' by adding a -prompt
option in the command line, in addition to the -play option. Hitting the <Enter> key
will execute the next action (default button of the monitoring dialog). It is possible to
wait for a set time between the execution of each operation with the -delay=<time>
option (where <time> is the time delay expressed in seconds).
Using this shortcut, all the script playing options are available in the launcher dialog:
-
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Scripting
Name of the file
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File type
Delay between actions
Option to monitor the execution.
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When the script is played, the license warnings are removed so that the script is not
stopped.
Toolbar use
To play a script, the

button must be pressed and the script file is then selected by the
user. While play is activated the user can stop the execution.
Play & Store

Purpose
It is possible to record a new script while playing a current script. It allows the user to
modify an existing script (change of camera axis, zoom level, or annotation layer
visibility for instance) without having to do it again entirely.
Launched option
To record a script file while another script is running PAM-STAMP 2G must be

launched with the option play=<filename> -prompt -save=<filename>. Please note
that <filename> must be enclosed in double quotes ( ).
Note
It is important to use the prompt option. If this option is not used, the name of
the new script will be asked to user, but the running script will not be saved. The
save action is done from the moment the user enters the new name.
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Using this shortcut, the file name of the script to read and the file name of the script to
save are asked by the launcher dialog.
The same options as in classic recording process are available here.
Recorded Actions
Record management:
At any time it is possible to record the:
-
Stop Point to allow direct user interaction.
Project management
It is possible to:
-
Open a project: the name of the project is written in the script file.
Activate a module: only in monostate mode (design, meshing, set-up, result state).
The name of the module is written in the script file.
Close project and save.
Leave the application.
3D view display management

Following 3D view display options can be recorder:
-
Change the point of view (by mouse or zoom actions) and the center of rotation. The
translation value, the rotation matrix, the zoom factor and zoom action are written:
X and Y translation values.
Rotation matrix.
Zoom factor.
Define a standard or a predefined point of view. The name of the standard actions
(unzoom, reset, fit) or the name of the predefined point of view are saved.
Activate the local coordinate systems for views
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Change the objects visibilities (without lock feature). The names of the displayed
objects are written in the script file. A flag allows showing or not the Others object.
Change the filter for objects display list.
Change the entity type visibilities.
Create a new 3D view.
Activate or deactivate the lights. The default light settings are then always applied.
Save of light effects in configuration file (Stamp2G.cfg)
Show or Hide Legend
Show or Hide Title
Show or Hide Triad
Show or Hide Non Uniform Drawbeads (with values)
Show, Hide or delete annotations
Show, Hide annotation layers
Import, Export Annotations (with corresponding layers, visibility)
Contours display management

Following contours display can be recorded:
-
Display a contour in the active view (all types with all parameters) except Imported
from file. The description of the contour with the options is written in the script file.
Change the contour display mode, element / banded / smoothed.
Show or Hide Legend
Display FLD contour in the 3D view and 2D view.
Maximize FLD and 3D view.
Create automatically Keeler FLC. The FLC and the object names, on which material
properties are set, are written in the script file.
Activate FLCs.
Fit FLD to window.
Customize:
FLC line width
FLC color
FLD axis color
FLD axis label front size
FLD axis label color
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File or images import/export

Files or images export can be recorded, especially:
-
Export mesh. The name, the directory and the type of format are saved.
Export curves in a file. The file name and directory are written in the script file.
Export 3D view as image (all formats). The file name the directory and the image
export options are written in the script file:
Image format.
File name.
Color.
Flags.
Image width and height.
Background color.
Image quality factor.
Image scale value.
Export all 3D views (in one or separate files). The same options as above are
available.
Export contour in a file. The file name, the directory and the format type are written
in the script file.
Export FLD view as image. The parameters saved in the script file are the same than
the ones of 3D view image export.
Import mesh. The name, the directory and the type of format are saved.
Analysis tools
It is possible to record the:
-
Creation of one or several history curves (all types with all parameters). The
description of the history curve with the options is written in the script file.
3D curves
Best fitting: The two
Show and Hide histogram
creation from free edges

objects names are saved in the script file
Projects or materials upgrade

-
Upgrade PAM-STAMP 2000 or Optris projects
Upgrade Material database files
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Selection
-
Selection of entities by rectangle. The coordinate of the rectangle, the entity type
and the selection mode (add, remove, replace) are saved in the script file.
Options
The -exitiffail command line option lets the user choose the behavior of the
Graphical User Interface when a scripted command playing fails: either the application
exits, returning an error code corresponding to the index (starting at 1) of the command
which failed, or the application displays an error message and lets the user decide
whether to continue or not the execution of the following commands.
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REPORTING
Reporting tools allow the user to build manually an HTML report including images and
annotations, a standard description of the simulation setup (process, model and material
description) and tables. Annotations are available for improving the report quality.
Configuration
General overview
An HTML editor must be available on your workstation, e.g. OpenOffice on a SUN
workstation. To be able to launch it through PAM-STAMP 2G, you must first configure
the interface.
Interface configuration
Select the Customize option in the main menu, then the Options item. On the GUI
Parameters tab, define the reporting part:
-
The Files directory is the default directory proposed for creating and saving new
HTML files.
The Editor command is the command typed by the interface for launching the
HTML editor. It must be followed by the FILENAME keyword for asking your
HTML editor to open the current HTML file containing the report.
For information, under Windows, the command is frequently:

C:\Program Files\OpenOffice.org1.1.0\program\soffice.exe -o
FILENAME
For a Sun workstation, the usual command to use is :

/OpenOffice.org1.1.0/program/soffice -o FILENAME &
Remark :
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Reporting
& must be added at the end of the command on UNIX platforms.
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Reporting Tools
To access the reporting functions, the Analysis menu item Report can be used. A better
solution is to display the Reporting toolbar that containing all the functions for
reporting:
Report selection
It creates/selects the report file (HTML file) to edit. The editor is launched, opening the
file. A new file can be created, or an existing file can be opened or copied (as a
template).
Image creation
The current window is printed in a file. By default, the file is created in the report
directory.
Material description
It concerns the current document (model and module). This description depends on the
loaded module. The list of objects whose material must be described is given (by
default, it is based on the object material attributes if existing). Image format, size and
background for all curves is proposed. A directory path (corresponding to the current
report directory) and a filename are proposed for creating a new HTML file for the
material description. The directory where the file is stored is the new report directory.
Model description
loaded module. The list of objects to be described is given (by default, all are selected).
A directory path (corresponding to the current report directory) and a filename are
proposed for creating a new HTML file for the model description. The directory where
the file is stored is the new report directory.
Process description
loaded module. A directory path (corresponding to the current report directory) and a
filename are proposed for creating a new HTML file for the process description. The
stage to report has to be selected.
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Table creation
A table can be written in the report file. A directory path (corresponding to the current
report directory) and a filename are proposed for creating a new HTML file for the
table. Either coordinates of nodes or contour on nodes/elements can be plotted in the
table. When choosing to pick objects, all nodes or elements are listed in the table. It is
not well adapted for large objects.
Report Types
It is recommended to create a directory for a report because different files are linked
together and it would be difficult to manage different reports in the same directory.
Two types of report exist:
-
Single HTML file report. In this case, you will insert (via the HTML editor) in the
report file the content of the files written by PAM-STAMP2G (process description,
material data, images, tables, )
Report consisting of a master file containing links to the other HTML files. In this
case, in your browser, follow the links to the files containing the descriptions; they
are not inserted into the main report file.
Creation of Report
Two possibilities are offered for writing the report:
-
From scratch: in this case, you will begin by creating a directory and a new HTML
file in it.
From a template: here, you also create a directory but you copy in this directory an
already existing file containing the main paragraphs and descriptions (and possibly
links).
Single file writing

In the new file, any text can be typed through the HTML editor. To insert process,
material and model description as written by PAM-STAMP 2G, the user can:
-
write the HTML files by PAM-STAMP 2G (through the corresponding icons of the
toolbar)
or use the INSERT function of the HTML editor where he wants in the main report
file and select the file written by PAM-STAMP 2G.
For inserting images / tables, the image / table must be written in a file through PAMSTAMP 2G and then opened in the report file.
The resulting file is a standalone file containing text, images, etc
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Use of template
This method is preferable. The idea is to have one or maybe many templates of reports
(depending on type of process, department, ). These templates (HTML files) are
stored in a directory and through the Open dialog, a new report directory will be created
by copying the template file in the directory.
This file contains:
-
a specific format,
some predefined paragraphs,
some predefined links pointing to the files which will be written in PAMSTAMP2G. Files are in the local directory and their names are fixed in the HTML
file. So when writing process description, material data, etc, these names must be
entered (an idea is to keep default names proposed in PAM-STAMP 2G because the
local directory contains only one report).
some areas for comments and analysis from the user.
So the user only has to do the following actions:

-
Write the material, model and process description files (using the correct filenames).
Add comments, images and tables in the main file (or another file, linked to the
main report file).
The report is then available on line.
Annotations
To use the Annotation functions, the Annotation toolbar must be displayed (obtained
through the right-mouse click popup menu or in the View menu, item Toolbars). This
toolbar contains all the functions for annotations:
New text annotation

New circle annotation
New arrow annotation
New contour value annotation
New Table in 3D view
Edit an annotation
Delete an annotation
Delete all annotations
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New text:
The user picks a position in the 3D view:
-
on the model: it is then attached to a 3D position,
outside: it is then attached to a position relative to the window.
The Annotation edition dialog is called after creating the annotation, in the mode text.
-
Text content in a text field (one line) can

be changed.
The font can be changed through a font

editor.
The color is displayed in a rectangle and

editable through a color editor.
The background color (optional) is

displayed in a rectangle and editable
through a color editor. A toggle is set to
activate the background color.
New circle:
The user picks a position in the 3D view (this will be the center of the circle). If the user
drags the mouse, the size (radius) of the circle follows the mouse. Otherwise, the radius
of the circle is the default one. The center type depends on the position of the picking:
-
on the model: it is then attached to a 3D position,
outside: it is attached to a position relative to the window.
The Annotation edition dialog box is called after creating the annotation, in the mode
circle.
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The color is displayed in a rectangle

and editable through a color editor.
The line width (value) and the radius

(value) are editable.
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Default values are the previous values (for

previous annotation).
New arrow:
The user picks a position in the 3D view (first point) and drags a line to a second
position (second point). Each point type depends on the position of the picking:
-
on the model: it is attached to a 3D position,
outside: it is then attached to a position relative to the window.
The Annotation edition dialog is called after creating the annotation, in the mode arrow.
-
The color is displayed in a rectangle

and editable through a color editor.
The line width (value) is editable.
The arrow type can be changed : a

drop list for 4 choices (arrow at the
beginning, at the end, at both sides or
no arrow) is available.
New contour value:

The user picks an entity in the 3D view (node, element,) where a contour is
displayed. A text annotation is created with default attributes (see below). Text is the
value of the contour corresponding to the picked entity.
New table in 3D view:

The user picks an entity in the 3D view (node, element,) whilst a contour is
displayed, this will create a table in the bottom right of the 3D view, subsequent points
can be added by holding the ctrl key, and dragging a previous point onto a new
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location. Points can be removed by holding the shift key & selecting them. Additional
contours can be added as columns in the table by first displaying the new contour, and
then right click on the table and select add view contour
Edit or delete an annotation:

The user by picking an annotation in the 3D view, can display the Annotation edition
dialog, the mode is the one corresponding to the type of annotation.
It is possible to delete a selected annotation in the 3D view or all the annotations.
Measure toolbar
See also the Measure toolbar that can put annotation during measurement. The
description is in the User interface analysis tools chapter.
Export view
It is possible to export images using the Image export functionality. The current
displayed views will be exported with the 3D view title (project name, displayed state
and progression value), but without the transfer tools.
It is possible to define the lengths parameters, the format of the image and the quality
level. It is also possible to impose a white background (texts will then be automatically
black), and to export at the same time several displayed views (for FLD or sections for
instance). In that case, the size ratio between views is respected in exported images.
The Ctrl+C/ Ctrl+V shortcuts enable the user to also copy 3D views imposing
automatically a white background and black texts. Only single views can be copied.
ANALYSIS TOOLS
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SIMULATION METHODOLOGY
FOR DESIGN AND STAMPING
FEASIBILITY
INTRODUCTION
A complex stamping simulation process can be divided into several steps, each
performed by PAM-STAMP 2G. Three main phases are available:
-
Die design: PAM-DIEMAKER enables the user to create a complex die mesh from
the initial part CAD data and load this mesh for subsequent process setup
Feasibility evaluation: a PAM-QUIKSTAMP simulation is easily performed with the

die mesh created with PAM-DIEMAKER or any other tool mesh. It requires a limited
number of input parameters and a high calculation speed. It gives the user an
evaluation of the formability of the die geometry in true process conditions and
takes into account multiple stages processes.
Tuning and validation for high quality stamping: accurate stamping calculation
using PAM-AUTOSTAMP can be divided into several stages: gravity, holding,
stamping, trimming - springback, flanging, hemming.
Process parameters which are entered for each stage are adjusted and validated so
that the obtained results are used to improve the real stamping process as much as
possible. (refer to the Simulation Methodology for High Quality stamping section).
The two first steps, Design and Feasability evaluation enable the definition of the
process (tools creation and process definition), which will be described in this section.
Procedure
The Die design, using PAM-DIEMAKER, is done in several main steps:
-
Part preparation: for taking into account symmetrical or double part, flanges or
holes in the part.
Binder generation: for defining and positioning the binder
Run-off and Addendum generation: to finalize the creation of the die by defining the
die opening line, the profiles or gainers.
It is also possible to perform re-engineering, to use existing die definition and to do a

new die from an existing one.
The evaluation of the tool design is done with PAM-QUIKSTAMP that performs very
fast simulations, with a very easy set-up. This step is optional. It can be done during the
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process verification with PAM-AUTOSTAMP. With PAM-DIEMAKER the chaining

of these steps is automatic:
-
Transfer data from PAM-DIEMAKER to PAM-QUIKSTAMP
Tools creation and Blank definition
Process set-up using Macro
Calculation and post-processing
Save as from PAM-QUIKSTAMP to PAM-AUTOSTAMP
Process modifications if needed
Calculation and post-processing
Lots of iterations can then been done at each stage of the evaluation.

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CUSTOMIZATION
Complete the User Macro Database with Stamp Tool Kit
The process macro enables the user to perform automatically several successive
operations, which generally occur during the data setup of each step of a stamping or
hydroforming process, see the Process Macro Chapter in the Simulation concept
section for further information on the Stamp Tool Kit functionalities.
The macro is created by the Advanced user, who defines the stages, the diagram of the
process, the groups of tools, the default process attributes and the attributes that will be
requested from the End-user in the standard software environment.
Data base
Process macros are available in the Public_macros database of the installation, but the
advanced user can create other macros to suit the usual processes of the users. It is
advised to complete the macro database by creating macros that fit the user process. It
will then minimize the number of information to enter during the process set-up.
The location of the macro data base can be defined in the Files location page of the
Customization menu.
The defined process macros are saved separately as an ASCII file.
Creation of a New Process Macro

The Stamp Tool Kit option enables definition of a new macro according to process
requirement. It is only available for advanced users, meaning that the Advanced mode
must be activated in the Customization menu (it can be done by default, in the
Customization / macro menu).
There are two ways of creating a new process macro:
-
Copy an existing macro from the public macro database, and modify it by adding or
removing stages or tools:
Open the existing macro from the Project / Open menu.
Use the Save as option to copy it as a new macro with a new name.
Modify the new macro.

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Create a macro from the beginning. In the file menu, New Stamp Tool Kit, the new
macros name, its type and its location have to be entered. The Stamp Tool Kit dialog
that appears, is used for a process macro definition.
It is advised to start from an existing macro, since it is easier to modify than to create a
completely new macro.
Procedure
The procedure is as follows:
1. Preliminary definition
2. Creation of the stage.
3. Schematic drawing of the groups (blank, die, blankholder, guides, symmetry plane,
punch, drawbeads, mark
4.
Behavior definition with creation of parameters if necessary.
5. Attributes definition with creation of parameters if necessary.

1- Preliminary definition
As soon as a new STAMP TOOL KIT is opened, a default configuration, which can be
modified, appears:
-
The blank group is called Blank, it is a single blank.
One parameter is created: the Thickness, as a real value, applied to the Blank.
In the Information zone, it is advised to write information on the process data setup that
will be done by the macro, so that the user has this information when selecting the
macro for his data setup.
If the process has double blanks or volume blank, the user must modify the blank type
from the beginning.
2- Creation of the Stage
After the creation of the first stage, the blank and the process pages are defined. A
Control attribute and the Advanced parameters attribute are automatically defined. The
control attribute is not complete, it will be defined later. The user must check that the
default contact type of the Advanced parameters attribute corresponds to the one he
wants to use for the macro definition.
The following stages are created with the Stages / Add option from the main menu,
selecting the stage type. A name is automatically defined, it can be modified. The
location of the stage must be also defined. The keep tools option can be used if there are
common tools between stages (e.g. between Holding and Stamping stages). With this
option all predefined tools are automatically drawn in the diagram.

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3- Schematic drawing of the groups
After the creation of the first tool, two parameters are automatically defined: Friction, as
a real value, and Stamping frame, as a coordinate system assuming that Z is the
stamping direction as described in the information zone of the parameter edition menu.
For QUIKSTAMP Plus macro, after the creation of the first tool, the option with offset
tool can be activated or not.
While drawing the tool shapes schematically, the tool outlines, which will be visible in
the end-user macro, are shown in the Preview panel.
If the Keep tools option has been used when creating the new stage, the unused tools
(like guides in the Stamping stage) have to be removed from the diagram.
All the default attributes defined when positioning the tool in the diagram must be
checked and modified if necessary.
4- Behavior Definition
Behavior icon must be dragged onto the tools or the blank.

For a QUIKSTAMP Plus macro, displacement behavior will be used instead of velocity.
For the holding stage for instance, a Holding displacement parameter, will be created as
a real with 0 as default value in Z direction, assuming that the tools are closed at the
beginning.
5- Attributes Definition
All the default attributes defined when positioning the tool in the diagram or when
defining the behaviors, such as the autopositioning attribute and the output of the
Control attribute, must be checked and modified if necessary.
Additional attributes can be added. It is for example advised to add an initial velocity of
1 m/s on the blank for an explicit gravity simulation.
All the attributes, defined in the Stamp Tool Kit, will be automatically created in the
attributes tree when the process macro is applied by the end-user.
6- Parameters creation
The following end-user parameters can be used for:

-
the gravity stage:
Stamping frame:
coordinate system.
Friction:
It is also possible to define a parameter for the gravity value, if the unit system is
not always the same.
real value.
the holding stage:
Stamping frame:
Friction:
coordinate system.
real value.

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Uniform level of refinement:
integer.
Maximal level of refinement:
integer.
Mass scaling for holding:
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real value set through a wizard.
For a QUIKSTAMP Plus macro, the same is done with a Die radius and Sliding radius
parameters.
-
the stamping stage:
Stamping frame:
coordinate system.
Friction:
integer (same as holding).
Maximal level of refinement:
integer (same as holding).
Blank holder force:
Stamping ramp curve: 2D
Stamping progression:
Drawbead Opening force:
Drawbead Restraining force:
Mass scaling for stamping:
real value.
real.
function, Advanced user, default curve.
real (default value 0).

Remarks
-
Autopositionning attribute is
automatically defined when putting tools in the

diagram. This attribute must be modified sometimes when it is the blank which is
positioned on the tools and not the tools on the blank.
Control
Control:
CPU Control:
CPU Control:
The Stamping velocity and the Stamping ramp curve parameters should be created
and imposed with a function defined by the stamping ramp curve and a
multiplication factor defined with the stamp velocity value in the Z direction. It is
attribute: It is partially filled and must be completed by the advanced user.

The stop criterion must be defined (Pinch test for High quality simulation). The
option Start at must be defined as 0 with the recomputed option, so that the
progression value does not depend on autopositionning; if the stop criterion is
progression. The states output can be defined by default using the total number. The
restart output could be synchronized with the states, and a number of history outputs
can be imposed by the supervisor as a cycle period for prints.
In case of explicit springback the outputs must be specified.
Mass scaling must be activated (it is not automatically defined) with a

corresponding parameter defined as real with the mass scaling wizard attached.
In case of explicit springback, the mass scaling parameter used for
holding must be renamed and used for this explicit springback stage also.

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better to define them as advanced parameter, so that the end-user does not have to
define it.
If no High quality simulation is performed, a single real parameter can be used with
a default constant value of 10 m/s.
For penalty contact simulation, it is better to define a 2D function, in order to have a
smooth contact between tool and blank.
-
For a QUIKSTAMP Plus macro, the same is done with a displacement behavior,
using a Stamping displacement parameter, as a real with 0 as default value in Z
direction. It is assumed that the tools are closed at the beginning.
Boundary conditions on points:
Trimmings: The trimming line is applied onto the blank along Z direction with
Stamping frame parameter as coordinate system. Another coordinate system
parameter, Trimming frame, can be defined so that the end-user can choose the
The attribute must be added without any specific

information for the implicit springback stage. It will be filled in by the end-user of
the macro, depending on the case. The boundary conditions on points attribute
should not be added, in case of explicit springback. It is better to do the simulation
with a completely free blank and to lock it in post process.
the
direction of trimming depending on the process.
Complete the Material Database
Initially, it is necessary to define the path where the material data will be stored and
from where the user will be able to load them again. This path definition is performed in
the Files Location list of the Customize menu. Specified here, are two directories from
which the stored materials are loaded.

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Two types of databases are available:

-
Public:
The user should only read the data. The access rights (read/write) for the
public material database depend on the installation.
Private:
The user can also store data (read, modify, add and delete).
In the private database, the user can create a new material or import an existing material
for a stamping process in a Material properties dialog. The import option allows the user
to import from another PAM-STAMP 2G project or to import (and translate) from an
Optris or PAM-STAMP 2000 material database.
Each material is written as a separate ASCII file and saved automatically. From then on
it can be used whenever it is needed (see Material file format chapter)
To create a new material, the user only has to activate the
button.
First the directory in which the material

will be stored must be selected. Then the
Reference and the File name must be
defined. All material properties and
coefficients are defined, depending on the
material law chosen.
The various types of materials are
described in the Material Properties
Chapter.
Salzgitter Flachstahl Data

For PAM-STAMP 2G v2008 we are pleased to provide additional materials data in the
database. The data which is found in the Folder Salzgitter_Flachstahl is kindly
supplied with the courtesy of Salzgitter Mannesmann Forschung GmbH
Salzgitter Flachstahl GmbH and Salzgitter
Mannesmann Forschung GmbH, including its
affiliates and subsidiaries, disclaim any and all
other warranties, conditions representations or
liability, relating to the material data or any part
thereof, including but not limited to errors or

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More information can be found at:

http://www.szmf.de
omissions contained therein; further including

without limitation, any and all implied
warranties
of
quality,
performance,
merchantability or fitness for a particular
purpose.
Customize the Meshing strategy

During the creation of tools default meshing strategy will be used. They are defined in
the Deltamesh page of the Customize menu. It is necessary to check once that the
proposed default meshing strategy fits with the type of simulated part and with the
imported CAD file. If it does not fit, the user must copy a default meshing strategy and
modify it.
More details about these options are defined in the Deltamesh Section.

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DIE DESIGN (PAM-DIEMAKER)

The die design process generally starts with a tooling idea. The main purpose of a die
design software is to easily generate a parametric 3d model. The way to go from the
tooling idea to the 3d model depends on the available data.
Creation of the Die from a Part

If no tooling information is available, the user will generally start with the part
geometry and construct his tooling from there.
The normal die creation process is usually divided into several steps as the following
diagram illustrates:

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Import and mesh part CAD
Tipping and part preparation
Blankholder design
Run offs and Addendum design
Transfer: update setup
The methodology within PAMDIEMAKER is straightforward and

intuitive: starting from the part geometry
one works his way through the various
phases and ends with the die face
geometry.
From v2007.0 A dedicated dialog box is
provided which helps to guide the user
through the die design process. The
concept of the dialog box is that it
presents the user with a logic to follow,
and offers only the appropriate functions
and tools for the active step.
The physical design process is divided
into the main logical modes, with each
one presented on his own tab page. The
user works his way through each tab
page and then onto the next one.
The user always starts with an initial tipping (the part is moved into the correct
stamping orientation), in order to make the best use of the following preparation
features. The tipping angle can be adjusted again after part preparation, if required.

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The user will do a preparation of the part geometry, as there might be areas on the part
geometry that cannot be taken into account as a die face. The optimum forming
direction will need to be adjusted with a new tipping. Once the tipping is done, the user
needs to define a binder surface (or blankholder surface). The next step is the run-off (or
addendum) definition. As soon as this phase is finished and satisfied, the user can verify
the general die face or simulation model.
Re-engineering the Die Face

If old tooling information is available, the user can capitalize on this information. PAMDIEMAKER contains a parametric re-engineering module that allows using old tooling
information in order to construct a new tool design. Of course, if a DIEMAKER model
of the old tooling is available, he can directly re-use this geometry and make the
appropriate changes. If he has never used DIEMAKER before, he can nevertheless use
DIEMAKER to continue his design process., The user can therefore start with a CAD
file or scanned data of the actual tool (mesh format) and simply decompose the existing
tool into a parametric model, i.e. re-engineering his old tools. Once this is done, he can
exchange the part geometry with the new information and make the appropriate changes
to the addendum and binder surface.
CAD part import and meshing

The CAD part is imported and automatically meshed using the standard tool-meshing
parameters.
The recommendations on mesh are the following:
-
The mesh should be connected around the part outline and in the neighborhood of
any holes
Double surfaces should not exist in the model
Elements should be small enough at the part outline to have enough nodes to
connect the profiles as described later.
It is also possible to import an existing mesh of the part using the Project / Import / Mesh
option and defining it as the design part. But the full surface export at the end of the die
design process is then not ensured.

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How to proceed
The procedure for importing the part is as follows:

-
Import part CAD
In the CAD import menu:
Select the CAD file(s) corresponding to the part
Select the Meshing strategy, which should be either Feasibility or Validation.
Check/modify: The Size factor. It is linked to the precision of the CAD

geometry and will be used for tolerances of CAD and mesh cleaning ( removal
of thin surfaces )
Import & Transfer
This option will import the part CAD, mesh it and transfer it in the design module.
The program automatically defines the meshed object as Design Part. It is a specific
object type, all operations performed within PAM-DIEMAKER module will refer to
this object.
Part Filleting
It is possible to fillet the sharp edges of the part object in DieMaker module. See
Filleting chapter for more details information.

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-
Open the DeltaMESH Fillet menu
Detect the sharp edges with the Autobuild

functionality
Define the radii. It can be constant or interpolated
Click on Fillet.
All meshing parameters will be set by the current

meshing strategy (Feasibility or validation).
It is also possible to modify a previously fillet sharp
edge (see Filleting chapter).

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PART PREPARATION FOR DIE DESIGN (PAMDIEMAKER)

Some areas of a part will not be
incorporated in the draw die. Therefore
some preparatory work needs to be
performed, such as hiding flanges, filling
inner and outer holes and creating a
symmetry plane.
Symmetrical part
Mode definition
PAM-DIEMAKER allows the user to treat
all kinds of parts. The part can be single,
symmetrical (half or fully imported) or
double (half or fully imported in case of
symmetrical double part or different
double part).

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Half symmetrical part
Full symmetrical part
Two options for defining the symmetry plane are available:

-
The user can define the symmetry plane manually by using all the possibilities
offered by PS2G (3 points, center and normal, center and main plane, 2 points and 1
vector).
The symmetry plane can be defined automatically by using an algorithm based on

the detection of the symmetric feature on the nodes of the part outline(s).
Notes :
The automatic algorithm can be used only in case of fully imported parts
(symmetric or double parts)
In case of single part, it is not useful to open the Symmetry dialog. The part is
automatically set as single part when imported.

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Double Part
Mode definition
PAM-DIEMAKER allows the user to treat
all kinds of parts. The part can be single,
symmetrical (half or fully imported) or
double (half or fully imported in case of
symmetrical double part or different
double part).
Half symmetrical double part
Full symmetrical double part
Different double part

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Two options for defining the symmetry plane are available:

-
The user can define the symmetry plane manually by using all the possibilities
offered by PS2G (3 points, center and normal, center and main plane, 2 points and 1
vector).
The symmetry plane can be defined automatically by using an algorithm based on

the detection of the symmetric feature on the nodes of the part outline(s).
Notes
The automatic algorithm can be used only in case of fully imported parts
(symmetric or double parts)
In case of different double part, the user will therefore able to do a component
position in order to make a positioning of each part according to the stamping
process
Tipping and Component Position

PAM-DIEMAKER supports multiple
coordinate systems: one global system and
several local systems. Initially the global
coordinate system refers to the imported
CAD coordinate system. Local coordinate
systems will be created to be used as a
stamping direction. When local
coordinate systems (tipping) are activated,
the model and his local system are moved
to coincide with the global system.
For double parts, the user can position the
double parts globally or has the possibility
to position each part according to the
tooling idea, using the component
position functionality in the tipping
dialog.
The procedure is as follow:
-
create a BBox for each part
position the parts by translating or rotating their corresponding frame (see next
chapter for more details)
The Set button then applies the transformation

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Note
If a symmetric double part is used the modification of one component will

modify automatically the second one in the same way.
Transition Area
For double parts, the user should create a
surface between both parts
Each transition area, created with the

button, will be defined with control curves,
using the Add, Edit and Delete functionalities. Two control curves are the minimum to
create the transition surface. The 3D curve editor allows the user to modify the curves
used for transition (set a segment as a line, set a radius on a point, )
The surface created will be automatically added to the Design Part object.
In case of complex transition surface, it can be useful to define several transition areas
with holes between each one. Then the new holes will be closed with the holes
functionality. In this way, the user can really give the desired shape to the transition
surface without too much constrains to the surface.
Note
If the Apply to all button is activated when the user deletes one transition area,
all transitions will be deleted
Tipping
PAM-DIEMAKER supports multiple coordinate systems: one global system and
several local systems. Initially the global coordinate system refers to the imported CAD
coordinate system. Local coordinate systems will be created to be used as a stamping
direction. When local coordinate systems (tipping) are activated, the model and his
local system are moved to coincide with the global system.
All objects created in later stages of the die design process depend on the orientation of
this system, therefore it is worthwhile to spend some time to find an optimal tipping
direction which minimizes draw-depth and/or undercut areas.
Two options for determining the tipping direction are available:
-
The user can define the tipping direction manually by rotating the new frame around
the global coordinate system

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An automatic algorithm can be used, which is able to find a forming direction based
on minimizing the draw-depth, undercutting or inertia moments
Once the proper orientation is found, the Set button activates the newly created
coordinate system. It could be needed to reverse the coordinate system using the reverse
tipping direction button
so that +Z is the direction going towards the bottom of the
die: +Z is the forming direction for double action process and -Z is the forming
direction for single action processes.,
Check options
Several verification functions are available, such as visualization of draw-depth and
undercutting by contour values.
An info field lists the transformations of the local frame as a rotation and translation
with respect to the global system.
Export system
The newly generated coordinate system can be exported to a CAD file in IGES or VDA
format.
Flanges
The component at this stage still represents the final part geometry, which might include
flanges created in the following operations and are possibly now in undercut. The part
could also be created as part on binder where the flange is actually part of the binder
surface. In these cases the flanges must be removed from the part object.
Two options for hiding flanges are available:
-
Manual detection. The user selects the surfaces (using the surface selection tool in
the selection toolbar) and hides them.
automatic
detection based on undercutting criterion with respect to the tipping frame
The flanges are hidden rather than deleted. This is done in order to allow visualization
of the hidden flanges during the profile construction, thus allowing the user to check
that he has allowed enough material in the addendum to lay out the flanges. These
flanges also contain useful information for blankholder and profile creation (e.g. the
length of a profile should be large enough to allow the cutting of the flange).

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Note :
If the user selects some elements instead of surfaces, the whole surface to which
belong the selected elements, will be automatically hidden.
Part splitting
If the initial CAD patches do not suit the flanges, it is possible to split these patches
directly into DieMaker with the Part Splitting functionality.
This function is available through DieMaker/Part preparation/Splitting.
The split of the surface is done using a 3D curve that must be selected or created using
the 3D curve editor. The 3D curve has to be created on the CAD surface in order to
guarantee the accuracy of the split surface.
The new created surfaces will be joined and meshed with the current meshing strategy.
They will replace the previous CAD surface in the DeltaMESH database (*.dtc files) in
order to allow the user to export Die CAD with the new surfaces.
Note:
Only the patches belonging to the Part object can be split
The split function requires the DeltaMESH database (*.dtc files).
The previous surface will be completely removed from the project.
Holes fillling
Some parts may contain holes (apertures or piercings) and should be filled.
All the holes can be filled automatically or the user can select the holes he wants to fill.
For more complex holes filling, control curves are available allowing the user to guide
the surface along. By selecting two nodes on either side of the hole, a 3D curve is
created that is used to span the surface. The 3D curve editor allows further
manipulations of this 3D curve, such as adding or removing control points, setting a
segment as line or setting a radius on one point of the curve.

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U end
For specific parts with an open head
shape (like a U-shape part for instance),
this option can be used to create an
additional surface in order to close the
part border
Two master curves are used to delimitate the flat areas (upper and lower) of the U-end.
Profiles give the shape of the U_end surface.
By picking four points on the part border, the user delimitates the different areas of the
U_end surface and the two master curves and profiles are automatically created. The
skeleton of the U_end is thus defined. The first two profiles (close to the part) are
created from the part border shape, and the third profiles shape is an extrapolation of
the first two profiles.

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The master curves and the profiles can be modified with the 3D curve editor (set a
segment as a line, set a radius on a point,). Two profiles are the minimum needed to
create the U_end surface. Three profiles are the minimum advised number of profiles to
get a proper shape
The surface created will be automatically added to the Design Part object such as the
rolling cylinders, the holes and the transition areas surfaces
Notes :
An Apply to all button is available to create all the U_end surfaces in one time
A Delete surfaces button is available to remove the surfaces of the active U_end
Add by one point allows the user to add a profile by picking on a master curve.
Add by two points allows the user to create a profile by picking one point on
each master curve. The profile will then be created in the plane passing through
these points.
Rolling Cylinder
This option is used to connect, or close 'open' areas at the periphery of the part in order
to obtain a smoother, less complicated outline for addendum connection later.

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Rolling cylinders can be automatically created using the Rolling radius parameter or
done manually. The tangency to the part is respected. The 3D curve editor allows further
manipulations of the curves, such as adding control points and removing them
The Rolling radius parameter defines the radius for rolling around the part. It detects the
start and the end of the part curves, to be created.
For more complex rolling cylinder shape, some control curves can be added by the user
to guide the surface along. By selecting one node on the part and another node on the
Rolling cylinder curve (Add by two points), a 3D curve is created that is used to span
the surface. The user can also use the Add by border part option to create a control
curve depending on the local curvature at the picked node on the part border. The 3D
curve editor allows further manipulations of this 3D curve, such as adding and
removing control points, setting a segment as line or setting a radius on one point of the
curve.
Notes :
The modifications available for the control curves are also available for the
rolling cylinder curve.
An Apply to all button is available in order to create the surface for all in one
time.
A Delete surface button is available to remove the surfaces of the active Rolling
cylinder.

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EVALUATION OF THE TOOL DESIGN (PAMQUIKSTAMP PLUS)

Offsetted or non offsetted QuikStamp plus
After the design of the die, QuikStamp will be used to simulate the stamping process
and check the feasibility of the die.
There are two ways of using QuikStamp:
The first one is for the initial iterations, when the die design and even the part design are
subjects to lots of modification. The tools meshes (punch and blank holder) will not be
offsetted. There are so no constraints on the mesh quality of the die.
-
The second one is for the last iterations, when the user feels confident about the tool
design. The tools meshes will be cleaned and offsetted. It will be easier to keep on
checking the process more precisely using AutoStamp.
Die transfer from design (Diemaker) to simulation

(QuikStamp plus)
When a die has been created in the design module it should be transferred to the set-up,
using the Update setup functionality:
For the first transfer a Workflow transfer rules menu appears. It has to be check and
validated by using the Transfer button. For further transfers (iterations between the
design of the die and the feasibility simulation) see the Iteration on Design and
Stamping feasibility chapter.

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Project mesh type

The project type must be QuikStamp plus.
If the project type was Mesh, the solver type must be defined before doing the transfer:
Go to setup
Define the project type as Quikstamp plus

Go to design
Update Setup
(see the previous description)
If the project type was AutoStamp, the project must be save as QuikStamp plus project
keeping the design modules.
Die import without using Diemaker

If the die CAD is directly available, it will be imported and meshed, using the Import
tools CAD option of the transfer functionality.
Please refer to the Deltamesh section for specific details on export options for each
CAD system. The needed quality of the CAD model is also described in the Deltamesh
section.

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Drawbead
It is important not to include the drawbeads on the CAD model, since they will be
modeled by equivalent drawbeads.
equivalent drawbeads
drawbeads
die
Reality
Modeling
Filleting
leads to a likely rupture of the blank, just as in the reality. The filleting can be
performed directly using the Fillet menu
Filleting chapter.
in Cad page of Data setup panel. See
Symmetry
The symmetry planes must be defined before any tool generation, since the offset takes
into account the symmetry plane. A plane-type object is created, its position in its
Definition attribute are defined. The Symmetry attribute with a specified tolerance will
be automatically defined. The default tolerance value is 0.1, see the Symmetry plane
chapter.
Chaining
The Tool editor will be used for the creation of the punches and the blank holders. It
will be automatically fulfilled depending on the information already defined in
Diemaker, in the attributes or in the wizard (like the thickness). The groups will be
automatically defined using the definition of groups in the group management menu.
How to proceed
The procedure for importing the tool is as follows:
Import tools CAD
Select the CAD file(s) corresponding to the Die
Select the Meshing strategy, which should be either Feasibility or Validation

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Check/modify the Size factor. It is linked to the precision of the CAD geometry
and will be used for all the tolerances of CAD and mesh cleaning (joining
tolerance, removal of thin surfaces )
Import & Transfer
Tools creation
The tools of the model have to be defined:
punch(s) and blank holder(s)
guides, locator pins
drawbeads
Creation of the Blank holder(s) and punch(s)
The blank holders and the punches are generated by means of offsets from the mesh of
the initial tool. A Tool editor is provided to automatically perform the required offsets
from the initial tool geometry, or to create tools without offset with using the No offset
option, see the Offset chapter.

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The Tool editor is already fulfilled with all the data defined during die design and
consolidated during the transfer to set up.
Parallel meshes
Non parallel meshes
Note
The tools normals must be oriented. Punches, Blank holders, Punch sources,
Blank holder sources will be automatically oriented by the Tool editor; but some
area of the Die (like the die entry radius) will not be automatically oriented. The
mesh orientation can be checked with the menu:
Several punches or blank holders (binder, pad )
The Tool editor can generate all the needed tools (punch or blankholder) defined from
an offset of the initial mesh. The Customize menu enables to set some of the definition
parameters concerning tools generating.
Non-offsetted QuikStamp
If No offset option is planned to be used (see the first paragraph), there is no constraint
or particular care about the model. A zero thickness value will be used in the Tool
editor.
It is recommended to study Creation of the tools chapter at first.
Description of the procedure of creating Non-offsetted tools in Tool editor is as follows:
Open the Tool editor.
Define OP parameters.
Define tool set.
Tick No Offset option.
Define direction from die to punch.

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Add Die and tools you need to create by a right click on Tools
Define Die source object (imported CAD)

o Select Build from definition
o Select Die source from list of source objects
Define Punch and Blankholder(s)

o Select tools sources objects from list of source objects
o Select side for creation at punch or at die
Use the Build button to create objects.

Offsetted QuikStamp
If offsetted QuikStamp is planned to be used, the user should take care of:
The die mesh quality
The offsets performed during the generation of tools may highlight problems in the
initial tool mesh. Even if QuikStamp plus is relatively non-sensitive to mesh quality it is
better to have correct mesh quality to use offsetted Quikstamp plus,
The free and multiple edges can be checked using the show toolbar:

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The Deltamesh history file gives information about the success or the problems
encountered during import, joining and meshing.
Several Mesh Quality contours can be used to find the elements which are warped, very
thin or distorted.
Angle between shells:
the value is the angle between the average normals of

these two elements. If it exceeds 20-30, that means that they can be a mesh
problem like overlapping or distorted element.
Warping angle:
Area:
big warping angle can indicate a problem of mesh quality.
if the area of the elements is very small (0.01 mm) problems could occur
during offset.
If a problem occurs during the mesh quality control, it must be repaired. If there are
several important problems, the best way to repair it is to change the meshing strategy
(see the Deltamesh section) for example reducing the Chordal error parameter to solve
the undercut.
If the problems concerns only a few elements, the easiest way is to use the tools from
geometry/edition of nodes or elements, like the merge node to node to eliminate the
problematic element.
The representation of the CAD surface (die side or punch side).
In general, the CAD surfaces represent either the die face (model on die side) or the
punch and run-offs (model on punch side). As these CAD surfaces are used for the
creation of the remaining tools, the accordingly two methods (die side and punch side)
are treated separately but their main methodology remains the same, see the Offset
section, for more details on the way the offset are done depending on the CAD surfaces
representation.
It is important to know what is represented by the CAD (die side or punch side) to
create correctly the tools with the good radii. A mistake could impact the results,
especially if it is planned to use the model later for high quality simulation (springback,
die compensation, surface defect analysis).
It is recommended to study Creation of the tools and Offset chapter at first.
The procedure of using the Tool editor is as follows:
Description of the procedure of creating Non-offsetted tools in Tool editor is as follows:

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Define OP parameters.
Define tool set.
Fill thickness value.
Define direction from die to punch.
Add Die and tools you need create by right click on Tools
Define Die source object (imported CAD)
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o Select Die source from list of source objects
Define Punch and Blankholder(s)

o Select tools sources objects from list of source objects
o Select side for creation at punch or at die
Use Build button to create objects.

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Guides or locator pins
The guides are designed to prevent undesirable sliding of the blank. It is mandatory to
use guides during gravity phases.
Their width must be greater than twice the size of the blank elements in order to prevent
a blank element from passing through a guide:
The locator pins, if any, are also designed to prevent undesirable sliding of the blank.
They must be meshed with enough elements in order to have a shape closed to reality:
flan
height
too small guide
A
BB
For implicit gravity, the elements of the mesh must be correctly oriented, facing the
blank.
Guides and locator pins can be meshed from a CAD file with DeltaMESH or created
using the Accessories functionality in Tool editor, as described in the following steps.

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Creation of the first guide:

-
Right click on Accessories and select Add guide. New sub-object Guide [1] is
created.
Select the type of guide, it can be standard, left side or right side.
Define the guide geometry. For Guide, check that the distance between point1 and
point2 is larger than twice the size of the blank elements. For Locator pin, make sure
that there are enough elements on the circumference to have a smooth definition of
the locator pin.
Define the extrusion by Guide direction, which should be the stamping direction
Define guide Height, which should be high enough
You can rename object by right click, if necessary.
To put all the guides in the same object use plus to add next sub-object Guide [2] and
do the definition in the same way as before.

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Drawbeads
The elements used for the representation of the drawbeads on the die are 3D curves with
a drawbead object type. These 3D curves are automatically transformed in 2-node bar
elements when launching the solver. See Drawbead chapter for further information.
The drawbeads can be defined by importing 3D curves (CAD format) or by using the
3D curve editor to define the drawbead lines clicking directly on the die surface.

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Blank definition
The blank mesh can be created
using the Blank editor. It can
also be imported through one
of the available translators
(Nastran, Patran, Ideas) or
created in Diemaker and
transferred.
Rules for the blank mesh

It is recommended to follow several rules during blank meshing:
-
There must not be too many 3-node elements, since they do not behave in the same
manner as the 4-node elements.
4-node elements must be as close to squares as possible and the 3-node elements as
close to equilateral triangles as possible.
The mesh must be as uniform as possible: the minimum characteristic length should
not be smaller than 25% of the mean characteristic length.
The normal of the blank elements must be oriented in the same direction.
Blank mesh refinement is governed by the Die geometry characteristics. The Mesh size wizard
asks to enter the Minimal sliding radius value this is not necessarily the smallest radius in
the part, but the smallest radius where sliding can be important i.e. it would not apply to small
depressions or features which are embossed. The Minimal Blank thickness is already fulfilled
from the value entered in the Tool editor (be careful to correct it if 0 value has been defined
previously for non offsetted tools). The initial mesh size needed is then calculated automatically
from this.
Note
If non offsetted tools have been created using a zero thickness value in the
toolbuilder, the thickness must be corrected in the blank mesh wizard (by default
it is zero).

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Surface blank creation tools

There are several ways of creating a mesh in PAM-STAMP 2G:
Outline:
Using a 3D curve, any planar blank can be meshed.
Four points:
The four corners of the blanks have to be defined, by clicking them in the
3D view or by entering the coordinates.
Rectangle:
The corner and the size of the rectangle blank are defined
Disk/Pie:
It enables to conveniently mesh part of disk. For die shape like cup, the
created mesh is always parallel to the die entry line, and the mesh size is optimized.
For most of these options, a Mesh preview is available to visualize the blank after the
mesh creation. The created mesh is put in the defined object that has automatically the
type Surface or Volume Blank, according to what the user selects.
D Curve
When the blank contour is already defined by

a CAD curve, it can be imported using the
Import CAD curves functionality and used as
Outline.
Modifications
All the planar blanks can be modified with the Outline option. A 3D curve is Created
from Mesh contour and can be edited using the 3D Curve Editor. It enables to cut the
corners, to offset the blank or to modify freely the contour.
The blank can also be remeshed by modifying the element size.

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Process definition
Process frame
A process frame will be used for the definition of the process parameters.
In the public Macro database, all the macros are defined with a stamping direction
corresponding to the +Z axis. To use these macros, the user must create a coordinate
system-type object with the Z-axis as the stamping direction. The frame created in
Diemaker and automatically transferred as global frame is the good one for double
action, but must be modified for single action, replacing Z by Z.
For macros created by the user, it is necessary to make sure that the coordinate systemtype object uses the same axis to define the stamping direction as used in the macro.
There are four ways of creating a stamping coordinate system:
1. defining three positions
2. defining an origin and a vector
3. defining a frame and an angle
4. importing it from an IGES or a VDA file.
QuikStamp Plus Macro-command selection

There are a number of pre-defined macros in the public macro database, but the user can
also create his own to best suit his processes, as described in the chapter
Customization/Complete the User Macro Database with Stamp Tool Kit .
The available macros for feasibility process in the public database are gathered in the
directory Feasibility.

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One macro will be used for the same set of tools. If there are several operations to
simulate with numerous set of tools, several macros will be used successively.
Several operations
macros and to define successive operations.
enables the user to load several
macros that appears in the drop list at the top level of the macro.
Definition of stages and tools

After loading a macro, the tools and the stages that are necessary for the process must
be selected and renamed if the name can lead to confusion (for example when loading
several macros).
Remarks on the stages selection:

-
A gravity calculation is not always necessary. It is normally recommended for the

large parts, as the blank bends significantly when placed in the press. In that case
guides are needed in most of the cases.

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If the blank holder is planar, the holding step is not needed.
If only the stamping stage is selected, the specific stamping only macro must be
used, since an autopositionning attribute is defined for the blank and the tools. In the
other macros the autopositionning is done at the beginning of the holding stage only.
Drawbeads groups can be duplicated selecting one existing drawbead and clicking the
icon
. The objects apply to this new group will have the same attributes as the first
one, but with another restraining and opening forces.
Automatic fulfill
Most of the parameters are already defined when loading the macros. This automatic
definition of parameters comes from:
-
the attribute tree: if some attributes are already defined they will be automatically
filled by the macro
the other menus or wizards: if a parameter, like the thickness or the friction has
already being defined in a previous menu or wizard, it will be used to fill the macro
parameters.
the macro itself: default parameters can be defined when creating a macro with the
Stamp Tool Kit. This value has priority on the other existing or used values.
It works the same way for the groups that are defined automatically when creating the
object with the different menus (guides, surface blank editor, toolbuilder ) and can be
check or modified with the group management.
Definition of the process parameters

The blank properties can be defined by loading a material from the data base (see
Chapter Customization/Complete the Material data base), or by creating a new material.
A Keep option enables to use the material already defined in the attribute tree. It will
not be erased when applying the macro and the data are used in the wizards of the
macro. It should be used especially if the blank comes from a computed model.
The macros proposed in the public macro database for feasibility imposes some
attributes or parameters described below and asks the user to define others:
-
Holding stage
Die entry radius:
this value is used for the refinement definition. The minimum

sliding radius is already defined, coming from the blank meshing wizard.
Stamping stage
Blank holder force:
it must be defined by the user
Drawbead opening and restraining forces.
A wizard enables to calculate the

forces from the geometry of the real drawbead.

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When a macro has been applied, all the attributes/parameters defined in the macro are
displayed in the Object attributes window.
It is better to open the attribute tree to check the attributes, especially if some stage has
been removed. In case of deletion of stages, some additional autopositioning can be
necessary.
Note
In single action macro, check that the default coordinate system is the correct
one.
Unit system
All the parameters must be defined with consistent unit system. All the macros of the
public material database are defined with the unit system mm / ms / kg.
Initial positioning
Autopositionning performs a translation along the stamping direction only:
blank
guide
Positioning
action
die
Manual positioning is recommended in the horizontal plane and in rotation in order to

reduce CPU time. This corresponds to a preliminary gravity action:
Positioning
action

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Process stroke
The tools are considered at the zero position at the beginning of the simulation before
any applied transformations (positioning, translation). The stroke will be displayed in
post-process from the value after positioning to the final position.
Example
After creation of the tools, they are at the position at the end of stamping. This is the
reference position equal to zero
Distance = thickness
The autopositioning of punch is automatically done when the simulation stops, and the
punch is translated from: -60 mm
Automatic punch autopositioning = 60 mm
The state 0, will then have the progression -60; and the final state, the progression 0
Starting the simulation

After the data setup is complete, the calculation can be started using the menu transfer
/start computation.

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The check attribute option is activated by default; it checks the compatibility between
attributes. Each stage will be automatically run one after the other, and a project will be
created at each stage. ???Will be added Multihost chapter ???
The user can check the progress of the solver via the menu Solver / Messages.
Post-processing the Data

For more details see the Analysis tools section.
During the calculation depending on the number of output states that were chosen
the program will display the results in the project / visibility dialog box. Double-clicking
on a state activates the results visualization.
To view the various results use the Analysis docking bar where all of the necessary
contours, sections and curves can be displayed. For a proper checking of the
formability, various criteria such as thickness, thinning and the quality contour by FLD
have to be used.
Gravity Simulation Analysis

It is interesting to look at:
-
The error messages to be sure that the calculation has converged.
The displacement field (contour).
The final position especially in the guides area
If any problem occurs, check:
The orientation of the element normals of the tools and the blank
The unit system, especially for the gravity field and the material definition
The presence of guides
Holding Simulation Analysis

-
The general shape of the trapped blank.
The final position of the blankholder with respect to the die, either in section view
or by using the distance between objects contour.
The unit system, especially for the material definition.
The warnings in the solver messages. If there is any initial penetration, check
the positioning of the tools.

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Stamping Simulation Analysis

-
The error messages to be sure that the calculation has completed with normal
termination.
The thicknesses, with eventually some profiles in some sections, and the thinning of
the blank in %.
The forming limit diagram:

Rupture risk to verify the distance to the forming limit curve.
Quality zones to verify existence of potential wrinkling and unstretched areas.
For thicker materials or shapes strongly dominated by bending, verify the rupture
risk for the upper and lower sides shell fibers as well.
The displacements, to quantify the sliding of the blank.

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PROCESS VERIFICATION (PAM-AUTOSTAMP)

Introduction
If high quality stamping simulation with analysis of springback, compensation of the
die, surface defect or press forces analysis is planned; refer to the Simulation
Methodology for High Quality Stamping section.
Transfer from QuikStamp Plus to AutoStamp

Save as
-
The user uses the save as new project in the transfer functionality
In the following menus, the user gives the new project name, the location. He
specifies the solver type as AutoStamp and selects the meshing modules he wants to
keep or not.
The save as project wizard helps doing the transition of the data
The information is already filled-in and has just to be check:
For current tools geometry tools are offseted or tools are not offseted.
AutoStamp contact type is accurate.
For holding and stamping stages, the stage type, the velocity (default value 2 for
holding and 10 for stamping without delay) are the correct ones for standard
simulation.

Process Verification (Pam-Autostamp)
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The refinement levels are automatically computed from the die radius, the blank
thickness and the blank mesh size.
When the save as is finished, warnings appear telling that:
The control attribute is reinitialized
An offset of the tools is necessary if tools were not offseted in Quikstamp plus
Tools modification
Mesh quality check
In order to carry out a simulation with Accurate contact, the quality of the tool mesh
must be good, as explained in the Contact and Friction chapter. Accurate contact
respects tool geometry as there is no penetration of the blank node in the tool mesh.
Therefore only tools with high quality mesh can be used.
Offseted Quikstamp plus
As the tools were already offseted it is needed to be sure that there was a gap between
the die and the punch. If the user does not remind it and did not already clean the
offseted mesh in Quikstamp plus, the best would be to open the tool builder and to
apply it again.
Note
Be careful the offset was done in Quikstamp plus as penalty type, it will be
proposed by default as accurate type (see offset chapter).
As described below the mesh quality requirement is higher for Autostamp with
Accurate contact than with Quikstamp plus. It must therefore be checked especially
after offset and repair if needed.
Non offseted Quikstamp plus
As the tools were not offseted in Quikstamp plus project, it is necessary to offset them.
The toolbuilder must be opened, it is automatically filled-in, the user only has to check
the data (especially the gap between die and punch) and apply it.
As described below, the mesh quality requirement is higher for Autostamp with
Accurate contact than with Quikstamp plus. Therefore it must be checked especially
after offset and repair if needed.
Attributes modification
Locator pins: refinement of blank
When using Accurate contact, the mesh close to the locator pins must not be refined, to
avoid penetration of new nodes in the locator pins. A new object containing the element
close to the locator pin must be created, a refinement attribute of 1 must be defined.
Another object containing the rest of the blank will have the uniform and maximal
refinement levels.

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Nodes created
with refinement
Friction
By default the friction value used in Quikstamp plus is 0.15; which is too high for an
equivalent Autostamp simulation. The user must modify it to 0.12 for Autostamp
simulation with accurate contact type. The easiest way is to open the attribute tree,
select the contact attribute (droplist at the top of the menu); and modify them all.
Starting the simulation

After the data setup is completed, the calculation can be started using the solver button
in the setup menu or transfer /start computation menu.
The check attribute option is activated by default; it checks the compatibility between
attributes. Each stage will be automatically run one after another, and a project will be
created at each stage.
The user can check the progress of the solver via the menu Solver / Messages.

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Post processing the data

For more details see the chapters of the Analysis tools section.

-
The error messages to be sure that the calculation has converged.
The final position especially in the guides area
For explicit gravity simulations, also check displacement curves and the kinetic
energy history.
The orientation of the element normals of the tools and the blank
The unit system, especially for the gravity field and the material definition
The presence of guides
The final position of the blank with respect to the blank holder for single action
process. The blank holder walls should have prevented any node of the blank
going below the blank holder. This can happen also if the blank mesh is very
large compare to the blank holder curvature. In that case use a finer mesh or
define a contact between blank and blank holder (there is already a contact
between blank holder and blank)

-
Termination. It is useful to check where the pinch test occurred, if it is used as the
stop criterion.
The final position of the blankholder with respect to the die, either in section view
process. The blank holder walls should have prevented any node of the blank going
below the blank holder.

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-
The error messages to be sure that the calculation has completed with normal
termination. It is useful to check where the pinch test occurred.
The animation of the stamping process.
the blank in %.
The forming limit diagram:
For thicker materials or shapes strongly dominated by bending, verify the

rupture risk for the upper and lower sides shell fibers as well.
The stresses field on the neutral fiber, but also on the top and bottom fibers if a
springback simulation follows the stamping process
The equivalent plastic strains.
The area where pinch test occurs, using sections. A bad mesh quality may have
stopped the simulation. Use the mesh quality criteria defined before.
Direct set-up (without coming from Quikstamp plus)

The initial set up of an Autostamp simulation without coming from Diemaker and/or
Quikstamp plus is quite the same as the one described in the Simulation methodology
for high quality stamping section.

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Creation of the tools
See the chapter Creation of the tools in the Simulation methodology for high quality
stamping section for detailed description of this step.
All actions will be done in the tool editor reachable from the set-up menu:
The procedure to create the tools is as follows:
Define an OP
Define the OP parameters and import the die geometry.
Die import and meshing
Import tools CAD.
Select the CAD file(s) corresponding to the Die
Select the Meshing strategy, which should be

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or Validation
Check/modify the Meshing size. It is linked to the size of the model and will be
used for for all the tolerances of CAD and mesh cleaning (joining tolerance,
removal of thin surfaces )
The Backup in DeltaMESH module must be activated.
Import & Transfer
Die filleting
See Filleting chapter for more details information.

-
Open the DeltaMESH Fillet menu,
Define the fillet with the Autobuild functionality,
Define the radii. It can be constant or interpolated,
Click on Fillet.

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Geometry defined
Depending on what the initial mesh represents, select on die side or on punch side
information.
OP direction and frame
The main direction of the OP has to be defined in the tool editor.

A process frame will be used for the definition of the process parameters.
In the public Macro database, all the macros are defined with a stamping direction
system-type object with the Z-axis as the stamping direction.
There are four ways of creating a stamping
coordinate system:
1. defining an origin and a vector
2. defining three positions
3. defining a frame and an angle
4. importing it from an IGES or a VDA file.
Symmetry
The symmetry planes must be defined before any tool generation, since the offset takes
into account the symmetry plane. A plane-type object is created, its position in its
Definition attribute are defined. The Symmetry attribute with a specified tolerance will

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be automatically defined. The default tolerance value is 0.1, see the Symmetry plane
chapter.
Define the tools to create and the sources.
the initial tool. The tool editor is provided to perform automatically the required offsets
from the initial tool geometry. See the Offset chapter.
Before defining the sources, select the tool set which will define the offsets and the
translation to do and create a base of tools.
If there are more than one punch and one blank holder in the model, add tools by right
clicking in the left menu of the tool editor.
For each tool mesh you want to create, create an object containing the part of the initial
mesh that will be used to create this new tool mesh.
For each tool, define the sources you would like to transform.
Then build the tools
Creation of guides if any

See the chapter Creation of other tools in the Simulation methodology for high
quality stamping section for detailed description of this step.
flan
height
too small guide
A
BB

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Guide or locator pins
The guides are designed to prevent undesirable sliding of the blank. It is

mandatory to use guides during gravity phases.
Their width must be greater than twice the size of the blank elements in order to
prevent a blank element from passing through a guide:
The locator pins, if any, are also designed to prevent undesirable sliding of the
blank. They must be meshed with enough elements for having a shape closed to
reality.
The creation is managed in the tool editor as accessories. All is stored and can
be rebuilt. For adding an accessory right clicks in the menu below the
Accessories list.
Creation of the guide:

Select the type of guide,
which can be a plane guide, a
guide with borders or a
locator pin
Define the guide geometry.
For guide, check that the
distance between point1 and
point2 is larger than twice the
size of the blank elements.
For locator pin, check that
there is enough elements on
circumference to have a
smooth definition of the
locator pin.

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Define the extrusion

direction, which should be the
stamping direction
Define guide height, which
should be high enough
Creation of the other guides: do the same as before but click on + button in the
guide definition, to put all the guides in the same object.
Blank meshing
See the Blank meshing chapter in the Simulation methodology for high quality stamping
section for a detailed description of this step.

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The blank mesh can be created using the

Blank Editor menu. It can also be imported
through one of the available translators
(Nastran, Patran, Ideas).
There are several ways of creating a mesh in
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Outline:
using a 3D curve, any planar

blank can be meshed.
Four points:
Rectangle:
Disk/Pie:
Tube:
the four corners of the blanks

have to be defined, by selecting them in
the 3D view or by entering the
coordinates.
the corner and the size of the
rectangle blank are defined.
it enables the user to
conveniently mesh part of the disk. For
die shape like cup, the created mesh is
always parallel to the die entry line, and
the mesh size is optimized.
it enables the user to mesh a tube.
Modifications
from Mesh contour and can be edited using the 3D Curve Editor. It enables the user to
cut the corners, to offset the blank or to freely modify the contour.

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Mesh Size wizard
The optimal element size is

computed by the wizard respecting
the rules described below.
The Minimal sliding radius and the Minimal blank thickness lead to the computation
of the Final mesh size (Half of the sum of sliding radius and the half-thickness of
the blank).
Assuming than the Accurate contact is used (Adavanced parameters), the size grows
from the final size to the initial size (factor 2 step by step) until it reaches the
maximal initial mesh size (set to 25 by default and defined in the Advanced
Parameters). So refinement levels (maximal and uniform equal to 1) are set. There is
no limit in the refinement levels.
Such a choice is a good compromise between CPU time and accuracy of the results.
Import or Creation of Drawbeads (if any)

a drawbead object type. These 3D curves are automatically transformed in 2-node bar
elements when launching the solver. See Drawbead chapter for further information.
3D curve editor to define the drawbead lines clicking directly on the die surface

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Analysis of entities
See the Analysis of entities chapter in the Simulation methodology for high quality
stamping section for a detailed description of this step.
Process set-up
See the Process set-up chapter in the Simulation methodology for high quality stamping
section for a detailed description of this step.
Macro selection
The available macros for high quality process in the public database are gathered in the
Feasibility directory.
simulate with several set of tools, numerous macros will be used successively.
The OP name can be put in order to select the good tools easily.

enables
the user to load several macros and to define
When applying the macros, the stages of each macro
will be added one after each other in the attribute
tree. The user can later check the data by opening
the different used macros that appears in the drop
list at the top level of the macro.
Macro use
The data setup is defined in the set-up page, having access by using the following
button

-
Load the macro
Select the OP which corresponds to this macro
Select the groups (tools) and stages in the opened Customize menu, and rename
them if necessary
Check or define the objects (active in this stage) to the corresponding Groups.

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Check or enter the global parameters common for several groups, several stages:
the friction coefficient between the tools and blank: if a default value is already
defined, it has to be checked
the stamping frame, assuming that the stamping direction is the +Z-axis.
the refinement levels (uniform and maximum), used for both holding and
stamping stages. It is automatically filled-in from the blank meshing menu
Check the pre-defined parameters and define the red one
Load a new macro and do the same actions
Apply all the macros
It is better to open the attribute tree to check the attributes, especially if some stages
have been removed. In case of deletion of stages, some additional autopositioning can
be necessary.
Duplication of groups
icon
The same functionality is available for blanks that can be duplicated for tailored blanks
simulation. But this procedure is no more useful since tailored blanks properties are now
defined through Blank and Tool editors (see Tailored blanks chapter for further
information).
Starting the simulation and post-processing

These two steps are described in previous paragraphs.
PAM-AUTOSTAMP setup
Here are described some advise for a good calculation with Pam-Autostamp accurate
contact for checking the process. If high quality stamping simulation with analysis of
springback, compensation of the die, surface defect or press forces analysis is planned
refer to the Simulation Methodology for High Quality Stamping section.
Tools mesh
-
Drawbead: It is important not to include the drawbeads in the initial CAD model,
since they will be modeled by equivalent drawbeads.

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drawbeads
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die
Reality
Modeling
Filleting: In order to obtain realistic results, the tools used in the stamping
simulation, which are represented by meshes, must be completely filleted as they are
in reality. A sharp edge leads to a likely rupture of the blank, just as in the reality.
The filleting can be performed directly using the DeltaMESH Fillet menu.
The Tool editor is already filled-in with all the data defined during die design and
consolidated during the transfer to set up.
Tools mesh must be parallel that is why punch and blank holder must be an offset of
the die mesh (or vice versa).
Parallel meshes
Non parallel meshes
The tools normals must be oriented. Punches, Blank holders, Punch sources, Blank
holder sources will be automatically oriented by the tool builder; but some area of
the Die (like the die entry radius) will not be automatically oriented. The mesh
orientation can be checked with the menu:
Representation of the CAD surface (die side or punch side): In general, the CAD
surfaces represent either the die face (model on die side) or the punch and run-offs
(model on punch side). As these CAD surfaces are used for the creation of the
remaining tools, the accordingly two methods (die side and punch side) are treated
separately but their main methodology remains the same, see the Offset chapter, for
more details on the way the offset are done depending on the CAD surfaces
representation.
Mesh Orientation: With the Accurate contact option, the mesh orientation should
not be a problem. But implicit gravity simulation uses a specific contact that
requires mesh orientation. So for implicit gravity only, the elements of the mesh
must be correctly oriented, facing towards the blank.
Mesh Quality
initial tool mesh.
-
The free and multiple edges can be check using the show toolbar:

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Undercut: Even if the initial CAD has no undercut, the mesh can induce undercut in
non-planar vertical parts. For example in the curved vertical surface, if the
discretizations on the top and bottom lines of the surface do not coincide, there will
unavoidably be some undercut elements.
Top view:
A
Cross section AA:
Edges on
bottom line
CAD
CAD
A
Mesh
Edges on
the top line
The maximum value of the undercut introduced during the meshing process is equal to
the Chordal error. The undercut area can be found using Analysis contour /Undercut. It
displays the angle or the critical areas (shown in red in the figure below) .
Threshold = 90+ critical angle
Undercut : 90
Critical : Threshold
Safe :
> Threshold
Stamping
direction
Element
surface
Other quality problems may appear because of a bad initial CAD data (overlapping
of surfaces, non trimmed surfaces) or a bad meshing. The Deltamesh history file
gives information about the success or the problems met during import, joining and
meshing.
Several Mesh Quality contours can be used to find the elements which are warped,
very thin or distorted.
the value is the angle between the average normals of

these two elements. If it exceeds 20-30, that means that they can be a mesh
problem like overlapping or distorted element.
warping:
Big warping can indicate a problem of mesh quality.

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Area:
Minimum inner angle:
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if the area of the elements is very small (0.01 mm) problems could appear
during offset.
if there is a very small angle in an element, problems
could occur during offset.
If a problem appears during the mesh quality control, it must be repaired. If there are
several big problems, the best way to repair it is to change the meshing strategy (see the
Mesh check and repair chapter of Deltamesh section) for example reducing the Chordal
error parameter to solve undercut.
If the problems concerns only few elements, the easy way is to use the tools from
geometry/edition of nodes or elements, like the merge node to node to eliminate the
problematic element.
-
If the mesh quality is not good enough, it is strongly advised to use Penalty contact
or PAM-QUIKSTAMP.
Rules for the blank mesh

It is recommended to follow several rules during blank meshing:
-
There must not be too many 3-node elements, since they do not behave the same as
the 4-node elements.
4-node elements must be as close to squares as possible and the 3-node elements
must be as close to equilateral triangles as possible.
The Final mesh size after refinement must be less than (R + thickness) where R
is the minimal sliding radius.
Process setup
-

The macros proposed in the public macro database impose some attributes or
parameters described below and ask the user to define others:
Holding stage:
Velocity:
a constant value of 2 m/s is imposed for blank holder in double action

or for die in single action

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Progression stop:
Mass scaling:
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A pinch test between the die and the blank holder is used for
stopping the simulation.
A wizard can calculate automatically the right value. It is advised
to use twice the smallest element size after refinement
Stamping stage :
Velocity:
a constant value of 10 m/s is imposed for punch in double action or for

die in single action
Blank holder force:
Drawbead opening and restraining forces.
Mass scaling.
Progression stop.
A wizard enables the user to calculate

the forces from the geometry of the real drawbead.
to use the smallest element size after refinement; ignoring the few elements with
very small size at the border of the blank.
A pinch test between the die and the punch is used for
Note :
If it is not possible to stop the simulation by a pinch test, a progression value

must be added in the attributes tree.
All the parameters must be defined with a consistent unit system. All the macros of
the public material database are defined with the unit system mm / ms / kg.
Autopositionning performs a translation along the stamping direction only, manual

positioning is recommended in the horizontal plane and in rotation in order to
reduce the CPU time. This corresponds to a preliminary gravity action
Process Stroke: The tools are considered at position zero at the beginning of the
simulation before any applied transformations (positioning, translation). The stroke
will be displayed in post-process from the value after positioning to the final
position.
Automatic fulfill: Most of the parameters are already defined when loading the
macros. This automatic definition of parameters comes from:
the attribute tree: if some attributes are already defined they will be
automatically filled-in by the macro
the other menus or wizards: if a parameter, like the thickness or the friction has
already be defined in a previous menu or wizard, it will be used to filled-in the
macro parameters.
the macro itself: default parameters can be defined when creating a macro with
the Stamp Tool Kit. This value has priority on the other existing or used values.
It works the same way for the groups that are defined automatically when creating
the object with the different menus (guides, surface blank editor, toolbuilder ) and
can be check or modified with the group management.

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Influence of Parameters on CPU
The user has to take into account what results quality and CPU time (calculation speed)
he should expect. Each parameter of the process impacts differently these two elements.
We therefore advice you to follow the figure below for better calculation results.
Time Step:
large+nobend
Time Step:
small+bend large

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BINDER GENERATION FOR DIE DESIGN (PAMDIEMAKER)
Blankholder construction
PAM-DIEMAKER offers several methods for blankholder surface construction:
-
Default:
manually constructs the

shape of the blankholder boundary
curves and/or sections
Part section: creates the

blankholder surface according to
one or two sections of the part (note
that only one section by plane can
be created: one section in XZ plane
and one section in YZ plane)

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Theoretical:
Import:
Assign Blank holder:
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automatic fitting of a
blankholder surface on a reference
object. The reference object can be
the part itself, the part border or any
other object created by the user. It
can be made of any entities type
(nodes, edges, elements and/or
surfaces).
A previously constructed blankholder surface can be imported. While
importing the surface, the user will be asked for the tipping and the symmetry of the
imported surface. If the iges file contains more than one group, the user will be
asked to choose the group to import. The selected group can be visualized in the 3D.
If a previously constructed blankholder surface exists in the
project (imported separately or with the part via DeltaMESH), it is possible to
assign it as the blankholder surface in DieMaker. As a multi-patches surface
cannot be used in DieMaker as blankholder surface, a new one-patch surface will
be automatically fitted on the reference surface.
The most flexible and accurate way to define the binder surface is via the Default
approach. Using this approach, the user has full control over the four outline curves of
the blankholder surface. By default, a flat surface will be visualized in the 3d screen. To
get more complex shapes, the user can add control points to the outline curves and
modify the shape by dragging and dropping the control points in 2D or 3D. If required,
the user can also define the binder surface by two outlines and one section curve, or by
2D section curves, parallel or perpendicular, all-of-which are modifiable in the 2D
editor again by adding/removing/modifying control points.
The user can create any kind of inner addendum area by copying the existing binder
surface or creating a new (inner) binder surface.
Note:
PAM-DIEMAKER automatically generates a mesh once the surface is

visualized. The meshing of the surface is controlled via the Diemaker page in the
Customize/Option dialog.
If a more global fit following the part geometry, or lying exactly on a selected flange
area, is required the theoretical construction option can be used. The complexity of
the surface can be adjusted to the users wishes: the higher the complexity, the more
detailed the resulting surface will be, but then it is more time consuming. If the user
wants a non-developable surface, he can force its creation with the appropriate toggle.
The final size of the blankholder surface is managed via the size ratio option: depending
on the size of the part, it will create a similar size (ratio=1), twice as big (size=2) or any
other value. If the fitted surface really has to be on the reference, the user can activate
the option part on binder. In that case, the complexity is grayed out and not taken into
account for the computation of the surface.

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Notes:
If no elements are selected, the object that was selected in the dialog will be
used to base the fitting upon. However, if elements were selected, the object will
be disregarded and only the elements will be used to fit a surface.
In case of part on binder surface, it is advised to select a non-developable

surface to better fit the reference object.
Blankholder positioning
The generated binder surfaces can be positioned intuitively by dragging and dropping
the surface from the 2D or 3D window. For more accurate positioning, the user has
access to a movement by keyboard (using the arrow keys) or to a dialog that allows
fixed / relative rotations and translation.
The surfaces generated by the outline / section approach and the theoretical fitting
approach are exportable as IGES or VDA surface. Verification tools are available to
visualize the draw-depth with respect to the generated binder surface and to check for
developability.
Interactive modifications and update

When a binder surface exists, it is possible to modify interactively. It is done via
orthogonal section or free section.
Initial situation
Select grid line
or define other lines

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The highlighted section can then be modified from the 2D or 3D window. This method
is very flexible and enables either intuitive modification in the 3D view or precise
modification in the 2D editor. It is also possible to modify imported blankholder
surfaces.
When the user modifies a blankholder surface, he has the choice between 2 kinds of recomputation of the surface: local or global. The local algorithm will deform locally the
surface to match the modification. The global algorithm will not take into account the
actual surface but only the contour frame, the binder sections and the part on binder if
any.
In a general point of view, the global algorithm gives a much better quality surface but
if the user wants to keep the actual shape, he has to create enough binder sections to
constrain the surface. The global algorithm is set by default.
Update mechanism
Even when the full die is created, the user can modify the blank holder. The user
modifies the blank holder (see before) and uses the update mechanism
. The blank
holder surface is then automatically updated as the addendum and the whole die.

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RUN-OFFS AND ADDENDUM GENERATION FOR

DIE DESIGN (PAM-DIEMAKER)
Once the blankholder surface is generated,
the user creates profiles and die opening
line to define the addendum area.
A profile is a 2D parametric
representation of the addendum and
connects the part geometry with the
binder surface.
Auto-addendum
The easiest and fastest method to create the
addendum is the Auto addendum function. This will
position addendum profiles automatically around
the part outline as required.
The number of profiles created will vary
automatically according to the complexity of the
part outline geometry and the Maximal distance
between profiles asked by the user.
The profiles created will be of the type specified by
the user and in the areas where the specified type
can not be build; the profiles will be spline profiles.
The user can ask for a die opening line creation by
a global offset of the part border. The die opening
line will be built before the profiles creation.
The auto-addendum function provides a rapid first shot addendum, which can then be
fine tuned & adjusted using the other existing functionalities.

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Note:
As the auto-addendum should be only a first-shot, it is allowed but not

advised to build the addendum surface at the same time. If the user asks for it,
then the modifications could take more time to compute because of the
continuous update of the surface.
Die opening line

For the run-off creation there are basically two possible scenarios:
-
The profiles are first defined and then the die opening line is created as a result
(free die opening line)
The die opening line is first defined and the profiles are automatically fitted inbetween the part geometry and the die opening line (fixed die opening line).
If the user chooses the fixed die opening line

definition, he can either, import an existing die
opening line from CAD, use an existing 3D curve or
create his own by offsetting from the part geometry.
Once the profiles created, the die opening line can be
modified.
Import Die opening line

DieMaker allows the user to import a previously created die opening line directly from
an iges file. As for the blankholder, the user will be asked for the tipping and the
symmetry to apply during the import. The imported curve will be automatically set as
die opening line in DieMaker and then it will be projected on the blankholder surface in
order to guarantee the connection between profiles and blankholder surface.
Assign Die opening line

If the user has already imported the Die opening line (via import CAD curve for
instance) or if he want to build the curve himself by picking points (via the 3D curve
editor), then the user can assign the curve of its choice as the Die opening line used by
DieMaker.
The user has to select the curve in the drop list or directly by picking it in the 3D and
then push the assign button. By assigning it, a new curve will be generated, actually the

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new curve is a copy of the users curve and then it will be projected on the blankholder
surface. The projection is done to ensure the connection between the profiles and the
blankholder surface.
Modification of the Die opening line

Whatever method is used to create the Die opening line, the user can modify it via the
3D curve editor. The user is able to set lines or spline segments, set a radius,
add/delete/move curves points, make some transformations on the curve like an offset
or a smoothing. After closing the 3D curve editor, the modified curve will projected
again on the blankholder surface and if any profiles exist, they will be updated.
Profiles
Profiles types
The program offers six different pre-defined types of profile:
Standard
Step
Bulge
Spline
Bulge and Step
Arc
Apart from these parametric profiles, there is one special profile available to model a
flange area (for part-on-binder functionality) and a user-defined parametric profile that
allows the creation of any kind of multi-segmented shape.
All profile types allow the option of Radial or Tangential transition from the part to the
run off. This transition zone may be defined as an offset of the part outline, or via free
interpolation between the profile curves. Once the profiles are attached to the part
geometry, they can be modified in the 2D by dragging-and-dropping or in the 2D editor
by changing the specific profile parameters. Modifications to the profile parameters can
be stored for usage in other projects.

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The parameter settings can be copied to use with another profile (same type) by clicking
the copy button in the 2D editor: the next profile that is attached to the part geometry
will then have the same shape. To go back to the default settings, one has to click reset.
Note :
When modifying a certain profile parameter, other parameters also change.

Sometimes the user wants to lock one or more of these parameters so that
another parameter will change instead. To do so, a lock/unlock mechanism has
been implemented for certain profile parameters in the 2D editor. Moreover, for
each profile, there is a toggle in the 2D editor that can be checked in order to fix
the end point of the profile.
Profiles creation and edition

For the manual interactive method, profiles are added to the part geometry by simply
selecting the desired type and clicking on the part border: the profile is then
automatically visualized in 3D if the 2D editor is open, it is also visualized here.
Through these 2D profiles the addendum surfaces will be constructed to create the die
face.
To copy a certain profile, the user can select it and, with the Ctrl key + drag and drop
mechanism, create a new one at another location which will have the same geometry.
Profiles can be moved to another location by dragging the start point to a new node. The
way the profile is moved, depends on the setting in the customize menu (DIEMAKER
page, addendum options)
The following modifications are possible: alignment of selected profiles and smoothing
of the line between selected profiles.

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Note:
Before shaping the addendum, it is assumed that the part edge is complete and
free of gaps. It should also be as smooth as possible i.e. without serrations
(see Rolling Cylinder paragraph in Part preparation for die design chapter).
User Defined Template: UDT Profiles

If the user does not find the desired profile type into the pre-defined ones, he can create
his own template.
He selects the UDT type in the
profiles toolbar and then picks a node
on the part border. Automatically, the
first segment of the profile will be
created and the 2D editor opens on
the Template Editor tab.
Then the user can choose the
transition type (radial or tangential)
and add circle or line segments.
When the desired shape is drawn, the profile can be finish by the appropriate button.
The profile has to end by a line that is why, when the finish button is pressed, the die
radius segment is added between the last segment and the blankholder surface. It is
possible to unfinish the profile to modify the template by adding/removing segments
Once the template is finished, the user can switch to the profile editor tab to modify the
parameters and adjust the profile.
If several user defined template have been created in the project, when the user select
the UDT profile type in the profile toolbar, a list appears under the profile step in the
main DieMaker menu with all the UDT available in the project. It is possible to rename
the template in the template editor (2D editor) so that it is easier for the user to select to
good one in the list of available UDT (new or existing template).
Note:
It is possible to delete the last segment. Successively it is possible to remove all

segments

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User Defined Templates management

DieMaker offers the user the possibility to create his own
template library through the UDT Manager, available via the
droplist of the profile step in the main DieMaker menu.
With the UDT manager, it is possible to delete a template
from the current project, load a template file to use it in the
current project and save a template defined in the project as a
separate file (*.udt)
Note:
A direct access to the export as *.udt file is available in the

template editor tab of the 2D editor.
Import Profiles as IGES

DieMaker offers the user the possibility to import profiles coming from CAD software
(*.iges file).
-
Open the Import 2D dialog
Import the iges file via the

dedicated button
Select the curve in the list below
Position it if needed with the Rev

and Rot buttons in order to have
the part region in the top left
corner and the binder region in
the right bottom corner
Approximate
Save it as UDT in the project

with the floppy icon
it with the
dedicated button
It is possible to save the profile directly as a separate file using the UDT manager. After
approximation, two information fields are available to check the length of the profile,
and the differences between the initial curve and the approximated profile.

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It is possible to modify directly in the 2D an approximated profile. The user can also go
on Profile Editor tab and modify there the parameters.
Note:
It is possible to pick the curve to approximate directly in the 3D view with the
picking button
As all the UDT profiles, it is not possible to have a profile ending by a straight
line. The die opening radius should be included in the imported curve.
Export Profiles as IGES

DieMaker offers the user the possibility to export the created profiles as IGES format
(NURBS entities) to then, import them into Catia for instance.
The export function is available through the Project/Export/Profiles menu.
Gainer and stiffeners
Gainer
Stiffener

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PAM-DIEMAKER offers the possibility to create gainers and stiffeners on the

addendum surface. Three scenarios are available:
-
create a gainer by its midline and some sections
create a gainer by its contour and some sections
import a mesh geometry and then approximate the contour and pick some relevant
sections
Gainers type
Three types of gainers are proposed:
In the case of a combined gainer, the same type is applied in both directions, but with
different values.

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Notes :
In the whole part Gainer and stiffener of this user guide, the term gainer is
used to simplify the text but each time it can be replaced by stiffener or
gainer and stiffener or stiffener and gainer depending of the desired type.
In the whole part Gainer and stiffener, only the oblique shape will be
treated but the user can choose between oblique, vertical wall and
spline shape.
Gainer creation by midline or contour

For these two kinds of creation the procedure is the same:
-
Creation of a new gainer entity, defining his name
Selection of the gainer type and shape
Creation of the skeleton by picking points of the midline or of the contour.
Each point of the midline will correspond to one section
For the contour creation the user can use straight lines or part of arc using
theCtrl key
Definition of the sections by adding , deleting or moving them is needed

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Creation the gainer surface
Trimming of the addendum using the corresponding button in the gainer dialog
(which is different from the trim blankholder for the addendum surface in the main
DieMaker dialog box)
Note :
The user can open the 2D editor to modify sections parameters or use the main
Gainer dialog
Gainer creation by approximation of an imported geometry

To add a gainer to the model from existing gainer geometry (mesh input type), the user
must follow the next steps:
-
Select the existing geometry in the list or import a new one.
Define the contour of the gainer in this geometry
Set the parameters for approximation (parametric or spline type, parameters for
parametric type, transition length) and use the automatic Approximate section
function
Position the approximate gainer on the addendum surface using the copy function
Create the gainer surface
Trim the addendum using the corresponding button in the gainer dialog box (which
is different from the trim blankholder for the addendum surface in the main
DieMaker dialog box)
Notes :
The mesh file used to import a gainer for approximation should be cleaned of
free edges and elements should have the same orientation. If not, the
automatically computed gainer system will be wrong and can not be easily
corrected.
The imported gainer should be composed of the gainer shape and of the radius
between the gainer and the addendum because the approximation will have this
transition anyway.

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Gainer modification
It is possible to modify an already trimmed gainer, but the user must first untrim it
before any modification.
The user can change the type and/or the shape of a gainer after its creation. It is also
possible to copy an existing gainer into a new one
Drawbead creation
DieMaker offers the possibility to create drawbeads from the die opening line by an
offset.
Two drawbead lines can be created via the advanced create drawbead dialog box
(available through a rick click on the + button). The drawbead lines are called inner-db
for the closest line from the connecting lines and outer-db for the second drawbead line.
The offset value for both drawbead lines can be defined in the advanced create
drawbead dialog box. It is also possible to modify the default value for offset and the
activation or not of the second drawbead line, in the DieMaker/Addendum options of the
customize menu.
After the drawbeads have been created, if the user press the - shortcut in the
connecting lines button, the drawbeads will be deleted at the same time as the
connecting lines. If the user then presses the + shortcut in the connecting lines button,
the drawbeads will be automatically created with the connecting lines.
Addendum modifications and update

The die design process is fully iterative, i.e. the user can define the addendum area in
any kind of order. He can define the profiles first, modify them individually, then
visualize the die entry line; add, remove or modify some profiles or parameters, go back
to the binder definition etc.

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To get a better understanding of the 3d geometry, the addendum surfaces can be

visualized. 3D nurbs surfaces are fitted between the profiles and will be created such
that there is full tangency on the control lines. In some cases manual guidance of the
surfaces is required, which is available via a Horizontal Control line option.
Update mechanism
Even when the full die is created, the user can modify the addendum. The user modifies
the profiles or the die opening line (see above), profiles and control lines then become
pink, and he uses the update mechanism
. The addendum surface is then
automatically updated. Addendum surface does not need to be removed for modifying
the profiles.
Note :
By default the update is explicit (the user has to press the appropriate button to
update the addendum) but it can be switched to implicit in the customize menu
DieMaker/Addendum options.
Simulation model tools
To finalize the die face (after profiles definition, creation of Connecting lines and
creation of the addendum surfaces) it is necessary to Trim Blankholder and to combine
the entire addendum parts into a Simulation Model
generated:
-
Die:
Die+Binder:
. Three model types can be
Simulation model is a single object with connected mesh.

Simulation model consists of two objects, each with connected mesh.

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Simulation model consists of three objects, each with
connected mesh.
The last option where DIEMAKER generates a model for the die, binder and die
radius is the most convenient as the objects are already separated. The user defines the
object he wants to transfer to the setup (Drawbead, Die opening line, part outline, blank
sheet).
Direct transfer
Since version 2008.0 of PamStamp 2G, it is no longer mandatory to trim the
blankholder surface and create the simulation model. When the addendum surface is
created, the user simply update setup with the appropriate function through the 3D
icons. The update setup automatically trims the blankholder and creates the simulation
model. Then the transfer dialog box is opened to let the user select the objects to
transfer.
The major interest of this new automatic simulation model creation is that it is not saved
in the design module. In case of iterations between setup and design modules, when the
user goes back to DieMaker, he will not have to delete the simulation model nor untrim
the blankholder surface.
Check options
The newly generated die face can be checked using the check options:
-
One of these options is the Die check, which will automatically create a number of
2D sections across the die face. Thus, the user can verify that the neighboring
sections do not vary too much in width, a potential danger for tears and wrinkles.
Other tools that are available in this stage are verification of the undercutting, a
verification of the draw-depth, and a verification of the final mesh quality and
develop flanges option.
Notes :
The develop flanges options will project the flange area on the addendum
surface and will result in a 3D curve that can be used later on for trimming
optimization.
If the user wants to use the check functions, it is not mandatory to create the
simulation model. Except for the develop flanges option, the checks can be done
once the addendum surface is created and even if the blankholder is not
trimmed.

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Die export as CAD file

After die face creation, DieMaker offers the user the possibility to export the die
geometry as CAD data (IGES format).
The export CAD option is available through the Project menu export/CADin the
main toolbar.
The exported geometry contains two groups. The first group contains the part geometry
(initial part geometry without the surfaces corresponding to the flanges areas) and the
second the whole geometry created in DieMaker (part preparation, blankholder, and
addendum).
Notes :
If the files from the meshing module are not present in the current directory, the
part will not be exported. Only the part preparation will be exported in the first
group.
If the blank holder is not trimmed when the CAD is exported, it will not be
trimmed in the exported file. If the user just wants the die geometry, he has to
trim the blankholder before exporting it.
In case of half symmetrical part, the half part created by reflexion will not be
exported.
The model will be exported in the active coordinate system (stamping frame by
default).

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RE-ENGINEERING THE DIE FACE (PAMDIEMAKER)

Purpose
If old tooling information is available, the user could capitalize on this information. The
parametric re-engineering module allows using old tooling information in order to
construct a new tool design instead of starting from the part only.
If a DIEMAKER model of an old tooling is available, it can be directly re-used after
exchanging the part (see exchange part option in Iterations on feasibility chapter) and
doing the appropriate modifications.
It is also possible to use DIEMAKER even if DIEMAKER was not used for the old
tooling. Thus, the user can start with a CAD file or scanned data of the actual tool
(mesh format) and simply decompose the existing tool into a parametric model, i.e. reengineering his old tools. Once this is done, he can exchange the part geometry with the
new information and make the appropriate changes to the addendum and binder surface.

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How to proceed
The re-engineering module allows the user to recreate a parametric 3d model of the die
face, starting from a meshed geometry of this die face. The mesh can be directly
imported from a mesh file; however, if surface data is available, it can be treated as
well.
The procedure for re-engineering a die is as follows:
Import
old tool, using Import tools mesh or Import CAD in design (reengineering)
Identify the part inside the tool by selecting the surfaces and defining them as a design
part
Die preparation.
Tipping: recalculate
Blankholder fitting:
Die entry line: fit
Identify the main regions of the die face, i.e. the areas of the
blankholder, the addendum and the flanges.
the optimum forming direction.
fit a nurbs surface through the area that was defined as

blankholder (see die preparation)
a fixed die entry line

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fit profiles through the area that was defined as addendum

area by using either spline profiles or parametric profiles (UDT)
the old part is then replaced by the new one
Die face preparation
In this phase the user identifies the various zones on the original die face. In order to
function correctly, the program needs to know what elements represent the blankholder
area and the addendum area. Normally, the part geometry is already defined at this time.
Once all zones are defined and the menu is closed, separate objects are created.
In case there is an inner addendum, the user should first define it. Various inner areas
can be defined interactively. When defining the remainder of the die faces, it must be
done for each inner and outer area separately.
If the user has a symmetrical die face (either modeled in full or only half), he can
identify the symmetry plane. Then further actions will be carried out using the
symmetry behavior of PAM-DIEMAKER, e.g. profiles will automatically be positioned
on both sides.
Tipping
If the imported geometry does not have a stamping direction, a new forming axis can be
estimated by using the tipping dialog box.
Blankholder fitting
The first surface to be re-engineered is the blankholder surface. The dialog opens by
default with the correct settings (fit from blankholder area, fit nurbs surface, using

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highest complexity, trim blankholder). Once the user accepts the settings, a nurbs
surface will be fit through the reference blankholder area.
Note:
When the case is a so-called part-on-binder dies, the user may put the
blankholder area which belong to the part, into the Part object (to respect the
part geometry) but also in the reference for the blankholder in order to improve
the precision of the approximation on the part border and avoid gap between
part and blankholder.
Flange profile
The flange profile is enabled in the re-engineering for two purposes. Firstly, it can be
used in so-called part-on-binder dies, where the part geometry lies partially on the
binder surface. Secondly, the flange curve can also be used for re-engineering of local
areas. In that case, the user has only identified the local zones (to be modified) as
addendum area, whereas the remainder of the die geometry is defined as part geometry.
Die entry line

Next stage is to fit the die entry line. This line is fitted automatically by projecting the
end-points of the addendum area onto the newly fitted binder surface.
Define profile by section

Now that the binder surface and the die entry line are fitted, the actual profiles can be
estimated. The fitting in itself is simply done by clicking on the part geometry, after
which the 2D profile is fitted.
For the estimation of the profiles, the user has two options: spline profile or parametric
profile. While the spline profile can ensure highly accurate fitting, the parametric profile
is a more logical option as it estimates the addendum area using straight lines and
circles.
New profiles can be created, in two ways: orthogonal and free. With orthogonal mode,
the user has to pick only the start point on the part boundary. The profile will be created
orthogonally to the local part boundary. With the free mode, the user has to pick the
start point on the part outline but also the end point on the die opening line. This method
can be useful to create several profiles per starting node, or to avoid tangency problem
in case of the normal to the part is not the same than the normal to the die opening line.
In case the addendum surface is not as expected, the user can add some control curves
between profiles. Control curves are editable through control points (add/edit/delete).
The tangency between following control curves is ensured automatically. The global
shape of control curves can be smoothed with the smooth control lines option in the
right click menu (design part / smooth control lines).

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It is easier to use control curves with spline profiles because of the capability to add
control point on spline profile by simply clicking on the desired position. In case of
parametric profiles, the user has to connect the control curves to the existing control
points.
Exchange part
To replace the old part with the new one, there are basically three steps: the user first
detaches the profiles from the current design, than swaps the part geometry with the
new design. Afterwards he re-attaches the profiles again. The profiles are then modified
so that they fit the new geometry again.
-
Detach profiles:
disconnects the profiles from the current part geometry. The color
of the profiles will change to red.
Exchange part:
opens a dialog box to select a new IGES or VDA file that should be
imported.
-
Re-attach profiles:
The user can decide how the profiles are modified to fit the new
part geometry: he can choose between displace (keep current size and direction of
the profiles), keep blankholder point (it keeps the end-point of the profile and
modifies the start point i.e. direction) or normal to part (keep start point and
direction, modifies the end-point).
Note:
In case of symmetrical or double part, the user has to do the part preparation
again because there can be some differences. When he imports the new part, he
will be asked for the deletion of the existing part preparation (he will logically
say ok). Then, when the new part will be imported, he will have to re-define the
symmetry/double part, hide flanges, close holes, create U-ends, create rolling
cylinders, and create transition areas if any Only after these steps, the user
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PROCESS VERIFICATION: PENALTY CONTACT

(PAM-AUTOSTAMP)
Introduction
In this chapter a particular use of process feasibility check (penalty contact) is
described, insisting on the differences with the standard use which is described in the
previous chapter Process verification (Pam-Autostamp).
If a user wants to use Penalty contact and not Accurate contact he has to follow some
specific rules described here.
Advantage
The main advantage of Penalty contact compared to Accurate contact is that the mesh
quality is not required to be so good.
If the quality of the CAD is poor and results in a bad quality mesh ie, a mesh with many
discontinuities, then the user faces a choice: either continue by using the Penalty contact
method, or clean and repair the mesh sufficiently to use Accurate contact, or return to
CAD to improve the quality of the model. (See Deltamesh section Check and repair
chapter for more details).
Note
If there is a need to perform a springback prediction, then it is strongly

recommended to use only the Accurate method, as this is the only method giving
very accurate stress predictions (assuming that all the rules are followed) - see
section Simulation Methodology for High Quality Stamping.
If only forming quality prediction is required, without springback, then the user
may select to use either penalty or accurate. Accurate contact is still considered
to be better, but may require more work to prepare the model if the CAD/mesh
quality is not adequate.
Transfer from QuikStamp Plus to AutoStamp

Save as
-
The user uses the save as new project in the transfer functionality

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In the following menus, the user gives the new project name and the location. He
specifies the solver type as AutoStamp and selects the meshing modules he wants to
keep or not.
The save as project wizard helps doing the transition of the data
The information is already filled-in and just has to be checked:
For current tools geometry tools are offseted or tools are not offseted.
AutoStamp contact type is penalty.
For holding and stamping stages, the stage type, the velocity (default value 2 for
holding and 10 for stamping without delay) must be modified, since it is advised
to add a delay for having a smooth contact.
The refinement levels are automatically computed from the die radius, the blank
thickness and the blank mesh size.
When the save as is finished, warnings appear telling that:
The control attribute is reinitialized
An offset of the tools is necessary if tools were not offseted in Quikstamp plus
Non offseted Quikstamp plus

As the tools were not offseted in Quikstamp plus project, it is necessary to offset them.
The tool editor must be open, it is automatically filled-in, the user only has to check the
data and apply it. See next paragraph on tool editor.
Direct set-up (without coming from Quikstamp plus)

The initial set up of an Autostamp simulation without coming from Diemaker and/or
Quikstamp plus is quite the same as the one described in the Process verification (PamAutostamp) chapter or in Simulation methodology for high quality stamping section.
The differences are described here below.

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Creation of the tools

Mesh Quality
It is not needed to do all the mesh quality checks that are advised for Accurate contact.
Tool builder
To proceed with Penalty, the user may set

up the calculation using the penalty
contact offsetting option, this option will be
more tolerant of the mesh quality when
performing the offset, and will jump
across small gaps, or discontinuities in the
mesh. The values for these tolerances are
set in the Customization menu.
If the Penalty method is to be used, then the
elements of all the tools must be correctly
oriented, they must all face towards the
blank sheet.
For a simulation using the Penalty contact, the parameters will be the following:
-
Penalty offset type
Orientation of the mesh. If the mesh quality is very bad it can be better not to orient
the mesh in the tool builder, but to do it using the Geometry / Check-repair /Element
orientation menu.
The gap between the die and the punch, as the blank holder walls are not needed. See
the Offset chapter.
Check the Element Orientation
The user has to orient the normals of the tool elements consistently into one direction
such that they define the contact surfaces of the tools. The normals must point towards
the blank.
The mesh orientation can be checked with the menu:

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Blank meshing
When using penalty contact, it is not advised to refine the blank more than twice. The
Mesh size wizard and the Refinement level wizard do not give same results for penalty
and for accurate contacts.
Mesh size wizard
The optimal element size is

computed by the wizard respecting
the rules described below
The Minimal sliding radius and the Minimal blank thickness lead to the computation
of the Final mesh size ( (R + thickness) where R is the minimal sliding radius).
Assuming than the Penalty contact is used (Adavanced parameters), the size grows
from the final size to the initial size with a factor 4. Refinement levels are set 1 for
uniform and 3 for maximal.
Process set up
Specific macros done with penalty contact must be used.
-
The pinch test can not be used for stopping the simulation. The stop criterion is thus
based on the stroke of the object. If the tools are in their initial position after offset,
the stroke is set to 0. The autopositioning will compute automatically the initial
position of the tools.
It is better to define a 2D function curve for the stamping velocity, in order to have
smooth contact between tools and blank. A value of 10m/s for stamping and 2 m/s
for holding can be used (same value than the one used for Accurate contact).
It must be noted that it is not possible to use mark attribute
It is advised not to refine too much blank elements (maximum level of 3 is advised).
The usual friction value is 0.15, which is equivalent to the 0.12 friction value with
Accurate contact.
The Penalty scale factor has a default value, suitable for two levels of refinement. It
could be needed to adjust this value. See Contact and friction chapter for more
details.

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ITERATION ON DESIGN AND STAMPING

FEASIBILITY
Introduction
The following described iterations are done after an initial feasibility study with:
-
Die design
Evaluation of the tool design (Quikstamp plus)
Process verification (Autostamp)
Iteration on Die Design

From the Quikstamp plus evaluation of the tool or from an Autostamp process
verification, it is decided to modify the die.
Initial Die done with Diemaker

Design module access
The user opens the project containing the design module.
It is advised to first save the initial project so that there is one project and directory
per iteration. The same project type (Quikstamp plus or Autostamp) is kept, the
design and the meshing modules are selected to be saved and a new directory is
created to put the project inside. The meshing module could be used later to export
the full die geometry as CAD data.
The user has to Go back to design module.
Die modification
Addendum modifications

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The user can do any modification on profiles or die entry line in the Addendum
page, he then updates the model using the update mechanism button
modifications are done with the complete visibility of the initial die.
-
. All the
Binder modifications
Several modifications are available to change the blankholder (in 2D or 3D view):
add/edit/delete binder sections on the current blankholder.
add/move/delete some control points on the blankholder contour in order to

modify the binder shape.
move the blankholder surface up and down to modify the draw depth
resize the blankholder surface (default and part section only)
All these functions are available without deleting the addendum surfaces. The
update mechanism button allows then to update the addendum surface taking into
account the modifications done.
If the user wants to create a new blankholder, he has to remove the addendum
surface, the connecting lines and detach the profiles through the exchange part
dialog (note that the user can also delete the profiles). After these operations it is
possible to create a new theoretical binder (or by outline or part section) but also to
import a new binder surface. In case of theoretical binder, it is advised to activate
the advanced option automatic repositioning. This option will reposition the new
binder surface according the previous surface (useful for instance if the profiles are
not deleted or if the user had rotated or translated the previous binder surface). The
profiles have then to be re-attached in the exchange part dialog.
Addendum must then be rebuild (see Die design (PamDiemaker) chapter)
-
Gainers and/or stiffeners add

It is possible to add gainers or stiffeners (see Die design (PamDiemaker) chapter) and
update the model with the update mechanism button
Quikstamp plus simulation
The Update setup functionality enables the user to replace the initial die by the new
one and to re-apply automatically the toolbuilder. The user can edit the transfer rules
to check the way the update is done.

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If such iteration often happens, the die design being subject to lots of modifications;
it is advised to use non offseted Quikstamp plus (see Evaluation of the tool design
(PamQuikstamp plus) chapter). In that case the calculation can be directly started
after the update setup.
If the modifications are done at the last stage, it is possible that offseted Quikstamp
plus is used. In that case the mesh quality must be check, especially on the punch
(see Evaluation of the tool design (PamQuikstamp plus) chapter).
If the binder surface has been modified it could be necessary to check the drawbead
geometry and the location of guides.
Initial Die done without Diemaker

It is also possible to use DIEMAKER even if DIEMAKER was not used for the old
tooling. Thus, the user can start with a CAD file or scanned data of the actual tool
(mesh format) and simply decompose the existing tool into a parametric model, i.e. reengineering his old tools. He then has the possibility to modify the die in order to
improve the stamping feasibility.
-
The user first saves the initial project so that there is one project and directory per
iteration. The same project type (Quikstamp plus or Autostamp) is kept and a new
directory is created to put the project inside.
The user imports CAD in design for reengineering the die.
He selects the Die CAD file and the Feasibility or Validation meshing strategy. He then
uses the Import & Transfer button. In the workflow transfer rules, he defines the
imported object as Die target group.
-
The user identifies the part inside the tool by selecting the surfaces and defining
them as a design part

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Note:
If the different zones are already defined in the CAD file (entities or layers in
iges file for instance) the user can define the part directly in the transfer rules
dialog.
In the reverse engineering page, the user must:
Do a tipping. The system should not be modified to stay in the same position as
in the previous import.
Open the Die preparation dialog and identify the main regions of the die face, i.e.
the blankholder area, the addendum area and the flanges area. If there are inner
addenda, they must be defined from holes and symmetric die must be reflected.
Do a binder fitting with the selected surface type.

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Create the Die opening line (see Die design (PamDiemaker) chapter for details)
Position profiles to re-create the addendum surface. (see Die design (PamDiemaker)
chapter for details)
Die modification (see Initial Die done with Diemaker section for details)
Update the model with the update mechanism(see Initial Die done with Diemaker
section for details)
Update set up
Run simulation
If the imported data was not clean enough and the user has done some manual work on
the mesh to improve its quality, it is advised to restart from the meshing module to
avoid doing the same work twice. The user saves the initial project as a new one to have
one directory and one project per iteration. He then goes back to the meshing module
and transfers it to the design module. Then he applies the same methodology as
described above.
Iteration on Fillet
From Diemaker: die entry line modification
It is possible to iterate easily on the die entry radius. The user has to Go back to design
module.
He selects one profile and, in the

2D editor, activates the option
apply the modifications on all
profiles and changes the die
opening radius parameter.
Another possibility is to select all

profiles in the 3D view and then
edit the die entry radius parameter
in the 2D editor (keeping the
option apply on selection
activated).

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This can be done on a die initially created with DieMaker or not. But in case of
reengineering, the user might control the profiles after modification, even more if the
profile type is spline. In case of parametric profile, the other parameters will be adjusted
automatically but in case of spline profile, the user will have to manually adjust the
shape by moving the control points.
After fillet modification the update mechanism is used to re-create the die surface and
the Update set-up functionality enables the automatic update of the Quikstamp plus or
Autostamp simulation.
From Diemaker: part fillet modification

If the initial part was not fully filleted in CAD software and was filleted in DieMaker
with the DeltaMESH Fillet function, it is possible to modify these fillets in case of
iteration.
-
In the DeltaMESH Fillet dialog box, the user selects the fillet to change and modify
the radius value. The modified radius can be constant or interpolated. He presses the
fillet button to apply the modification and close the DeltaMESH Fillet dialog box.
If the modifications to do in Design module are finished, the user updates the setup
module with the appropriate function.
Iteration on part: Exchange Part Geometry

After having done a first Quikstamp plus evaluation of the tool or an Autostamp process
verification, the part is modified.
The exchange part geometry is used to exchange the current part geometry (that he is
working on) with a new geometry.

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Design module access

-
The user opens the project containing the design module.
It is advised to first save the initial project so that there is only one project and
directory per iteration. The same project type (Quikstamp plus or Autostamp) is
kept, the design module is selected to be saved and a new directory is created to put
the project inside.
Part modification
There are basically three steps to exchange the part: the user first detaches the profiles
from the current design, than swaps the part geometry with the new design; and finally
he re-attaches the profiles again. The profiles are then modified so that they fit the new
geometry again.
-
Detach profiles:
disconnects the profiles from the current part geometry. The color
of the profiles will change to red.

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opens a dialog to select a new IGES or VDA file that should be
imported.
-
Re-attach profiles:
The user can decide how the profiles are modified to fit the new
part geometry: he can choose between displace (keep current size and direction of
the profiles), keep blankholder point (it keeps the end-point of the profile and
modifies the start point i.e. direction) or normal to part (keep start point and
direction, modifies the end-point).
Note:
In case of symmetrical or double part, the user has to do the part preparation
again because there can be some differences. When he will import the new part,
he will be asked for the deletion of the existing part preparation (he will
logically say ok). Then, when the new part will be imported, he will have to
define again the symmetry/double part, hide flanges, close holes, create U-ends,
create rolling cylinders, and create transition areas if any Only after these
steps, the user will have to re-attaches the profiles again
Die adjustment and update setup

After re-attachment of the new part, the die must be adjusted. Modifications are done
and update mechanism is used. (see previous paragraph Iteration on die design). When
the new die is done, the Update set-up functionality enables the automatic updates of the
Quikstamp plus or Autostamp simulation.

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FOR STANDARD FORMING
INTRODUCTION
A complex stamping simulation process can be divided into several steps, each
performed by PAM-STAMP 2G. Three main phases are available:
-
Die design: PAM-DIEMAKER enables the user to create a complex die mesh from
the initial part CAD data and load this mesh for subsequent process setup (refer to
the Simulation Methodology for Design and stamping feasibility section).
Feasibility evaluation: a PAM-QUIKSTAMP simulation is easily performed with the

die mesh created with PAM-DIEMAKER or any other tool mesh. It requires a limited
number of input parameters and a high calculation speed. It gives the user an
evaluation of the formability of the die geometry in true process conditions and
takes into account multiple stages processes (refer to the Simulation Methodology for
Design and stamping feasibility section).
Tuning and validation for high quality stamping: accurate stamping calculation
using PAM-AUTOSTAMP can be divided into several stages: gravity, holding,
stamping, trimming - springback, flanging, hemming.
Process parameters which are entered for each stage are adjusted and validated so
that the obtained results are used to improve the real stamping process as much as
possible.
This last high quality stamping simulation enables the analysis of springback, the
compensation of the die, surface defect or press forces analysis, which will be described
in this section.
Procedure
To perform a high quality simulation, the process is always the same whether for double
action, single action or triple action press:
1. Creating a new project.
2. Creating tools (using the tool editor):
Defining the OP direction
Creating the tools: die, punch(s) and blankholder(s) with symmetry plane (if
any). Filleting them if needed.
Checking the quality of tool meshes.
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Trimming tool, guides, locator pins, spacers and springs can also be created.
3. Creating the blank.

4. Creating the drawbeads.
5. Defining the analysis and marking entities.
6. Setting-up the process:
Using macro-commands.
7. Starting the calculation.

8. Post-processing each process.
9. Performing further analysis:
Surface defect analysis.
Press force analysis.
Springback measurement comparison.
10. Compensating the die

PamStamp2G proposes a guided setup workflow
that helps the user doing the setup and iterating on
it. This guidance does not reduce current
flexibility of any setup.
The available tools can vary according to the type
of process (Stamping, Hot Forming, Tube,
Hemming).
To improve the usability of PamStamp2G, each
dialog has Next and Previous buttons to easily
jump to the set-up steps dialogs. When a step is
applied, the button is checked.
Note:
It is possible to choose the order of buttons for Tools and Blank. The user can
right click on the button (Tool editor or Blank editor) and change the position of
the button. The buttons position will be swapped and new position will be saved
in project.

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Creation of a New Project

To create a new project, use the Project/newproject menu items, select Standard
stamping process and then select PAM-AutoStamp solver type.
The location of the project is already defined by default.
We advise you to create a directory per project, so that all files linked to the project are
located in the same area. You can add a title and a comment that can be used in case
you make several iterations.

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High quality simulation after feasibility

If feasibility simulations have been done previously with the same part and tools and the
user would like to perform then a high quality simulation to do further analysis, he has
to be careful on some topic to ensure the quality of the simulation.
High quality after Diemaker

The procedure to follow is the one described in this section, except for the Tool import,
which come from Diemaker. The user must transfer Diemaker Results in the setup as
described in the Evalutation of the tool design chapter in the Simulation methodology for
design and stamping feasibility
He must check:
-
The mesh strategy: if another strategy than Validation or Springback has been used
when importing the part, the part has to be re-meshed using the Exchange part
functionality.
Fillets must be fillet again with the good chordal angle, linked to the mesh strategy
High quality after Quikstamp plus

The procedure to follow is the one described in the Process verification chapter in the
Simulation methodology for design and stamping feasibility section with the following
main differences:
-
The user must check the mesh strategy: if another strategy than Validation or
Springback has been used when importing the part, the part has to be re-meshed
using the Exchange part functionality.
Fillets must be fillet again with the good chordal angle, linked to the mesh strategy
When executing, the save as High quality option must be selected.
Tool Editor
must be applied again with gap and walls.
High quality after Autostamp normal simulation

Autostamp with accurate contact
Save as
option is used, then the user must do several checks and modifications:
The user must check the mesh strategy: if another strategy than Validation or
Springback has been used when importing the tool, the tool has to be re-meshed
using the change meshing strategy functionality.
Fillets must be fillet again with the good chordal angle, linked to the mesh strategy,
using unfillet functionality.

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Perhaps Tool Editor should be applied again (see the recommendation of the
Creation of the tools chapter of this section).
A new macro done for High quality must be applied again, with a particular check
on blank refinement (see Blank meshing chapter of this section).
Autostamp with penalty contact
As there are several important differences between Accurate and Penalty contacts (see
Contact and friction chapter), it is advised after the save as, to follow the procedure
described in this section.

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CUSTOMIZATION
hydroforming process, see the Process Setup Chapter in the Simulation concept
The macro is created by the Advanced user, who defines the stages, diagram of the
process, groups of tools, default process attributes and the attributes that will be
Data base
advanced user can create other macros that suit the usual processes of the users. It is
Customization menu.

requirement. It is only available for advanced user, meaning that the Advanced mode
must be activated in the Customization menu (it can be done by default, in the
-

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that appears is used for a process macro definition.
It is advised to start from an existing macro, since it is easier to modify one than to
create a completely new macro.
Procedure
3. Schematic drawing of the groups (blank, die, blankholder, guides, symmetry plane,
punch, mark
4.
Behavior definition with creation of parameters if necessary.
5. Attributes definition with creation of parameters if necessary.
modified, appears:
-
The blank group is called Blank, it is a single blank.
One parameter is created: the Thickness, as a real value, applied to the Blank.
If the process has double blanks or volume blank, the user must modify the blank type
from the beginning.
After the creation of the first stage, the blank and the process pages are defined. A

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common tools between stages (like between Holding and Stamping stages). With this
option all predefined tools are automatically drawn in the diagram.
After the creation of the first tool, two parameters are automatically defined: Friction, as
a real value, and the Stamping frame, as a coordinate system assuming that Z is the
stamping direction as described in the information zone of the parameter edition menu.
For QUIKSTAMP Plus macro, after the creation of the first tool, the option with offset
tool can be activated or not.
If Keep tools option has been used when creating the new stage, the unused tools (like
guides in the Stamping stage) have to be removed from the diagram.
The Behavior icon must be dragged onto the tools or the blank.
For a QUIKSTAMP Plus macro, displacement behavior will be used instead of velocity.
For the holding stage for instance, a Holding displacement parameter, will be created as
a real with 0 as default value in Z direction, assuming that the tools are closed at the
beginning.
defining the behaviors, such as the autopositioning attribute and the output of the
Control attribute must be checked and modified if necessary.
Additional attributes can be added. It is for example advised to add an initial velocity of
1 m/s on the blank for an explicit gravity simulation.
Parameters creation
The following end-user parameters can be used for:

-
the gravity stage:

Stamping frame: coordinate system.
Friction: real value.
It is also possible to define a parameter for the gravity value, if the unit system is
not always the same.
the holding stage:


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real value.
integer.
Maximal level of refinement: integer.
Mass scaling for holding: real value set through a wizard.
For a QUIKSTAMP Plus macro, the same is done with a Die radius and Sliding radius
parameters.
-
the stamping stage:

Friction: real value.
Uniform level of refinement: integer (same as holding).
Maximal level of refinement: integer (same as holding).
Blank holder force: real.
Stamping ramp curve: 2D function, Advanced user, default curve.
Stamping progression: real (default value 0).
Mass scaling for stamping: real value set through a wizard.
Remarks
automatically defined when putting tools in the

diagram. This attribute must be modified sometimes if the blank is positioned on
the tools and not the tools on the blank.
Control
Control:
CPU Control:
CPU Control:
The Stamping velocity and the Stamping ramp curve parameters should be
created and imposed with a function defined by the stamping ramp curve and a
multiplication factor defined with the stamp velocity value in the Z direction. It
is better to define them as advanced parameter, so that the end-user does not
have to define it.
If no High quality simulation is performed, a single real parameter can be used

with a default constant value of 10 m/s.
attribute: It is partially filled and must be completed by the advanced

user. The stop criterion must be defined (Pinch test for High quality simulation).
The Start at option must be defined as 0 with the recomputed option, so that the
progression. The states output can be defined by default using the total number.
The restart output could be synchronized with the states, and a number of
history outputs can be imposed by the supervisor as a cycle period for prints.
Mass scaling must be activated (it is not automatically defined)

with a corresponding parameter defined as real with attached the mass scaling
wizard.

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For penalty contact simulation, it is better to define a 2D function, in order to

have a smooth contact between tool and blank.
For a QUIKSTAMP Plus macro, the same is done with a displacement behavior,
using a Stamping displacement parameter, as a real with 0 as default value in Z
direction. It is assumed that the tools are closed at the beginning.
Trimmings:

information for implicit springback stage. It will be filled in by the end-user of
the macro, depending on the case. The boundary conditions on points attribute
should not be added, in case of explicit springback. It is better to do the
simulation with a completely free blank and to lock it in post process.
The trimming line is applied onto the blank either along a user
direction with Trimming frame parameter as coordinate system or orthogonally.
A refinement under curve type may be specified: maximal level of stages
attributes, maximal level of target elements or imposed level.

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Two types of database are available:

-
Public:
Private:
button.

Chapter.

the Deltamesh page of the Customize menu. It is necessary to check at least once that
the proposed default meshing strategy fits with the type of simulated part and with the
modify it.

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CREATION OF THE TOOLS

Introduction
The tools can be created using the Tool Editor menu. This dialog is accessible from the
set-up page.
Through this dialog, the user will manage the project operations (Ops). The user can
add/remove/rename/order operations.
Tools and accessories will be defined for each operation and built from various modes
and parameters.
Note:
The name of operation will be used as prefix for each tool (and also for each
stage of the actual operation).
All the information on tools and accessories is now stored in att file.

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Operation
Tools are associated to an operation (called OP). An OP corresponds to a set of tools
used for a simulation like in an actual press stage.
Each OP has global parameters set in its page.
By default, or when opening previous setup files, all tools are considered as Mono OP.
An OP can be added or renamed.
Tool Import and Meshing

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The geometry will be imported using the Import button

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. It can be a CAD file or a
Or it can be imported outside the Tool editor.
In the usual way, the CAD represents one tool: on die or punch side. A purpose of the
tool editor is to create the other tools starting from this one, by suitable offset.
CAD creation
Please refer to the Deltamesh section for specific details on export options for each
CAD system. You will also find a description of the required quality of the CAD model.
How to import & mesh the CAD model
-
Import tools CAD.

1. Select the CAD file(s) corresponding to the Die.
2. Select the Meshing strategy, which should be Validation, Springback or
Compensation (the difference is on the element size which is smaller for
compensation).
3. Check/modify:
The Meshing size factor.
It is linked to the size of the model and will be used for mesh cleaning
(removal of thin surfaces) and the meshing parameters. A size of 1

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corresponds to model of 300 to 3000 mm, with radius of a few mm, mm

being the model units (this is the usual factor for automotive parts).
Select whether the system used in the CAD system is the one to use in
simulation. If the CAD model is in the car frame, the user may want to keep
it or transform the model into the press system (usually called tipping
system) in order to have the global system in the simulation equal to this
tipping frame.
Process options: some information can be defined beforehand to correctly
prepare the use of the CAD for tool creations. These information are
optional;
Select if the CAD is on die or on punch side
Select the press type
Enter the thickness of initial blank (in order to be used in offset
information for creating tools).
4. Import & Check

This option will transfer the mesh in the meshing module with all the tools, to check the
mesh quality and to apply various strategies to improve it if needed.
See the Deltamesh section for more information on the way to proceed for checking and
repairing the mesh.
-
When the mesh quality is good enough for a high quality simulation transfer the
mesh in the set-up, select update setup.
In the Workflow transfer rules menu:

5. Check/Complete the target object name and the target group (Die).
6. Transfer.

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Die Filleting
Mesh before filleting
Mesh after filleting
The die entry filleting is mandatory, and is created using the same rules as applied to
other fillets.
leads to a likely rupture of the blank, just as in the reality. However, all fillets do not
need to be created in the CAD, since the filleting can be performed directly on the
mesh.
See Filleting chapter for more details information.
How to proceed
The DeltaMESH Fillet dialog can be accessible from Tool editor using the mesh
button
or from Cad page through the icon

1. Open the DeltaMESH Fillet menu,
2. Define the fillet with the Autobuild functionality,
3. Define the radii. It can be constant or interpolated,
4.
Click on Fillet.

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All meshing parameters will be set by the current meshing strategy (springback or
compensation), this also includes the maximal angle criteria which must be set to 7,5.
Mesh check and cleanup

The mesh can be checked and cleaned if necessary, using the
button. This will
open the Mesh check and cleanup menu. It is recommended to check the mesh defects
and generally let this automatic tool correct them.
See the Mesh check and cleanup chapter in the Simulation concept section for more
details.

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Mesh quality
In order to carry out a simulation with accurate contact, the quality of the tool mesh
must be good, as explained in the Contact and Friction chapter. Accurate contact
respects tool geometry as there is no penetration of the blank node in the tool mesh.
Therefore only tools with high quality mesh can be used.
The mesh quality has also an influence on the stress calculation, and is mandatory for a
good springback simulation.
This section of the tool is not good

enough to be used in Accurate contact as
well as for any springback simulation.
If the mesh quality is not good enough, it is strongly advised to use Penalty contact or
PAM-QUIKSTAMP (see the Simulation Methodology for Design and Stamping feasibility
section).
Undercut
Make sure that there are no undercuts in the mesh. Even if the initial CAD has no
undercut, the mesh can induce undercut in non-planar vertical parts. For example in the
curved vertical surface, if the discretizations on the top and bottom lines of the surface
do not coincide, there will unavoidably be some undercut elements.
Top view:
A
Cross section AA:
Edges on
bottom line
CAD
CAD
A
Edges on
the top line
Mesh
the Chordal error.
The undercut area can be found using Analysis contour /Undercut. It displays the angle
or the critical areas (shown in red in the figure below) .

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Undercut : 90
Safe :
> Threshold
Stamping
direction
Element
surface
Free or multiple edges
We advise you to avoid free or multiple edges inside the mesh, since their presence can
not only impede the execution of an offset during the generation of tools, but also affect
the results accuracy if the holes or overlaps reach 10% of the blank thickness.
The free and multiple edges can be checked using the show toolbar:
Other quality problems to check
Other quality problems may appear because of a bad initial CAD data (overlapping of
surfaces, non-trimmed surfaces) or a bad meshing.
The following Mesh Quality contours can be used to find the elements which are
warped, very thin or distorted.
-
the value is the angle between the average normals of these

two elements. If it exceeds 20 for the fillets (10 if a springback calculation is
planned), and 30 for the rest, that means that there can be a mesh problem like
overlapping or distorted element.
warping:
Area:
big warping can indicate a problem of mesh quality.
if the area of the elements is very small (0.01 mm), problems might appear
during offset.
if there is a very small angle in an element, problems could
occur during offset.

Remark:
The Deltamesh history file gives information about the success or the problems
met during import, joining and meshing. It is available in the Deltamesh module
created when importing the model.

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Repair
If a problem appears during the mesh quality control, it must be repaired.
Several possibilities are proposed to the user for repairing the mesh:
-
As written above, using the Mesh check and cleanup function available in the tool
editor using the button
. This will open a menu Mesh check and cleanup. This
is powerful tool used in order to detect and solve issues by modifying the mesh a
posteriori. This tool is presented in Mesh check and cleanup in Simulation concept.
Using the geometry/edition tools from nodes or elements, to eliminate the

problematic element. For instance, you can use the merge node to node option. This
is useful if problems concern only few elements and could not be solved
automatically with previous automatic tool.
If there are several big problems due to the CAD model, the best way to repair it is
to change the meshing strategy or the CAD cleaning using Mesh check and repair in
Deltamesh module. For example the Chordal error parameter can be reduced to
solve an undercut.
If the mesh quality is still of a poor quality, you can then use the penalty contact (if no
springback simulation is expected).
Sliding radius
The sliding radius value is not directly involved for tools construction but is used in
some other simulation setup functions like default blanks mesh size. If Blank editor is
done before Tool editor, sliding radius value is already fulfilled.
Die side or punch side

In general, the CAD surfaces represent either the die face (model on die side) or the
punch and run-offs (model on punch side). As these CAD surfaces are used for the
creation of the remaining tools, both methods (die side and punch side) are treated
separately. Yet, the main methodology remains the same. See the Offset chapter to have
more details on the way the offsets are done depending on the CAD surfaces
representation.
It is important to know what is represented by the CAD (die side or punch side) to
create the tools properly with the good radii. A mistake could seriously impact the
springback results.

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OP direction
A process frame will be used for the definition of the process parameters. It is defined
under the OP direction parameter in Tool editor; it is common to all created tools of the
operation.
In the public Macros database, all the macros are defined with a stamping direction
system-type object with the Z-axis as the stamping direction.
For macros created by the user, it is necessary to make sure that the coordinate systemtype object uses the same axis to define the stamping direction as used in the macro.
There are four ways of creating a stamping coordinate system:
-
defining an origin and a vector
defining three positions
defining a frame and an angle
importing it from an IGES or a VDA file.
Note:
Frames can be added, deleted or edited.
Symmetry
If the part to be stamped includes a symmetry plane, the meshing must be performed on
half of the model only. There is no benefit to simulate the whole model, which is also
more CPU-consuming. A CAD model of half the tool is enough. It is then necessary to
create a plane-type object in order to define its position in the Definition attribute. This
will be done through the Tool editor. The Symmetry attribute with a specified tolerance
will be automatically defined. The default tolerance value is 0.1. All the faces, edges or
nodes whose distance to the plane at the initial instant is lower than the defined value,
will have symmetry conditions automatically applied to them.

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See the Symmetry plane chapter for more information.

Inside the dialog, you can add, delete or edit a symmetry plane.
Note:
A maximum of two symmetry planes can be included in an operation.
If only a full CAD model is available, it will be first fully meshed.
Then you need to have at least one node of the blankholder (or other tools without
imposed displacement) in the symmetry plane. Two methods are available:
1. Increasing the symmetry tolerance so that a blank holder node should be taken
into account by the symmetry plane (refer to the Symmetry plane chapter). Make
sure there is only one rank of blank nodes in the symmetry plane (using the
Selection by plane option).
2. Modifying the die mesh by adding a line of node using the Geometry/Meshing
tools/Meshing line tool.

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Drawbead
It is important not to include the drawbeads on the CAD model, since they will be
modeled by equivalent drawbeads.
drawbeads
die
Reality
Modeling
Non-offset tools
The CAD will be used to perform the meshing of the tools. If the punch or the die
cannot be differentiated from the other using an offset, the CAD of both tools will be
needed and will be meshed separately.

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Die and punch
Make sure the gap between both tools is big enough. In most cases, an offset between
10%-20% of the thickness must be performed to compensate the non-parallelism of the
mesh.
To check the gap between the tools, use the distance contour or the distance
measurement in a 2D section.
Mesh Orientation
With the Accurate contact option, the mesh orientation should not be a problem. But
implicit gravity simulation uses a specific contact that requires mesh orientation. So for
implicit gravity only, the elements of the mesh must be correctly oriented, facing
towards the blank.
Note
Several contact types available in the program have a dependency on the mesh
orientation: penalty, Lagrangian and implicit contacts.
Blank holder
If the blank holder goes beyond the tangent point between the lower blank holder
surface and the die entry fillet, the fillet must be done in Setup, not in CAD:
Blank holder
R
Tangent point
Die
Once you have completed the CAD mesh and the filleting of all the sharp edges, except
those of the die entry, you have to generate all the tools and then create the die entry
fillet. This enables the extension of the blank holder beyond the die entry fillet. If this

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prolongation is not represented, it will affect the behavior of the blank on the die entry
fillet, as well as the results, particularly for springback.
The behavior of the blank on the die fillet significantly influences the springback
behavior.
Tools
the initial tool. The Tool editor allows performing automatically the required offsets
from the initial tool geometry. See the Offset chapter for more information.
Parallel meshes
Non parallel meshes
Note:
As the symmetry plane is taken into account by the offset, the planes must be
defined before any tool generation.

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In Tool editor, there is a specific page for creating the tools. A Tool set toolbar allows
the user to create a set of tools in one click. Several tool sets are available:
-
Double action
Double action with binder on die
Single action
Single action with binder on die
Crash forming
Flanging
Depending on the selected tool set, a list of tools is automatically created and these
objects are correctly assigned to the right group.
It is also possible to add extra tools manually for an operation by right-click on Tools
item.

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Note: Tool construction status by color:
A tool listed in red color indicates that build setup for this tool is incomplete.
A tool listed in orange color indicates that this tool needs to be built (tool was
not built yet) or rebuilt (some parameters have changed since last build)
A tool listed in black color indicates that this tool is already built and up to date.
Thickness
The blanks thickness value is used during the constructions by offset. Its default value
is retrieved from the Blank editor (if available).
Tailored blank
In case of tailored blank, the dialog box allows to define the tool building lines and the
zones with their specific thickness. See the Tailored Blanks chapter for more
information.
The direction from die to punch selects the tools offset direction: direct operation
direction or inverse operation direction.
Advanced Parameters
Mesh orientation
The normals of the tool elements can be oriented consistently in the direction of offset
such that they define the contact surfaces of the tools. They will point towards the
blank. Tools creation can be performed only after the normal orientation.

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If the mesh is really of bad quality (lots of overlaps and holes), the automatic orientation
may fail. In this case it is better to manually orient the poorly meshed local zones with
the orient mesh menu, and then de-activate the Orient mesh check box before creating
the tools.
Gap
For PAM-AUTOSTAMP with Accurate contact, it is essential to add a gap between the
die and the punch objects. The gap is generally 10% of the material thickness. This is
configurable from the Customization /ToolEditor dialog. For all other contacts
(including PAM-QUIKSTAMP Plus), this is optional. The gap can be set as a constant
value called absolute gap - (0.1 mm for instance) whatever the thickness of the blank.
If a gap is defined, the offset value between the die and the punch is the sum of the
blank thickness and the gap. The gap allows counteracting possible undercuts and
enables part of the blank whose thickness has increased, to pass between the die and the
punch.
Binder wall height
For PAM-AUTOSTAMP with Accurate contact, it is recommended to add blankholder
walls. Typically the height would be 10 or 15 mm depending on the size of the
blankholder surface. This is configurable from the Customization /ToolEditor dialog
The Wall will not have any influence in PAM-QUIKSTAMP Plus, so for easy iteration
between the two, it is recommended to use the walls by default.
The vertical walls on the blank holder are used to prevent a node of the blank from
passing over the blank holder during the holding stage, when the contact does not use
the orientation of the elements:
Blank holder without vertical walls
Blank holder
Blank
Blank holder with vertical walls
This node cannot pass above

the blank holder

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Clean mesh before Offset

The purpose is to clean the mesh before offsetting to avoid local problems introduced
by the offset action.
The model is scanned, starting from the smallest edges to the longest ones. Then an
offset is simulated. For each element, if the meet some criterion, then its weakest node
is removed. Therefore a quadrangular becomes a triangular, and a triangular is deleted.
This option is time consuming and if the user already checked and cleaned the model
using the Mesh check and cleanup functionality, it is not relevant because the model is
already clean.
The criteria are based on:
Warping: before and after offset
Element angle: before and after offset
Variation between normals: before and after offset
Die tool
Two methods are available to build the tool mesh:
Build from definition
which gathers the contents of several source objects and

performs offset or mesh duplication according to the operation parameters. Any
change of the parameters or source object will lead to asking the user to rebuild
the tool.
Fixed content
which does not perform any mesh construction and leaves the
current tools mesh unchanged. In that case, the tool can be either imported here
using
or it can be imported outside the Tool editor and selected afterwards
using the Assign objects button

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Punch tool
This page is similar to the die page, same parameters apply.
Blank holder tool
This page is similar to the die and punch pages except that the blank holder location, on
punch side or on die side, has to be specified.
Trimming tool
The trimming is performed with one or several curves that are projected onto the blank
in pre-defined directions or orthogonally.

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This page allows defining a trimming object, which means adding new or existing
curves to this object and specifying the trimming direction.
Trimming curves
Actually several successive trimmings are performed with different trimming tools.
With PAM-STAMP 2G each trimming tool is represented by a trimming curve.
The trimming curve can be created directly in the Tool editor dialog through the button
to create new curve or the button
to import from CAD or mesh file. The
trimming curve can also be imported from a CAD file outside this dialog; using Import
CAD curves or created in PAM-STAMP 2G using the 3D curves editor.
Notes:
The trimming curves can be opened (no need of closed trimming curves).
The trimming curves can cross each other.
Several non-connected trimming curves can be put in the same object, if they
have the same trimming direction.
There should be one object per trimming direction.
It is better if the trimming curves end points are not exactly on the border of the
blank.
If necessary the 3D curve editor can be used to modify existing curves.

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Trimming direction
For each trimming object, a trimming direction can be defined if the trimming is not
orthogonal. Or the user can choose orthogonal trimming if he wants to trim the mesh
orthogonally. This mode requires that the trimming curves are very close to the mesh
and properly discretized.
To complete the trimming operation definition, the trimming must be activated in the
simulation stage where trimming happens. It is done in the process step. The objects to
trim, zones to keep and meshing parameters are defined in per-stage trimming definition
in the Mesh transformation attributes of the Global object
Blank mesh size
For adaptive mesh, the elements on the border are refined to follow the curve the best
way. The Maximal level of target elements option uses the maximal level already
reached by the blank during the previous simulation. It can be used for trimming before
springback. The Maximal level in stage attributes option uses the maximal level of
refinement defined in the attributes of the following stage. It can be used for trimming
before flanging. In both case these options should not refine the blank on the border
more than in the other areas for not impacting the time step and so the simulation time.
These options will be defined during the data setup (see section Process setup).
The size of the newly created elements is managed not to be smaller than 20% of the
refined initial element size.
For non-adaptive mesh or when using the trimming at the first stage like blanking (see
the section Blank meshing), it is possible to force the refinement under the curves using
the imposed refinement option. It is not advised since it will modify the time step.
Notes:
For all modes the real level reached will at least correspond to a level among
the selected object (the blank in the presented case).
It is not possible to lock the refinement if the mesh is already adaptive.
Positioning before trimming

It is important to check that the trimming curve is well positioned towards to the blank,
particularly in the following cases:
-
Trimming curve comes from experimental data and springback occurs on real blank
before trimming. Or trimming curve is a theoretical one and springback simulation
is done before trimming.
Trimming curve is a theoretical curve coming from flanged blank, but springback
occurs before flanging
For all these cases it is advised to use the flattening option to project the trimming curve
on the blank and follow it during springback. It enables the user to check that the right
trimming curve is used.

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After springback, the blank can be positioned in a new system and held before the
trimming operation. In that case, the transformation attribute is defined at the beginning
of the holding stage, and then a trimming stage can be performed using the default
macros of the installation directory.
Optimize for flanging
An Optimize for flanging option is available in the Advanced parameters menu of
trimming. It is used to put more regular quadrangular elements on the trimmed border.
Such elements have better behavior when they are submitted to important curvature,
which could occur during flanging simulation. There are two levels of optimizations;
the first one corrects only the most deformed quadrangular elements, while the second
level leads to a global correction.
No option activated
Optimize for flanging option activated
When this option is activated, the user can also choose to force edges of the boundary to
be orthogonal to the trimming line by checking option Force orthogonal edges.
Flanging tool
See the Flanging chapter for more information.

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Free tool
This page allows definition of a free tool either by translation or offset of source objects
with custom translation distance and direction or offset distance.
Fixed content
mode for already meshed tools is also available.
Note:
It is possible to delete, rename or rebuild a specific tool by right-click on the main tree.
How to proceed
To create a new operation, the procedure is as follows:
1. Open the Tool editor dialog,
2. Define the name for the first operation,
3. Fill in the OP parameters page as described previously,
4. In Tools page, select a tool set, then a list of predefined tools will be created
5. Define the thickness if not yet defined,
6.
Define the direction from die to punch

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Check the Advanced Parameters:
Orient mesh
Definition of a gap value, equal to 10% of the blank thickness or more if there is
a small undercut,
Definition of Binder wall height.
8. In Die tool page, select the building method and fill in the appropriate field,
9. Repeat the operation 8 for each object tool of the tree,
10. For each tool mesh you want to create, create an object containing the part of the
initial mesh that will be used to create this new tool mesh,
11. Add any number of tools necessary for the operation and complete the
corresponding pages,
12. Add accessories if any,
13. Click on Build to build the different tools meshes (default is build only modified but
it is possible to build all if needed).
Mesh Quality
initial tool mesh. Perform the mesh quality check again (see the paragraph Die cleaning
for more information), and repair it as described if needed.
Accessories
It is possible to add any number of accessories of any type by right-click on the main
tree in Accessories item.

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Spacer accessory
The spacer page is similar to the free tool page. The difference between them is that the
created spacer is fully compatible with a spacer created in the Stamp Toolkit.
Guide accessory
The guides are designed to prevent undesirable sliding of the blank. It is mandatory to
use guides during gravity phases.
Guide mesh
Their width must be greater than twice the size of the blank elements in order to prevent
a blank element from passing through a guide.
flan
height
too small guide
A
BB
Mesh orientation
For implicit gravity, the elements of the mesh must be correctly oriented, facing the
blank.
Several guides can be built inside the same object. They are managed by the 'Plus' and
'Minus' buttons.
In the same object, all guides have the same height and direction. Only the base points
and profile are individual.

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Locator pin accessory

The locator pins, if any, are also designed to prevent undesirable sliding of the blank.
They must be meshed with enough elements to have a shape close to reality.
Blank refinement
When using accurate contact, the mesh close to the locator pins must not be refined, to
avoid penetration of new nodes in the locator pins.

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Like for the guides, several locator pins can be built inside the same object. They are
managed by the 'Plus' and 'Minus' buttons.
In the same object all locators have the same height and direction. Only the base point,
the radius and the number of elements on the circumference are individual.
Note :
In Stamp Toolkit, guides and locator pins are now under a unique object type
guiding. Whereas in input, there are specific groups guide and locator pin in
order to improve the chaining in the process data setup.
Spring accessory
It is possible to model gas springs used within a die, either in place of blankholder
force, or as applied to other moving tools.

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Each gas spring will be modeled using a 2-node BAR element. One node must belong
to the tool to be controlled, and the other must be given a Cartesian Kinematic condition
(either fixed or imposed velocity).
Several springs can be built inside the same object. They are managed by the 'Plus' and
'Minus' buttons.
In the same object all springs have the same height and direction, are attached to the
same base object and created end nodes are placed in the same object. Only the base
points are individual.
See the gas springs chapter for more information.
How to proceed
There are two methods of obtaining these accessories. They can be meshed from a CAD
file in DeltaMESH using the fixed content method and importing the file. The other
method is to create the geometries by using build from definition method, as described in
the following steps.
To create accessories, the procedure is as follows:

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1. Add the accessory,

2. For a guide object,
Select the type of guide, which can be a plane guide or a guide with borders,
Define the guide height, which should be high enough (default value is 100mm)
Define the extrusion direction, which should be the stamping direction,
Pick in 3D view the 2 points which delimit the guide,
Make sure that the distance between point1 and point2 is larger than twice the
size of the blank elements,
To define other guides in the same object, press 'Plus' button and do the same as
above.
3. For a locator pin object,
Define the height, which should be high enough (default value is 100mm)
Define the extrusion direction, which should be the stamping direction,
Pick in 3D view the base point,
Define the radius and the number of elements (default value is 20 elements)
Check that there is enough elements on circumference to have a smooth

definition of the locator pin,
To define other locator pins in the same object, press 'Plus' button and do the
same as above.
4. For a spring object,
Define the spring height, which should be high enough (default value is 100mm)
Define the spring direction, which should be the stamping direction,
Pick in 3D view the tool point,
Select the base object to which the spring is attached (usually the blankholder)
End points object
To define other springs in the same object, press 'Plus' button and do the same as
above.
is automatically created and selected
At that point, the different objects can be built using the Build button.
Once the operation is completed, you can click on
button to apply and go to next
step in the workflow, which is in this case the Blank editor. Or, you can define all the
operations of the process.
Once done, all the objects will be sorted by OP in the objects tree as shown below

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Notice that the main dialogs of set-up page have now the same bottom toolbar, to make
the workflow easier.

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BLANK MESHING
The blank mesh can be created using the Blank Editor menu. This dialog is accessible
from the set-up page.
The blank mesh can also be imported through one of the available translators (Nastran,
Patran, Ideas).

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This dialog allows the user to define a tailored blank using welding lines represented by
3D curves (refer to the Tailor blanks section).
The 2 pages Definition and Material have a check-box that allows skipping data (mesh or
material) when clicking on Apply if unchecked.
Rules for the Blank Mesh

General rules
-
The mesh must be oriented so that the edges are as parallel as possible to the die
entry fillet on which they will slide.
There must not be too many 3-node elements, since they do not behave in the same
manner as the 4-node elements.
4-node elements must be as close to squares as possible and the 3-node elements
must be as close to equilateral triangles as possible.
Final Element size

This is one of the most important parameters for a calculation, especially a high quality
simulation. The size of the elements for the blank must be small enough to analyze
precise phenomenon like surface defect or springback.
To obtain a correct representation of the blank sliding on a fillet, the size of the blank
element must be smaller than the value of the fillet radius.
For springback calculation or other high quality stamping simulation, the size (d) of the
deformed elements of the blank that slides on a fillet must be smaller than 25% of the
curvature radius of the blank at its neutral fiber when it passes over a sliding fillet, i.e.
25% of the sum of curvature radius of the fillet and the half-thickness of the blank.

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To sum up:
Element with maximal level
d
fillet on which
the blank slides
d 0.25 (Rmin + 0.5 th)

for a calculation with
springback
Rmin
Rmin+0.5 th
d = size of the elements of
maximum adaptive level
during calculation
Rmin = smallest fillet

radius on which the
blank slides
Blank deformation
These rules should be respected even after the deformation of the blank. Therefore, if
the blank is likely to elongate a lot on the sliding fillets, it would be better to use an
initial mesh fine enough in order to comply with the rules for the mesh size, at any time.
This precaution is particularly recommended for springback calculations.
Blank size and thickness
This criterion remains valid even if it leads to an element size smaller than the thickness
of the blank. Only the fillets on which the blank slides are to be taken into account in
the calculation of the fineness of the mesh. The die entry fillet is obviously one of them.
Adaptive meshing
The use of adaptive meshing on the blank is strongly recommended to significantly

reduce the CPU time and lower the memory space requirements. Since each adaptive
meshing level is half the element size you should multiply the element size without
adaptive meshing by 2(n-1), where n is adaptive meshing levels used in order to find the
initial element size.
Hence, the user has to make sure that the elements of the maximum level respect the
previous rules during the holding and stamping phases.
Initial mesh size and refinement levels

If the adaptive mesh is activated, the elements size at the end of the computation is
defined by the above rules. The initial elements size and the refinement levels (these
parameters cannot be separated), must be set according to the following rules: it is
advised to use an element size smaller than 25 mm at the beginning of the holding. If
the size of the elements is too large, the stiffness of the blank elements located under the
blank holder might be too large.
This parameter is used by the Mesh size wizard and can be customized either in the
Advanced parameters menu as Maximal initial mesh size or in the Custom options.

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Refinement levels are defined by the final mesh size and the initial mesh size. There is
no constraint on refinement when using the accurate contact.
Automatic mesh size / Mesh Size wizard
If Tool editor is done before Blank editor, then sliding radius value is transferred
automatically to the Blank editor dialog.
The optimal element size is computed automatically or by the wizard respecting the
previous described rules:
-
The Sliding radius, the Blank thickness and the High Quality option lead to the
computation of the Final mesh size.
Assuming that the Accurate contact is used (Adavanced parameters), the size grows
from the final size to the initial size (factor 2 step by step) until it reaches the
maximal initial mesh size (set to 25 by default and defined in the Advanced
Parameters). Therefore refinement levels (maximal and uniform equal to 1) are set.
There is no limit in the refinement levels.

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Blank Creation Tools

There are several ways of creating a mesh in PAM-STAMP 2G:
-
Outline:
using a 3D curve, any planar blank can be meshed.
Four points:
Rectangle:
Disk/Pie:
Tube:
the four corners of the blanks have to be defined, by selecting them in

the 3D view or by entering the coordinates.
the corner and the size of the rectangle blank are defined.
it enables to conveniently mesh part of disk. For die shape like cup, the
created mesh is always parallel to the die entry line, and the mesh size is optimized.
it enables to mesh a tube.
For most of these options, a preview is available to visualize the blank after the mesh
creation. The created mesh is put in the defined object that has automatically the surface
blank type.
-
Already defined: This
dialog has no parameters, the user can select it to avoid

creation of blank mesh, when mesh is imported or created outside the blank editor.
This mode is selected automatically when mesh is imported through the blank
editor. It is possible to import a blank mesh from a mesh file or a computed model
(restart file).

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Volume Blank
Blank editor enables the meshing of a volume blank, by first meshing it in the plane,
respecting the previous rules, and then doing an extrusion of the mesh.
3D Curve
When the blank contour is already defined
by a CAD curve, it can be imported using
the Import CAD curves functionality and
used as Outline.
When the blank contour is a mesh file, it
can be imported using the Import from file
button
then, the mode Already defined
is selected automatically and 3D curves are
added to the Outline object.
Modifications
from Mesh contour and can be edited using the 3D Curve Editor. It enables to cut the
corners, to offset the blank or to freely modify the contour.

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Progressive Die
For blank contours with very small curvatures, like the ones used for the following
operations, the mesh can be locally refined along the contour curve. Using the Outline
functionality, it is possible to apply refinement parameters, with imposed refinement
option. The user defines the refinement level that will be used for adaptive meshing
during the simulation.
It is also possible to define a Four points blank and to trim it when the simulation starts.
In that case, a transformation/trimming attribute will be defined with a Maximal level in
stage attributes refinement parameter.

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Blank material definition

The Blank material can be defined in the
Blank editor; defining the Blank thickness
and loading the material from the material
database (See the Customization chapter
for more information on the material
database update).
If Tool editor is done before Blank editor,
thickness value is transferred
automatically.
How to proceed
To create a new blank object, the procedure is as follows:
1. Open the Blank editor dialog,
2. Add a blank object using
type),
button (default name is Blank and it has surface blank
3. In Definition page, select the type of blank (default is outline) and complete the
parameters,
4. In the mesh frame of definition page, define the meshing parameters (default is
automatic),
5. It is possible to check the mesh by checking mesh preview toggle,
6. If material is available, go to page material and define the material definition,
7. Click on Apply or you can click on next button
which is in this case Drawbead editor.

Blank Meshing
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CREATION OF DRAWBEADS
The Drawbead editor is accessible from the set-up page.
It provides functionalities to build drawbead curves. This dialog allows the user to
manage main geometric properties of drawbead objects.
Note:
button is available only in standard stamping process. It is not

available in hot forming or roll hemming context.
Drawbeads
Import or Creation of Drawbeads (if any)

a drawbead object type; they can be also represented by 1D-bar elements. These 3D
curves are automatically transformed in 2-node bar elements when launching the solver.
See Drawbead chapter for further information.
3D curve editor to define the drawbead lines clicking directly on the die surface

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Note:
3D curves or bars are projected on the tool on which they rely (usually die or
blankholder) in order to precisely have the tool shape. This projection is done at
the simulation stage automatically: curves are transformed in small segment
lines in order to respect the tool shape. Moreover, inside the solver, those
segments are transformed into bar elements, which are visible in the results files
in postprocessing.
How to proceed
To create a new drawbead object, the procedure is as follows:
1. Open the Drawbead editor dialog,
2. Add a drawbead object using
button (default name is Drawbead and it has
drawbead type) and select the operation where the drawbead is active,
3. In Location page, select the type of geometry (default is curves) and create or
import the data.
4. In Tools page, check the parameters; most of the fields are already filled,
5. In Blank page, select the type of drawbead (uniform or non-uniform), select the right
blank to restrain and complete the forces data,
6. Activate any option needed
7. Click on Apply or you can click on next button
which is in this case Process setup.

Creation of DRAWBEADS
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ANALYSIS ENTITIES
Definition of Analysis and Marking Entities
When the blank slides on the die entry fillet; scratches appear on the blank. Therefore,
you have to create an object that contains the fillet elements to identify the parts of the
blank that slide over the die entry fillet. Other marking objects can also be defined.
For a high quality computation, it can be convenient to have additional information in
specific areas to be studied (high springback area, surface defect and so on.). A history
object can be created that contains some specific elements of the blank to follow the
characteristics of such elements as function of time (thickness or stresses for instance,
that are defined in the control attributes, in the setting menu). The same thing can be
done for nodes.

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PROCESS SETUP
Influence of Parameters on CPU Time and Results Quality
The user has to take into account what results quality and CPU time (calculation speed)
he should expect. Each parameter of the process impacts differently these two elements.
We therefore advice you to follow the figure below for better calculation results.
Time Step:
large+nobend
Time Step:
small+bend large
Refinement Parameters
(See Adaptive Meshing Chapter)
-
No Refinement:
adaptive meshing improves the CPU time without decreasing the

quality of the results, therefore its use is recommended.
Refinement by area:
the refinement by area enables the user to better adapt the

refinement levels to the geometry of the part. It saves CPU time and improves the
quality of the results because the user can allow a very fine blank mesh only where
it is necessary. It is useful for studying surface defect.

Process Setup
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Refinement angle:
Radius criterion: the
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the default angle value of 10 is well adapted and leads to a good

blank mesh. A refinement angle lower than 10 does not improve the quality and
leads to higher CPU time.
geometrical curvature radius criterion is essential to detect
ruptures properly. This criterion should be applied if a springback calculation is to
be performed. If the geometrical curvature radius criterion is not activated, the
elements are only refined when an angle criterion is reached. Therefore the tool
geometry is not necessarily respected and the stress field is not very accurate. This
criterion is time consuming but necessary for the good quality of results.
Numerical Parameters
-
Gauss integration rule: defines
the distribution of the integration points across the

thickness, the weight of each point being different. This rule leads to better results
quality (see Elements Chapter).
Number of integration points:
Strain order:
Time step: Large / large bend options improve results quality when the mesh is
regular. Small / large bend options improve results quality without depending on
mesh shape but are time consuming. The Small / no bend options reduce calculation
time (see Time Step Chapter).
Shell antidrilling:
Reduction factor:
Mass scaling:
Rigid Body:
a value of 5 combined with Gauss integration rule is

satisfactory for a better quality of the results, especially if springback is expected,
but it is time consuming. If this value is 5, the calculation speed is better but it is
not suitable for the springback calculation. Values higher than 7 rapidly reduce the
calculation speed, without further improving the quality (see Elements Chapter).
2 is used when the second order term in the strain and thickness
calculation is taken into account, which improves the quality of the results but is
time consuming. If this value is equal to 1, the second order term in the strain and
thickness calculation is neglected, the quality of the results is decreased but the CPU
time is improved (see Elements Chapter).
if it is not activated, the quality of the results will be significantly

impaired, but it can improve a little the CPU time (see Elements Chapter).
represents the coefficient by which the time step of each element
is divided during the mesh refinement. When high calculation speed is needed, the
curvature radius criterion can be deactivated and the reduction factor of 1.33 is used.
The precision of the results will be reduced (see Time Step Chapter).
this parameter increases the mass of elements whose characteristic
size is smaller than a user-selected value. This increases the time step and reduces
the number of calculation cycles. If it is correctly used (see below) the user can
decrease CPU time without affecting the quality of the results (see Time Step
Chapter).
the use of the standard rigid body for tools with imposed movement
saves CPU time without influencing the quality of the results (see Rigid Body
Chapter).

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Process Definition Parameters

-
Symmetry plane:
using symmetry planes, only part of the blank is modeled and used
for a calculation, thus decreasing CPU time. Symmetry should be used whenever
modeling symmetrical components (see Symmetry Plane Chapter).
Autopositioning:
Final mesh size:
Contact type:
Bad mesh for tools:
when this parameter is used, tool meshes are positioned as close to

each other as possible. This leads to a shorter calculation time. It should be used as a
matter of routine.
this parameter has a large influence on the quality of the results and
on CPU time, so it should be chosen depending on what is expected (see Blank
meshing Chapter).
an Accurate contact is recommended if more precise results are
needed (for high quality simulation). The use of a Penalty contact is suitable in case
the tool CAD data is of bad quality (see Contact and Friction Chapter).
the number of elements for the tools has some influence on
CPU time, which is why it is better not to have too many elements when they are
not needed. However, not having enough elements to describe the radii, can lead to
bad quality results (see Creation of the tools Section).
Calculation with Springback

The springback calculation requires several precautions during the data setup of the
calculations. This paragraph gives all the rules that must be followed to obtain highly
reliable springback results.
-
Discretization of Fillets:
the higher the number of elements in the fillets, the better

the results of the springback. Consequently, the fillets on which the blank slides
should be meshed (die entry radius, punch radius) so that the maximum angle
between two neighboring elements of the fillet, is equal to 7.5. This leads to twelve
elements on a quarter of a circle. (see Creation of the tools Chapter)
High mesh quality for the tool is necessary because tool

adaptive meshing. (see Creation of the tools Chapter)
Gap between die and punch, blank holder walls:
Blank meshing and adaptive meshing:
Contact Type:
geometry is respected during
when the tools are created, the gap

between die and punch has to be used, and the blankholder must be built with
vertical walls (see Creation of the tools Chapter)
it is possible to use adaptive meshing in the
calculations of holding and stamping operations that precede a springback
calculation (this is even recommended for reasons of CPU time). The number of
adaptive meshing levels must follow the rules previously stipulated concerning the
size of the blank elements. (see Blank meshing Chapter). The default angle of the
geometrical criterion, 10, is an optimal value to ensure precise results.
only an Accurate contact should be used (for all stages). This contact
does not allow any penetration during calculation.

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Rigid body:
Mass Scaling:
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Blankholder is defined as an advanced rigid body that takes into account

a mass and deformation height and is slightly deformable.
Mass scaling can be used (local artificial growth of the density), in
the holding and stamping calculations. This possibility should not be over-used,
however, since it may affect the quality of the springback. In the case where the
final size of the blanks elements (ie. the size of the elements with the maximum
refinement level) is d, the following rules must be observed to obtain the mass
scaling value:
Holding calculation: The mass scaling value to be input cannot exceed twice the
final size of the blank elements: 2 d
Stamping calculation: The mass scaling value to be input cannot exceed the final
size of the blank elements: d
Time step reduction factor:
In order to have accurate results during a springback

calculation, it is not advisable to use the time step reduction factor option.
Stamping Velocity:
The maximum stamping velocity used should be 5 m/s.

However, in order to be sure that the blank holder is balanced when the punch
touches the blank, it is advisable to delay the moment when the punch or the die sets
off by defining the following velocity curve:
V (m/s)
5
t (ms)
0.5
Note:
When a blank is stamped without blankholder, a velocity maximum value of 2

m/s should be used to minimize the blanks vibrations.

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Definition of the Operations: Macros selection

-
The Process macro dialog is accessible from the set-up page.
The available macros for high quality process in the public database are gathered in the
directory High Quality.
simulate with many sets of tools, numerous macros will be used successively.

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To define the process, the user has to choose first the required macro. This macro is
subdivided into several parts in which the user defines the parameters (See the Process
macro chapter).
Note:
Save button enables to save all the data already defined in a macro to memory.
After re-opening this macro, the data will again be available.
Multiple operations
enables to load several macros and to define
macros that appear in the drop list at the top level of the macro.
Example
The data setup of the following process must be done:
Gravity - Holding1 - Holding2 - Stamping1 - Stamping2 Trimming Springback
translation Holding Trimming - Springback.
The user loads the successive following macros, renames them, and selects the useful
stages that have to be renamed.
-
Double action High Quality: Gravity - Holding
Double action High Quality: Holding - Stamping
Double action High Quality: Stamping Trimming - Springback
Trimming: Translation Holding - Trimming
Double action High Quality: Springback

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Definition of stages and tools

Customize
After loading a macro, user must select the corresponding operation (defined previously
in Tool editor), the tools and the stages that are necessary for the process and he can
rename them if the name can lead to confusion (for example when loading several
macros).
Remarks on the stages selection:
-

Automatic fulfill
The groups are automatically fulfilled if the previous steps of the workflow have been
done.

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It can also be done using the group management menu whenever the user wants.
Remove translation, rotation or trimming

The mesh transformations like translation, rotation or trimming do not correspond to a
stand alone simulation, they are done at the beginning of another simulation (holding,
springback ). It is then impossible to select or deselect them as a stage. This is the
procedure for selecting/deselecting them if they are defined in the macro:
-
For selecting or not trimming, select or deselect the trimming curve group.
For removing a translation, put zero as displacement value
For removing a rotation, put the same frame for the initial and final frame.
Duplication of groups
icon
The same functionality is available for blanks that can be duplicated for tailored blanks
simulation. But this procedure is no more useful since tailored blanks properties are now
defined through Blank and Tool editors (see Tailored blanks chapter for further
information).

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Definition of the process parameters

Blank Material
The blank properties can be defined by loading a material from the data base (see
Chapter Customization/Complete the Material data base) or by creating a new material.
A Keep option enables to use the material already defined in the Blank editor or
attributes tree. It will not be erased when applying the macro and the data are used in
the wizards of the macro. This option is activated by default when loading a macro. It
should be used especially if the blank comes from a computed model: when the blank
object is selected, the material properties, the initial thickness and the initial rolling
direction of the blank are retrieved and cannot be modified.
Parameters
Most of the parameters are already defined when loading the macros. This automatic
definition of parameters comes from:
-
the attribute tree: if some attribute are already defined they will be automatically
fulfilled by the macro.
the previous steps dialogs : if a parameter, like the thickness or the friction has
already been defined in a previous menu or wizard, it will be used to fulfill the
macro parameters.
the macro itself: default parameters can be defined when creating a macro with the
Stamp Tool Kit. This value has priority on other existing or used values.
It works the same way for the groups that are defined automatically when creating the
objects with the different menus (Blank editor, Tool editor ) and can be check or
modified with the group management.
Unit system
All the parameters must be defined with consistent unit system. All the macros of the
public material database are defined with the unit system mm/kg/ms/C.

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High Quality process macros

The macros proposed in the public macro database for high quality process impose
some attributes or parameters described below and ask the user to define others:
-
Holding stage
Velocity:
a constant value of 2 m/s is imposed for blank holder in double action

or for die in single action
Progression stop:
Mass scaling:
A pinch test between the die and the blank holder is used for
to use twice the smallest element size after refinement
Stamping stage
Velocity:
a stamping velocity curve is imposed with a delay of 0.5 ms when the

velocity is null, then after 1 ms the velocity is constant at 5m/s.
Blank holder force:
Mass scaling.
Progression stop.

to use the smallest element size after refinement; ignoring the few elements with
very small size at the border of the blank.
A pinch test between the die and the punch is used for
Trimming and Springback stage
Trimming frame
coordinate system: it must be defined by the user, assuming that

the trimming direction is the +Z-axis.
Remaining area after trimming:
A position has to be defined or selected in the 3D
view.
Lock points:
For implicit springback only, the blank must be locked during the
simulation to avoid the rigid body movements. The menu allows the user to
define for each position the boundary conditions that will be applied to the blank
node closest to this position or to select an automatic locking. See Springback
measurement chapter for more details.
Notes:
If the springback is explicit, no lock point is defined.
If the springback is explicit a mass scaling must be defined. The wizard can be
used by selecting Holding as the type of stage.
If it is not possible to stop the simulation by a pinch test, a progression value

must be added in the attributes tree.

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When springback simulation is required

Trimming and springback
If the user is interested in the post-trimming springback, it is not necessary to calculate

the springback before trimming, to cut the part and to calculate a second springback.
Since there is generally no plastification during a springback stage, the results do not
depend on the pathway followed. Therefore, the part is normally trimmed after
stamping and the springback will be performed afterwards.
The user must be however careful about the position of the trimming curve towards the
blank (see Creation of the tools section). It could be necessary to calculate a springback
before trimming to have the same position between the trimming curve and the blank as
in reality.
Several sets of tools
It is highly advisable to let the blank relax after any sudden tools removal, which
occurs between two stamping stages with different tools sets, between a stamping stage
and a pre-flanging holding stage This avoids vibrations that would decrease the
springback results quality. It is useless between holding and stamping since there is no
sudden removal of the tools. It is not necessary to reach convergence to let the blank
relax.
Therefore, an explicit springback calculation will be performed with a final time equal
to 5 ms, which is enough for the relaxation to be done.
Initial positioning
Autopositionning performs a translation along the stamping direction only:
blank
guide
Positioning
action
die
Manual positioning is recommended in the horizontal plane and in rotation in order to

reduce the CPU time. This corresponds to a preliminary gravity action:

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Positioning
action
Process stroke
The tools are considered at the zero position at the beginning of the simulation before
any applied transformations (positioning, translation). The stroke will be displayed in
post-process from the value after positioning to the final position.
Example
After creation of the tools, they are at the position at the end of stamping. This is the
reference position equal to zero.
Distance = thickness
Distance = thickness + gap
In the Control attribute, the following parameters are defined:

-
Start at = 0
Option recomputed : on
Stroke of the object: punch
Stop with pinch test
The autopositioning of punch is automatically done when the simulation stops, and the
punch is translated from : -60 mm

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Automatic punch autopositioning = 60 mm
The state 0, will then have the progression -60; and the final state, the progression 0
How to proceed
The data setup is defined in the attributes tree, whose access is done with the following
button
The attributes tree can be fulfilled manually or automatically using the Process Macros
(see the Process Macro chapter).
-
Load the macro using
button
Select the operation, groups (tools) and stages in the opened Customize menu, and
rename them if necessary
Define the objects (active in this operation) to the corresponding Groups. Most of
the groups should be automatically fulfilled
Define the blank properties: Load a material from the data or create a new material,
enter the thickness and the rolling direction. Or check the keep toggle if the material
was previously defined
Enter the global parameters common for several groups, several stages:
the friction coefficient between the tools and blank: if a default value is
already defined, it has to be checked
the process frame, assuming that the stamping direction is the +Z-axis.
the refinement levels (uniform and maximum), used for both holding and
stamping stages
Check the pre-defined parameters and define the red ones
Load as many macros as needed for the process definition and do the same actions
Apply
all the macros or you can click on next button

step, which is in this case Solver start.
to apply and go to next

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It is better to open the attributes tree to check the attributes, especially if some stages
have been removed. In case of deletion of stages, some additional autopositioning can
be necessary. It is also recommended to make a data check to check the possible errors
or warnings before launching the computation.

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SIMULATION AND POSTPROCESS

Starting the Calculation
Once the data setup is complete, the calculation can be started using either the
corresponding Solver button or the menu Transfer /Start computation.
The Check attribute option is activated by default; it checks the compatibility between
attributes. Each stage is automatically run one after another, and a project is created at
each stage.
Check the online help for more details about host definition.
Post-processing the Results

For more details see the Analysis section.

Once the analysis is performed, check the following:
-
The error messages, to make sure the calculation has converged.
The final position, especially in the guides area.
For explicit gravity simulations, check also displacement curves and the kinetic
energy history.
The orientation of the element normals of the tools and the blank.
The unit system, especially for the gravity field and the material definition.

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The presence of guides.
process.
The blank holder walls should have prevented any node of the blank going
below the blank holder. This can also happen if the blank mesh is very large
compared to the blank holder curvature. In that case, use a finer mesh or define a
contact between the blank and the blank holder (there is already a contact
between them).

-
Termination.
It is useful to check where the pinch test occurred, if it is used as the stop criterion.
The final position of the blank holder with respect to the die, either in section view
process. The blank holder walls should prevent any node of the blank going below
the blank holder.
The warnings in the solver messages.

If there is any initial penetration, check the positioning of the tools.

-
The error messages, to make sure the calculation has completed with normal
termination. It is useful to check where the pinch test occurred.
The animation of the stamping process.
the blank in percentage.
The forming limit diagram and more specifically:

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For thicker materials or shapes strongly dominated by bending, verify the

rupture risk for the upper and lower sides shell fibers as well.
The stresses field on the neutral fiber, but also on the top and bottom fibers if a
springback simulation follows the stamping process.
The equivalent plastic strains.
The warnings in the solver messages.

If there is any initial penetration, check the positioning of the tools.
The area where pinch test occurs, using sections.

A bad mesh quality can stop the simulation. Use the mesh quality criteria
defined in the section creation of the tools.
Springback Simulation Analysis

-
The error messages, to make sure that the calculation has finished with convergence.
The displacement fields.
If explicit springback is used, lock the model in post-process before any analysis.
The blank shapes before and after springback, with distance contours.
Some contour cut done from a section to compare results and experiments.
The error in the solver messages.

If there is any factorization problem in implicit simulation, check that the blank
is correctly locked during the simulation.

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FOR SPECIFIC PROCESSES
TAILORED AND PATCHWORK BLANKS
Introduction
Blanks with tailored properties are becoming more and more standard, in cold as in hot
forming. With PAM-STAMP 2G V2012, it is now faster to setup and define such
processes, and also to analyze the results of the simulations. Also iteration support to
fast & easy find the perfect tailoring is supported.
To simplify the setup of tailored blanks and also the iterations on process and welding
lines, dedicated functionalities are proposed for tool creation as for blank creation.
The starting point for a multiple blanks simulation is a standard set-up (see Simulation
Methodology for Standard Forming section). Therefore, the rules for a standard stamping
set-up have to be followed. From this starting point, additional parameters specific to
tailored properties need to be added to the input. Only the specificities linked to tailored
and patchwork blanks will be described in this chapter.
Tailored Blank Definition

The blank definition is done through the Blank editor. A functionality dedicated to the
creation of tailored blank is proposed.
It allows the user to define a tailored blank using welding lines represented by 3D
curves.
SIMULATION METHODOLOGY FOR SPECIFIC PROCESSES

Tailored and Patchwork Blanks
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After activation of the option tailored blank, 2 sub-pages Contour and Tailored blank
appear in the Definition page. There is no more Material page.
The mesh is defined with 2 pages:
Page Contour which sets the type of Blank and is equivalent to the standard
blank
Page Tailored blank which allows the user to define the welding lines and
material thicknesses of sub-parts of the blank.
For Contour page, see details in Blank meshing chapter.

In Tailored blank page, there are 2 frames:
1. Line objects: This list corresponds to the objects containing welding lines. The user
has to define the welding lines by using one of the tools described here after.
: Create a new welding line and add it to the list
: Edit the selected welding line
: Import welding lines from a CAD file or a mesh file.

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: Opens the curves selector, allows the user to define the content of the
selected welding line.
: Opens the objects selector, allows to set the objects in the Line objects list.
2. Material objects: This list is automatically updated using the Contour data and the
welding lines.
Example:
If only one welding line is defined, there will be 2 sub-blanks created.
If 2 welding lines are defined, 3 sub-blanks will be created.
: The user can pick in the 3D view the areas contour, or double- click on an
item in the Material objects list, to edit the name and the thickness of the selected
material object.
Notes :
For this version, the number of straight welding lines is limited to 2 for a blank.
Only one welding line with a corner is possible, like shown here after

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The next step is to create the blank meshing (see Blank meshing chapter).
In case of tailored blank, there is a new parameter refinement under welding lines which
is available in Mesh parameters.
If the user has selected automatic meshing, then he can choose to set an automatic
refinement under welding lines. If not, a value must be set in the edit field.
If the user has not selected automatic meshing, then it is mandatory to set a value for
refinement level.
The objective is to refine automatically the mesh under the welding lines at the higher
level at the beginning of the computation so that no adaptive meshing is created during
the calculation on this area.

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Here is an example of tailored blank with refinement under welding lines of level 4.
Note :
Preview feature to check that the mesh preview is not available in case of
tailored blank.
Once the definition of tailored blank is applied, the blank mesh is created and objects
for each blank domain are automatically created as surface blank type. The user has
then to define material for each sub part of the blank. Only the Material page is present
in the dialog.
Thickness is already set if user has defined it in the material objects section.

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Note:
The whole blank and the sub-blanks are all surface blank type. The blank object
will be used for contact, positionning, trimming, gravity, springback and postprocessing; Whereas sub-blanks are used only for blanks material definition and
drawbead restraining forces.
After blanks definition, the user can click on the next button
next step, which is in this case Tool editor.
to apply and go to
Patched blanks
For patchwork blanks process, user will create two independent blanks through the
Blank editor. Each blank will have its mesh definition and own material.
It is recommended to mesh the patch area on a bigger blank and the whole patch blank
at the highest level (uniform refinement) at the beginning of the computation in order to
avoid any adaptive mesh creation during calculation because some instability may
occur.
This will be defined through the refinement attribute under local initial level parameter.

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Spotwelds definition must be done as usual.
Tools Definition
Tools are defined in the same way as described in creation of tools chapter.
In Tools page of Tool editor, a new functionality dedicated to the creation of tools for
tailored and patched processes is proposed. This is accessible through the tailored blank
button.
This dialog box enables the user to define the tool building lines and the zones with
their specific thickness in order to build locally the tools (by offset) according to the
local blank thickness as in the diagram below.

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Tool building lines:
This list corresponds to the objects containing tool building lines.

The user has to define the tool building lines by using one of the options described here
after
: Creates a new object that will contain the curve(s) used to build the tools
: Edit a curve of the selected object
: Import tool building lines from a CAD file or a mesh file.
: Opens the curves selector, allows the user to define the content of the selected tool
building line.
: Opens the objects selector, allows to set the objects in the tool building lines list.

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The last option

welding lines.
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enables to create the tool building lines by an offset of the blank
Note:
The offset of the curve will be a translation (in blank plane) of value offset of the
welding line in the direction from the thicker blank area to the thinner blank
area, like described below

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The tool building line is automatically extended so as to cover the whole tool geometry.
Zone definition:
This list is automatically updated using the Blank editor data and the
tool building lines.
Thickness for each zone is automatically set (retrieved from the Blank editor dialog).
But user can double click on a zone if the related thickness needs to be changed.
After the tool building lines definition, user will build the tools as usual (see creation of
tools chapter for more information).
Note:
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Punch and blankholder tools will be offseted according the zones definition and
associated thickness.
After tools definition, the user can click on next button

step, which is in this case Drawbead editor.
Patched blanks
Same methodology is used to create tools for patchwork blanks process. The tool
building line will be an offset of the patch blank outline.
Example: If you take for instance a blank thickness 1mm and a patch blank thickness
0.8mm, the thickness for zone 1 (blank1) will be 1mm and the thickness for zone 2
(patch area) will be 1.8mm. The offsets of tools will be done accordingly.

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Note:
As for tailored blank process, the step is done in punch side.
Drawbeads Definition
In reality, drawbead physically represents a part of the tools, it is therefore common for
all blanks of one OP. However his action (restraining and opening forces) depends on
the blanks (friction, material, thickness). So there must be one drawbead object with one
set of forces definition per blank. Such process is now handled in PamStamp2G v2012
(see drawbead chapter).
It is possible to define drawbeads for multiple blanks (tailored blanks as well as
patchwork blanks) like shown below.
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There can be two configurations of drawbeads in connection with multiple blanks. The
first one is: drawbead curve lies on one of multiple blanks (picture above vertical
curves). And the second one is: drawbead curve lies on both blanks (picture above
horizontal curves).
Drawbead definition must be carried out in this way:
-
Create an object drawbead which contains all the drawbead curves
Fill in the pages Location and Tools as described in drawbead chapter
In Blank page, the button

enables to add as many restrained blanks as needed.
Here in this case, only 2 blanks are welded, so we add only one blank card. Then, 2
pages Blank 1 and Blank 2 appear
In each page, select the type of drawbead and select the right restrained blank in the
drop list (blank_mat_1 or blank_mat_2)
Define the drawbead forces as usual for each sub-blank

Here is an example of such definition:
In IOSL, drawbeads nodes and bars (after conversion from 3D curves) are duplicated so
that for each restrained blank, a standalone interface drawbead/blank is sent to solver.
Therefore, solver will apply the correct force for each restrained blank. Duplicated
nodes and bars are destroyed in IOSL so that they don't appear in results files.
Note:
The user can define null force in blank1 page for the drawbead zone which will
never cross over blank1 because it will not be used by solver. Same for blank2.
Only one set of drawbead forces can be displayed at once

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After drawbeads definition, user can click on next button

step, which is in this case Process setup.
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Patched blanks
Described methodology is same for patchwork blanks process. If drawbeads cross the
patch area, the solver will apply both drawbead forces defined in the 2 blank pages.
Process setup
For tailored blank process, the setup is similar to standard forming. See process setup
chapter for more information.
There is no need to define a specific macro for tailored blank process. User will load the
standard macro available.
Note:
The user will activate the blank object (the sub blanks will be implicitly
activated).
In material panel of process macro, the user has to activate the keep option (activated by
default) in order not to redefine blanks material data since they have already been
defined in the Blank editor.
Patched blanks
For patchwork blanks process, the setup is not standard. A specific macro with double
blanks and spotwelds is required in order to manage contact between blanks.
Post Processing
On the post processing side, it is easy to follow where the different areas are moving
during the forming operation. Blank welding lines and tool building lines are visible in
post processing.
Sub-blanks are also automatically activated in each post-processing stage. Thus, the
user can easily manage each blank separately.

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Note:
The import curve from pre-processing option is still available in order to be

able to do it for projects older than v2012.
Optimization
Die compensation and blank optimization are supported for multiple blanks
configuration.

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HOT FORMING
Introduction
PAM-AUTOSTAMP proposes Hot Forming processes simulation. These processes
include as well Hot Stamping of Boron Steels for instance, as Warm Forming of
Aluminum. The starting point for a Hot-Forming simulation is a usual PAMAUTOSTAMP set-up (see Simulation Methodology for design and feasibility or
Simulation Methodology for Standard Forming sections). Therefore, the rules for a
standard stamping set-up have to be followed. From this starting point, additional
parameters specific to thermal behavior need to be added to the input. Only the
specificities linked to hotforming will be described in this chapter.
Courtesy AP&T
Which simulation for which objective?

PamStamp2G proposes different hotforming processes depending on the intention of the
user:
Hot Forming computation can be done either in the early phase of the project
(feasibility) or in an advanced phase of the tool development (process validation). For
these two types of projects, the target remains the blank sheet behavior and the process
description.
Besides, it is possible to do an automatic cyclic cooling simulation which aim is to
validate the cooling channels design. The target here is the tool behavior.

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The possible simulations are listed here after:
Feasibility
PamStamp2G offers the possibility to
carryout a fast calculation at an early stage
for:
-
checking the hotforming feasibility
estimating the quenching time and

thus the production cycle time, thanks
to phase transformation calculation
optimizing the initial blank shape
Process Definition
PamStamp2G provides all the needed
functionalities for a very accurate
simulation of Hotforming process taking
into account most of the thermal,
mechanical and metallurgical phenomena
occurring during the process, such as:
-
Thermo-mechanical quenching
Evolutive tools temperature
Blank expansion
Convection with ambient temperature
This enables the user to validate the

process to make sure that it will be right
the first time.
Cooling Channel analysis

An analysis of the cooling channel design
can be done through an automatic cyclic
functionality. This enables to check the
tools temperature taking into account the
thermal exchanges with blank and with
cooling channels.
Hotforming processes with tailored blanks, patchwork blanks, tools or blanks having
multi-zones of temperature can be also simulated with PamStamp2G.

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Feasibility
Simulation can be carried out to quickly check the hotforming feasibility and have a
rough estimation of the quenching duration in a short time and so production time. This
will be simulated generally at the early stage.
Hotforming context
At creation of a new project, the new process type called Stamp hot forming must be set.
It is dedicated to hotforming application and thus user can get access to specific
functionalities which are available in this context only.
The general setup of the project has to be done following the procedure for a standard
PAM-AUTOSTAMP project. Afterward, some specific hotforming parameters will be
defined to build the complete hotforming input.
Material Properties
Blank Material
The material for the blank is stored in the material data base. Material parameters are
described in the Thermal material option chapter.
For defining the blank material the user has to go through the following steps:
Select the material
The material can be loaded from material database or created in the Material dialog.
There is a hotforming folder in the Public database which contains materials dedicated
to hotforming application:

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Once the material is chosen the user can decide whether or not he wants to activate the
thermal and metallurgical material properties.
In the standard material provided in the material database, chemical composition has
been added. See Metallurgical material option chapter for more details.
Note: These input parameters are necessary for getting hardness values in post
processing.
If metallurgy is activated, then the four

pages corresponding to each phase
fractions (for STEEL) will be filled.
If metallurgy is deactivated, then only the

All phases page will be filled.

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Define initial blank temperature and phase fraction
Once blank material is defined, the user has to define initial temperature and initial
phase fractions of blank. In this primary dialog, some messages will inform the user on
the activated material parameters (strain rate etc)
Initial temperature
is the temperature of the blank when starting the calculation

then after the temperature is calculated by the solver
Initial phase fraction
described the metallurgical status of the blank sheet when

starting the calculation (which will be 100% austenite in most of the case). Then
during the simulation the phase fractions are updated by the solver.
Tools Material
For feasibility, there is no need to use tools with evolutive temperature. Tools having a
constant temperature or a temperature imposed by the user give enough precision for
that purpose. There is no thermal material to define for tools.
Thermal Exchanges
Thermal conditions and exchanges are defined per object through the Thermal Behavior
attribute.
Thermal Behavior for blank
For feasibility, in addition to heat transfer, only the free convection with air for blank
will be taken into account.

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Free Convection with air can be defined. This convection will act on both upper
and lower faces of the blank.
-
587
Reference temperature
is the ambient temperature, typically 20C.
In the Thermal exchanges by contact frame, there will be automatically a list of

all the tools in contact with blank object. If a tool is not in (mechanical) contact
with blank object, then it will not appear in the list because it will be considered
there is no heat transfer between this tool and the blank.
The user has several options available:
Conductivity coefficient:
It can be a constant value, or can be defined as a

function of gap between the blank and the tool. This gap treatment makes the
heat transfer more realistic than a straightforward on/off transfer, as in reality,
heat transfer will build up progressively through radiation and convection as the
gap becomes smaller, resulting in significant heat transfer before physical
contact occurs.
Surface heat transfer coefficient:
Constant or variable, function of gap and/or

function of pressure. The variable surface heat transfer coefficient definition
allows the user to input the gap treatment as above, but also allows the user to

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define a dependence on the contact pressure. This definition allows for the most
accurate definition, with the gap treatment dealing with the variation up to the
point at which there is actual contact. After this point the pressure dependent
treatment will take over.
At feasibility stage, for the final calculation it is advised to define the heat transfer
definition dependent on gap as a constant. For heat transfer dependent on pressure,
there is no influence on CPU time.
Thermal behavior will be defined for each calculation (at the stage level).
Notes :
The unit system is Energy/(Length*Temperature*Time) for the conductivity

coefficient and the Energy/(Area*Temperature*Time) for the surface heat
transfer coefficient
If Surface heat transfer coefficient is not known, the material conductivity

coefficient can be used instead, as an approximation, although less accurate.
It is recommended NOT to define any heat transfer definition between guides

and blank.
Thermal Behavior for tools
There is no convection to define for tools here because they have an imposed
temperature.
describes the temperature of a tool during the calculation. It can

be defined as a single static value or as a curve, to describe the evolution of temperature
with time
Imposed temperature
Typically as an initial approximation, a constant value for the tool temperature is a good
starting point, although one must be consider that the tooling temperature often
increases during the forming process. As a result, using a good approximation of the
temperature evolution at the surface of the tool would be more accurate.

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Notes
Thermal behavior has to be defined for each tool at each stage.
No heat transfer will be defined between tools and spacers
Quenching
A new type of stage, Quenching stage is available when context is hotforming. As most
of the blank nodes are in contact with tools, the blank convection with air should be
deactivated during this phase.
Kinematic Conditions
In Feasibility phase, user has generally no idea yet of the kinematic conditions of the
tools during the quenching and which pressure to apply to the press.
Tools will be supposed as fully locked. And the blank must be free.
Quenching Parameters
For feasibility, it is advised to run the quenching phase in purely thermal mode. No
mechanical effects will be considered, only thermal exchanges will be simulated.
This parameter is accessible through the Quenching parameters attribute under Global
object in quenching stage only.
Notes
Caution: if this attribute is not defined, thermo-mechanical mode will be used by

default.
In case of pure thermal cooling simulation, contact pressure is picked from

previous stamping stage, and will remain constant during this cooling stage,
and be used in the contact heat transfer when dependent on contact pressure.
It is possible to get adaptive mesh coming from the previous stage but it is
however useless to define refinement for blank during the quenching stage.
Therefore, in pure thermal quenching refinement attribute is ignored.
The blank nodes must not be locked because otherwise they will not be
considered in the contact heat transfer.
The progression type for quenching stage is always Time.
In terms of state plots, it is interesting to have a lot of plots for a quenching

stage particularly in order to well check the blank behavior during the cooling.

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CPU Time Optimization

For a good CPU time, it is advised to optimize the data setup by adjusting the following
parameters.
These parameters can be accessed through CPU control attribute of the Global object.
Mechanical Mass Scaling

Mass scaling can
Step Chapter).
be used as in standard forming during holding and stamping (see Time
Velocity correction
Some physical (mechanical or thermal) properties depend on physical variable rates.

But the velocity used in simulation is often faster than the real one, in order to reduce
CPU time. In that case, it may be needed to scale some parameters in order to
counterbalance the speed up and retrieve the real physical rates. This is the aim of the
velocity scale factor.
The current parameters rates corrected by this velocity scale factor in PamStamp are:
-
Strain rate
Heat flux
Temperature rate for metallurgy
Sliding velocity for advanced friction
Real time oriented inputs (mainly for SuperPlastic Forming)
Since heat equations depend on heat flux in case of hotforming simulations, it is then
necessary to define a velocity scale factor.
Velocity scale factor
Global object.
parameter is accessible through the CPU control dialog under

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Example:
If the punch velocity is multiplied by ten in the simulation model with respect to
reality, then the Velocity scale factor = 0.1
In hotforming, user can keep the usual simulation process velocity (e.g. 10m/s
for Stamping stage). But the real process velocity is much lower than in
standard forming, about 0.2m/s which gives a velocity scale factor equal to 0.02.
In pure thermal quenching, the velocity scale factor will not have any effect on
CPU time. Therefore, the value can be kept to 1.
Progression and input curves abscissas can be expressed in simulation time or in real
time.
Note
The thermal analysis time step scale factor is a safety factor used for the thermal
time step. Its value is 0.9 by default. This parameter is located in the Advanced
parameters attribute of the Global object.
Thermal Shell Integration Points
In addition to the mechanical integration points set to

the blank, thermal shell integration points have been
introduced for both blank and tools.
These parameters are defined with default values and are
accessible through Global advanced parameters attribute
under All stages
Since blank is thin compared to tools and for CPU saving,
only 1 integration point through thickness is generally
used for blank (default value) and 5 for surface tools
(default value) in case of thermal tools.
If the tool has an imposed temperature, only 1 thermal
integration point will be taken by solver.

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Process Validation
This type of simulation is usually done at advanced phase for precising the process. It
could be done after a feasibility project. Small changes need to be done and some
parameters to be added.
The workflow for a validation project is the same as feasibility project except that
thermal materials will be applied to tools with evolutive temperature and the quenching
phase could be thermo-mechanical.
Hotforming context
See Feasibility paragraph for details.
Material Properties
Blank Material

In the validation project, the user can also take into account the blank expansion during
the process.
Indeed, when the blank is warmed up, it expands. The blank expansion phenomenon
occurs. And during the quenching phase, when the blank is cooled down, on contrary, a
shrinking phenomenon occurs. This can be simulated within PamStamp by defining one
of the options described below (see details in the Thermal material option chapter).
Two ways are possible:
Expansion coefficient:
It is the mean dilatation coefficient between Tref and current T

values where Tref is the initial temperature in a physical expansion test leading to the
measured strain curve.
Thermal strain:
it is the thermal strain function of temperature th (T , Tref )
Tools Material
At validation stage, in order to be as much accurate as possible, it is recommended to

define an initial temperature on tools which will vary during the process. The change of
temperature on the tool surface is due to contact with hot blank and convection with
inner tool. The temperature inside the tool will be supposed constant. This can be
simulated by applying a thermal material on tools.
Tool surface
Free convection

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The Material attribute is to be defined in allstages for each object tool.
Thermal thickness
corresponds to the thickness through which we assume there

is a gradient of temperature. The default value is 6mm. In the first 6mm
(between the upper and lower fibers), the temperature will vary due to heat
exchange with hot blank and convection with inner tool. Then, below the lower
fiber, the tool temperature will be supposed constant.
Initial temperature
is the temperature of the tool surface when starting the

calculation then the temperature is updated by the solver from the heat exchange
with blank and convection with inner tool.
Some additional thermal properties have to be defined inside this dialog (see details in
Thermal material option chapter.
The material can be loaded from the public material database by pushing the button Get
from material database or created directly in the dialog.
Notes
A tool material created inside the project cannot be uploaded into the database.
If material definition is the same for all the thermal tools, then it is better to use
the copy/paste action.
No thermal material is to be defined for guides, locator pins or spacers since

they will have an imposed temperature.

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Thermal Exchanges
Thermal conditions and exchanges are defined per object through the Thermal Behavior
attribute.
Thermal Behavior for tools
In the validation process, we consider the temperature variation inside the tools. The
tools are modeled by a thermal thick shell.
for tools can be defined. This parameter represents the free

convection with tool volume on lower fiber like described below.
Convection
Tool surface
Tool volume
Free convection
Reference temperature represents
the average temperature inside the tool
volume.
Notes
The reference temperature value has to be modified according the stage type.
For example, in a Stamping stage, the average temperature of the inner tool will
be around 20C (ambient temperature) but in the Quenching stage, the value
will be much higher, around 60 or 80C because the tool is in contact with hot
blank during a longer period.
Tools convection with air is not simulated here because it is negligible

compared to convection with inner tool.
No heat transfer will be defined between tools and spacers.

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Heat convection coefficient estimation for 2D tools cooling system:

The cooling system action is averaged on the lower surface of the 2D tool.
The equivalent heat convection coefficient to be used on the lower tool surface depends
on the physical heat convection coefficient described further in Cooling Channels
Analysis paragraph, but depends also too much on the 3D cooling system geometry
itself.
Thermal Behavior for blank

In a validation phase, the user can take into account some additional variables to obtain
more accurate results.
In addition to the convection and radiation with air (see above paragraph), it is possible
to define an initial dilatation for the hot blank.
-
is purely geometrical. It will offset the initial blank shape

of the user-value (% of blank size). It can be useful to define this parameter if the
user wants to have a more realistic shape of the initial hot blank. Usually the initial
geometry of the blank represents the blank in a cold state. But after heating into the
furnace, the blank kind of enlargens.
Initial dilatation coefficient
Note
Caution: the user should take care of the guides if they are in the model.
Radiation:
Heat flux dissipated by radiation increases very quickly with the

temperature of the heat source, here it is the blank. In Hotstamping, the blank
temperature reaches a sufficiently high value that makes radiation effect much more
important than convection with air. The input value is the emissivity coefficient.
Thermal exchanges by contact:

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Friction dependent on temperature
In v2012, it is now possible to define the friction dependent on temperature. It allows

the user to simulate in a more accurate way the real friction conditions inside the press.
The friction is very much depending on the temperature and is significantly higher at
elevated temperatures. This has been introduced through a lookup table definition
(dependency on pressure, velocity and temperature). See contact and friction chapter.
Quenching Stage
A new type of stage, Quenching stage is available when the context is hotforming. As
most of the blank nodes are in contact with tools, the blank convection and radiation
with air should be deactivated during this phase, because it is included in the contact
heat transfer coefficient as function of gap.
The velocity correction factor must be used in this stage to save CPU time (see details
in CPU Time Optimization paragraph).
Notes
The blank nodes must not be locked because otherwise they will not be
considered in the contact heat transfer.
It is advised to activate the picking of nodes velocities between stamping and

quenching stages.
The progression type for quenching stage is always Time.
In terms of state plots, it is interesting to have a lot of plots for a quenching

stage particularly in order to well check the blank behavior during the cooling.

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Kinematic Conditions
At validation phase, the user should get a rough idea of the kinematic conditions of the
tooling system (pressure etc). Then he can apply the desired conditions on tools; they
will generally be under press force.
Quenching Parameters
At validation phase, the quenching stage can be run in thermo-mechanical mode. Thus,
all the mechanical effects can be taken into account. The add value of simulating
quenching with such analysis type is the taking into account of expansion effect and
contact pressure variation during the process, which can be important.
CPU Time Optimization

Since validation process is more CPU consuming, it is mandatory to optimize the
calculation time by using the parameters below.
Notes
Convection with inner tool simulation implies that the tools mesh must always
be oriented towards the blank.
The tools mesh quality is a major factor in the time consumption. For better
quality results and faster calculation, the mesh of the tools needs to be of good
quality.
If the mesh is bad, the thermal mass scaling for tools should be used. See the
section hereafter.
Mechanical Mass Scaling

Velocity correction

In case of thermo-mechanical quenching, the velocity scale factor can also be used to
accelerate the mechanical part resolution, hence reduce the CPU time. It is not
recommended to exceed 0.001 to avoid too big inertia effects.

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Thermal Shell Integration Points
See the related paragraph described above for more details.

Notes
The default value for surface tools is 5 because this is needed to simulate
temperature variation through thickness in case of thermal thick shell tools. But
the user can set a higher number if needed.
It is possible to increase the number of thermal integration points for blank in

order to get more accurate results through the thickness. However, the
calculation time will be affected.
Thermal Mass Scaling for Tools
Thermal mass scaling has been introduced for hotforming applications only.
Definition
When simulating hotstamping with thermal tools, the tool mesh may not be sufficiently
regular and this can cause two types of problems:
-
Bad thermal accuracy on the non-regular tool mesh zones but could be
acceptable if the bad mesh quality zones area is very small compared to the
tool surface area
Very small time step caused by very small elements on tools
Thermal mass scaling makes it possible to impose a minimum thermal time step. The
purpose of this parameter is to reduce the calculation time by increasing the thermal
time step, which can be very low due to very small elements (usually on tools).
This increase of the thermal time step leads to a reduction of the number of thermal
cycles, hence to a significant reduction of the CPU time, since the latter is proportional
to the number of cycles. To do this, the thermal mass (Rho*Cp) of some elements is
artificially increased, therefore the elements thermal time steps are increased too.
Since thermal mass is scaled, this can cause big accuracy regression on the scaled
zones. These scaled zones area should always be very small compared to the tool
surface area in any case.
Notes
This option is used in case of thermal shell tools as well as thermal volume
tools.
Thermal mass scaling parameter is to be used cautiously.

The higher the temperature rate, the higher the thermal mass scaling impact
on accuracy.
Since Hotstamping cannot be considered as thermally quasi-static, the
thermal mass scaling action should be limited to the very small bad meshed
tools areas only.

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Increasing the thermal mass of the elements also increases the heat
capacitance of these elements. When heat capacitance is increased, the
temperature variation of the element is decreased (due to increased thermal
inertia) and this can lead to erroneous results.
Rules to follow:
-
Thermal time step is the minimum value between the in-plane thermal time step
and the thickness thermal time step. To keep the action of thermal mass scaling
limited to local areas, it should act only on in-plane thermal time step. This is
why it is recommended not to put a too high value, so that it wont act on
thickness thermal time step.
Data Set-up
In the CPU Control attribute of the global object, define the Thermal mass scaling for
tools by activating the Characteristic length toggle and entering the value required
(expressed in the unit of length used during the project). A wizard can help the user to
define a value quite well adapted to the simulation. It is also possible to select the
Automatic mode for computing the thermal mass scaling by selecting a tool. The
calculation will be done automatically when launching the solver respecting the rule
described here after.

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Thermal mass scaling wizard or automatic calculation

The wizard or the automatic mass scaling computes the characteristic length the
following way:
-
First, we consider only the elements of the tools objects selected by the user
All elements with angle more than 40 are ignored (in order to suppress sharp
edges)
The radius Rlim is computed on the selected tools objects so that 0.2% (default
value of surface ratio) of the total surface of the tools is with curvature radius equal
or lower to Rlim
Then, the length for thermal mass scaling is set to 10% of this value Rlim.
Once value is computed, user can display the impacted elements to quickly check the
amount of elements and also the localization of these elements.
The value entered by the user corresponds to a characteristic length of element; the
corresponding element thermal time step is automatically calculated and given to the
solver.
All the elements with a characteristic length smaller than this value will have their mass
increased in order that their element thermal time step corresponds to that of an element
which has a characteristic length equal to the value input by the user.
This increase of mass and modification of element thermal time step is done at the
beginning of the computation.
Here is an example on a B-Pillar case:
Rlim computed on this case is 3.6mm which gives a thermal mass scaling set to 0.36.
When displaying the impacted elements (on the right picture), it clearly shows that the
amount of elements is very low and that they are quite spread.
If we compare now this thermal mass scaling length with the minimal characteristic
length (in this case 0.1mm), it means we could speedup the thermal calculation by a
factor close to 4 without impacting accuracy of results.

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Note
The user can change the proposed value and press the display button to update
the impacted elements.
Cooling Channels Analysis

The target of this process type is the Tooling for anticipating the problems that may
appear.
The goal of cyclic cooling is to simulate the temperature life cycle on tools during the
Hot Stamping of the first few parts for checking that a good steady state is reached
afterwards.
During the Hot Stamping of these first few parts, the tools temperature is not yet
stabilized under the action of cooling system load and contact heat transfer with the hot
blank. The user wants to get through this simulation an idea about the temperature
stabilization time on the tools in steady state.
Tools definition
The cyclic cooling simulation is possible with both 3D tools and 2D thick thermal shell
tools (with a high number of thermal integration points through thickness = 9).
However, since the aim is to have an accurate behavior of the tooling system, it is
advised to simulate the cyclic cooling process by using 3D tools.
Tools
The 3D tool mesh to be used can be relatively coarse and must be rather regular. Since
it can be difficult and CPU consuming, to build a 3D tool mesh sufficiently fine to be
acceptable by mechanical contact treatment, volume thermal tools are limited to only
pure thermal quenching application.
Courtesy of AP&T

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3D mesh of volume tools:

At this stage of the process, we assume that user should have the geometry of the tools.
In most of cases, it will require a first step of CAD cleaning with CAD software where
user will remove the unnecessary parts (keep only tool sections in contact with blank
and cooling channels) and heal the surfaces.
Courtesy of AP&T
After tool simplification, the volume tool can be meshed with Visual Mesh and then
imported inside PamStamp2G. Here are below the main steps for 3D meshing:
Automatic assembly of tool segments
The volume CAD file is

automatically
imported,
and
different volumes are detected,
repaired and assembled.
Sample tool which consists of several segments

Courtesy of AP&T
Automatic generation of the mesh

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Surface mesh is defined and

created first on the tool skin
(usually finer mesh for cooling
channels). Then, the volume mesh
is created automatically as a fully
connected mesh, suitable for
simulation of the cooling channels.
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Volume mesh created with Visual Mesh
For more details on the procedure, refer to Visual mesh documentation.

Cooling Channels
For the cooling channels definition, it is also possible to create them inside Visual Mesh
by using a tool which enables to extract 2D facets from 3D elements. The cooling
channels will then be 2D shells.
To define the cooling channels inside PamStamp2G, there is a new automatic tool
which enables the detection of cooling channels in a 3D model. This is accessible via a
shortcut by right-click on 3D view as shown below: Select cooling channels It brings
the nodes page of the selection by geometry menu. A new type of selection called
cooling channels is available. The default angle for nodes selection is 50.

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When pressing Select button, it will automatically select all border nodes of the cooling
channels in the displayed volume tool object. If the angle value is not suitable enough,
user can modify it and make again an automatic selection. Then, user can add these
nodes to a new object. 2D facets will be created automatically by solver and used for
the thermal exchanges (convection).
Different types of channels can exist, here are some examples:
-
Straight channels:
Curved channels

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Crossing channels
Note: there are some cases where selection tool can be limited like for non-circular
shape (quadrangular).
If cooling behavior (fluid temperature, velocity) is the same as in all the channels,
then only one object containing all these channels must be defined.
If cooling behavior is different, then define as many objects as needed.
Cyclic quenching
Input description
To simplify the simulation, the drawing phase will not be repeated during the cyclic
chain, and the stamping blank temperature results will be used as starting point of the
cyclic simulation. This is because the contact heat transfer effect of the stamping phase
is negligible compared to the quenching phase, where the contact occurs on full blank
during a time duration which is much longer than the stamping time.

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The initial temperature value of blank is applied to the object content at the beginning
of the simulation, but also at each time period, set in the input. If there is picking from
the previous stage, it is the picked temperature which is applied to the object content at
each time period.
The tool temperature is picked at the beginning of the cyclic quenching.
The contact heat transfer will be activated during quenching phase and deactivated
during the blank transfer time.
Note :
In case of pure thermal cyclic cooling simulation, contact pressure is picked

from previous stamping stage, and will remain constant during all the cyclic
simulation, and used in the contact heat transfer when dependent on contact
pressure.

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How to proceed
The setup for such process is quite simple.

Compared to a single quenching stage, the user has to go through the following steps to
define a cyclic quenching stage:
Define a stage of type Quenching
After defining the whole process, the user has to define a last stage which type is
quenching. In this stage, the 3D tools, cooling channels and blank must be activated.
Add a thermal behavior for blank object
Only the thermal exchanges with tools must be defined.

See Thermal behavior section for details.
Add a thermal behavior for each cooling channel object
In case of volume thermal tool, we consider the convection between the channels
surfaces and the cooling fluid as described below:
Thermal behavior is to be defined for each cooling channels object.

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Convection
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with cooling channels surfaces can be defined.
Reference temperature
is (in this case) the temperature of cooling fluid (infinite
temperature).
Note :
The reference temperature should be an average of the in and out value of fluid
temperature e.g. if the in temperature is around 20C and the outer value is
around 30C, the user should put 25C to be closer to reality.
No contact heat transfer will be defined here because this is defined between the
volume tools and the blank.
Heat convection coefficient estimation for 3D tools cooling system:

The heat convection coefficient in cooling system depends on many physical properties
of the cooling system, as follow:
hc=f(d,Cp,k,,um,)
where:
hc is the heat convection coefficient
d is the cooling system diameter
Cp is the heat capacitance of the fluid
k is the conductivity of the fluid
is the density of the fluid
um is the fluid rate
is the fluid viscocity
The dependency function f can be expressed as follow:
hc = Nu . k / d
where Nu is the Nusselt number (adimensioned).
Nu can be expressed in the particular case of cooling of fluid inside the tube in a
turbulent mode as follow:
Nu = 0.023 Re 0.8 Pr 0.33
Where :
Pr = Cp / k is the Prandlt number (adimensioned)
Re = um d / is the Reynolds number (adimensioned)

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Activate the cyclic cooling toggle in the quenching parameters
Quenching duration
corresponds to the time needed for the quenching phase.
Transfer duration
Number of cycles represents
is the time during which the tool is no longer in contact with hot
blank. After quenching, the blank is transferred from the Press to another workshop
whilst the tool is receiving a new flat blank ready to be stamped.
the cycles number (10 cycles by default) needed for the
tool to reach a steady state.

Note :
The cyclic quenching stage can be only purely thermal.
To speed up the CPU time, user can define a thermal mass scaling for volume tools. See
thermal mass scaling for tools paragraph.
A new stop criterion has been added in the Control panel: Cyclic cooling. This toggle
has to be activated in case of cyclic cooling and no other stop criterion must be selected.
For a cyclic cooling simulation, it is recommended to plot several states so that user gets
at least one result file for each end of cycle, plus some in-between states.

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Process Macro
Some predefined macros for hotforming are delivered for each process type. They are
under STAMP/Hotforming directory:
Feasibility:
-
HF_DoubleAction _Feasibility.ksa
HF_SingleAction _Feasibility.ksa
Process Validation:
-
HF_DoubleAction_ Validation.ksa
HF_SingleAction_ Validation.ksa
Cyclic Cooling:
-
CyclicCooling_DoubleAction.ksa
CyclicCooling_SingleAction.ksa
The user can easily create his own macros for such processes (see the Process macro
chapter) so that the above operations are carried out automatically, without any
additional data set-up compared to a standard stamping simulation.
The parameters which have to be added compared to a standard stamping simulation are
the following:
-
Thermal behavior for each object (to be filled according the recommendations listed
above)
Material for tools (if the user considers tools with evolutive temperature)
Volume tools (if the user wants to simulate a cyclic quenching)
Velocity scale factor
Thermal mass scaling (to define only in case of thermal tools during quenching)
Quenching parameters (available only in quenching stage)
Cyclic cooling stop criterion (to activate only in cyclic quenching stage)
Note:
Spacer object has been added in hotforming macros.

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Post Processing
In a hotforming simulation, there are no particular output to activate. Thermal based
calculations will automatically include the necessary data for displaying the postprocessing contours and histories.
Contours
Specific contours are available for thermal computations: Thermic, Cooling rate and
Metallurgy.
Thermic
Once the analysis is performed, the user can check the following thermal contours:
-
Nodal temperature (on
upper/lower fibers and membrane)
This contour shows the nodal temperatures. In case of thermal shell with thermal
integration points > 1 (usually for 2D tools), it is possible to display the temperatures on
the upper fiber (which corresponds to the external surface of the tool) or in the lower
fiber (which corresponds to the inner tool).
-
Thermal flux (vector
= (Energy/surface)/time)
This contour corresponds to the average value on thickness and gauss integration points
of the internal heat flux. This contour is available only for shell elements.
-
Enthalpy (scalar= Energy/Mass)
This contour displays the mean value of enthalpy. This is available only for shell
elements.
Cooling rate
To get the cooling rates contour, the cross temperature must be defined in input. This
parameter is activated by default in thermic frame of advanced parameters attribute in
each stage with a default value of 400C.

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Cooling rate (scalar= Temperature/Time
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on upper/lower fibers and membrane)
This contour will display the instant temperature rate; that is positive if temperature rate
is negative (and vice versa).
-
Critical value (scalar= Temperature/Time)
It corresponds to the "cooling rate at crossing temperature" from the solver.

Note: there can be not valid values (for elements which did not cross the input
temperature 400C for instance).
-
Critical by zone
This contour uses the "cooling rate at crossing temperature" from the solver. In the page
a limit rate which is called minimal cooling rate is asked (default = 25C/s). The zone
with values over the limit is "safe", the zone with values below is "critical".
Note: there can be not valid values (for elements which did not cross the input
temperature 400C for instance).
Cooling rate in a tailored part

Metallurgy
When metallurgy is activated in the project, a specific contour Metallurgy is available as

well in post processing. It lists the four phase fractions (value in membrane) and the
hardness contour (if chemical composition of the material has been defined in input):
-
Austenite phase fraction
Ferrite phase fraction
Bainite phase fraction
Martensite phase fraction
Hardness (scalar=
HV Vickers)

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Hardness value after quenching in a tailored part

For a quick display of these four phase fractions, it can be useful to use the Multiple
contour display option (see the Quick multiple display of contours subsection in the
Analysis Tools chapter).
Upper/lower pressure
This contact pressure is available only in hotforming context. It enables to display

contact pressure on upper or lower fiber. This is especially useful for displaying contact
pressure on thick shell thermal tools.
History
For a hotforming computation, it can be convenient to have additional information in
specific areas to be studied.
A history object can be created that contains some specific elements of the blank or
tools to follow the characteristics of such elements as function of time (heat flux or

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enthalpy for instance, that are automatically generated if a post analyze attribute has
been defined). The same thing can be done for nodes (for nodal temperatures).
The histories which are available are these ones:
Thermic
contains thermal flux and enthalpy histories, which are available only for
shell elements.
Shell thermic
Node Thermic
contains nodal temperature history, which is available only for nodes.
Cooling rate
Cooling rate history can be displayed per node if a node history has been defined. It can
also be displayed in the global object (blank), in this case it will show the object
resultant history curve on minimal or maximal critical cooling rate value. It is also
possible to display the critical value history per node.
Metallurgy
Metallurgy history can be displayed either in the global object (blank), in this case it
will show the object resultant history curve on phase fraction or per shell element if an
element history has been defined.
Hardness history can be displayed per shell element.
Note
Existing real time history output is available for thermal simulations.

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Unit system
Thermal units are available either C or K.
The units need to be consistent in a project. The thermal unit is not very important when
it is consistent. But if radiation is defined, thermal unit is then important; it is used by
the solver to define the absolute zero:
Absolute zero is located at -273.15 C.
The user must take care with units for thermal calculations. Here below is a table
summarizing the various parameters required for thermal calculations according the unit
system:
m.kg.s
mm.kg.ms
mm.t.s
E (Young modulus)
1 Pa=kg/(m.s)
10-9
10-6
Nu (Poisson coefficient)
None
None
None
Expansion Coefficient
1/K
rho (mass density)
1 kg/m3
10-9
10-12
k (conductivity)
1 W/(m.K)=(kg.m)/(s3.K)
10-6
Cp (heat capacitance)
1 J/(kg.K)=m/(s.K)
106
H (enthalpy)
1J/kg= m/s
106
h (heat exchange)
1 W/(m.K)=kg/(s3.K)
10-9
10-3
Notes
The Thermal behavior is not considered during Gravity and Springback stages;
these stages will have an isothermal calculation.
If the user would like to take into account the thermal exchanges which occurred
during gravity, it is possible by creating first a standard gravity and then
followed by a pure thermal quenching stage. The duration of this quenching
stage will be the time needed for gravity and only the thermal exchanges will be
simulated.
Picking of temperature is automatically done between stages.
The use of thermal properties with volume blank is quite limited. The material
properties cannot be temperature-dependent and metallurgy is not available.

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Aluminum warm forming

The formability advantage by heating the material is not only for steel but also for
Aluminum. The formability is increased by elevated temperatures.
In V2012, PamStamp2G offers the possibility to perform simulation of warm forming
aluminum parts including typical phenomena such as strain annealing, friction
dependent on temperature... using the material model Barlats YLD2000-2D model (see
Barlat2000 material law chapter for more information).
Warm formed aluminum parts
Strain annealing:
It is possible to scale the strains on an object when starting a simulation. It is done
through the Values initialization attribute on blank object (see Picking chapter). The
scale factor can be a non-zero value (between 0 and 1).

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FLANGING
Presentation of a Standard Process
The hemming process is widely used to assemble two panels, particularly in the
automotive industry. The external panel is usually folded over the internal panel:
External panel
Internal panel
The hemming is preceded by a flanging step, often performed after the trimming of the
panels to be hemmed. The flanging is usually performed on a die different from that
used in stamping. This makes it possible to compensate for the springback generated by
the flanging.
<0
springback
springback
compression on
flanged edge
The change of tool will then necessitate a holding before flanging.
Case Presentation
The following steps must be modeled for a complete study on the flanging:
-
The trimming of the panel to flange and springback after stamping
The holding of the flanging
The flanging, which simulates the phenomena that occur when the flanging tool
moves down on the outer contour of the blank

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The springback after flanging. It is of course dispensable to calculate the

springback. It will only be calculated if you wish to know the strains generated by
the flanging.
These various steps will be studied later on. It is assumed that the stamping of the panel
has been simulated.
The present subsection provides explanations on the trimming and stresses relaxation of
the panel, flanging (holding, flanging and springback). The pre-flanging holding,
flanging and springback after flanging stages can be grouped in a same project with
the multistage option.
A complete approach of the flanging is thus presented in the following text. All the
steps are described and demonstrate PamStamp 2Gs ability to simulate most of the
phenomena involved during the metal sheet forming.
Trimming of the Outer Panel to be Flanged and Stress

Relaxation
After stamping the panel, it is strongly recommended to let the stresses relax before
introducing them in a new calculation (see springback rules in paragraph Rules to
follow for Autostamp), because the sudden tools removal generates large vibrations
that can damage the quality of the springback., The trimming operation of the panel will
therefore be combined with a stress relaxation calculation.
The panel will be picked in the stamping calculation, then it will be trimmed and a
springback data set-up will be performed. (If the user uses the multistage option, he can
analyze the trimming and the springback of panel independently in the related projects).
Flanging with Multistage Option

The procedure to set up the flanging with the multistage option is the following:
-
Picking of the outer panel in the trimming calculation, the symmetry plane if any
Define the flanging tool in the tool editor by importing the tool or by building it
from a source. It is possible to define the main frame for the holding and the
flanging direction separately.

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Use the process macro-command for the flanging stages description

-
Holding
If the flanging tools are different from the ones used during the stamping stage, a
holding stage comes before the flanging stage. The methodology to be applied is
comparable to that of a standard holding. The few existing differences are detailed
hereafter.
flanging blank holder
flanging die
blank
(external panel)
Flanging
The methodology to be applied is comparable to that of a conventional stamping.
The few existing differences are detailed hereafter.

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Springback
Following the flanging, a deformation of the panel is often noticed, which is caused
by the strains introduced in the flanged edges. This strain is quantified in a
springback calculation.
The methodology to be applied is comparable to that of a conventional springback
using the Boundary conditions on point attribute to fix isostatically the panel in
order to prevent it from moving.
Post-flanging springback
Use of the flanging macro-command

The main part of the flanging setup is done with the flanging macro-command of High
Quality process from the public_macros database.
-
Refinement levels
of the blank and the flange area are defined as automatic.
The other parameters (Flanging velocity, Blank holder force, mass scaling) are
defined as for a standard stamping with springback
Creation of a process macro-command (Stamp Tool Kit)

operations, which generally occur during a standard flanging process.(see the
subsection Complete the user macro database with Stamp Tool Kit)
The process macro-command that the user creates is as following:

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Holding, Flanging and Springback stages
The shape of the flangings tools: flanging_die, flanging_punch,

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The following parameters must be defined:

-
The objects and parameters (velocity, force, die) are defined as in a standard
stamping for double action
The stop criterion of the punch: in Flanging stage, Process page, Global object,
Control attribute, progression attribute, a value different from the default value must
be defined. Pinch test between die and punch is also activated
The refinements of the blank and the flanging area are automatically set.
Determination of refinement zones

The panel mesh along the flanging line has to be very fine. Its final element size should
be a quarter of the sum of the panel thickness and the flanging die fillet radius (see
subsection Rules to follow for Autostamp /Springback calculation).
The adaptive meshing per zones is strongly recommended to prevent generating too
many elements.
On the part of the panel which is not deformed during flanging, define the maximal level
of refinement equal to 1 in order to prevent refinement. On the part of the panel
deformed during flanging, the refinement levels should be high enough so that the final
elements respect the size requirement.

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The zone with higher maximal level of refinement, Blank level max, should be large
enough according to the rules in the subsection Adaptive meshing: The difference
between two neighbor elements cannot exceed 1. Therefore, if the difference between
the respective maximum levels of two neighboring refinement zones exceeds 1,
PamStamp2G will automatically reduce certain maximum levels.
High maximal level zone
(final mesh size imposed by the thickness and the
radius of the flanging die)
Flanging line
separation between
refinement zones
As shown in the following figure, ensure that there is at least one element row on both
sides of the separating line of refinement zones, which has the same initial refinement
level.
Separation between zones
High maximal level zone
3
2
Zone of maximal
level equal to 1
3 3

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ROLL HEMMING
Presentation of the Process
As seen in the flanging chapter, the hemming process is used to anchors two panels,
usually inner panel and outer panel, without welding.
In the Automotive industry, this process is widely used to assemble skin panels with
their inner panels and reinforcements because this process allows to:
-
hide hazardous cut edges
ensure high quality surface of the hemmed panel
The generic term Hemming includes actually several kinds of processes:

-
Die Hemming: This process uses a press as the stamping process but the punch is
replaced by a hemming tool. It needs two steps: pre-hemming and final hemming,
so two presses are needed. Like for stamping process, one tool set is needed per
product (die and hemming tool)

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Tabletop Hemming: This process uses a particular installation on which both prehemming and final hemming will be done. Usually the pre-hemming tool goes
horizontally and the final hemming tool goes vertically. This process implies one
tool set per product (hemming bed and hemming tool)
Robot Roller Hemming (also called Roll Hemming): This process uses a
programmable robot 3 or 5 axes with a roll at its extremity as hemming tool. The
roll will go parallel to the flanging border in order to hem it. Usually two or three
steps are needed in order to hem a part but oppositely to the other hemming process,
the same roll can do all steps. More over, it is possible to change the roll geometry
to have a completely new tool.
Here after, only the roll hemming process will be treated.
Different possible configurations

In the following section, we will see some possibilities and the way to represent them in
PamStamp 2G. We will suppose that only two steps are needed one pre-hemming and
one final hemming step.

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Two robots in 2 steps

In this case one robot with a conical roll (45) will go first to pre-hem the flange border
and then a second robot with a cylindrical roll will hem the flange border.
In PamStamp 2G, this process will be represented by a two stage project in which the
first stage will correspond to the pre-hemming stage with one robot (conical roll). Then
a second stage will take place with a second robot (cylindrical roll).
Return
In this case, the same robot will pre-hem and hem the flange border.
It will go first in one way and then it will go in the opposite way to return to its initial
position. For the first way, the arm of the robot will be rotated of 45 (in case of
cylindrical roll) in order to pre-hem the flange border. And during the second way, the
rotation will be removed in order to hem the flange border.

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In PamStamp 2G, this process will be represented by a mono-stage project in which the
robot will have a rotation angle for the first way and no rotation for the return. The
change of angle will be done when the robot will be at the end point of its trajectory.
Two simultaneous robots

In this case the pre-hemming step and the hemming step are made in the same time. The
pre-hemming robot will be followed by the hemming robot with a delay in order to
avoid any collision. This process is used to reduce the cycle time in production.
In PamStamp 2G this process will be represented by a mono-stage project in which two

robots will follow the same trajectory but with a delay.
Another possibility is to pre-hem (and hem) two flange border in the same time. It
means that one robot will follow a trajectory and in the same time another robot will
follow another trajectory in order to reduce the cycle time in production. Then another
set of roll will do the same for the hemming step.

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In PamStamp 2G this process will be represented by a two stages project in which two
robots will do the pre-hemming in the first stage. Then, two other robots will hem the
two flange borders.
Two linked rolls

In this case, two robots will act in the same time and both robots will be linked together
(using a beam for instance). One of them will move as the master robot, and the other
one will follow as the slave robot.
In PamStamp 2G this process will be represented by a mono-stage project in which both

robots will be linked together using a Multi Body System attribute (see the
corresponding MBS chapter, and the following robot behavior section for further
information)
Special roll shape

In case the roll shape is non conventional (non-cylindrical or non-conical), the user has
the possibility to import a roll geometry as CAD data and to assign it as roll in the
process. See the following robot component section for detailed procedure.
Hemming without inner panel

In this case, no inner panel will be present and the outer panel will be hemmed over
itself.

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In PamStamp 2G this process will be represented by using a special contact type on

outer panel object. The Self-contact will be used here in order to take into account the
folding of the blank over itself. (See Self-contact chapter in the manual)
Attacks and Outputs

In the real process, the robot does not always attack or exit the outer panel along the
same direction. It could be orthogonally to the trajectory or along a specific direction.
Sometimes, the robot can also start on another point than the extremity (to avoid
wrinkles for instance).
With PamStamp 2G it is also possible to simulate different entries and outputs:
-
Orthogonal (1)
Along a direction (2)
Along a part of the path (3)
With a return (4)
Robot modelisation
In the real process, the robot is composed of several parts, which have a fixed geometry,
and all together have a certain behavior. All these features are also integrated into
PamStamp 2G and are the point of the next paragraphs.
Robot components
A robot is composed by a roll, a base and a robot frame. The base, created along the Zaxis of the robot frame, is used to define the robot trajectory.

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In PamStamp 2G, the user can create his own robot using the Robot Builder
.
Two shapes of roll can be chosen: cylindrical roll or conical roll.

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To create a robot, some information is mandatory:

-
the diameter of both extremities of the roll or the diameter of one extremities and
the angle if its a conical roll
the width of the roll
The robot base and the robot frame will be created automatically.
Note:
The robot can be modified afterward (select an existing robot in the name
droplist)
To create a new robot, a new name has to be written in the suffix field. The name
entered in this field will be automatically added to the name of each object.
The option fill sides allows the user to fill both sides of the roll by an
automatic creation of triangle elements. This is useful when the path is made of
small curvature radii and the blank is susceptible to be inside the roll when the
robot goes through these radii
Once the robot is created, the different components are linked together. The user has the
possibility to check this link and eventually to edit it through the attributes tree.
In the all objects section, a robot component attribute is available for the robot
object.
In this dialog, the user can see the currently linked objects with the robot. If the user
changes one of the object (for instance, it is possible to import a new roll geometry and
to assign it here to the robot), the change will be keep for further modification through
the robot builder. It means if the user opens again the robot builder and selects the

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previously edited robot, the new object will appear in the corresponding droplist and its
content will be overwritten if the user creates a new geometry.
Robot behavior
In the real process, the roll is linked to the robot by a mechanism which allows the roll
to move regarding the robot (axial translation and rotation). Moreover a force is applied
on the roll through a spring in order to hem the flange border.
In PamStamp 2G, all these behaviors are available.
Here after the common used modelisations for the robot:
-
Model 1: free rotation of the roll around its axis + friction between roll and outer
panel + free translation of the roll along the robot axis + applied force on the roll.
This model represents what happens on the real robot but it is very complex and CPU
time consuming.
In the graphical interface this will be setup by a MBS attribute on the Base object (all
stages section) and a follower force attribute on the roll object (Hemming stage section).
(See the corresponding MBS and Follower force sections in the manual).

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Model 2: free translation of the roll along the robot axis + applied force on the roll.
This model is a simplification of the first representation. The rotation of the roll around
its own axis is removed and the friction between roll and outer panel is removed also.
This model is less CPU time consuming than the first one but it is still accurate enough
for a good prediction of the reality.

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stages section) and a follower force attribute on the roll object (Hemming stage section).
(See the corresponding MBS and Follower force sections in the manual).

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Model 3: This model can be coupled with the two first models. The translation is
limited to a certain interval.
This model allows the user to get a behavior close to the real process with a limited
displacement of the roll along the arm of the robot (stroke of the springs).
This function is also used to extract the roll at the end of the step.
In the graphical interface this will be setup by activating in addition to the MBS and
follower force attributes the Minimum and Maximum displacement fields in the MBS
attribute.

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Model 4: This model is fully locked.
This model is used to simplify the representation and thus to reduce CPU time. This is
useful to check the feasibility of the process. This configuration allows also the user to
get the force to apply to hem the panel.
stages section). (See the corresponding MBS section in the manual).
Notes
If the rotation of the roll is used, it is advised to use a double precision solver.
To reduce the CPU time, it is advised to choose a Translational link type with a
null friction between the panel and the roll.
In case of two linked rolls, the MBS attribute should be defined on the leading base
object. In this MBS, two links will be defined. The first one will link the leading roll to

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the base (as defined in a single robot stage, translational type for instance). The second
one will link the leaded roll with the leading roll. This link can be of type translational
but in any case it should be defined in the leaded robot frame to respect the real
movement.
Then, a third link can be eventually defined between the leading base and the leaded
base in order to get a consistent graphical behavior (the leaded base will follow the
leading base displacement). If this link is defined, it should be defined as lock type to
avoid any relative movement between both base objects.
Note:
The user has to position manually the leaded robot regarding the leading robot
in order to respect the real process. This positioning can be done using the
translation and rotation transformations available in GUI (transformation to do
in leading robot frame).
In the stages attributes, the user has to define a kinematic path attribute on the leading
base and then the corresponding follower force on both rolls in the corresponding
frame.
Regarding the autopositioning attribute, both robots have to be selected in the same
attribute.
Notes:
The user has to take care the path is long enough to allow the second roll to go
until the end of the process.
It is not possible to activate/deactivate a robot temporarily (in small radii areas

for instance)

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Robot Trajectory
The path
The path is the trajectory followed by the robot during the roll hemming process plus
the angle of the robot along this trajectory.
Construction of the path

To build the path, the user will use a 3D curve to define the trajectory. He will define
then a starting point and an ending point plus some intermediate points. Finally the user
will define on these points the angle of the robot.
Path discretization
The construction of the path is based on a 3D curve (see 3D curve) on which the user
defines at least the first point and the last point. Between these points (steps), the
program will compute a discretization according to the parameters set by the user in the
dedicated section.
-
Two ways of discretization are proposed in the dialog:
1. by points: the user set the number of points which will be created between the
minimum curvilinear abscissa en the maximum curvilinear abscissa (can be
different from first and last point)
2. by chordal error: the user set a maximal value for chordal error to drive the
discretization of the curve
However, it is possible to combine these two methods.

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If the user wants to edit the discretizations points, he has the possibility to convert the
discretization into steps with the dedicated function in Operations tab.
Each step is located on the curve via its curvilinear abscissa so the curve should be an
open curve.

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Notes:
A number of 2 points for the discretization is the minimum value. It means

actually, no points except the first and last step (discretization by point not used)
A 0 value as chordal error means that the discretization will be done only by
point (chordal error is not used)
Roll angles
To complete the path, the user has to set the angles defining the orientation of the roller
regarding the path for each step. These angles and are defined in the Frenet frame
(e1, e2, e3):
-
e1: vector tangent to the path
e2: vector normal to the path, tangent to the reference surface (usually inner panel or
hemming bed)
e3: vector normal to e1e2 plane
: rotation around e3 axis (used to avoid wrinkle in complex area)
: rotation around e1 axis (forming angle, usually 45 for pre-hemming stage and 0
for hemming stage)

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All these vectors are automatically computed by PamStamp 2G but if needed, the user
can define them manually (or edit the computed vectors).
Between 2 steps, the angles for each discretization points are computed by interpolating
the values at both steps at solver launch.
Other possibilities
The user can display steps only (step path) or steps and discretization (exact path) in the
3D view. He can also display the computed e1 and e2 vectors (e1/e2) or the vectors
which will be used by the robot ( and angles applied) (robot direction)/

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Notes:
The vector e2 should be pointing outward the reference surface. If it is not the
case, it is possible to reverse them by pushing the button
It is also possible to reverse the vector e3 by pushing the button

represents the direction of the base object.
. This vector
It is possible for the user to change the order of steps using the dedicated buttons
and
. The user can also set the new step ID through the contextual menu.
As indicated in the previous Attacks and Output section, the robot can start at a different
point than the extremity of the curve. This could be useful to avoid wrinkle for instance.
In this case, the user will define a first point with a different curvilinear abscissa than 0
and then set a second step at curvilinear abscissa 0 and then set the other points.
In the same way, the user can make a return by defining 4 points and a discretization.

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Another possibility could be to have a 3D curve all around the part and there is only one
small area to hem. In this case, the user can start and finish with curvilinear abscissas
different from 0 and 1.
From an existing path, the user can copy it to create a new path. All the defined steps
and the discretization will be copied to the new path.

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Distance from Path

Once the path is defined and the robot geometry is fixed. The last parameter to check is
the position of the robot regarding the path. This positioning will influence directly the
hemming radius and the shape of the hemming profile.
In PamStamp 2G, this positioning is done via two values given in the robot builder:
-
the distance between the path and the roll parallel to the roll profile
the distance between the path and the roll perpendicular to the roll profile
Note:
The distance parallel to roll profile will pact the hemming shape whereas the
distance perpendicular to roll profile will impact the hemmed thickness.

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Attack and Exit

Attack
In order to follow as close as possible the real process, the user can choose the way the
robot attacks the outer panel. This will be done by a special autopositioning mesh
transformation roll hemming positioning. This special transformation will do the
following operations:
-
Position the robot along the path
Autoposition the robot onto the no freeze outer panel along the direction given by
user (can be orthogonal or user defined)
The robot positioning adds automatically an extension to the path to put the roll on the
top of the flanged part.

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robot positioned onto the outer panel
Exit
Still in order to be as close as possible to the real process, the user has the possibility to
drive the robot out of the blank after the hemming.
In the kinematic path attribute, the user can activate the complete path on exit option.
Once it is activated, the user has to set the distance and the direction of the drive out.
The direction can be either orthogonal or user-defined.
The complete path on exit option adds automatically an extension to the path after the
end point.
Positioning the robot on the path

Once the robot and the path are defined, the user must position the robot at the
beginning of the path. This action is available through the robot positioning dialog.

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The user chooses the robot to position and the path which will be used to position the
robot on.
With the help of the Position on Path function, the user will position the robot on the
first step of the path, with respect to the orientation given by e1 and e2 vectors and and
angles.
In the next frame (Re-position elements of the robot) the user can refit the roll on the
base object (if a new geometry of the roll has been imported for instance). He can also
reverse the roll (used for a conical roll for instance). The last possibility is to refit the
robot frame on the base object (used if a transformation has been applied on the robot
translation or rotation for instance).
Position of the robot

on the first step of
the path
Position of the robot

when it has been
created
Advice
In case of 2 simultaneous robots on the same flange border, the user will have to copy
the first path into a new one even if the Frenet vector are identical (roll geometry
defining the pre-hemming or hemming angle). In case of the user uses only one path for
several robots, the initial positioning of the robot can not be ensured because of the
potential difference between their respective positioning regarding the path (see section
Distance from path).

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In case the same robot will hem several flanges border, it is advised to not use the same
robot on several paths because of the initial positioning of the robot on path. Between
two paths, the robot will keep its orientation. It means the next hemming will not be
done with the expected angles. To avoid this problem, it is advised to copy the robot
geometry into a new robot through the robot builder.
What kind of simulation depending on the project phase?

The roll hemming computation can be done either in the early phase of the project
(anticipation of the roll hemming deployment) or in an advanced phase of the tool
development. In a simulation point of view, it means that the roll hemming computation
can be done from the CAD definition of the flanged outer panel or from the result of the
flanging computation (full chain computation for instance).
TIME
PART
PROCESS DESIGN
DESIGN
PART
CAD
STAMPING PROCESS
DESIGN &
VALIDATION
ROLL HEMMING
FEASIBILITY
ROLL HEMMING
SIMULATION
ROLL
HEMMING
VALIDATION
Feasibility computation
As the feasibility check is done in an early phase of the project, only CAD data is
available so the starting point of any feasibility simulation is a meshed design part.
Starting from CAD data

Here after is the methodology to apply for a hemming feasibility simulation.
Note:
The following paragraphs are only recommendations; taking into account that
the simulation of the roll hemming process is still under development, the
advices given here might not be optimized in all cases.
The objective of the meshing step is to have a mesh respecting the blank meshing rules
in the working area (see corresponding paragraph in the users guide), and to have a
rough mesh in the non working area of the part during hemming processes. This
strategy will help to save CPU time during computation.

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Outer panel
The meshing of the outer panel will be done in several steps:

1. CAD import (advanced mode)
The import of the CAD geometry can be done in one time but the user has to pay
attention to import and join only. No mesh should be created at this step.
To do so, the option import CAD part available in 3D shortcuts will create a new
DeltaMESH module and open directly the advanced import dialog in which the user
will select the cad file to import.
2. Preparation of the CAD

Once all the surfaces are imported and joined, the user has to create some sub-objects in
order to apply different meshing strategies regarding the concerned areas.
-
radius:
Select all the patches corresponding to the radius which will be hemmed during the
process and add them to a new object (do not remove them from the initial object).
flanges:
Select all patches corresponding to the flanges to hem during the process and add
them to a new object (do not remove them from the initial object).
other patches:
Select all other patches (patches non-affected by the hemming) and add them to a
new object (do not remove them from the initial object).
Now the meshing module should contain at least the following objects.

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3. Meshing
The meshing can now be done with a special strategy for each zone.
In the Advanced Deltamesh Import menu, select only Meshing action and in the
mesh page, deselect Apply to all objects.
Set for each object the corresponding meshing parameters

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Radius object :
o Uniform mesh
o No Quad surface detection
o No Nodes only
o No Chordal error
o No Angle criteria
o Minimum size = 0.1 (Default)
o Maximum size = must respect the
rules of blank element size versus
the radius, ie 0.25 (Rmin + 0.5 th)
Note:
The activation of quad surface detection

depends on the quality of the definition of
the surfaces (orientation of isoparametrics)
Flanges object :
o Progressive mesh
o Progressive ratio = 1.2
o Quad surface detection activated
o No Nodes only
o No Chordal error
o No Angle criteria
o Minimum size = 0.1 (Default)
Maximum size = 2x maximum size from

radius object

Note:

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Other patches object:

o Progressive mesh
o Progression ratio: 3
o No Quad surface detection
o No Nodes only
o Chordal error = 1
o Angle criteria = 45
o Minimum size: 0.1 (default)
o Maximum size: 100
Note:

The value used for the chordal error

depends on the geometry
The value used for the angle criteria

The value used for the maximum size


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Once the outer panel is fully meshed, it can be transferred to the setup module.
In the transfer dialog, it can be interesting to define the name and the group of the
object. If the name and the group are defined during the transfer, then the chaining will
be easier during the setup. More over in case of iteration on the same model, the mesh
will be replaced in the setup module without further manipulation from the user.
Note:
It can be useful to define a transition area between radius and other

patches in order to better represent the real process.
To do so, a CAD splitting algorithm has been implemented in DeltaMESH

module

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It is possible to select/create an object in which the newly created surfaces will be put
(additionally to the initial object). The previous surfaces will be removed from the
initial object and replaced by the new ones.
The meshing strategy in this area should be the same than for the flanges object.
Inner panel
After the import of the outer panel, the user has to import the inner panel. As the inner
panel wont be deformed during process, the user can mesh the inner panel with a
predefined strategy (validation strategy for instance).
Kinematic check
When is this used?
The feasibility allows the user to check if the path is correctly defined, if the data setup
corresponds to the users idea of the real process. This computation is useful because
due to the size of elements, the computation of the hemming process might take some
time.
The feasibility computation, also called kinematic check, will take into account only the
kinematic of the robot. No contact will be defined or computed.

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Setup
To sum up, the feasibility data setup is as follows:

-
Freeze the inner and the outer panels.
Use lock as MBS between base and roll objects
Use a velocity of 20 m/s or more
Stop the computation with kinematic path criterion
Use a double precision solver
As the only purpose of this simulation is to check the precision of the path, no contact
will be defined between roll and panels in order to reduce CPU time. Starting from that
point, the panels should be frozen in order they do not move during the computation.
As the robot will not be in contact with the panels, the roll should be locked regarding
the base and no force should be defined on the roll. This will reduce again CPU time.
As no deformation will be induced on the objects of the project, the velocity value will
have no impact on the result quality so it is advised to set a velocity value at least equal
to 20m/s. Next to that point, the interval of writing states should be small enough in
order to catch the detailed displacement of the robot along the path.
The minimal time step is not driven by the mass scaling as there is no contact during the
computation. A new option has been implemented: Automatic or Roll Hemming.
When the setup is finished, the user can start the computation using a single precision
solver.

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Roll Hemming simulation on design part

When is this used?
When the path is correctly defined, the next step is to check the hemming process. If the
stamping process is still not validated, it could be interesting to start anyway the design
of the hemming process starting from the design part to save time during process
development.
Setup
To sum up, the feasibility data setup is as follow:

To sum up, the feasibility data setup is as follow:
-
Use dynamic freeze
Use lock as MBS between base and roll objects
Use a velocity of 10 m/s
Stop the computation with kinematic path criterion
Use a double precision solver
In order to save CPU time, all areas far from the hemmed border should be frozen,
assuming the fact that nothing happens if the distance to the hemmed border is big
enough. It will reduce the number of elements on which the contact will be computed.
This will be done with the Dynamic freeze attribute.
This attribute is used to freeze the whole model, except in a bowl of a given radius and
centered on a selected node (usually the centre of the roll). Several dynamic freeze
attributes can be set simultaneously in case of several robots per stage. The main
advantage is that the non frozen area will follow the robot.
In case of dynamic freeze attribute and if there is only one robot moving in the stage, it
could be more efficient to use SMP solver than a DMP solver (the other cores will just
be waiting for the end of the process).

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At this process development, the force to apply is not necessary known so it can be
interesting to lock the roll regarding the base. Then it will be possible to get the force
needed to hem the outer panel through history curves. Another advantage of this
modelisation is the reduction of CPU time.
As the mesh size is very small for Hemming computation, the mass scaling should be
checked carefully in order to not take into account the element which will be frozen
When the setup is finished, start the computation using a double precision solver.
Roll-Hemming simulation
Starting from a flanging computation
If the process is more in an advanced development phase of the process, it is possible to
start the computation after a flanging simulation.
The user can either gather all the process in one *.pre file (multi-operation setup) or
create a special *.pre file for the hemming stage. If a special setup is done, the user will
follow this procedure:
Outer panel
The user has to import the outer panel by picking from the *.end.res of the flanging
stage (see Picking section of the manual). The user can also import the inner panel from
the corresponding project by the same way.

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Note:
It is possible to mix the import method, importing from CAD data the inner
panel and from a computed flanging stage the outer panel for instance.
When is this used?

The hemming simulation is used after the feasibility checks. It corresponds to real
process simulation. During this computation, the roll will be in contact with the panels
and the flanges will be hemmed.
Due to the length of the process in time, the computation takes much more CPU time
than a standard stamping computation.
To sum up, the roll-hemming data setup is as follow:
-
Use dynamic freeze.
Use translational MBS between base and roll objects
Apply a follower force on the roll object
Use a velocity of 10 m/s
In order to save CPU time, all areas far from the hemmed border should be frozen,
assuming the fact that nothing happens if the distance to the hemmed border is big
enough. It will reduce the number of elements on which the contact will be computed.
The robot will be modelised with a translation degree of freedom between roll and base
(translational MBS). In order to avoid any unrealistic movement of the roll, the
minimum and maximum displacement will be also activated in MBS dialog.
Because the roll has a free translation along the axis of the base, a follower force has to
be applied in order to hem the panel.
As the mesh size is very small for Hemming computation, the mass scaling should
checked carefully in order to not take into account the element which will be frozen
When the setup is finished, start the computation using a single precision solver.

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Optimize CPU time

It is possible to improve the data setup in order to reduce the CPU time following the
next points.
Refinement
If the panels were imported by picking a restart file, the elements are already refined to
a level sufficient for flanging. It is not necessary to refine more the panel for the
hemming so it is advised to put a refinement maximum equal to the same value than for
the flanging.
Regarding the inner panel, it is advised to set a value of maximal refinement equal to 1
in order to avoid any useless refinement.
MBS
In the hemming simulation, the user can choose between several MBS types:
translational (friction roll-panel = 0) and translational + rotational (friction roll-panel
0) should be the more used.
In order to save CPU time we recommend using only the translational type of MBS.
Multi-robots
Still in order to save CPU time, it is possible to use several robots in one stage. Either
several border in one stage, or a pre-hemming robot followed by a hemming robot in the
same stage (the second robot will have a velocity as curve with a null value at the
beginning), or a combination of both methods.
DMP solver with double precision

It is recommended to use a DMP solver with a manual decomposition (see
DISTRIBUTED MEMORY PROCESS [DMP] section for further details). The manual
decomposition must be done so there is only one robot per core.
The user should avoid that one core compute only frozen elements. If it happens, this
core will compute for nothing, it will just wait for the other cores; therefore not efficient
and the decomposition could be improved.
It is recommended to use double precision solver, because the number of solver cycles
in roll hemming is usually higher than 1 000 000, there can therefore be some stability
issues with single precision..

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Output
In terms of output, it is interesting to have a lot of plot for a kinematic check in order to
well check the feasibility.
In the opposite way, for the hemming simulation, it can be useful to limit the number of
plot (especially if the files are not written locally) to reduce the elapsed time.
More over as the process can be very long, it is advised to limit also the number of
history (variable and interval) and the number of cycle print (especially for all DMP
computations)
Mass scaling
We recommend checking the scope of this parameter. The user should focus on the
elements belonging to the radius only because even if there are some elements in the
flanges or in the frozen area which are impacted by the mass scaling, the result will be
ok compared to the saved CPU time by the limitation of the minimal time step.
Macro
Two macros concerning the feasibility and the roll hemming are available. Pam Stamp
2G disposes of special tools for the creation of roll hemming macro.
Roll Hemming in Stamp Toolkit

The macro enables the user to simulate automatically several successive operations,
which generally occur during the roll hemming (see the subsection Complete the user
macro database with Stamp Tool Kit).
The process macro-command that the user should create is:
-
A stamping stage,
Two blanks,
A hemming bed,
A robot (create a robot will automatically create also the roll and the base body).
A path as free tool
The following parameters must be defined:

-
Concerning the robot:
On the base body: rigid body, kinematic path (velocity and exit distance),
multibody system (MBS type, minimal and maximal displacement) dynamic
freeze
On the roll object: rigid body, follower force, and contact with outer panel (no
freeze area)

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Concerning the panels:
:Refinement (1 for inner blank), contact between inner and outer panels
Concerning the hemming bed: rigid body, cartesian kinematics, contact with outer
panel
Process:
Mesh transformation: robot positioning (along the path, on the outer panel)
Start/stop: progression as time, stop by kinematic path
Output: it depends on the aim of the macro (feasibility or hemming)
Mass scaling or time step depending on the aim of the macro (feasibility or
hemming)
Postprocess
Once the analysis is performed, it can be interesting for the user to check the following :
-
the general shape of the hemmed panels (wrinkles, cracks),
the sequence of the process using the animation creator,
the stresses and the thickness using contour menu,
the pre-hemming and hemming angles using sections and the angle analysis
the roll-in and the length of the hemmed border using sections and distance analysis

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the hemming thickness using sections and the distance analysis,
In hemming feasibility it is possible to get the force to apply on the robot to hem the
panel. This history output has to be activated before the computation in history
settings and a node history attribute has to be set on the node located at the center of
the roll. Then the force is available through history curve. The force can be
expressed in the robot frame.

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Xi-
Another history curve which can be interesting to check is the displacement of the
roll in the robot frame. This history output has to be activated before the
computation in history settings and a node history attribute has to be set on the node
located at the center of the roll.

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HEMMING
-
It is possible to simulate hemming process in Pam-Stamp 2G.For the meshing and

import of CAD, the same rules applies as for Roll hemming (see Roll hemming
chapter). The difference to roll hemming is that user has to use project type
Autostamp. The rules for set-up of hemming process are the same like for any other
Autostamp project (see Autostamp chapter).

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CONTROL TABLE
Presentation of process on Control Table
A control table is a device designed for a quality inspection of sheet metal pressed
components. Such checking fixture consists of several clamps in given locating systems
which hold the workpiece in a particular position enabling to check complex surface of
a part.
In a quality control process the stamped part is fixed between clamps on the Control
table, which is called clamping.
It is possible to simulate clamping process using PS2G and the whole quality control
process on Control table.
Complete study of a quality control process on a Control table involves several steps:
-
Springback1 of a blank on lower clamps/tool just after forming
Clamping process of the blank between lower and upper clamps
Springback2 of the blank between lower and upper clamps
Springback 1
Clamping

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In simulation in Pam-Stamp 2G, each step is represented by asingle stage Springback1, Clamping and Springback2.
It is assumed that a forming of the panel follows rules for High quality simulation in
chapters creation of the tools, blank meshing and process set-up.
A complete approach of the Control table is thus presented in the following text. All the
steps are described and demonstrate PamStamp 2Gs ability to simulate most of the
phenomena involved during the metal sheet forming.
Springback of a blank on lower clamps/tool just after forming

After sheet metal forming, it is strongly recommended to let the stresses relax before
introducing them in a new calculation, because the sudden tools removal generates
large vibrations that can decrease the quality of the springback and therefore the shape
of the part.
A trimming operation of the panel can be a part of this step.
Clamping process of the blank between lower and upper clamps

After the first step, a relaxed blank lays on lower clamps/tool. In a following clamping
process all upper clamps fully close a blank against lower clamps/tool which fix the part
for final shape control.
On a control table there are usually several pairs of clamps, there can be dozens of them
and during the clamping process each upper clamp travels different distance to its close
position, dependent on particular blank shape in appropriate locations.

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Springback of the blank between lower and upper clamps

After the clamping process, as well as after forming process, it is strongly
recommended to let the stresses relax again to receive the proper shape of the part
required for final control of the component.
Control table process setup

The blank must be picked from the last forming calculation and setup of control table
process performed. A multistage setup can be used, of course, springback on lower
clamps/tools follows just after the last forming operations then.

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For simulation purposes a macro for Control table process simulation is provided with
Pam-Stamp 2G installation - Clamping_full_process. The three mentioned stages with
four pairs of clamps are available in the macro. The macro can be customized in Stamp
toolkit according to user needs, eg. number of pairs of clamps can be changed
depending on the particular control table.
Springback1
For springback with contact it is convenient to use advanced implicit solver which
enables an involvement of the contact. A gravity option must be used in this kind of
simulation.
In springback with contact simulation no blank locking is set because the blank position
is clearly determined by lower clamps/tool. The user should be sure the blank does not
slide down of clamps/tool.
Lower clamps/tool are fixed.
It may happen a blank is not refined in areas of clamps. For proper initial springback
simulation, to assure proper contact condition between clamps/tool and blank, it is
necessary to maximally refine the blank in these locations : to do this, a help stage in
explicit with local initial refinement only preceding Springback1 stage should be used.
This help stage with refinement is not a part of the provided macro.

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Clamping
In clamping process, lower clamps/tool are fixed and upper clamps move in appropriate
coordinate system frame.
In Pam Stamp 2G it is possible to simulate closing of all upper clamps in a single stage
by using a Stop on a last pinch option. In clamping stage, pinch test is defined for each
pair of clamps and Stop on last pinch option enabled. Whenever a pinch test is activated
between a pair of clamps during a simulation run, corresponding clamp movement is
stopped, however, simulation continues until all pinch tests are activated. Simulation is
finished as soon as all pinch tests are activated.
Springback2
From the setup point of view, the final springback stage is the same as for initial
springback on lower clamps/tool, upper clamps are active too.
All clamps/tool are fixed.
Evaluation of part quality on Control table

In the control table simulation, there are no particular outputs to activate.
Reference geometry can be imported and a distance of the clamped blank to this
geometry can be measured, which gives the information about the part shape quality.

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Advanced possibilities for Control table process simulation

An Advanced contact is available for use in both Springback stages. It has been
optimized for higher accuracy and lower CPU time. Some rules described in Friction
and contact chapter must be followed.
A Small sliding contact is available for use in both Springback stages, especially in
Springback2 stage, where blank slides tightly between 2 closed clamps. Only small
sliding of blank between tools is allowed. Some rules described in chapter Friction and
contact must be followed.
Note
Small sliding contact is at protype level.

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DIE COMPENSATION AND MULTI-OP

Purpose
PAM-STAMP 2G includes a Die Compensation and a Multi-OP module in the
Optimization window.
The first function, the Die compensation, provides an automatic method of correcting a
die shape in order to compensate for the effects of springback. The module is a closed
loop system, which recalculates the forming and springback with the new geometry,
makes a comparison with the reference or target geometry, and continues to iterate until
the objective is reached.
The module, integrated in the Graphical User Interface follows the industrial
methodology developed by Renault and Arcelor.
Several options allow to obtain a good quality of the die and to control aspect of the
shape during the compensation.
The second function, the Multi-OP, allows to create some tools during a full chain
process on which one operation has been compensated or in order to take into account
the springback from one OP to another one. Several functionalities have been
implemented for answering different process types:
-
Create compensated tools for OP30.
Adapt the tools of a previous operation. The aim is to get a more suitable final
blank before the next operation when this next operation has been compensated.
Transfer any springback field to a next or previous operation.
The button
in the data setup window allows the user to access to the Optimization
menu. Note that user can also access to it through the Process/Optimization menu. The
user can select the Die compensation function in the Optimization type drop list. To use
the function, the user should progress through each tab page at a time, entering required
information.

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The general workflow of the module is as follows:

Master setup
Export new die
Gravity
New iteration.pre
Holding
New tools
creation
Stamping
Deformation of
gravity die with
linear solver
Trimming
Blank iteration 0
= Target shape
Shape
control
option
Difference x (-1)
compensation
factor
Springback
Comparison
part after spbk/
target shape
Not OK
Difference
OK
Stop
The initial simulation with the springback stage corresponds to the iteration 0.

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Initial set-up (iteration 0)

The starting point for any Die compensation simulation is a successful springback
calculation, and of course it is recommended that the forming stage has some degree of
safety or formability margin, to allow for the fact that the compensation will change the
die shape, and this will inevitably have an influence on the forming of the part.
To compensate die after springback, it is necessary to do High quality simulation (see
Simulation methodology for High quality Stamping sections). The creation of the tools,
the blank meshing and the process set-up must follow all the rules defined in the
previous chapters. It is particularly important:
-
To use accurate contact
To respect blank mesh size.
There is no problem using already defined set-up parameters like the velocity (5m/s)
or the mass scaling.
Tools definition
There are several pre-requisites on tools meshes to provide correct Die compensation
results.
Mesh strategy
As for any high quality simulation, it is necessary to have a very good tool mesh, fine
enough to be sure that springback simulation is good. The radii in the critical area of the
tools must be correctly filleted with a maximal 7,5 between elements. Moreover the
tool mesh discretization must be fine enough since it will be used to modify the die
shape.
If the die mesh is not fine enough, in a wall or in the blank holder area for example, it
must be changed. The user should go in the master project, import Tools CAD selecting
the Compensation / Mesh strategy, and during the transfer replace the die by the new
one. Then the tool builder must be applied again. The first simulation (iteration 0) must
be run again.
Toolbuilder
The toolbuilder must be used for the definition of the tools, since the new tools creation
will be done by applying the toolbuilder. If it has been done manually for the initial
simulation, the user only has to fulfill and save the toolbuilder in the master set-up of
the initial simulation.
Punch side
For tools created with CAD from Punch side, a new toolbuilder must be saved with the
definition from Die side in the master setup.

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Setup attributes
Positioning
All the positioning of the tools or the blank must be defined using the Mesh
transformation attribute. It allows the definition of autopositionning, translation or
rotation. In that way, it is certain that the blank and the new tools, created from the
deformed die, are automatically positioned correctly in each iteration set-up. These
attributes can be added in the master setup and in the iteration setup (gravity, holding or
stamping) after the initial simulation, if it did not change the simulation.
If the iterations simulations are not done from the beginning but from an intermediate
stage like holding, Mesh transformation/autopositioning attribute for the blank and tool
must be added in the stage from which the user wants to iterate.
Stop criterion
In the control attribute, the stop criteria must be pinch test; avoid problems of stroke
modification in the successive iterations.
Needed for simulation

The following files are needed to start the die compensation simulation, where gn is
the generic name of the initial project. It is a project with four stages, gravity, holding,
stamping, springback and that the iteration is done from holding stage.
-
gn.pre: the master setup file is used to have the information about all the existing
stages of the process.

-
gn_01_gravity.i.rst: it is needed to start holding iteration simulation.
gn_02_holding.pre: it is used to create the new iteration file, to create the new
tools and to extract the first die to compensate.
gn_03_stamping.end.res: it is used to know the final position of the die.
gn_04_springback.pre: it is used to define die compensation setup.
gn_04_springback.1.res: the target shape comes from this file.
gn_04_springback.end.res: it is used to compensate the first die.
The best is anyway to keep all gn_i_stage.pre, gn_i_stage.1.res,

gn_i_stage.end.res and gn_i_stage.i.rst files.
Note:
It is possible to ask die compensation to reduce the amount of disk space used
for each iteration , using the Files management/Minimize the number of files
in the Run page. Only the .pre, .1.res, .end.res will be kept, only one restart file
will be stored.

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Parameters for optimization

Loop definition
If the blank holder modifications are important it is not possible to iterate from
stamping only, the iterations must be done from gravity or holding stages. The default
stage is the first stage of the iteration 0 project.
Definition of objects
The user must choose which object is the Target, and which object is the Die to
compensate. This is to tell the module which object it should modify the geometry of
(this is always the die) and which object it should measure the springback of (the blank)
and compare with the reference, which is automatically the blank shape BEFORE the
initial springback but after trimming. This information is automatically fulfilled by the
graphical interface.
Parameters for Die deformation

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Compensation factor
This defines the factor applied to compensated displacements. The default is 1. In some
cases it may be preferable for the user to reduce the value to avoid the generation of an
undercut die. If the automatic mode is active the coefficient remains the same for all the
iterations.
Undercut correction
This option gives the user the possibility to limit the die compensation in order to avoid
the creation of undercut geometry. It is not activated by default, because it will require
additional CPU usage, and should therefore be activated by the user in situations where
he thinks that the springback magnitude may give rise to undercut. In certain situations
where the user thinks that undercuts are unlikely but maybe marginal, then it may be
better to use a lower compensation coefficient, without the undercut correction.
However the safest way is to activate the undercut correction with the compensation
factor of 1.
If there are some undercuts in initial die shape, the undercut correction will not correct
them, so the user should make sure that there is no undercut in initial die shape. The Die
compensation algorithm has a pre-set limit value of 89.9 the user must therefore check
that this value is respected in the initial die.
Best fit (blank displacements)

In addition to the springback effect, the blank can have a rigid body motion and then it
is advised to apply the best fit (blank displacements) option so that it is repositioned on
to the blank shape before springback.
The objective is not to change the positioning of the tool but the springback
displacement field should be independent of the locking points.
It is advised to put the best fit option with isostatic locking points.
By default the best fit is activated.

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Die modification options

In the Options page, some options exist either to control the quality of the shape or
constrain some areas which are working during the simulation.

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Tool quality control
It is possible to control the modifications of the die either by limiting oscillations

(smooth tool surface) or limiting compensation (avoid compensation on blank holder
surface for example).
Three options are available:
-
Free:
In a free area (defined by one object contained in the die) the displacement of nodes
will not be driven by the compensation.
-
Sample of nodes
A sample of nodes collects nodes homogeneously on a given object. The collected

nodes will get an imposed displacement (they will catch the compensation; other
nodes will be set free). The default value is 20%. It corresponds to the ratio of nodes
with imposed displacement (one out of 5).
A preview of the kept nodes can be visualized by clicking on the
-
button
Stiffness factor
For areas containing free nodes, a specific stiffness can be defined to obtain a die
mesh more or less smooth. The value is a factor; when it is greater than 1, the area
stiffness is greater than default stiffness, leading to smoother mesh (aim: limit the
oscillations in the free areas).

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The user defines the objects on the die area he wants to control and selects the option
free or sample on it. He can apply stiffness on this selection. The user is able to choose
several areas on the die.
Note:
The object used for sample options must be created in the iteration setup (gravity,
holding or stamping). It is advised to do the same in master setup for data
consistency.
Working surface control
It is possible to include additional constraints for the die modification to protect given
parts of the original die shape.
This may be useful for a number of reasons. In some cases the user may wish to
compensate the die without modifying the blank holder area, or some other specific
feature, this is particularly useful when using the module to compensate an existing
physical die without needing to produce a new blank holder casting. It should be noted
that too much constraint may mean that it is impossible to completely correct the
springback.
The user defines a corresponding object on the die area he wants to protect and selects it
in the Locked object drop list. He defines the locking conditions on it.
Each object can have an associated transition. It is also possible to define a Transition
object. The area can be set through an object or automatically by giving a distance. By
default, the distance is 50mm. The mesh will remain free and will not be compensated.

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Note:
The object and/or coordinate system used for locking must be created in the
iteration setup (gravity, holding or stamping). It is advised to do the same in master
setup for data consistency.
The Lock die free edges mode is independent of the Locked object option. It allows the
locking of the nodes on the free edges of the die. This condition overwrites the
conditions set in the Locked object option.
Iteration set-up options
Update drawbeads
This option forces the program to update the geometry of any drawbeads (3D curves),
to conform to the modified die shape. By default it is set to on.
Update trim lines

This option forces the program to update the geometry of any trimming curves, to
conform to the modified die shape. By default it is set to on. This option is important
to avoid any problems of poor projection of the trim lines in cases where the die is
modified significantly and creates a large distance between trimming curves and die.

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Problematic nodes exclusion

The Thickness tolerance (in the Definition page) is used during die deformation for
excluding information coming from problematic blank nodes. Only nodes within
tolerance are used. When the distance between blank at the end of stamping and die is
greater than 0.5*thickness*(1+ tolerance/100), the node will be considered as too far
(wrinkle) and when it is lower than 0.5*thickness*(1- tolerance/100), the node will be
considered as penetrating.
Default
The default value is 0.3 (30%)
Export die
This option enables to export the mesh of the modified die in each iteration. The user
can choose different formats for the export of the modified die mesh (ANSYS, ASCII,
IDEAS, NASTRAN, STL ascii, STL binary).
Note
In the User-defined button, it is possible to activate an option for projecting a

list of curves on the deformed dies and to export them. These curves can be used
by external program for building the CAD of the new deformed die. The user
must enter the following line: crvmapping = <filename>. In place of
<filename> the user inputs the name of grid file.
Positioning
At the end of the stamping phase the blank must be at the same position between the
iterations, so that the Boundary Conditions for springback are well applied and the
calculation of the distance between the blank after springback and the target is correct.

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For that purpose the tools are positioned at the beginning of each iteration:
-
The fixed tools (die in double action and punch in single action) determine the blank
position at the end of the stamping. They should be carefully positioned.
Initial positionings of other tools (not fixed) are important for the process and are
managed by the Mesh transformation attribute (autopositionning and translation).
Fixed tools positioning
This option sets the tools automatic repositioning. The transformed tools initial position
is computed using the reference point.
The reference point is projected on the tools and the tools are positioned so that this
point is the same between iterations.
The reference points can be automatically defined using the locking conditions for
springback or taking as reference the blank node with minimum displacement value.
It can also be defined by the user, selecting Reference set by user and defining a 3D
point on the fixed tool.
It is useful for locked tools in the recomputed stage without automatic positioning. for
example:
The blankholder in gravity stage of single action process
The die in double action process
After compensation of the die by the linear solver, the tool editor is applied and then the
repositioning is done by measuring the distance between the reference point and the
tool.
Notes:
Fixed tool repositioning is activated by default. To de-activate it, the user has to use
the following command line in the User-defined button with 0 as value : repos =
0
If the reference point is defined by the user it should be selected in an area with
little springback.
Blank repositioning
If the blank has rigid body movements during springback it can be repositioned
automatically using the following command line in the User-defined button:
remove_rb = 1.
This option is available if best fit is not active and is automatically activated if there is
no locking condition.
It is a former best fit used by default. It is not the same method as the best fit available
in the definition page. This transformation is based on the minimization of average
rotations around main axis.

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Single action
The blank holder initial position is defined by the mesh transformation/translation

attribute in the initial setup. This can lead to problems if the blank holder curvature is
highly modified by the compensation. In that case the process should be adapted by the
user to the new die; it can not be done automatically since it depends on the know-how
of the user. The proposed solution moves the blank holder always from the same
distance (defined by the user), that was not satisfactory in some cases.
Convergence parameters
The Automatic mode manages automatically the iterations and stops them using the
following target criteria:
-
Maximal number of iterations:
This is the maximum number of iterations the user

wants to allow. If the target is achieved the calculation will stop iterating, but the
maximum is used just in the case where the target is not achieved. The default for
maximum is 8 iterations; this is normally more than sufficient. A typical
compensation project (with default target and range) will usually stop after three to
six iterations.

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Proportion below max. distance: This is the percentage of the blank sheet which
must be within the Maximal distance in order for the compensation to be considered
finished. The default is 95% which is a reasonable target, this means that if 95% of
the blank surface is within 1mm or less, the calculation will automatically stop. It
may be modified as required, but using a value of 100% may well result in
additional iterations.
Note:
If the stamp computation is run remotely (the solver cannot be started from the GUI
on the local machine), the automatic mode does not prevent the job from starting
(remote start). See Running the die compensation paragraph.
Running the die compensation

The information for starting the die compensation functionality is gathered in the Run
page here after.
The user can either:

o Run Stamp solver: This is the default. If this option is selected, the solver
automatically starts after the modification is applied.
o Write preprocess only: If this option is selected, the solver is not started. The
algorithm will only generate the preprocess file for the stamp solver. The user might
use this option if the solver is to be run on a remote computation server or if he just
needs the compensated die.

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o Post-process only: If this option is selected, the application will post-process the
results of the stamping computation. This option must be used when the
computation could not be launched by the compensation algorithm.
The user is required to give the inputs to tell the module which existing calculation is
the springback stage, and which stage of the forming calculation the solver should restart from (recomputed from). The choice of this stage is important for CPU use, but
will be only valid in certain conditions. For example if the user chooses to run from
Forming stage only (missing out gravity & holding) then this would only be valid if the
blankholder source object is locked in the Options page. If the blankholder source is not
locked, then the user must start the loop from the holding stage (or gravity).
Hosts
The user can define the solver hosts to be used during the compensation run. This gives
great flexibility and allows the user to make the best use of the available hardware
resources, for example using different computers, and different solver executables as
required. A host is a definition of machine and solver executable. For each host, the
working directory can also be set, which simplifies the file management.
The definition needs to be done for the die compensation and each stage involved in the
compensation run:
Iteration manager:
the Iteration manager allows to manage the compensation loop.

It is launched by the Optimizer.bat or optimizer.sh file. It defines the machine on
which the user wants to run the Die compensation routines, generally (but not
necessarily) this would be the machine on which the user runs the graphical user
interface. The solver which must be defined is the Optimizer.bat or optimizer.sh.
Linear solver:
Stages:
Gravity:
Holding and Stamping:
Springback:
the linear solver task is the die compensation program, running

independently of the GUI. It will create the compensated die. A host can be created
or a similar host can be chosen. SMP/DP solver is mandatory. The solver launcher
should be pointed on the LinearSolver.bat.
for each stage, the user has to define the host and the work directory which
will be used for each stage.
it is the host (machine and solver) and the work directory which will be
used for the gravity stage. SMP/DP solver is advised.
it is the host (machine and solver) and the work directory
which will be used for the holding and for the stamping stages. Generally (but not
necessarily) the SP solver will be used, this can be a multiprocessor machine (if the
user has such hardware and corresponding license), and it may be defined as SMP
or DMP run.
it is the host (machine and solver) and the work directory which will be
used for the springback stage. SMP/DP solver is advised, and the machine must
have enough memory for implicit springback simulation.

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Notes:
When opening the Run page, the tasks/stages are all listed in red text in the
central panel, once the solver host for a given task is defined, the text changes to
black to indicate that the information is entered already.
If no host is listed or if the requested host needs to be modified, the user can
create and/or configure a host with the standard Host dialog box, opened with
the Hosts dedicated button.
Start
Once the entries on each tab have been set, the user can Start the compensation run. The
process runs on each stage, on whichever solver hosts were defined. Iterations are
created and analyzed by optimizer. Each iteration has a complete set of files; the user
should take care to ensure that enough disk space is available for the entire run.
The user can also choose to create the input only.
At this state, an input file <projectname>.opt_inp is automatically written by GUI.
Console
Compensation progress can be monitored in Console page.
- Results overview: Quick summary of results.
Red=error
Orange=not successful yet
Green=successful

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- Current state: Optimizer running state (current task)

- Iteration i: Statistics for each iteration, coloured iteration is the best one
- Progress: detailed log
Files
Files managment
Some parameters for files management can be defined:
-
Minimize the number of solver files: Output parameters in iterations projects can
be changed to avoid saving non necessary files (non final state files, more than one
restart file)
Created by compensation
The following files are created during the die compensation simulation, where gn is
the generic name of the initial project. Files are listed for iteration 0 & 1 only; the same
files are created for each subsequent iteration:
-
gn_iteration0_outifo.results: ASCII file used internally
gn_LinearAnalysis.xxx: New project file created and deleted automatically
gn_iteration1_01_gravity.xxx: New project file created automatically
gn_iteration1_0i_stage.xxx: New project file created automatically
gn_iteration1_04_springback.xxx: New project file created automatically
gn_iteration1_die.nas: Nastran format mesh file of the modified die
gn_iteration1_outifo.results: ASCII file used by optimizer and GUI for
contour display
-
gn_outifo.history: history file of compensation
gn.opt_inp: ASCII input file for die compensation
gn_iteration1.opt_inp: ASCII input file for each die compensation iteration
gn_outifo.lis: Internal output file of linear solver
gn_opt.out: Die compensation output file

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Restart Optimization
Restart capability is implemented. The user can restart from any iteration after having
modified (if necessary) some parameters in this iteration. This is interesting for example
to reduce compensation factor. When the user wants start a compensation loop, he has
the choice to begin at his computed iteration and from the beginning or from where it
was stopped.
Post-Processing
Dedicated post processing tools are provided for assessing the Die compensation.
The post processing is provided in two ways; contours, and history curves. Contours are
useful to interrogate a specific iteration, whereas curves allow viewing the evolution of
a particular variable through the iterations.
Contours
To access the Die Compensation contour results, the user must first load the reference
(initial) springback result. From here, the user can interrogate directly the results of any
iteration of the compensation run.

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The post processing contours provided are:

-
Signed distance to reference model
This is the distance of the blank after springback (of the chosen iteration) from the
reference (target shape), shown as positive / negative values. The sign is with
respect to the mesh orientation of the blank.
-
Distance to reference model
This is the distance of the blank after springback (of the chosen iteration) from the
reference (target shape), in absolute terms. All values will be positive regardless of
the direction of the springback.
-
Springback magnitude
This is the magnitude of springback (of the chosen iteration). The magnitude will
not necessarily decrease from iteration to iteration.
-
Undercut angles on Die
This contour shows the die with undercut by angle.

-
Die elements in undercut
This contour identifies which elements of the die are in undercut.

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Die compensation history

The Die compensation history window is gathered in the Analysis page here after:
History curves
In Analysis menu, the user chooses the curves to create. Once generated, the curves are
opened automatically in the standard curve editor window.
The following history curves are provided:
-
Maximal distance to reference
The maximum value of distance to the reference object, one point plotted for each
iteration.
-
Average distance to reference
The average value of distance to the reference object, one point plotted for each
iteration.
-
Blank surface ratio within range
The ratio of the total blank surface area which is within the target range. The range is
specified in the menu, so a number of different ranges can be checked easily.
-
Maximal springback magnitude
The maximum value of springback magnitude, one point plotted for each iteration.

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Multi-OP Process
Purpose
There are 4 tools which have been implemented in the Multi-OP page. There are useful
for the user which has a full chain process to optimize.
The button
in the data setup window allows the user to access to the Optimization
menu. Note that user can also access to it through the Process/Optimization menu. The
user can select the Die compensation function in the Optimization type drop list. To use
the Multi-OP function, he should open the corresponding tab page and fill in the required
information.
1. In the simulation the OP20 and OP30 have been merged. The trimming action
has been included into the springback stage of OP20. The gravity and the
holding stages in the OP30 have no impact on the final blank. It is considered as
an elastic phenomenon. If in OP30 the tools re-open before trimming, the blank
gets back to its initial shape.
With the compensate trimming die option, the user is able to create the die for
the OP30 by removing the effect of the trimming action.

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The general process for the Compensate trimming die in the Multi-OP page is as
follow:
Real process
Simulation
Gravity
Gravity
Holding
Holding
Forming
Forming
Multi-OP
Compensate trimming die
OP20
Springback
Gravity
Springback
Holding
OP30
Trimming
Trimming
Springback
Springback
Select tool
to deform
Extract diff
before/after
trimming
Deformation of
the selected tool
with the diff
Export of the
deformed tool
2. The user can compensate the operation he wants, OP20/30 or OP40 or OP50
by modifying the die, the process can be blocked because the blank coming from
previous operations does not fit at the start of next operation. The goal of the
adapt next die and the adapt previous die options is to avoid this issue.
The general process for the Adapt previous die and the Adapt next die in the
Multi-OP page is as follow:
Multi-OP
Adapt previous die
Adapt previous die
Gravity
Holding
OP20-30
Transfer the
compensation onto
the previous tools
Gravity
Trimming
Holding
OP20-30
Springback
Forming
Holding
Trimming
OP40
Springback
Restriking
Compensate
the die OP40
Holding
Best
OP40
OP50
Springback
Holding
OP50
Restriking
Compensate
the die OP40
Best
OP40
Springback
Holding
OP40
Forming
Flanging
Springback
Flanging
Transfer the
springback field onto
the next tools
Springback
Adapt next die
Multi-OP
Adapt next die

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3. With the compensate die from multi-op springback option, the final springback
can be transferred to a previous operation. In some cases it is useful to take into
account the final springback very soon in the process in order to avoid
consuming time at each operation with a lot of iterations.
The general process for the compensate die from multi-op springback in the
Multi-OP page is as follow:
Gravity
Holding
OP20-30
Forming
Trimming
Compensate
the new die
(with final
spbk)
Springback
Holding
OP40
Restriking
Springback
Holding
OP50
Flanging
Springback
Transfer the final

springback onto a
previous tool
Compensate die from

multi-op springback
1
Multi-OP
Compensate die from
multi-op springback
Files
Created by Multi-OP
The following files are created during the multi op simulation, where gn is the generic
name of the initial project:
-
gn.opt_inp: ASCII input file for multi-op simulation
gn_Multi-Op.log: MultiOP log file

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Needed files
For the compensate trimming die option, it is necessary to keep the files from the
die compensation loop and especially the springback files from the best iteration. A
springback stage will be run without trimming from this iteration.
It is advised to keep all the files.
Note:
Due to the computation of the springback stage without trimming, it is necessary

to define the hosts in the Run page.
The user has to define the Run page with the host for all stages and save it by
clicking on Input Only.
How to proceed
1. Compensate the OP20-30 with the die compensation

2. Select the best iteration of the compensation loop
3. Fill in the Multi-OP page with:
o The selected iteration
o The tool to deform
The die OP30 can be different than the die OP20 like in reality.
The die to deform should be placed into the project.
o The name of the new tool

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4. Apply
o The springback from the selected iteration runs without trimming.
o The difference of the two springbacks (with and without trimming) is
transferred in the new die OP30. If some nodes are free, an interpolation
will be done by the solver.
Adapt previous die
Needed files
For the adapt previous die option, it is necessary to keep the files from the die
compensation loop and especially the res files from the springback stage from
the best iteration. The previous OP main pre file is also useful.
How to proceed
1. Compensate the OP with the die compensation (not the first OP of the process)
2. Select the best iteration of the compensation loop
o The selected iteration
o The previous OP project
If the user compensates the OP40, the previous stage is the OP20-30.
The file to select is the pre file of this stage.
o The die to modify
o The name of the new project

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4. Apply
o The compensation of the selected iteration is transferred to the die to
modify in the previous stage. A new project will be created with the new
project name.
Adapt next die
Needed files
For the adapt next die option, it is necessary to keep the files from the previous
springback stage and especially the res files. The next OP main pre file is also
useful to transfer the springback field in the next die.
It is not necessary to run a compensation loop for this process.
How to proceed:
1. Compute the project until the OP to adapt (i.e: OP20-30).

2. Open the pre file to adapt (OP40).
o The previous springback (from OP20-30)
o The die to modify
4. Apply
o The springback field from the previous stage (OP20-30) will be
transferred on the die of the next stage (Die OP40). A new project will
be created with the new project name.

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Compensate die from multi op springback
Needed files
For the compensate die from multi-op springback option, it is necessary to keep
the files from the final springback stage to transfer and especially the res files.
The pre file to modify is also necessary.
How to proceed
1. Compute the full project.

2. Open the pre file of the OP to modify.
o The final springback to transfer
o The die to modify
4. Apply
o The springback field from the final stage will be transferred on the die of
the stage to modify. A new project will be created with the new project
name.
5. There are two different processes to follow:
o Run the new project and transfer the springback field after each OP with
the adapt next tool option.
o It is possible to compensate the first OP of this new project and transfer
the springback field on the next OP.

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BLANK AND TRIMMING LINE OPTIMIZATION

Purpose
PAM-STAMP 2G includes an Optimization module. 2 types of Optimizations are
available:
-
Blank optimization which will optimize the initial blank line
Trimming line optimization which will optimize the trimming curve(s) in

intermediate stage.
This function provides an automatic method of modifying the blank contour or

trimming curves (resp. blank optimization or trimming line optimization) in order that
final blank matches the target geometry.
The module is a closed loop system, which recalculates the process with the new blank
contour (blank optimization) or new trimming curves (trimming line optimization),
makes a comparison with the target geometry, and continues to iterate until the
objective is reached.
The Optimization function is integrated in the Graphical User Interface and can be
accessed through the Process/Optimization menu. Like for die compensation, to use the
function, the user should progress through each tab page at a time, entering required
information.
This optimization tool works with multi-stage simulations and is independent on the
solver; it works with AUTOSTAMP as well as QUIKSTAMP PLUS.

Blank and Trimming Line Optimization
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The general workflow of the module Blank Optimization is as follows:
Master setup
Import Target
New iteration input
Stage 1
Stage 2
Stage i
New blank mesh creation
Stage n-1
Modification of initial blank
contour with Optimizer
Stage n
Comparison
Result / Target
OK
STOP
The initial simulation will correspond to iteration 0.

Not OK
Difference
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The general workflow of the module Trimming Line Optimization is as follows:

Master setup
Stage 1
Stage 2
Import Target
New iteration input
Stage i
Stage n-1
Modification of trimming
curves with Optimizer
Stage n
Comparison
Result / Target
Not OK
Difference
OK
STOP
The initial simulation will correspond to iteration 0.
Initial set-up (iteration 0)

The starting point for any Optimization simulation is a successful process computation
for the initial simulation. It has to be run as usual (no use of optimization tool).
The case must be robust enough. Otherwise, it does not make sense to run an
optimization. It should not contain any cracks or big wrinkles in order to have a good
feasibility result.
Note:
Blank draw-in inside the die entry line: the distance will be a straight distance.
This could lead to small mistake if the blank draws completely inside the die.

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Distance calculation
To do a Blank contour optimization, it is mandatory to create the blank meshing from

an outline through the blank editor. Indeed, the optimizer will use the blank meshing
parameters to rebuild the new blank mesh.
Notes:
The automatic meshing option is not compatible with optimization.
The project must not have objects containing part of the blank mesh (for
instance, nodes objects with kinematics condition or element objects with
refinement attributes). These objects can not be automatically fulfilled during
the iterations.
Blank/trim line optimization is also fully compatible with tailor welded blanks
To do a Trimming line optimization, the only pre-requisite is that all the optimized
curves must be gathered in a single object as it can manage multiple trimming lines.
This single object is just a container for optimization setup so trimming operations
during calculation can still be defined in Global object attributes with curves spread in
several other objects.
The Optimization input must be done in the first stage involved in the optimization
loop. It is then possible to create some objects if needed. This project will be the
reference when new iterations will be built.
This reference project must contain the initial outlines that will be optimized and the
target (mid-skin of CAD model).
Files needed for Optimization input

The following files are needed to start the optimization simulation, where gn is the
generic name of the initial project. It is a project with several stages and the iteration is
done from stage i.
-
gn_i-1_stagei-1.rst: it is needed to restart iteration simulation
gn_i_stagei.pre: it is used to create the new iteration file and to create the new
blank mesh or the new trimming curve(s). The optimization input will be defined in
this stage and the target object must be imported in this stage. Note that for initial

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blank contour optimization, the first stage of the loop will be always the first stage
of the project.
-
gn_n_finalestage.end.res: it is used to extract the compared object
The best is anyway to keep the master pre file and all gn_x_stage.pre,
gn_x_stage.1.res, gn_x_stage.end.res and gn_x_stage.rst files.
Parameters for Optimization

Loop definition
The user is required to give the Stages which have to be included in the optimization
loop. For blank optimization, the optimization process will start from the first to the last
stage of the project. For trimming line optimization, the optimization process will start
from an intermediate stage where the trimming curves are active (trimming stage for
instance) to the last stage of the project.
Comparison results / target

Objects selection
The user must choose which object is the Target, which object is to be used for
comparison with target (Compare target with) and which Object to modify after
comparison.

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Target:
the target object can be directly imported from this dialog or by the standard
import function and then selected in the drop list. The target can be an outline or a
mesh; if it is a mesh, the outline will be automatically detected. Once the target
object is selected, the outlines of this object will be displayed in the 3D view.
If there are two target curves and only one trimming curve, merging should be used.
For merging is necessary to pick points, in order like on the picture. On each curve
have to be defined the start, end and center points of the merging zones. After the
picking of last point, the message to verify ignored bands definition has to be
confirmed.
Notes:
Targets can be also merged in 3D curves editor.
The target should be well positioned and offseted of half of the thickness (if
needed) to be in the middle-plane.

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Object to modify after comparison:
in this field, the object containing the initial

outlines to modify according to comparison with target must be selected; the object
to modify can be the blank (blank contour) or trimming curve(s) depending on the
optimization type. Once this object is selected, the outlines will be displayed in the
3D view.
Compare target with: in this field, the object Blank is selected; its final outline will
be compared to the target object at each iteration. Once this object is selected, the
outlines will be displayed in the 3D view.
Expansion factor
As for Die compensation, this coefficient defines the factor by which the compensation
will be applied. The default is 1. That means the distance between final outlines and
target will be compensated with factor 1 on the initial outlines. In some cases it may be
preferable for the user to reduce the value to avoid the generation of non-smooth
outlines. If the automatic mode (on the iterations table) is active, the coefficient remains
the same for all the iterations.
Advanced
This button opens a dialog where Sampling length parameter (in mm) can be defined.

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Sampling length is the distance between two neighboring curve points (see details in the
picture in Preview chapter). When this option is not filled, the solver uses automatic
value (it is recommended).
Ignored bands definiton
The user can define ignored bands, which are areas of target curves to ignore during
modification/comparison. This is necessary for the optimization of blank contour with
for example progressive die. Some interactive tools are available to add or remove
ignored areas. An ignored area is defined by picking 3 positions: 1st and 3rd are the
border of the ignored area and the 2nd point is inside (see pictures below). The outline
will become red in the 3D view and will not be modified during optimization run.
Optimization by stretching or positioning
Compared to the previous versions, guidelines are not used. It is necessary to link
each triplet of the 3d curves only (Target/Modified/Compared) by stretching or
positioning.
Preview
Once all the parameters have been set, the user can use the Preview option before
starting the computation. It allows interactive visualization of the first optimized
contour including points, modification of the set-up in order to achieve an optimized
shape and it also allows error tracking. This option is very helpful as it enables to have a
quick overview of the outline smoothness and trend.

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For Sampling length see Advanced chapter.
Optimization convergence
The Automatic mode manages automatically the iterations and stops them by using the
following convergence criteria:
-
Maximal number of iterations:
This is the maximum number of iterations the user

wants to allow. If the target is achieved the calculation will stop iterating, but the
maximum is used just in the case where the target is not achieved. The default for
maximum is 8 iterations; this is normally more than sufficient.
Proportion below max. distance: This is the percentage of the blank outline which
must be within the max. distance in order for the optimization to be considered
finished. The default is 95% which is a reasonable target, this means that
optimization will be stopped when distance between target and at least 95% of final
outlines points is lower than 0.7mm. It may be modified as required, but using a
value of 100% may well result in additional iterations.

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Two types of distances are available.

-
3D distance
Projected distance
Optimization will add or remove material on initial blank by stretching outer outline so
effect on distance between final outline and target is in final outline plane only. In some
cases, it can happen that tools do not keep the final blank on the target plane until the
final state; therefore the target outline might not be in final outline plane so optimization
will never be able to fully compensate the real 3D distance separating them. So
projected distance option allows specifying that the distance that must be considered is
the projection of real 3D distance on final outline plane.
Final state
OP40_die
OP40_pad
Direction of
optimization effect
Target

Blank
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Running the Optimization

The information for starting the optimization functionality is gathered in the Run page
here after.
The user can either:

o Run Stamp solver: This is the default. If this option is selected, the solver
automatically starts after the modification is applied.
o Write preprocess only: If this option is selected, the solver will not start. The
algorithm will only generate the preprocess file for the stamp solver. The user
might use this option if the solver is to be run on a remote computation server or
if he just needs the modified outline.
o Post-process only: If this option is selected, the application will post-process the
results of the computation. This option must be used when the computation
could not be launched by the compensation algorithm.
Hosts
The user can define the solver hosts to be used during the optimization run. This gives
great flexibility and allows the user to make the best use of the available hardware
resources, for example using different computers, and different solver executables as
required. A host is a definition of Machine and solver executable. For each host, a
specific working directory can also be set if the project directory path is different on this
host, otherwise the working directory does not have to be defined

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The definition needs to be done for the optimizer and each stage involved in the optimization
run:
Optimizer
task is the optimizer program, running independently of the GUI. It is

launched by the diecompensation.bat file.
Stages:
for each stage, the user has to define the host and optionally the work
directory which will be used for each stage.
Notes:
When opening the Run page, the tasks/stages are all listed in red text in the
central panel, once the solver host for a given task is defined, the text changes to
black to indicate that the information is entered already.
If no host is listed or if the requested host needs to be modified, the user can
create and/or configure a host with the standard Host dialog box, opened with
the Hosts dedicated button.
Start
Once the entries on each tab have been set, the user can Start the optimization run. The
process runs on each stage, on whichever solver hosts were defined. Iterations are
created and analyzed by optimizer. Each iteration has a complete set of files; the user
should take care to ensure that enough disk space is available for the entire run.
The user can also choose to create the input only.
At this state, an input file <projectname>.opt_inp is automatically written by GUI.
Console
Optimization progress can be monitored in the Console page.

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Results overview: Quick summary of results.
Red=error
Orange=not successful yet
Green=successful
Current state: Optimizer running state (current task)
Iteration i: Statistics for each iteration, coloured iteration is the best one
Progress: detailed log
Files
Files management
Some parameters for files management can be defined in the Run page:
-
Minimize the number of solver files: Output parameters in iterations projects can
be changed to avoid saving unnecessary files (non final state files, more than one
restart file)

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Created by optimization
The following files are created during the optimization run, where gn is the generic
name of the initial project.
-
gn.opt_inp: input text file containing optimization parameters
gn.opt_res: binary file containing internal data and results as 1D elements. Can
be imported in PS2G as standard mesh file
gn.opt_out: output text (XML) file containing optimization log, results for each
iteration and summary
the following files are listed for iteration 1 only; the same files are created for each
subsequent iteration:
-
gn_iteration1.opt_inp: input text file containing optimization parameters for

iteration 1
gn_iteration1_i_stagei.xxx: New project files created automatically
Restart Optimization
Restart capability is implemented. The user can restart from any iteration after having
modified (if necessary) some parameters in this iteration. This is interesting for example
to reduce compensation factor or to correct the position of guidelines on result contour
(these guidelines are repositioned by the algorithm but it's sometimes very tricky).
Because of the way it is designed, optimization setup is not dependent on the iteration
loaded on screen, the user can do setup of iteration 3 in iteration 0 project. That is why
an iteration selector list has been added in the dialog that allows switching between
iterations from initial project for instance. Useful for restart of course but also for quick
checking of optimization result (one can see target and final blank contours for selected
iteration).

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Post-Processing
Dedicated post processing tools are provided for assessing the Optimization in the
Analysis page.
The post processing is provided in three ways; contours, history curves and optimized
outlines. Contours are useful to interrogate a specific iteration, whereas curves allow
viewing the evolution of a particular variable through the iterations.
History
The history curves are accessed through the Analysis tab
In this drop list, the user chooses the curves to create. Once generated by the Plot
button, the curves are opened automatically in the standard curve plotter window.

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The following history curves are provided:

-
Proportion below maximal 3D distance (or projected distance)
The percentage of the blank outline which is within the user distance (between
target object and final blank outline), one point plotted for each iteration.
-
Average 3D distance (or projected distance)
The average value of distance to the reference object, one point plotted for each
iteration
-
Maximal 3D distance (or projected distance)
The maximal value of distance to the reference object, one point plotted for each
iteration
-
Minimal 3D distance (or projected distance)
The minimal value of distance to the reference object, one point plotted for each
iteration
Contours
The Optimization contour results are accessed through the Analysis tab inside
Optimization dialog:

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Or through the Contours page of Analysis dockable bar:
The post-processing contours provided are:

-
3D distance to target
This is the 3D distance of the final blank outline (of the chosen iteration) from the
reference outline (target object), in absolute terms. All values will be positive
regardless of the direction of the optimization.
-
Projected distance to target
This is the projected distance of the final blank outline (of the chosen iteration) from
the reference outline (target object), in absolute terms. All values will be positive
regardless of the direction of the optimization.

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Optimized outlines
The user can import the optimized outlines from each iteration.

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Comparison between final blank and target outlines:
Before Optimization
After Optimization

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SPRINGBACK MEASUREMENT
Set-up
To analyze springback it is important to do High quality simulation (see dedicated
section). The creation of the tools, blank meshing and process set-up must follow all
the rules defined in the High Quality simulation chapters. It is particularly important to:
-
use accurate contact
respect blank mesh size.
have a very good tool mesh.
use a correct velocity (5m/s with delay)
respect mass scaling rules.
Boundary conditions for removing body motion

For measuring springback it is necessary to remove any rigid body motion to be sure
that only springback phenomenon will be analyzed.
Three different ways to setup boundary conditions for the simulation are available:
Manual selection of boundary conditions on points
When doing implicit springback it is necessary to lock the model during the simulation.
This can be done by putting nodes of the blank in objects and defining Cartesian

Springback Measurement
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attribute on them. The difficulty is when springback setup is defined from

the beginning (before stamping), that the user does not know where the nodes will be
located after stamping. By setting Boundary conditions on points attribute on blank, the
user will defined position (usually selected on die to see the final part shape) and locks
conditions. Before starting the springback simulation PamStamp 2G will find the nodes
closest to the defined positions and apply lock on them.
kinematics
The selection of points and the applied locking must be done carefully as described in
the Locking definition paragraph.
Note
It is advised not to use Boundary conditions on points attribute when doing an

explicit springback simulation. Explicit springback simulation must be done
without any locking.
Post-processing
In post-processing it is possible to display the nodes selected to apply the locking, using
the show/Locked nodes functionality.
Isostatic locking

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The user can let PamStamp 2G find the nodes and apply on them Cartesian kinematics
conditions for locking the model in an isostatic way.
Node selection
Node 3
The nodes selection is done based on the three

relatively distances between nodes on the edge.
A global box containing all the nodes is taken
into account, and a global direction is defined
based on the maximal boxs dimension
(Lmax). This global direction defines the nodes
1 and 2. Node 3 is defined so that the distance
between node1-node3 and node2-node3 is
maximal.
Node 2
t
Lmax
Z
Node 1
Cartesian kinematics definition
t
Node 3
A local frame is defined:

-
The 1st vector (r)is node1-node2
The 2nd vector (t) is normal to the plane

node1-node2-node3
The last vector (s) is so that the frame (r,s,t)

is right hand normalized base.
The Cartesian kinematics in the local frame

(r,s,t) are:
-
Node 1: locked in translation in r, s, t.
Node 2: locked in translation in s and t
Node 3: locked in translation t
t
Node 2
t
r
Lmax
Z
Node 1
Symmetry planes are taken into account in the node selection and Cartesian kinematics
definition.
Post-processing
In post-processing it is possible to display the nodes and the frame defined

automatically by the solver.

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Note
It is advised not to use Automatic Boundary conditions on points attribute, when

doing an explicit springback simulation. Explicit springback simulation must be
done without any locking.
Automatic rigid body removal
In this situation PamStamp 2G will automatically compute the rigid body movement
during the implicit computation and remove this rigid body from the global movement
of the model.
Locking definition
Here are advises to correctly lock the model in an isostatic way:
-
The part should not be constraint during the simulation, all deformation must be
possible.
The nodes must be selected in the area with few springback not to be sensitive to the
location of these nodes
For a good convergence of implicit springback it is advised to put the locking nodes
far from each other.
It is easier to understand the locking when it is done along the frame, especially
because the Cartesian kinematics are generally defined in this global frame. This

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means that two of the locked nodes are parallel to one direction of the frame, and
the plane defined by the three locked nodes are normal to one direction of the frame.
(see example below)
-
As described before, locking must be done during the simulation for implicit
springback and must be done in post-processing for explicit springback (free blank
during simulation)
You can find below an example of locking, other lockings are possible with several
number of nodes.
Full model:
Node A: Lock in translation: Tx, Ty, Tz

Node B: Lock in translation: Ty, Tz
Node C: Lock in translation: Tz
-
(NodeA, NodeB, NodeC) plane is parallel

to (XoY) plane and the three nodes are
locked in translation Z:
Tz degree of freedom is locked
Rx degree of freedom is locked
Ry degree of freedom is locked
(NodeA-NodeB) line is parallel to X, and

these nodes are locked in Y:
Ty degree of freedom is locked
Rz degree of freedom is locked
Node A is locked in translation X

Tx degree of freedom is locked
Half model
Node A: Lock in translation: Ty, Tz

Node B: Lock in translation: Tz
-
Symmetry plane (YoZ):

(NodeA-NodeB) line is parallel to Y, and

these nodes are locked in Z:

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-
Node A is locked in translation Y

Quarter model
Node A: Lock in translation: Tz

-
Symmetry plane (YoZ):

Symmetry plane (XoZ):

Node A is locked in translation YZ

Post processing Model locking

It is possible to remove rigid body movement in post-processing, using the Model
Locking functionality.
The user selects three nodes if there are no symmetry planes, two nodes if there is one
symmetry plane and only one node if two symmetry planes are used during springback.

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The following actions will then be automatically performed:

-
Node 1:
Node 2:
Node 3:
it is a fixed node, its displacement is always nil between states.
This node remains on the initial (Node 1, Node 2) straight line. This means
that the (Node 1, Node 2) straight line does not move between states.
This node remains in the initial plane (Node 1, Node 2, Node 3). This means
that the (Node 1, Node 2, Node 3) plane does not move between states.
If one symmetry plane is defined:

-
Node 1:
This node remains on the line normal to the symmetry plane between states.
This node is fixed if it is included along a symmetry plane.
Node 2:
This node remains in the plane perpendicular to the symmetry plane and
that passes through the initial Node 1 and Node 2 nodes.
If two non-parallel symmetry planes are defined, Node 1 remains in the plane
perpendicular to two symmetry planes. This node will be fixed if it is included in the
intersection of the symmetry planes.
Notes :
It is advised to use Post-process Model locking functionality when carrying out

an explicit springback simulation. Explicit springback simulation must be done
without any locking.
It is advised to select the node in the first state (before springback) and then
display the final state.

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Model positioning for post-processing

Before doing any springback analysis, it is necessary to make sure that the part is well
positioned. A bad positioning can lead to bad interpretation of the results.
This functionality first enables the
correct positioning of the part after
springback in order to compare it with
another model (for example real part)
and then proposes direct measurements
between the two parts.
It should be activate to move the current

model.
Frame modification
It is possible to modify the position of part (post-process model), by moving it in

another frame (car frame for example). The model is moved in the displayed state.
The current stamping frame is defined in the new frame (car frame for example) by a
list of rotation, and its origin.

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Positioning one model on another

Positioning will be done by positioning:
-
one plane surface of the simulated model on the defined plane
one line of the simulated model on the other pre-defined line
one point of the simulated part on the other defined points.
Changing of frame (stamping frame to car frame)
These three types of positioning are defined by the user who set the order of these
transformations.
Points definition
The user defines the points used for moving the model.
-
button is used to add points

For each point, there are two definitions: the one picked on the current model and
the objective position that can be defined theoretically given the coordinate in the
car frame.
- The user can also use a position wizard
that will look for the blank node closest

to the theoretical point (doing the frame change). This is used to put a node at his
initial position (before springback):

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Computation: node coordinate in the current state (after springback in the stamp
frame)
Theoretical: same node coordinate in the initial state (calculated in the car
frame)
Transformation definition
Transformations types are defined
Points used by a transformation must be set, selecting the transformation and the
point, and then click on the arrow to assign the selected point to the selected
transformation.
Transformation must be set as active.
Note
The switch to car frame transformation moves the model in the car frame.

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Import and export

Import and Export functionalities
enable to
select the frame in which the model
should be positioned.
If Imported mesh defined in car frame is
selected, the imported mesh is assumed to
be defined in the car frame and
coordinates of nodes are transformed to
allow comparison in the stamping frame.
The standard import dialog is opened.
exports the mesh in its current
position. The standard export dialog box
is opened.
Export
Measurement
Selecting a position on the current model and a direction, the point is projected on the
displayed object and the distance is computed.
Examples
Example 1:
Available data:
-
springback simulation
real part geometry (mesh, CAD or STL file) in car frame
stamping frame definition in car frame
coordinates in car frame of locked points of real part

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For a good positioning, the user must:

-
Display the final stamping state
Define the stamping frame in the car frame (list of rotation, and its origin)
Import the real part geometry, activating Imported mesh defined in car frame. The
two parts (model and real) are thus positioned in the same frame, (the stamping
one).
Define the real points used for locking:
Theoretical: enter the coordinates of the real locked points (defined in the car
frame)
Computation: click in the model on the corresponding locked points (referring to

the geometry, like holes )
Define the locking: lock points, planes respecting the order
Activate the positioning
Example 2:
Available data:
-
coordinates of theoretical locked points in stamping frame

-
Define the points used for locking, using the Point definition wizard:
Closest node of object Blank in State 1
To position: enter the coordinates of locked points

The node will thus be selected before springback, to be sure to consider the good
node for positioning.
This will do the same as Model Locking functionality but with free definition of the
positioning.
Example 3:
Available data:
-
coordinates of theoretical locked points in car frame

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Define the stamping frame in the car frame (list of rotation, and its origin)
Define the points used for locking, using the Point definition wizard:
Closest node of object Blank in State 1
To position: enter the coordinates of locked points in car frame

The node will thus be selected before springback, to be sure that the good node
is considered for positioning.
Best fitting
Functionality, which enables the correct positioning of the part after springback in order
to compare it with another model (for example real part).
The main objectives is to position an object (blank after springback), as close as
possible to another object (objective shape, stl measured part ) on specific areas on
both parts.
Most common objects fitting scenarios:
Par to Part
Part to Die
Part to Clamps
Best fit tool is available in PRE and

POST phases through the icon
in
transformation page in Data setup panel,
or through menu:
Geometry\Transformation\Best fitting.

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Object selection
Pre:
Select the object to fit and the reference object in the list of objects.
You can select current object by mouse picking in 3D view through this button
well.
as
Apply transformation to additional objects is available in PRE only and allows user to
transform selected objects directly with same transformation matrix like Object to fit.
Post:
In POST the computed model moves on an imported model. Best-Fit move all the
computed models, so the additional objects are not useful.
In Object to fit only objects of computed elements are available.
In Reference object it is possible to select only imported objects.

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Initial position
The result is very sensitive to the initial position, so the initial position needs to be
close to the final one (translation of a few percentage of the model and rotation of a
few degrees). If the initial position is far, it may not move enough to reach the correct
position.
Therefore, the user has to manually move the object to initial position before trying to
fit it. It can be done initially or after the best fit (if the position is not the expected
one) and re-run the best fit.
For manual position is necessary to use Initial position management:
The user has to pick couple of nodes N1-P1, where N1 is a node of the object to fit and
P1 is a corresponding node of the reference object. Nodes must be from corresponding
objects selected in dialog, otherwise it is not possible to pick them together.
Once couple of nodes is successfully picked, green connection line is shown in 3D

together with number, because each couple of nodes has its own number.
In this way, it is possible to pick couples as much as is necessary.
The object to fit is then moved in order to minimize the distance between selected
nodes.
The user may delete couple of nodes
, or re-pick node of picked couple in 3D
Picking each couple of nodes moves with part and finally, there is new a position of
fitted part which is possible to save as start position for best fitting
back to original position
, or canceling
. Be careful, cancel operation is irretrievably. To cancel to
original position it is possible to use the

for Best-fit reset (more in Reset paragraph).
button as well, which is generally
Best fit
The average projection is computed for each iteration, after launching the best fit
algorithm and the object to fit is moved accordingly.

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Best fitting is controlled by advanced parameters, the user can set. Here after, Best fit
advanced parameters set: as default.
Post Best fit

As was written the idea is to move the computed model on an imported model.
The transformation is computed based on initial position, which computation is based
on nodes, which may not be present in various states. So, changing state has limitations.
After the user carries out initial position and best fit, Activate is activated and
transformation matrix is stored. It is the one computed in the state, where the best fit
was computed.
The transformation is stored as new transformation (with objects information) only,
when applying Best fit button.
It is not possible to modify objects when Activate is activated, because position and
pushing Best fit is not active in this case (pictures below). If user deactivate current Best
fit, computed model is put in normal position and then the user can do initial positioning
and best fit again. If he activate again, the previous Best Fit transformation will be
applied.
Reset
Reset
button reset the complete transformation including the initial positioning.
The reset is done for the corresponding objects To fit /Reference. Once the user changes
these objects, no reset can be done.
Reset
is possible to apply to couple of nodes resetting as was written.

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Springback Measurement tools

Tools like section or multistate mode are very useful to analyze the springback, they are
not described in details in this chapter (refer to Analyze section).
Displacement amplification
of Model locking can be used
to amplify the displacement of the springback.
Combined with the Multistate mode, loading the
blank before springback enables a good
qualitative analysis. 2D sections can also be
done.
Amplification factor
Note
It is advised to use an amplification of 3.
Displacement
contours (see Contours chapter) can give quantitative springback results.
These values must be analysed very carefully since they depend on the locking of the
model. There are relative values (The relative amplitude is always the same) but the
user defines the zero displacement area with the locking.
Displacement

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Same springback, same shape
The locking points must be displayed when analysing displacement, using the
Show/Locked nodes functionality or the Visualize in 3D (for Model Locking in postprocess)
It is anyway interesting to display Displacement in different direction to better
understand the qualitative springback movement.

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Distance
contours (see Contours chapter) can give quantitative springback results by

computing the distance between the blank before and after springback. Before any
distance measurement, the user must carefully ensure that the parts on which distance
will be measured are well positioned (see Model positioning in the previous paragraph).
Distance
It is useful to use the Multistate mode, by loading the first state of the computation.
When the user computes distance with imported real part, he must be careful about the
side of the imported mesh, that represents the outer of the real part (on die side or on
punch side).
Distance to 1st set or 2nd set
The distance is measured for each node of the first set, finding the minimal distance to
the second set. This signifies that the distance from the first set to the second can be
slightly different from the second set to first, especially for the border nodes. That is
why the user must be careful about the maximal distance value.
2nd set
2nd set
1st set
1st set
Numerical or Physical
The Numerical distance is a distance mesh to mesh, as the Physical distance

corresponds to the numerical distance minus half the thickness (real element thickness).

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Signed distance
It gives the user the relative distance with a signed value, which is very useful for
springback analysis

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COSMETIC DEFECTS ANALYSIS

The purpose is to simulate the cosmetic defect appearing during the full chain and to
analyze them through dedicated tools.
Cosmetic defect analysis

The Stoning contour & sections tool is available from the cosmetic defect analysis
dialog.
After clicking on the Cosmetic defects button
in the Analysis tool bar or after
selecting Analysis / Result analysis / Cosmetic defects, the user has to select in the
drop list the Stoning contour & sections analysis.
This tool is able to visualize and measure the cosmetic defects on the simulated blank
by creating a contour of the defect area with the corresponding depth. The measurement
as for real stoning is done through stoning lines (analysed area sections). The direction
of the stoning lines corresponds to the point of view of the worker in the real process.
Three methods are available: Stoning, Sensor and Rolling. The difference between
these methods is the way of evaluating the area on the stoning lines.

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Stoning method
The stoning method has been implemented in order to have similar results as reality. It
is like a straight stone which is moved on the blank along straight lines.
The input parameter is the length of the stone: W.
A stone with a length of W mm is moved along each section curve (stoning line). The
stone remains at the surface of the part. The defect value is calculated by measuring the
distance between the section point and the stone.
This method can be used when the defect is a hollow or a bump in a convex or a flat
area of the part (e.g. the defects on the door corner or on the door handle).
Rolling method
The rolling method can be compared to the stoning method. But this method has a
curved stone. It is useful for part which has known curvature.
The input parameters are the length of the curved stone: W and the radius of the
curvature: R. The curved stone remains at the surface of the part. The defect value is
calculated by measuring the distance between the section point and the curved stone.

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This method can be used when the defect is a hollow or a bump in a concave area of the
part (e.g. the defects on the door handle).
On this kind of shape, the stoning gives defect instead of no defect. The rolling method
detects the expected defect.
Sensor method
This method describes the action from a probe. The 2 sensors which have fixed distance
W measure the variation of the blank shape.
The sensor method is not so different than the stoning method, but it authorizes the
intersection of the virtual line between the 2 fixed sensors and the blank.
The input value is the length between the 2 contact points: W.
-
As in reality the distance between the blank and the virtual line of the two contact
points are measured.

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This method can be used when the defect is a hollow or a bump in a concave or convex
area of the part. Sensor values are positive, if defect is hollow and negative values in
case of bump.
Stoning lines creation

The measurement is done by moving the stone or the sensors along the sections. The
user needs to create some sections. Two modes are available. The user can create
stoning lines automatically or manage the sections manually, one by one.
Manual creating of stoning lines is available through buttons
(add line, delete line, delete all). It is possible to create lines in several directions. The
contours will take into account each direction.

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There are two ways of creating section automatically:

1. Multi-direction
Analysed area is equally covered by stoning lines in basic directions (horizontal,
vertical, diagonal) as you can see on picture below:
2. Fixed direction
It is possible to directly select the direction in which will be stoning lines
created. It is also possible to create sections in several directions. The contours
will take into account each direction.
If direction definition is done, the user has to choose spacing or number option in order
to create desire density of stoning lines.
After the Create lines button is used, or the first stoning line is manually created, the
button is changed to Replace/Add lines mode. Replace lines delete previous created
lines by a new configuration, while Add lines preserves present lines and adds new
one.
Notes:
The spacing and the section number are configurable. The names in the cfg file
are: STONING_SECTIONS_NUMBER and STONING_SECTIONS_SPACING

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Blank side
A part can be analyzed on both sides. The user selects the one he wants to analyze by
using the
button.
A stone or sensor is visible in the 3D view, if the Show stone option is activated.
It corresponds to the side on which the stone or the sensor is put on the real part.
How to proceed
1. Open the Stoning contour & section analysis tool.
2. Select the object to analyze.
It is advised to create an object corresponding to the analysed area: the handle, the
door corner...
3. Define the stoning lines.
4. Select contour type: Stoning, Sensor, Rolling and fill in the corresponding
parameters.
5. Choose the analysis direction, above or below the part to analyse.
6. Compute.
The contour will appear in the 3D view.
It is possible to visualize the defect curves in the curve plotter.
7. Depth annotation
It is possible to visualize easily the minimal or maximal value of the contour by using
the local min or max value in the annotation toolbar.

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It is easy to re-compute the contour if the user wants modify some options: the sections
direction, the sections number, the part...
Notes:
The radius R and the length W are configurable. The names in the cfg file are:
STONING_RADIUS and STONING_WIDTH
Renderer tool
The Renderer tool is available from the cosmetic defect analysis tools
After clicking on the Cosmetic defects button
in the Analysis tool bar or after
selecting Analysis / Result analysis / Cosmetic defects, the user has to select in the
drop list the Renderer analysis.
The GUI layout of this tool is as follow:

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The Renderer functionality will allow to generate a movie of highly realistic images of
the model lighted in particular conditions. The goal of such rendering is to visually
localize the surface defects on a part by exposing it to intensive moving lights.
The Renderer tool exports a computed model into a specific file format that will be
processed by a 3rd party 3D rendering software in order to generate images of the model
moving in particular lighting conditions. These images are then output into a movie file.
To use the renderer tool it is necessary to do a correct data set-up, as described before.
Definition
Scene
When the Renderer menu is activated, some graphic symbols are drawn in the 3D view
to represent:
-
the rendered scene limits (red rectangle in the 3D view)
the visualized area, i.e. the camera capture area (blue rectangle in the 3D view)
the lighting parameters (vertical or horizontal bands)
The model and the lights displayed in the 3D view are the same as what will be seen in
the generated images: watching the model in the 3D view is equivalent to filming the
part in the lighted room, where the view point is the same.
The 3D view (whole scene is fully captured)
The computed image

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The computed image
(small part of the model is captured)

Lights and camera movements
The movement applied to the lights and the camera must be defined. They can be
attached and have the same movement (Apply to lights and camera) or a movement can
be applied only to the camera (Apply to camera only). This allows to navigate inside a
static scene.
Several types of movements can be defined:
-
No movement (single image)
in the position currently visualized in the 3D view.
Rotation around X, Rotation around Y, Rotation around Z :
Translation along X, Translation along Y:
The relative position of

the model and lights currently visualized in the 3D view is the reference for angle
values.
The relative position of the model and
lights currently visualized in the 3D view is the reference for displacement values.
The number of image that will be generated between the initial angle / displacement and
the final angle / displacement can be defined using the Frames option. The Add inverse
path option allows generating a cyclic movement by computing images for the inverse
movement in addition to the normally defined movement.
Notes:
The model movement can be simulated just by reversing the desired model
movement and applying it to the lights and camera.
It is recommended to define a large number of frames in order to get a smooth

movement. Example: for a movie frame rate equal to 24 frames per second and
a movie length equal to 10 seconds, the number of frames must be equal to 240
(the movie length must always be adapted to the movement amplitude)
The Add inverse path option doubles the number of images and the CPU time.
The use of Also include images in reverse mode in the movie creation options

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dialog gives the same results without CPU time cost, by re-using the images
computed for the direct path.
Renderer Launch
When applying the Renderer option, a specific input file is generated and the calculation
process is launched.
The Input file location and name must be defined. Three additional input files whose
name root is the master input file name are also generated and contain the lights, scene
and model data.
Default option:
The default path points to the model project directory and the default filename is
the model project name with .rib extension.
The option Do not run the renderer (input only) allows not launching the renderer, but
only generating the input file. Otherwise the calculation is immediately launched as a
separate process running with the same user account than the application. This process
is not launched through the solver manager (like stamping calculations) and might
therefore be killed when closing the user session.
The 3rd party renderer
Images are computed by a photorealistic renderer delivered within Pam-Stamp 2G

installation (Windows and Linux only). This renderer is Pixie, an open source project
licensed under GPL license.
This renderer binary distribution can be found in the folder named renderer located in
the binary folder of Pam-Stamp 2G.
Manual launch
This is the procedure to manually run the renderer from an input file (.rib extension):
-
go to the folder where the input file is located
set the environment variable PIXIEHOME to the renderer folder path
run the renderer executable file ($PIXIEHOME/bin/rndr.exe) with the master

input file name as argument
Example on Windows platform:

> set PIXIEHOME= C:\Program Files (x86)\ESI Group\PAM-STAMP\2012.0\Binary64Bit\GUI\renderer
> %PIXIEHOME%\bin\rndr.exe Box.rib
Images are generated in the input files folder.
Movie Creation
It is possible to generate a movie from the images created by the renderer. If this option
is not activated, only images will be available.

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If the user wants to modify the parameters of the movie and creates a new one, there is
no need to re-compute the renderer images. The Movie creation utility, which can be
opened from the Analysis / Result analysis / Movie creation utility, enables the creation
of a movie by defining the first and last images and the options of the movie.
Note
The name of images must match imagename_xxxxx.tif, where xxxxx is

a five digit number defining the order of images in the movie. Only images in
TIFF format are accepted.
Set-up
To detect cosmetic defect it is important to do High quality simulation (see dedicated
sections). The creation of the tools, the blank meshing and the process set-up must
follow all the rules defined in the High quality simulation chapters. Cosmetic defects
appear after springback, so it is particularly important to use:
-
Accurate contact
Blank mesh size well adapted to the detection of defects:

-
In the analyzed area, it is advised to refine uniformly from the beginning of the
simulation. This uniform level could be set equal to the maximal level advised
by the refinement wizard for high quality simulation. For that purpose a
separated object corresponding to the analyzed area must be created.

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In the global area of the blank (outside the analyzed area), the mesh size can
follow the usual rules of high quality simulation, as it is defined through
meshing and refinement wizards.
Tool mesh size fine enough, so that defects that are analyzed do not correspond to
numerical defects link to tools mesh:
-
Globally it is better to follow the springback meshing strategy for the tool
mesh
In the analyzed area, the tool mesh size could be divided until reaching a size
similar to the blank mesh size, using the mesh splitting functionality. The
part splitting option can be used for splitting the CAD and creating separated
tools objects with special meshing in the analyzed area.
Velocity and mass scaling

-
Usual velocity and mass scaling can be used for the tools. But it is advised to
reduce the velocity to 0.5 m/s with a ramp during the last 0.5 mm of stroke to
avoid any dynamic effect at the end of the simulation.
Substructuring (local run)

Substructuring functionality enables accurate local simulations on a user-selected zone
of a stamped part, see Substructuring section for more detailed information about the
way of using it.

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A first global simulation will be done with high quality level. Then local simulation will
be done with only a part of the tools and the blank for which the level of refinements
will be increased.
Thanks to the substructuring it is possible to have finer mesh on areas where surface
defect is studied. It is also possible to modify the tool, meshing and filleting it finer and
then to run only the studied area, saving CPU time.
How to proceed
During the first global simulation, the local zones on which surface defect will be
studied are defined. It is not recommended to use very large zones (optimal local area
size is around 10% of initial blank size, but it is not a rule and it depends on specificity
and conditions of each case). For each stage, an independent subrun file, saving
information of the border nodes, is created. The border nodes are automatically refined
at the maximum refinement level, so it will not impact the time step and enable saving
precise information.
A local stamping simulation, defined only on this local blank zone is then performed
with the needed level of refinement. The border nodes will have a constrained
displacement imported from the substructure file (coming from the global simulation),
and will not be refined more than previously in the global simulation.
The procedure is as follows (see Substructuring section for more detailed information):
-
During the first global simulation, the objects containing the local zones of the blank
where surface defect will be studied are created.
In the first global simulation, substructure export attributes are defined for each
local zone.
A local Subrun project is created with the Subrun project creation option.
Refinement level of the local area can be increased. It is advised to keep the whole
tools without cutting them (do not use the option use part tools) if it is planned to
locally modify the tools (more precise fillet)
Tools can be locally modified or exchanged by a finer meshed or filleted tool, using
the import menu and the workflow transfer rules to replace the content of the object
or the filleting option.
Several iterations can be done on this local simulation.
Then all the tools like the Stoning contours & sections or Renderer can be used on the
local studied area.

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Detachment contour
This contour enables to detect the lost of contact between punch and blank. This lost of
contact during the last millimeter of the stamping stroke, could be a reason of some
surface defect.
Definition
This contour is based on the distance between the tools elements and the blank node,
taking into account the real blank thickness. When the distance is higher than half of the
blank node, there is a lost of contact.
A security margin (SCLTHK) is used for not taking into account tools mesh
discretization and contact noise.
if Distancenode-element < 0.5.(1 + SCLTHK).NodeThickness,
Detachment contour indicates Contact with tools
if not, it indicates no contact with tools
A pertinent value must be used for the security margin. By default it has been calibrated
to 0.1, with the following test:
Margin :0
Margin :0.05
Margin :0.1
Normal contact pressure max over time

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How to proceed
During the data setup the user has to
select Detachment minimal value in the
Contour settings menu, accessible from
the Control/outputs attribute.
After the end of the simulation in the end
state, it is possible to display the contour
Contact/Marks/Detachment.
Combined stress and strain analysis

Another method to detect surface detect is to use combined user criteria based on stress
and strain analysis. The zone contour, described in the Contours section enables such
type of analysis.

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PRESS FORCE ANALYSIS

Purpose
The purpose of this option is to find from the tools contact force, the real press force
value:
Final contact force value
Real Press Force value
Punch Contact Force versus times
The difficulty is to know the real criterion that determines in the workshop the press
force value. Several criteria are proposed in PamStamp 2G to find this real press force
value.

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Contact force history

Contact forces are calculated during the whole
simulation per contact interface, and can be
displayed as curves versus progression or times. To
find press force it is necessary to display the contact
force history curve either on the punch (the blank
holder force should then be added) or on the die.
The user selects the object (punch or die) and the
stamping direction in the Value page.

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These curves are available if the Contact

forces per interface option have been
activated in the History curve settings of
the Control attribute. By default it is
activated.
Criteria definition
Two criteria are proposed in PamStamp 2G:
-
Double contact:
The press force is high enough, to mark the part in specific areas. In
these functional zones, the stamped part has been well in contact in each side with
punch and with die. Moreover these functional zones should be well positioned in
the part, to confirm that the part is well balanced.
Distance tool-blank:
The press force is high enough to respect the theoretic shape,

especially in some specific important areas. This means that the difference between
the stamped part at the press force value and the dies shape in these functional
zones is smaller than a pre-defined tolerance.
Likewise it is also possible to stop the simulation when the contact force is higher than a
pre-defined press force value, with Maximal force criterion.
Notes
Double contact
and Distance tool-blank criteria are available for Accurate
contact only.
Maximal force
criterion is available for both Accurate and Penalty contacts.
Functional zone
As described before the press force criteria are based on important areas of the blank
where geometric shape must be perfectly formed (to be welded or other adjustments).

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These areas will be selected on the die during the set-up for checking if the criterion is
reach.
Several functional zones can be defined. The press force for each zone will be given;
the final press force should be the higher one.
Double contact and Distance tool-blank criteria

Criteria
Functional zone (part of Tool 1)

The double contact criterion is:
Distance Blank node-Functional zone

& Distance Blank node-Second tool
Th
k
is the tolerance
Tool 2
Functional zone (part of Tool 1)

The distance tool-blank criterion is:
Distance Blank node-Functional zone

&
Distance Blank node-Second tool
Th
k
is the tolerance
Refinement
To be sure to well capture the criterion, the blank mesh is automatically refined when it
is in the neighborhood of the functional zone.

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Area ratio
Tool Functional zone = Szone

The press force is reached when
this criterion is reached for a predefined percentage of blank nodes.
Scriterion / Szone Area ratio
Blanks nodes
Respect of criterion = Scriterion
Maximal force criterion

The maximal force criterion should be used to stop the simulation when it is reached. It
is used as stop criteria in the control attribute.
The contact force curve is filtered to be sure of having the right maximal press force.

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Set-up
To analyze press force it is important to do High quality simulation (see dedicated
section). The creation of the tools, blank meshing and the process set-up must follow
all the rules defined in the High quality simulation chapters.
Double contact & Distance tool-blank criterion
The user must create one object per functional zone, containing elements of the die. On
this functional zone a Press force analysis attribute must be defined. The distance toolblank or the double contact criterion is selected; the Tolerance and the Area ratio must
be defined.

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Maximal force
The user must define a Press force analysis attribute on punch or die. He activates the
Maximal force option setting the corresponding value. In the Control attribute, the
Maximal press force stop criteria must be selected.
Press Force analysis

Double contact & Distance tool-blank criteria
In the solver message the user can see for each functional zone:
-
The time and progression when the criterion has been reached
The ratio of blank node respecting the criterion.
The user must then open the contact force history curve of the punch or of the die to
find the press force value corresponding to the progression value.
Maximal force
In the solver message the user can see the time and progression when the maximal force
has been reached.

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VOLUME BLANK
It is possible to model a blank sheet in a forming process using solid elements instead of
the more conventional shell elements. Shell element does not describe thickness
pressure stresses, but solid element can describe this type of stress; normally this is
required only when:
- The blank thickness is very large (plate rather than sheet)
- Through thickness; stresses are critical to the forming (ironing). When the gap
between the tools is less than the thickness of blank
- Bending over very small radius compared to blank thickness occurs
Blank and tools creation

Blank definition
The blank is defined using the Blank editor. The blank element size
must respect the rules for the blank mesh (see Blank meshing chapter in the Simulation
methodology for high quality stamping section). Since there is no refinement possible
for solid element, it is necessary to mesh the blank with the final element size (be
careful if you are using the blank meshing wizard).
The global shape of the blank is defined in the Definition dialog, and an extrusion is
defined in the Extrusion data button.

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Tools definition
If accurate contact is used, as a thickness will be defined on tools (see afterward) an
additional offset equal to half of their thickness must be done on tools.
Solid element, material and contact

Solid element
See the Element chapter for further information on elasto-plastic volume elements.
By default a Uniform solid element integration rule is defined. However if the mesh of
the volume blank degenerates during the calculation, a Selective reduced integration
rule can be defined even if calculation time increases fourfold.

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Time step
Time step will be quite small because of non use of adaptive meshing. See Time step
and Increments chapter for the definition of the time step calculation of solid elements.
Mass scaling can be used as for shell elements.
Material
Anisotropic behavior is available since version 2009. For anisotropic solids it is
necessary except for standard parameters which are the same like for 2D elements.
There is an additional parameter called thickness direction, which always defines
normal direction to initial blank, this vector is then used for solids thickness calculation.
The material laws that can be used are Hill 48 and Barlat law. Hill 90 theory does not
exist for 3D so this law is not available for solids.
See Hill 48 material law and Barlat material law chapter for further information.
Accurate Contact
As described in the Contact and Friction chapter, a thickness must be given to the tools
(it will be used for the contact) because the nodes of solid element are balls with nil
diameters. This 0.1 thickness is defined in the thickness attribute of the all stage for
each tools. As described above, the tools must be given an additional offset equal to half
of their thickness for not modifying the contact surface. If physical drawbeads are used
during simulation it is recommended to decrease deformation height factor e.g. 0.1 to
improve the contact with blankholder.
Penalty contact
With penalty contact the user can either use the same method than for accurate contact
(defining a thickness and doing tools offset) either use a small contact thickness to
avoid doing tools offset.
-
If there is no tools offset, a small contact thickness should be defined (0.005 mm

for example).
As the stiffness of the penalty contact is proportional to the contact thickness and to
the scale factor, and a very small contact thickness is defined, it is advised to

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increase the scale factor (avoiding values larger than 0.3, which may lead to contact
instabilities). With this method the stiffness of the contact is kept.
-
To keep a robust contact despite the small contact thickness, it is better to search the
contact each cycle. The contact acceleration is thus modified from 10 (standard setup) to 1.
Autopositionning tolerance
should also be modified to respect the contact thickness,
defining it as 0.006.
To summarize the advised values for penalty contact without tools offset are the
following:
-
No tools offset
Contact thickness
Scale factor
Contact acceleration
Autopositionning tolerance
= 0.005 mm (Advanced parameters of the Contact attribute)
= 0.1 (Contact attribute parameter)

= 1 (Advanced parameters of the Contact attribute)
= 0.006 mm (Transformation attribute)
Data set-up
For stamping simulation with volume blank the user should follow generally the same
rules as with shell blank, see Simulation methodology for design and stamping
feasibility or in the Simulation methodology for high quality stamping sections.
The differences to be observed when using volume blank are described below.
-
There should be no refinement attribute
Blank object should be defined as Volume blank in object type attribute.
If accurate contact is used, Thickness attribute of 0.1 should be added on surface

tools in All stages. These tools must be offseted of 0.05 (see before).
As there is no pinch test available to stop the simulation, the stop criterion of the
simulation must be defined as progression.
- Gravity simulation must be defined as explicit, since no implicit is available with

solid elements. Gravity calculation is time-consuming; hence it is better to replace it
with accurate locating the blank on the tools.
- Springback simulation can be defined both as explicit and implicit using the
Advanced implicit
solver with Selective reduced integration of elements.
The trimming operation is not available for the solid elements.

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Notes:
EWK rupture model is

EWK rupture model
available for the volume blanks, for more see chapter
There is element elimination available based on plastic strain and EWK damage
factor
Process macro
Three macros for volume blanks in the installation are created:
-
DoubleAction_Volume_Blank_2009.ksa
SingleleAction_Volume_Blank_2009.ksa
Springback_Volume_Blank_2009.ksa
These macros are used the same way like for shell blanks. User should only put
additional offset on all tools of 0.05 mm, because tools thickness is defined as 0.1 mm
Sprinback and Gravity stages are defined as the explicit ones.
If the user needs to create some macro for his special process this can be defined easily
in the Stamp Tool Kit (see Process macro chapter) so that the above operations are
done automatically, without any additional data set-up comparing with a standard
stamping simulation.
The best way to proceed is to open an existing macro for
shell blank and to modify it by activating Volume blank .
The user can then add thickness to the

tools if accurate contact is used, and
modify the attributes as described before.

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Post processing
The following post processing contours are available for solids:
Thickness of solids:
It measures the distance between the outer surfaces. The

blank size must be larger than the thickness since it is based on the smallest
distances between the outer surfaces.
Strain contours:
Equivalent plastic strain
Strain tensor
In plane strain tensor: 2D strain

parameter thickness direction
Normal solid strain:
Forming Limit Diagram
in one element layer layers determined by
normal strain to one element layer
Stress contours:
Stress tensor
In plane stress tensor: 2D stress

parameter - thickness direction
Normal solid stress: normal
Max. absolute stress: from
Min. absolute stress: from
in one element layer layers determined by
stress to one element layer
three main values the one with the highest absolute

value is used (this value can also be negative).
three main values the one with the lowest absolute
value is used (this value can also be negative).
Note on thickness
An other way to display thickness that works independently on the blank size is to
create a custom command with thickness, based on the distances between the external
faces of the blank.
To create such button in the toolbar, the user must process as follows (more details are
available in the User interface analysis tools chapter):
-
Using the propagation selection functionality, the user selects the nodes of one
blank face and put them in an object called faceA (one must always use the same
name). The same must be done for faceB of the blank.

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The user displays the distance between faceA and faceB.
This contour can be saved in a Thickness button of the custom toolbar.
If faceA and faceB are created in the master .pre file, the contour will be available in all
the stages, in set-up as in results views.
In cases where solid thickness does not work well, it is recommended to decrease
parameter, Maximum angle on a face in Customize/Contour general options menu:

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SIMULATION WITH IRONING - T.T.S ELEMENT

It is possible to model a blank sheet in a forming process using solid elements instead of
the more conventional shell elements. Standard shell element does not describe
thickness pressure stresses, but solid element does; normally this is required only when.
But solid elements are CPU time consuming so in some specific process types the user
can use the T.T.S (Through Thickness Stress) option for shell instead of using solid.
Convenient process types for T.T.S are cases with ironing or squeezing phenomena and
also cases where press force is used to calibrate the stamped part.
Usually in such processes the gap between the tools is somehow smaller than the
thickness of blank. The following images describe the two basic phenomena which
T.T.S is able to describe
Squeezing:
Ironing:
Note
is still only a shell so all rules/limitations concerning thickness vs.

element size remain valid!!
T.T.S

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T.T.S. activation in graphical interface

For the activation of the T.T.S option the user should add an attribute called Ironing
in the stage where this option should be active.
Ironing (T.T.S) option is compatible with following yield criteria: Hill 48, Vegter,
Hill 90, Barlat 89, Barlat 2000. The only one incompatible is Barlat 91.
Note -Important
Pinch tests should never be used together with T.T.S - see the solver activation
paragraph, because no ironing or squeezing occurs before pinch.
If there is a springback after a stage with T.T.S. it is always recommend to

activate Ironing attribute also in springback stage, to obtain a correct
recomputed transmission between 3d and 2d plasticity
T.T.S. activation in solver

T.T.S. option
works (if activated in GUI) only for deformable shell element which is
pinched between rigid tools with imposed kinematic. During the computation where
the blank element is not pinched, it behaves like a standard shell with no normal stress.
Once a pinch (distance between tools is smaller than blank thickness in the specific
node) is detected for a specific element in a specific stage, T.T.S. option is switched on
in this element and remains active in until the element is pinched or until the end of
stage. So since T.T.S is switched on until the end of the stage, 3D plasticity is computed
for that element. The normal stress force applied on specific elements is then computed
from the total residual penetration of the element into the pinching tools using specific
algorithm. This force is then used for computation for thinning of the element.
In the out file if some elements are switched to T.T.S the following message appears
*** INFO *** SHELL ID.
274430 T.T.S. ELEMENT ACTIVATED AT CYCLE 290700

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For the following stage T.T.S option is again deactivated until another pinch occurs
(and if the Ironing attribute is active.)
Post processing
There are two special default contours for T.T.S
Ironing value:
Displays (in length units) how much of thickness was reduced by ironing
:
Ironing zone:
Displays which elements are currently switched to T.T.S:

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GAS SPRINGS
It is possible to model Gas springs used within a die, either in place of blankholder
force, or as applied to other moving tools.
Each Gas spring will be modeled using a 2-node BAR element. One node must belong
to the tool to be controlled, and the other must be given a Cartesian Kinematic condition
(either fixed or imposed velocity).
Creation
These elements can be created using the Tool editor by adding a Spring in the accessory
tree.

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Attribute
The spring objects must be defined as bar, and given a behavior attribute.
This attribute defines the Traction curve (Tension / Displacement) of the spring
behavior, and can be calibrated to match the characteristics of specific gas springs from
particular suppliers.
If this method is frequently used, then it is recommended to build up a library of
Tension / Displacement curves (using the .bf file export option) for future use.
The correct input method for the behavior is as follows:
- The abscissa (X axis) represents the Displacement, this should normally go from the
maximum travel of the spring expressed as a negative value (fully compressed) to
zero (fully extended)
- The ordinate (Y axis) represents the Tension; this should normally go from the force
when fully compressed expressed as a negative tension, to zero when fully
extended. The initial slope of the curve is often very high.

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The mass wizard computes the mass of the rigid bar so that the bar does not impose the
time step during the computation (see the Time step chapter for a bar element).
Process macro
It is advised to create a macro for such process if it is used several times. This can be
defined easily in the Stamp Tool Kit (see Process macro chapter) so that the above
operations are done automatically, without any additional data set-up compared to a
standard stamping simulation.
tools are available in the
Stamp tool kit to use them in the process
macro.
Gas spring
It can be located only on standard tool.
free tool is automatically

created and has the same Cartesian
kinematics than the tool on which it is
located.
End of springs
Gas spring Behavior is accessible by

clicking the right mouse button.
Automatically a Traction curve 2D
function parameter and a Gas spring mass
real parameter are created. This last
parameter will be proposed to the user of
the process macro with a wizard.

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DRAWSLIT OR LANCING
It is possible to include a drawslit, or lance within an AUTOSTAMP calculation.
Used options
In order to do lancing, the user must divide the draw simulation into 2 parts (or more in
case of multiple non simultaneous slits) and activate some options:
-
Velocity: The velocities will be kept in the beginning of the second stage, so that the
simulation is close to reality, using the Pick node velocity option during picking.
Pre-process curves management: The keep time origin option enables the user to use
the same pre-process curves (for velocity, forces ) in the second stage. At the
beginning of the simulation the first value of the curve used, is the one having an
abscissa equal to the time origin.
Progression management: The keep progression option enables the user to have a
continuity of the values of progression between the first and the second stages. See
the Control parameters chapter for more details.
Post-processing: During post processing the multi-stages mode, will enable the user
to see the whole simulation (before and after lancing) in the same project. See the
Other analysis tools chapter.
Procedure
It is possible to include lancing in a multistage calculation, described as follows:
-
Do the data set up of the first stage with a stop criterion corresponding to the
progression in which the drawslit or lancing must be included
Copy this first stage in a second one, using the Manage stage option:

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Add a picking attribute for the global object, and activate the Pick nodes velocities,
the Pick time origin and Pick progression options.
Modify the stop criterion of the second stage to correspond on the final stroke
Define the lancing, with the Mesh transformations/trimming attribute
Remove the Mesh transformations/autopositioning attribute.
It is advised to create a macro for such process if it is used several times. This can be
defined easily in the Stamp Tool Kit (see Process macro chapter) so that the above
operations are done automatically, without any additional data set-up compared to a
standard stamping simulation.

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CRASHFORMING
It is possible to simulate crashforming process in Pam-Stamp 2G. There are no big
differences compared to standard stamping simulation set-up.
Procedure
Because the crashforming process is done without blanhkolder, the stamping velocity
should be lower to avoid unwanted inertia effects. Typical recommended value is 2-3
mm/ms. It is also important to use fine enough mesh to detect well possible wrinkles,
because, wrinkles often appears ofter such process
-
If you want to make set-up using process macro, you can use only holding stage
from the Double action macro and put the lower pad as Die and upper pad as
Blank holder. There is also a special macro for crashforming. This macro is only
for crash forming processes with pad. Stamping velocity there is 5mm/ms, but if
there is a lot of material free, better is to decrease velocity to 2-3 mm/ms

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STAMPING INVERSE
Purpose
The inverse simulation allows the user to calculate the initial blank from the finite
element model of the stamped part, and to have information on the feasibility of the
stamped part.
The starting point of inverse simulation is the Finite Element model of the stamped
part.
The inverse algorithms find the position of the nodes of the blank in its original,
horizontal or curved surface. A displacement field is thus associated to the stamping
operation considered. This search is carried out without any intermediate position that is
why it is called one-step.
Once a displacement field is known that assures the equilibrium of the nodes of the
stamped blank, it is possible to compute the residual thickness, stresses and strains.
Inverse simulation seeks to impose the equilibrium of the final configuration of the
stamped part. This is the most important simplifying assumption of the approach, which
does not take into account the shapes of the blank at any other point of the stamping
process. As a consequence, strain paths are assumed to be linear (radial strain path) and
the effect of the history of deformation of the material is neglected.
The formulation of the problem is summarized in the following figure:
Initial surface
Initial blank
Thickness
u P0
P
Stamped blank
Thickness

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Solver Characteristics
The characteristic feature of the inverse problem is that the unknowns are distributed
between the initial blank (result of the computation) and the stamped part (starting point
of the computation):
Known quantities
Unknown quantities
Initial blank
Stamped part
thickness
null stresses, strains
u,v displacement for a given

node
blank contour (cutting

pattern)
geometry
thickness
w displacement for a
given node
stresses and strains
blank contour
blank holder force,

friction
The problem can be thus posed in mathematical terms: Find the displacements u and v
so that, given a field of vertical displacement w, the stamped part is in equilibrium
under the action of:
Internal stresses
Reaction forces
Friction forces
Restraining forces
In order to find the solution, we must find the minimum of the total energy functional:
Min u,v ((ij)+W(ui))
With:
: internal strain energy
W: work of external forces
The inverse problem in sheet metal forming simulation is a static, non-linear problem.
Simplifying assumption of inverse simulation

-
Radial strains: the history of deformation is neglected (one step method

assumption).

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Radial
strain path
Actual strain
path
Static analysis: the history of contact between tools and blank is not taken into
account. However, approximate models for contact history are available (stick
model). This is the most important source of error ! Much of the problems involved
are solved using initial curved blank.
Pre flattening option
In PAMSTAMP inverse, we calculate first an initial flat solution, from which we start
the inverse FEM equilibrium computation. The current standard initial flat solution is
not sufficient in case of stamped parts with high undercutting.
The Pre-flattening option is an advanced solution, based on implicit solver, added to
solve high undercutting problems. It makes also the inverse solution accuracy and
stability less sensitive to the mesh size dispersion.

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Stamped part
OR
Standard initial
flat solution
Pre-flattening:
Stamped part X1
Advanced
initial flat
solution
Implicit solver
Pre-Flattening
Inverse computation (FEM equilibrium)

Flat part
Solution, Flat part
In the Advanced parameter attribute, the convergence parameters of the pre-flattening

option are described.
Default
This option is active by default.
Element
The inverse elements are membrane, 3- and 4- node elements. The formulation is total
Lagrangian, using large displacement and large deformation.
Material
The only material law that can be used is the Hill 48 isotropic hardening. (See Finite
element and numerical model section).

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Inverse Project
The inverse method is used in an Inverse
type project.
Inverse Meshing
A specific meshing is used for inverse simulation. DeltaMESH Stamping Inverse is a
patch independent mesh generator that makes it possible to create a mesh with a finite
element quality. The generation of this mesh consists of importing either a CAD model
or a DeltaMESH geometrical database and to join it (topological model creation). From
this topological model, DeltaMESH Stamping Inverse creates zones from connected
faces groups (for example, blank holder, ). Inside a zone, the boundaries of internal
faces are not considered for the discretization. Thus, the mesh is coarser than usual
DeltaMESH Stamping mesh but with a finite element quality.

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The user access the Inverse CAD meshing

dialog from the Import CAD option of the
3D view.
The meshing algorithms are:

-
Uniform: Chordal error and Angle criterion parameters are not available
Progressive
The default values are customizable and stored in the configuration file.
A finer mesh yields more accurate results. Even if it is better to have mesh with uniform
size, the solver can manage mesh with non-uniform size, especially when using the preflattening option.
Warning:
The inverse mesher meshes all the surfaces, and the mesh that is created does
not take into account the limit of the surfaces. This means that the initial
separation of the mesh in several objects cannot be kept. In particular, it is not
possible to keep the content of the objects ref_punch, ref_radius and
ref_bholder.
The convergence of the solver is better with an inverse mesh than with a usual
mesh done by Deltamesh for tools.

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Inverse macro and attributes

Macro
Specific inverse macros are available
to simplify the data set up of an inverse
simulation, accessible from
(See Process Macro) .
Attributes
The available attributes are:
-
Object type:
that are Surface blank or Surface tool
Material
Inverse object
with thickness: See previous paragraph
part type: Part, binder, surface
friction
Stick option
Cartesian Kinematics:
Inverse condition:
Symmetry option
Control
only lock in X, Y or Z axis
options for taking into account filleting or drawbead
for the symmetry plane with definition
attribute with:

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Projection direction
Pre Flattening
option
Binders force
option
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definition
Mapping export
Advanced parameters
Number of layers
And pre-flattening parameters
Part type
The objects used to define the mesh are
defined by a Part type:
-
Part
Surface
Binder
Part
The final stamped part is defined as the Part inverse type.

Surface
The initial surface on which the stamped part will be projected is planned or curved. If
it is curved, an object containing a mesh of this curved surface must exist. It will be
defined as the Surface inverse type.
Binder
If initial data is the complete die and not the stamped part, an object containing the
binder area will be created, with the Binder inverse type.
The inverse solver needs at least a Part object.
Material and thickness are defined separately for each object. It is advised to use the
same.

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Parameters and options

Control parameters
The Projection direction from the
final stamped part to the initial part
must be defined.
The pre-flattening option is described
in the previous paragraph solver
characteristics
menu list the
contours to be available in postprocessing.
Contours setting
Projection surface
There are two ways of doing the projection:
-
On a flat surface: the Stage information is

then Flat blank. A theoretical flat surface
perpendicular to the projection direction and
located at the higher point of the deformed
blank is considered by inverse solver.
On a mesh: An object containing the mesh of

the projection surface is created and defined
as a Surface part type. The Stage information
must be Curved blank.
Binder
The contact for the blank's part held between the
blankholder and the matrix is bilateral. The
friction between the blank and the blankholder is
taken into account through a restraining force.
This one is applied to the blank's nodes defined
as belonging to the Binder inverse type object. It
is opposite to the elements' displacements. The
restraining force per unit of surface is defined to
be twice the fiction coefficient.

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The Binders force corresponds to the force

applied on the blank holder during the stamping.
It can be taken into account in the computation
of the restraining forces.
Locked nodes
If the user wants to lock the border of the part to
simulate a stamping process without sliding of
the blank border (lock drawbead or very high
blank holder force), he uses the Cartesian
kinematics attribute applied on an object
containing the nodes to block (or the edges).
Locked nodes are nodes staying in the plane perpendicular to the projection direction
(as a guide). So the translation must be Lock in the two directions perpendicular to the
projection direction that must be kept free.
Drawbead
Drawbeads can be used during inverse
simulation. An object (undefined object type)
containing the nodes (or the edges) of the part
mesh where the drawbead is located must be
created. This object must have the Inverse
condition Drawbead line with the definition of
the Drawbead restraining force value.
This drawbead restraining force will be taken
into account in the inverse restraining forces
computation.

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Filleting
Non filleted part can be used during the inverse
simulation. An object (undefined object type)
containing the sharp edges of the part must be
created. This object must have the Inverse
condition Filleting radius with the definition of
the Local radius of fillet.
It is also possible to take into account the
bending phenomenon in the fillet by selecting
the Bending radius action and fulfilling the
Curvature radius parameter.
Stick option
The stick phenomenon is to define a
certain part of the blank stuck to the
punch. This will ensure little
deformations and thinning at the
bottom of the punch; these will be
allocated on the curved areas of the
punch. This option enables to consider
the deep sheet metal forming of a
blank.
Stick model
The part of the blank, which is in contact with the punch, is placed underneath the
bottom of the punch. This part is pushed in the matrix, without being subjected to any
deformations. On the other hand, the blank's parts, which are underneath the curved
areas of the punch, will be caught between the punch and the matrix wall. This explains
the strong deformations and the strong variations in the thickness, at the level of this
area and above. This phenomenon will protect the blank's part, which is underneath the
punch.
The user has to separate the part in two
objects part_bottom and part-wall (part
type), and to activate the stick option for
the part_bottom object.
Warning
The Stick option works at the level

of the curved areas of the stamped
blank. However, the Stick option
has to include a part of the
surrounding flat areas.

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Export mapping
See Mapping chapter for more information on this option
Automatic creation
When the user is working in an existing project of any type (AutoStamp, QuikStamp
Plus etc), it is possible to automatically:
-
Create a new inverse project
Import the object to simulate
Fill the macro appropriately
Do the data setup

New project
Importing and
Meshing the
CAD
Data setup
Automatic
creation
Inverse solver
Analysis of the
results
The new inverse project is then ready to be launched.

From the design module, with the automatic creation:
-
the user can do a part check:
The mesh can be re-done with an inverse mesher
The data preparation can create automatically a project that can be launched
The user can check the feasibility or obtain the initial blank after the die creation:
The mesh of the whole die is done again using an inverse mesher
All the die is put in the part
In the project automatically created the user has to separate the binder
The user updates and applies the macro
The project can then be launched

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From the set-up module, with the automatic creation:

-
the user canto do a part check on the part only and to have the initial blank size
The mesh is not modified
The data preparation creates automatically a project containing only the part. It
can be launched directly
Entry points
The user is able to do an automatic creation from two entries:

-
In the Diemaker module, as 'part check'
In the Setup module, as 'Blank unfolding'

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Data preparation
This function allows the user to input

data to create automatically an inverse
project
-
Part geometry: The input
object(s)
to be exported (multi selection
allowed) have to be defined. From
the design module, it will be
automatically the Part object of
Diemaker This option is not
available if the Build inverse mesh
option is selected, since all the
surfaces will be meshed again with
inverse mesh.
Part object: It
Build inverse mesh:
Material and thickness definition:
Projection direction:
is the name of the

output object for the inverse
simulation.
In the Diemaker module, the surfaces are available. It is then

possible to use the inverse mesher to produce a structural mesh. By default this
toggle is activated when the menu is opened from the design module.
A material has to be defined from the material
database. From the Set-up module, the material and the thickness are read in the
attribute tree if they are already defined.
It indicates the direction from the final geometry to the initial
one. This will introduce an automatic orientation of the part object. From the design
module, by default it is automatically Z of the tipping frame.
Results
Visualization of flattened part
The flattened part can be visualized in the State 1 of the simulation.

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Export flat blank contour

From the flat blank, it is possible to create an iges curve corresponding to the blank
contour. The 3D curve editor enables the creation of a curve from free edges. It is then
possible for the user to export the 3D curve in IGES format using the export
functionality.
Contour results
All the contours are available only on membrane fiber. To have them in several fibers,
the user must define several Layers in the Advanced parameters attribute. See Contour
chapter for more information.
It is possible to display:
-
Thickness: value and thinning
Mesh Quality
FLD
Undercut
Strains values and tensor
Imported contours
Stress values and tensor
User defined contours
Displacement
Attribute
Position
Refinement level
Distance between objects

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FOR TUBE
INTRODUCTION
A complex stamping simulation process can be broken down into several phases, each
being performed by PAM-TUBE 2G. Three main process phases are available:
-
Tool design: PAM-TUBEMAKER enables the user to create a complex tool setup
from the initial part CAD data (see Design Module section) and load these tools for
subsequent setup of bending and hydroforming processes.
Quick evaluation for bending: A PAM-INVERSE simulation is easily performed

with the straight and bent tube created by PAM-TUBEMAKER, and requires a
limited number of input parameters. It gives the user an evaluation of the
formability of the bending process even taking account effects of ovalisation during
bending.
Simulation: Accurate tube forming calculation using PAM-AUTOSTAMP can be

divided into several stages: gravity, bending, preforming, hydroforming, springback,
Process parameters which are entered into these stages are adjusted and validated
so that the obtained results are used to improve the real forming process as much as
possible. Moreover, the hydroforming process may be optimized automatically in
order to reach an objective.
All the above phases of the program mutually influence each other. Iterative process
of tuning leads to the continuous quality improvement of results.
In the following chapters, the methodology to follow will be described in order to

achieve the following purposes:
-
Tool design for bending and hydroforming, driving all setups and computations.
Simulation of bending :
Feasibility : Quick evaluation for bending using the inverse method
Accurate tube bending: incremental explicit approach simulating the process

with the tools and process parameters.
Simulation of hydroforming processes :

-
starting from results of simulation of bending or from estimated data using the
Simplified tube bending (analytical method).
With optimization of the hydroforming process

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Procedure
A tube project (of type AutoStamp for the final accurate simulation of the process) has
to be created first.
Using the new project item of the File menu or with the
icon of the standard toolbar,
the following dialog appears for defining the kind of project to be created:
-
The Context must be set to Tube : this is needed for using tubemaker, to get access
to specific functionalities and GUI design and all predefined groups and macros
specific for tube.
The solver Type must be set to AutoStamp for managing the complete design and
simulation.
Then, in the setup of the project, the final tube part is imported as a part inside PAM
TUBEMAKER module of this project.
The complete tube (with its addendum) and the tools for bending, pre-forming and
hydroforming operations are then performed in the TUBEMAKER module, following
the toolbar :

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For editing operations, there is a separate toolbar:
From the TUBEMAKER module of the project, the user will select the activity he
wants to perform with the
icon:
choose between classical, freeform, stretch or press bending. For classical bending,
more are options available:
feasibility study of the bending (One Step method): it will create automatically an
inverse project for tube with the setup and launch the computation. Results of the
computation can be analyzed in the post processing of this inverse project.
accurate tube bending simulation : the tools of the bending process can be built (also
the initial tube mesh) and they will be transferred from TUBEMAKER into the
setup of the project. Here the user will define the setup with macros and launch the
accurate tube bending simulation.
accurate tube hydroforming simulation : the tools of the hydroforming process can
be built (also the initial tube mesh) and they will be transferred from TUBEMAKER
into the setup of the project. Here the user will define the setup with macros and
launch the accurate tube hydroforming simulation. In that case, moreover, results
from bending simulation can be used, coming:
-
from the accurate bending simulation. The tube resulting of the simulation of
bending is picked in the hydrofoming setup.
from feasibility study by importing mapping from the results of the inverse
project ran before : this attribute has to be defined in the setup.
or from an analytic computation called simplified tube bending which can be

performed in the setup.

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CUSTOMIZATION
hydroforming process, see the Process Macro Chapter in the Simulation concept
The macro is created by the Advanced user, who defines the stages, diagram of the
process, groups of tools, default process attributes and the attributes that will be
Data base
advanced user can create other macros that suit the usual processes of the users. It is
Customization menu.

requirement. It is only available for the advanced user, meaning that the Advanced
mode must be activated in the Customization menu (it can be done by default, in the
-

Customization
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that appears is used for a process macro definition.
It is advised to start from an existing macro, since it is easier to modify one than to
create a completely new macro.
Procedure
3. Schematic drawing of the groups (tube, pistons, upper and lower dies, pistons, balls,
etc)
4. Behavior definition with creation of parameters if necessary.
5. Attributes definition with creation of parameter if necessary.
modified, appears:
-
The tube group is called Tube, it is a single blank.
One parameter is created: the Thickness, as a real value, applied to the Tube.
After the creation of the first stage, the tube and the process pages are defined. A
common tools between stages (like between two bending stages). With this option all
predefined tools are automatically drawn in the diagram.
After the creation of the first tool, a new parameter is automatically defined: Friction, as
a real.

Customization
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If the Keep tools option has been used when creating the new stage, the unused tools
have to be removed from the diagram.
The Behavior icon must be dragged onto the tools or the tube.
defining the behaviors, such as the Advanced parameters attribute may be checked and
modified if necessary.
Additional attributes can be added.
6- Parameters creation
Depending on the stage type, many end-user parameters can be set in the macro (the
Thickness and Friction real values- being automatically created in the macro):
Uniform level of refinement: integer.
Maximal level of refinement: integer.
Mass scaling: real value set through a wizard.
Remarks
-
not automatically defined when putting tools in the

diagram. This attribute must be set sometimes for the closing stage.
Control
Control:
CPU Control:
CPU Control:
attribute: It is partially filled and must be completed by the advanced user.

The stop criterion must be defined (Pinch test for High quality simulation). The
Start at option must be defined as 0 with the recomputed option, so that the
progression. The states output can be defined by default using the total number. The
restart output could be synchronized with the states, and a number of history outputs
can be imposed by the supervisor as a cycle period for prints.
Mass scaling must be activated (it is not automatically defined) with a

corresponding parameter defined as real with attached the mass scaling wizard.
information for implicit springback stage. It will be filled in by the end-user of the

Customization
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macro, depending on the case. The boundary conditions on points attribute should
not be added, in case of explicit springback. It is better to do the simulation with a
completely free blank and to lock it in post process.
Automatic creation of a New Process Macro for bending

There is an option to automatically create a process macro for tube bending using
the Tube macro builder:
As the tube bending process does not only depend on the tools, but is also very much
defined by the bending curve, the user here selects which bending curve to use, and
based on that, the correct bending parameters will be read from the curve and fed into
the macro, enabling the user will get a almost ready to go process description. Only the
forces and amount of movement of the tools plus of course material data need to be
defined.

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Two types of database are available:

-
Public:
Private:

Customization
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Chapter.

the Deltamesh page of the Customize menu. It is necessary to check at least once that
the proposed default meshing strategy fits with the type of simulated part and with the
modify it.

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TUBE DESIGN MODULE (PAM-TUBEMAKER)

The tool design process generally starts with the final part geometry. The difficulty is to
go backwards to the beginning and design a process with the needed tools and
parameters, which will ensure the feasibility of the part. The way to go to achieve this
depends on the availability of data.
If no tooling information is available, the user will normally start with the part geometry
and construct his tooling from there. If more information or data is available, some steps
might be skipped. For the sake of completeness, the whole process, assuming only the
final part geometry is available will be described.
The normal tool creation process is usually divided into several steps as the following
diagram illustrates:
Import part CAD and mesh creation

of the part
PAM-TUBEMAKER:
Creation of the tool and process design
Tipping
Part preparation
2D-strains evaluation
Addendum creation
Bending curve determination
Tool creation
PAM-INVERSE:
Evaluation of the bending process
PAM-AUTOSTAMP:
Evaluation of the bending or /and
hydroforming process

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The steps in the TUBEMAKER module will off course also vary depending on if
hydroforming and / or bending are to be performed. But basically, PAMTUBEMAKER offers the full flexibility to handle different scenarios. Depending on if
the bending simulation will be done using the PAM-INVERSE or PAM-AUTOSTAMP
solver, the process and tool design are slightly different. Both cases will be described in
this chapter.
Import of CAD Part, Meshing

Two possible ways of initial data loading are available. The user can either import an
existing mesh of the component using the Project / Import / Mesh option or use Project /
Import / CAD menu to import a CAD surface then mesh it. The latter uses the DeltaMesh
interface to perform the import of the CAD surface and its meshing. This is also the
preferred option to load the part geometry, as it will ensure full surface export at the end
of the die design process.
By default, the standard tool-meshing parameters are satisfactory. The only
recommendation is that the elements should be small enough at the part outline (to have
enough nodes to connect the profiles as described later).
Note:
Double surfaces should not exist in the model; furthermore the mesh should be
connected around part outline and in the neighborhood of any holes.
The procedure for tool meshing is as follows:

-
Create a new project, select Tube

option

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Select Import part CAD
Click Import & transfer in order

to automatically put the resulting
mesh in the Design module,
where TUBEMAKER will be
used. It is recommended to use
the meshing strategy
Springback or compensation.
If the mesh needs to be checked

first, select Import & check.
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PAM-TUBEMAKER: Creation of the tool and process design

General concept
The methodology within PAMTUBEMAKER is straightforward and
intuitive: starting from the part geometry
one works his way through the various
phases and ends with the die face
geometry.
Part preparation and tipping
The user always starts with an initial

tipping (the part is moved into the correct
forming orientation), in order to make
the best use of the following preparation
features. The tipping angle can be
adjusted again after part preparation, if
required.
Addendum creation
Then the user will do a preparation of the

part geometry, as there might be areas on
the part geometry that cannot be taken
into account as a tool face.
Define base tube
Separating plane
Bending curve
Transfer to setup
Then the base tube will defined using a 2D-based strain estimation. Based on that, the
addendum design will be performed. As soon as this phase is finished and satisfied, the
user can generate a separating plane and a bending curve. Following that, the tools for
simulation will be generated. As a last phase, he can export the 3d surfaces to CAD or
move from the design stage to the setup stage and continue with a simulation.
The user will be guided through the different steps following the toolbar from left to
right:
Part Preparation and tipping
Before the real design work can start, some preparatory work needs to be done (if
applicable):
-
tipping
define symmetry or double part

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create transition area
hide flanges
defined part outlines (tube ends)
fill holes
rolling cylinders
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Tipping
PAM-TUBEMAKER supports multiple coordinate systems: one global system and

several local systems. The global coordinate system refers to the imported CAD
coordinate system, while the local coordinate system should be used as a stamping
direction.
In order to correctly generate the upper and lower tools, it is necessary to find the
correct closing direction, or 'tipping, for the part. Hence, the user first creates a new
coordinate system. Usually, the user would let the program calculate the tipping
direction automatically, which is done via a maximization of Projected surface. When
required, the tipping angle can be adjusted or defined manually.
Once the proper orientation is found, the newly created coordinate system needs to be
activated. Several verification functions are available, such as visualization of a preview
of upper and lower tool and draw-depth by contour values. Also, the newly generated
coordinate system can be exported to a CAD file in IGES or VDA format.
Define Symmetry or Double Part
See the Diemaker section for explanation of the symmetry definition.

Create transition area
See the Diemaker section for explanation of the symmetry definition.

Fill holes
The program will automatically try to guess which two holes are the end faces. If this is
not correct then select the two holes (by holding Shift) and select Set as end face.
All other holes should be filled.
See the Diemaker section for explanation of the hole filling.
Rolling Cylinder
Rolling cylinders can be added along the outline of the tube in order to smooth this area,
before adding the addendum. See the Diemaker section for explanation of the rolling
cylinder definition.
Define base tube
Once all the preparation work is done, the first objective is to find which base tube
(cross section / diameter) can be used. The first step is to generate a centroid, which will

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describe the centre of gravity of the part geometry (of the geometry itself, not of the
volume described by the part).
Centroid
The generation of the centroid is automatic. PAMTUBEMAKER automatically tries

to guess how many control points
are needed to describe the part.
The user can easily change this by
pressing more or less complex part
buttons.
The centroid can also be edited manually directly in
the 3D-view by using these icons:
The possibility to lock movement in 2D-plane is

given.
Note:
The centroid should describe a smooth curve too many control points or a too
nervous curve can lead to problems in the generation of cuts and automatic
bending curve..
Cuts and strains
Along the centroid PAM-TUBEMAKER will then generate 2D-cuts. The number of
cuts automatically proposed is depending on part size, but can of course also be
changed by the user.
Once the cuts are generated, the circumferences will be displayed in a 2D-view. Based
on the smallest circumference found, PAM-TUBEMAKER will propose a base tube
diameter. The user can then activate this, or another choice of his own. Up to 3 different
circular base tube diameters can be compared. In addition a conical tube or a user
defined cross section can be defined.
Based on this choice, the strains in 2D can be calculated. These can be used for an early
feasibility check of the part.
In the same graph, the curvature from the centroid can be displayed. This information
can be used to get information on where strains from bending are to be expected.

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Other features:
-
the length of the tube is calculated and displayed
x-axis can change between cut no and tube length in mm
min and max strains are displayed
strains and circumferences can be printed or saved as ASCII files for further use
single cuts can be viewed and edited in a separate 2D-view
Notes:
The curvature is only displayed from a qualitative point of view, not

quantitative.
Negative strains can be displayed, but can lead to problems in production.
User defined cross section
PAM-TUBEMAKER offers the possibility to

define user-defined cross
section. These can either be
imported as dxf-files or created
/ drawn by the user in a
separate 2D-window.
The user has full flexibility to create any cross
section. A cross section can
consist of any number of
straight lines and circular parts.
The cuts or tube ends are
available as references.
The cross sections generated here can be used
for PTL / addendum creation
and for tube meshing.

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The can be saved and loaded in separate files

(*.ptl) in order to be reused in
different projects.
Notes:
At least one straight line must be part of a cross section.
It is not possible to have two circular parts next to each other.
It is allowed to have straight lines next to each other.
The profile must be closed and can not be sectioned.
The selection done here for base tube diameter / cross section is not final, but
will be stored for later use.
Addendum Creation
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One click addendum
There is a One click addendum option, which works for standard parts. This creates all
the objects needed for the addendum, and joins the surfaces with the original part.
Manual addendum creation
For more complicate parts, or if the user wants to do a special addendum, then this can
be done manually in a four step process, going through the tabs in the dialog:
1. Define shape and position of the
Profile Termination Lines (PTL =
where the new part + addendum
will end). A PTL can either be a
circle or a user defined cross
section see above.
By default the PTL is copied from
the base tube shape and diameter
defined in the 2D strains dialog.
The distance is by default the
double diameter, and the tubular
part 2/3 thereof.
2. Define 2D-profiles between the

part outlines and the PTLs. These
profiles are used to describe the
addendum area. Profiles are added
to the part geometry by simply
clicking on the part border: the
profile is then automatically
visualized in 3D if the 2D editor
is open, it is also visualized here.
By choosing the automatic option,
the program automatically
distributes the given number of
profiles around the circumference

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and adds connection lines.
3. Generate the addendum surfaces.

Based on the profiles and the
tangency of the end surfaces of the
part, and addendum surface will be
generated. 3D nurbs surfaces are
fitted between the profiles and will
be created such that there is full
tangency on the control lines.
4. Combine the new surface with the

part.
Notes:
Before shaping the addendum, it is assumed that the part edge is complete and
free of gaps. It should also be as smooth as possible i.e. without serrations
(see Rolling Cylinder).
The surfaces generated in step 3) are only temporary surfaces which are not
connected to each other, and are not smoothed. The quality will improve once
the surfaces are combined with the part.

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Meshing quality is based on the user-defined settings in the customize menu,

(TUBEMAKER page, Meshing options).
When surfaces are combined with the part, the part outlines, the centroid and
the cuts are updated automatically in the background..
Profile
The
profile
offered
by
PAMTUBEMAKER consist of two parts one
straight (tubular) part, and one transition
area which is a spline curve. The
transition area connects the part and the
straight line ensuring a tangential and
smooth transition area.
Once the profiles are attached to the part geometry, they can be modified in the 2D or
3D screen by dragging-and-dropping or in the 2D editor by changing the specific profile
parameters. Modifications to the profile parameters can be stored for usage in other
projects.
Notes:
The parameter settings can be copied to use with another profile (same type) by
clicking the copy button in the 2D editor: the next profile that is attached to the
part geometry will then have the same shape. To go back to the default settings,
one has to click reset.
Profiles can be moved to another location by dragging the start point to a new
node. The way the profile is moved, depends on the setting in the customize
menu (TUBEMAKER page, addendum options)
When modifying a certain profile parameter, other parameters also change.

Sometimes the user wants to lock one or more of these parameters so that
another parameter will change instead. To do so, a lock/unlock mechanism has
been implemented for certain profile parameters in the 2D editor. Moreover, for
each profile, there is a toggle in the 2D editor that can be checked in order to fix
the end point of the profile.
Connecting lines
Connecting lines offer the possibility to influence the creation of the surface by adding
control lines. There are two main areas of use:
-
At the edge between tubular part to transition area. Without control lines, the tubular
part surfaces will be influenced by the topology in the transition are. By setting an

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additional circular control condition here, the quality of the surfaces in the tubular
part ins improved.
-
In complicated addendum designs, there might be a need to add additional control

lines between the profiles.
Separating plane
Based on the tipping direction and on the cuts, PAM-TUBEMAKER will automatically
create a separating plane.
Smoothing functions
(global and local) are
built in for better result.
The level of smoothing
can be decided by the
user.
Smoothing can be
applied before or after
manual editing of the
separating plane.
The width of the plane
is by default half the
chosen base tube
diameter, but can be

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The separating plane can

be edited manually in a
separate 2D-view.
Click and draw the green spots marking
the crossing between
separating plane and part
in order to modify the
plane.
If the button Save
is
activated, the change can
be seen directly in the
3D-view.
changes on the fly
If the Move all option is

selected, then by
clicking-and-moving the
2 wheels on the side, then
the whole separating
plane will be moved
within the given
tolerance. This is helpful
when the model contains
vertical walls, and the
plane is nervous.
Note:
The separating plane is not a CAD-based plane it is only a visualized plane to

show the user where the part will be cut in order to generate the upper and
lower tools.

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Bending curve
Creating a bending curve
The bending curve generation consists of an

automatic and a manual module. The automatic
module is only available if a design part is
available. In case of bending only projects, the
bending curve has to be built manual or
imported from a file.
Bending curve generation modes:
-
Automatic mode, features:
Automatic guess of number of needed

bends
Automatic search for the same bending

radius for all bends
Possibility to restrict segment length

and minimal bend radius
Optimization of the position of the

bending curve based on the trimming
curves from the separating plane
Evaluation of maximal distance to the

centroid
Keep the end direction this forces the

program to use the normal direction of
the endfaces as starting and ending
direction
Shorten the bending curve by a given

amount this to make sure the tube is
well inside the tools and no problems
occur during closing
Manual mode, features:
Add, edit or delete points in excel-style

table of in 3D-view
Set all radii the same with one click
Direct access different local planes of

the bending curve with one click
Enforce 2D-mode of the curve (in the

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separating plane)
By pressing the Preview button, a preview of
the tube to be bent will be shown in the 3Dview.
The current length of the bent tube based on the
bending curve is also displayed.
PAM-TUBEMAKER supports several bending
curves in the same project for variation studies.
For the generation of the meshed tubes and the
bending tools, a bending curve, and the
parameters for bending and the base tube have
to be selected.
Note:
In some cases it is not possible to generate a bending curve with the given
parameters. In such cases, PAM-TUBEMAKER will mark the problem areas
(normally overlapping) with a red star in the 3D-view.

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Selecting bending curve & method
In the select bending method & tube

parameters dialog, the user decides which
bending curve and which tube parameters to
be used.
Select a bending curve by clicking in the list,
or by selecting in the 3D-view.
PAM-TUBEMAKER will automatically
propose, based on this data, which bending
method should be used. This can of course be
overridden by the user.
For the AutoStamp calculation, the user can
choose between Classical, free form, stretch or
pressbending.
This decision will influence the further
workflow.
Note:
Once the decision has been made, it

should not be changed until a whole
set of tools and tube(s) has been
generated. Using different setting for
different tools/tubes might lead to
solver crash.
The user can decide on which side the tools/tube(s) will be generated. By default this is
the left side which will be indicated by a marker in the 3D-view. The meaning of this
option has different influence depending on which bending method is selected:
-
No bending ( straight tube)
The tube will be generated starting from the PTL on the selected side. If the left and
right PTL are not parallel this will lead to different results.
-
Simplified bending
OneStep calculation
No influence the tube will be generated along the bending curve.

The straight tube will be generated starting from the PTL on the selected side but
this has no influence for the calculation.
The bent tube will follow the bending curve and will have differences.

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If the cut correction is set, this will lead to minor differences if left or right side is
chosen.
-
AutoStamp calculation
The tools will be generated on the starting point of the bending curve on the selected
side.
The straight tube will be generated positioned for the first bend, starting from the
selected side.
Note:
Conical tubes are not compatible with Simplified bending or with AutoStamp
calculations. User defined profile is not compatible with Simplified bending or
with AutoStamp calculations.
A bending curve can be imported (as a *.dat-file) which format is in this form:
point no x y z
0 x0 y0 z0
1 x0 y0 z0
where the points are the crossing points of each bend.
Tailored tubes

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The user can choose to use a tailored tube as a starting point. The thickness and the
diameter can be changed in the length-direction of the tube. For different thickness in
circumference direction, please use the rollforming mapping import (see below).
The number of sections, their position, the diameter and thickness can be set by the user
either by sliding in the 2D-view, or by editing the values in the table.
Continues transition would be the equivalent to tailor rolled tubes, whilst Transition
with steps would be equivalent to tailor welded tubes.
The user can choose to either keep the outer or the inner diameter of the tube constant,
or to keep the centre of the tube constant.
Note:
At the moment tailored tubes is only supported for circular tubes.
Again which options will be active here is depending on what is selected earlier, and if
a part is available or only bending is performed.
Tools for hydroforming
The creation of the upper and lower tools is based on the separating plane. Using that
trim curves are generated which are 3D-polygon lines describing where the part is going
to be cut. These 3D-lines are generated as objects and can if necessary be edited in the
Geometry editor.
Once the part is cut and two new objects are created, the user can chose if he wants to
add flanges and at which angle and with which width these are to be added.
There are two types of pistons included in PAM-TUBEMAKER flat or shaped.

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local coordinate system (frame) will be generated, which can be used later in the setup
to describe the movement of the pistons.
Notes:
Flanges can be generated in a way which is not feasible in real life. Still this can
be calculated using PAM-AUTOSTAMP. For an early feasibility check this can
be useful; if the hydroforming step fails, no time has been wasted on finding a
closing or preforming step that works. Results using non-flat flanges should
though always be evaluated with caution.
Shaped pistons are only available for circular cross section. For user defined
cross sections, automatically flat pistons will be generated.
Tools for performing
There is an interactive method to generate

preforming tools. As the design of
preforming tools is very much depending
on the part geometry and the
manufacturing strategy chosen by the
engineer, the application is programmed
very flexible.
The user starts by adding areas or planes
where preforming tools should start or
stop by clicking anywhere on the model.
These can be moved by click-and-draw
along the part.
Then tools are defined between 2 of these
temporary planes. Tools can either be
quarter or a half of the part.
After the tool creation, flanges can be
added in any angle and width.

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Sample of preforming tools created.

Mesh tubes
In the case that simplified tube bending is chosen, this step is not necessary. In all other
cases, a straight tube will be generated, and for the case that one-step bending is chosen,
also a bent tube will be generated.
Several tubes can be stored in the same project, both bent and straight tubes.
No of elements
The number of elements is automatically proposed by PAM-TUBEMAKER. The user

can easily change the number of elements in circumference. Normally 40-50 elements
are recommended. The optimal number of elements in the length direction is then
automatically calculated. It is not recommended to change this.
Weld line
PAM-TUBEMAKER includes an option

to incorporate a weld line. The weld line is
element based, and by default the width of
the weld line is 1 element, and that of the
heat affected zone is 2 elements.
Rollforming
PAM-TUBEMAKER includes an option

to incorporate thickness and strain
variations introduced from Rollforming of
the tube. Every line of elements in length
direction of the tube can have a different
thickness and pre-strain. This is written to
a mapping file, which must be added in
the setup. This option is only available for
autostamp bending..

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Properties for bent tube
Cut correction
When meshing the bent tube, the plane of elements where the transition between
straight part and bent part will sometimes lead to too extreme values in the
calculation of the strains depending on the discretisation of the mesh in
comparison to the bending curve. Using this option will distribute that transition to
the 2 element rows before and after the transition row which will lead to smoother
and more realistic simulation results in these areas.
Boundary conditions
Either the tube can be fixed at the ends or for each bend in order to take into account
the effect of the clamping of the tube during bending. Normally the tube is not
clamped directly at the end of the bend, but some distance into the tube. By default
this value is 2 element widths, but can be changed individually by the user. Adding
boundary conditions will restrict strains and thinning etc. to within the area of the
bend which is closer to reality.
If boundary conditions are selected, a separate object containing the nodes which
belong to the boundary conditions will be generated. This will be named name of
bent tube + BC.
Boosting
Boosting can be incorporated by stretching the straight tube in the areas of the bend.
Different boost values can be applied for each bend. A value of 1.1 will mean that
the bend will be stretched by 10%. During calculation this will mean that that part
will be shortened which is the effect of boosting. If boosting is applied, it is
strongly recommended to use boundary conditions per bend, to avoid the effect of
boosting to be spread too far into the straight parts of the tube.
Ovalisation for bent tube
During bending the shape of the tube in the bent areas will change its no longer
circular it will get an oval shape. In cooperation with Uni Siegen and analytical model
for calculation of this change of shape has been developed and implemented in PAMTUBEMAKER. This change of shape of the bent tube will significantly change the
results of the one-step calculation which will again lead to more realistic results.
In order to calculate this effect, the user needs to enter the material properties to be
used: Unit system, E-module, Tensile strength, Yield stress and Uniform elongation.
Proposals for values for mild and strong steel and aluminum have been included.
Notes:
Weld line is not available for one-step bending.
Ovalisation module is only available for bending without mandrel and not for
compound bending.
If the bend is too sharp to be feasible with one-step, but this is still chosen by the
user, the ovalisation calculation will be too extreme.

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Tools for bending classical bending
This option is only available if incremental bending is chosen. For each bend, one set of
bending tools will be generated, except the mandrel, mandrel balls and piston, which
there will only be one set of. The different tools that will be generated and the options
available for them are:
-
Pressure die
Length, position (in length direction) and delta
height (dH) can be defined by the user.
Wiper dies
Length, position (in length direction), tilting (in
degrees) and delta height (dH) can be defined by
the user.
Piston
Shaped or flat piston.
Mandrel shank
Diameter, length and position (in length direction)
can be defined by the user.
If no mandrel balls are selected, the mandrel
shank will be generated with a half ball at the end.
Mandrel balls
The number of balls (if any) needed is
automatically calculated by the program, but can
of course be changed by the user.
Diameter in length and cross direction, gap, width
and distance to last ball (or shank for the firs one)
can be defined by the user.
Bend die
The bend die will be generated as a 270 degree
tool.
Delta height (dH) can be defined by the user.
Clamp die
An automatic check is included to see if
compound bending is found. This condition is
depending on the length of the clamp die. This
can be modified by the user, and a new check can
be forced.
For each clamp die, the user can define length,
position, delta height inner (dHi) and delta height
outer (dHo).
If compound bending is found, the user can select
if plain compound clamp dies are to be generated
or advanced compound clamp dies. The advanced

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clamp dies use the ovalisation prediction (see

above) to modify the shape of the clamp die to
better fit the tube, and reduce risk of slipping
during bending.
For all tools there is a possibility to add rounded corners where sharp edges are a
potential problem. The radius of the rounded corners are by default 2mm, but can be
Also a spacing parameter is available. By default 0.1 mm spacing will be introduced
between the tube and the tools. Because of the discretisation of the meshing, the tube
and the tools will penetrate during calculation if no spacing is selected.
For each bend and pressure die generated, a local coordinate system will be generated.
These will speed up the setup process.
All the bending data (points and information on bend operations) can be saved to a file
by pressing the Save bending data button. This information can be used for setup or for
setting up a bending operation on a bending machine.
Note:
Meshing quality is based on the user defined settings in the Customize menu,
(TUBEMAKER page, Meshing options).

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Tools for bending freeform bending
This option is available if the freeform bending

option is chosen.
One main roll will be generated, and on the other
side of the bend a user defined number of rolls
default is 3.
Diameter of each roll can be set individually, and
also the position.
In addition a piston can be generated.
Each of the rolls get a coordinate system allowing
the user to control them easier in the setup.

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Tools for bending stretchbending
This option is available if the stretchbending

option is chosen.
Two sets of clamp dies (upper and lower) will
be generated on each side.
In the middle a bend die will be generated, the
main diameter is taken from the bend curve,
but can be changed by the user.

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Tools for bending pressbending
This option is available if the pressbending option is

chosen.
Two tools will be generated, an upper and a lower one.
The contour of the dies will be taken from the bending
curve, so that the tools after the press
bending has been performed will form the
tube to shape the bend curve.
Transfer to setup
When all steps have been done, the generated tools and tube(s) can be transferred to
setup:
-
Generates an inverse tube project.

Use this button to open a predefined dialog which will automatically generate an
inverse project, and prepares to launch the inverse solver.
Transfer to tube bending.

Use this button to transfer the straight tube and all the tools to the setup module.
Also the frames will be transferred. The last macro is opened, and if that was a
bending macro, the tools will be predefined.

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Transfer to hydroforming.
Use this button to transfer all the tools needed for hydroforming simulation. Also
the frames will be transferred. The last macro is opened, and if that was a bending
macro, the tools will be predefined.
Transfer to simplified tube bending

Use this button if you want to use simplified tube bending. All the needed tools and
the bending curve(s) are transferred to the setup module. The simplified tube
bending dialog is opened automatically. The possibility to use this result for
hydroforming is given.
Depending on the selection in select bending method, not all buttons are active. Before
the bending method is selected, none of them are available.

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BENDING SIMULATION FEASIBILITY

Purpose
The inverse simulation allows the user to calculate the bending operation of a noncritical bend and/or to have information on the feasibility of the bending stage.
The starting point of inverse simulation is the Finite Element model of the straight
and bent tube both meshes are needed.
The inverse algorithms calculate the difference of the positions of the elements in the
two meshes. Once a displacement field is known that assures the equilibrium of the
nodes of the bent tube, it is possible to compute the residual thickness, stresses and
strains.
Element
nr. 1
Element
nr. 12
The meshes of the straight and the bent tube have to correspond.
Inverse simulation seeks to impose the equilibrium of the final configuration of the bent
tube. This is the most important simplifying assumption of the approach, which does
not take into account the shapes of the tube at any other point of the bending process.
As a consequence, strain paths are assumed to be linear (radial strain path) and the
effect of the history of deformation of the material is neglected. Also the fact that the
mesh of the final geometry of the tube is given, means that detection of wrinkles will
not be possible.
If there are no non-linearities during the process (non-critical bends), the calculation is
very precise. The more non-linearities that occur, the less precise will the results be.
Also the setting of boundary conditions will increase the quality of the results.

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Solver Characteristics
The characteristic feature of the inverse problem is that the unknowns are distributed
between the initial tube (straight) and the bent tube:
Known quantities
Unknown quantities
Initial tube
- thickness
- null stresses, strains,
displacements
- geometry
Bent tube
- geometry
- w displacement for a given node
- thickness
- stresses and strains
The problem can be thus posed in mathematical terms: find the stresses and strains so
that, given a field of displacement w, the bent tube is in equilibrium under the action of:
-
Internal stresses,
Reaction forces,
Friction forces,
In order to find the solution, we must find the minimum of the total energy functional:
Min u,v ((ij)+W(ui))
With:
-
: internal strain energy,
W: work of external forces.
The inverse problem in forming simulations is a static, non-linear problem.
Simplifying assumption of inverse simulation

-
Radial strains: the history of deformation is neglected, which is usually a small

error.
Radial
strain path
Actual strain
path
Static analysis: the history of contact between tools and blank is not taken into
account. Nonetheless, approximate models for contact history are available (stick
model). This is the most important source of error! Nonetheless, much of the
problems involved are solved using initial curved blank.

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Element
The inverse elements are membrane, 3- and 4- node elements. The formulation is total
Lagrangian, using large displacement and large deformation.
Material
The only material law that can be used is the Hill 48 isotropic hardening with
Krupkowsky hardening curve (See Material Properties).
Contact and friction

The contact data are:
-
The friction coefficient,
The bending frame.
Inverse project
Project creation
From scratch
The inverse method is used in an Inverse type project. This kind of project can be
created by the New project functionality.
The project must be of context Tube
and of Solver type Inverse.

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From TubeMaker as Part check
An inverse project can be directly created from TubeMaker of a project for checking the
part at an early design stage : this is the so called One-Step bending simulation.
From the Setup of an AutoStamp project
An inverse project can be directly created from the setup of an AutoStamp project as
described:

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In that case, the following dialog

is displayed and the user will in
one action:
-
create the inverse project
setup the simulation through

a macro
launch the computation
load the inverse project
The information to enter will be described below in the Data setup description.
Regarding the Solver host, the solver type associated to the host must be Inverse
solver.

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Data setup
Inverse macro
A specific inverse macro is available to simplify the data set up of an inverse simulation
(See Process Macro)

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Attributes
The available attributes are:

-
The material with thickness,
The bent and straight tube object type,
The friction,
The bending frame
See the Stamping inverse chapter to refer to the attributes available for an inverse
calculation.
Objects
The following objects can be activated in the macro:

-
Plane object to define the symmetry option at the symmetry plane.
The object defining the locked area if any (boundary conditions objects)
Bent tube object

This object will form the final part object. In its inverse object attribute, the Part type is
set to Part.
Straight tube object

The name of the source object that will be used by the solver to compute the inverse
project. In its inverse object attribute, the Part type is set to Surface because it is
considered as the initial surface on which the tube is reset.
Boundary conditions objects

The objects have the attribute Cartesian kinematic, with lock displacement set. This
means that their nodes will not move on the surface during the equilibrium (after the
displacement from the straight to the bent tube) . It is used to control the feed by fixing
some sections of the tube.
Results
All the contours are available only on membrane fiber.
It is possible to display:
-
Thickness: value and thinning.
FLD.
Strains values:
Major and minor strains.

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Strain mode.
The directional strains .
The Plastic Strain.
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Strains tensor:
Tensor of Major Strain.
Tensor of Minor Strain.
Tensor of both Major/Minor.
Stress values:
Major and minor stresses.
The directional stresses.
The max and min absolute stresses.
The equivalent stress.
Stress tensor:
Tensor of Major Stress.
Tensor of Minor Stress.
Tensor of both Major/Minor.
Displacements.
Mesh Quality.
Undercut.
Distance between objects.
Position.
Imported contours.
User defined contours.

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TUBE BENDING
The accurate tube bending simulation is done using AUTOSTAMP. Once tools are
imported, or created in TUBEMAKER and transferred in the setup, the simulation is
defined with macros and the user can launch the simulation.
Several Possibilities to Start Tube Bending Calculations

Tools and initial tube have to be imported in the setup. Different possibilities are
available:
Tools are imported (user-defined profile):

In that case the tools have to be imported and meshed. The profile shape does not have
to be circular, and can also consist of more than one closed profile.
CAD Design
To do the simulation the user first needs the CAD surface of the tools. Please refer to
the DeltaMESH section for specific details on export options for each CAD system.
This CAD will be subsequently used to perform the meshing of the tools. In order to
obtain realistic results, the tools used in the simulation, which are represented by
meshes, must be completely filleted as they are in reality. A sharp edge leads to a likely
rupture of the tube, just as in reality. However, all fillets do not need to be created in the
CAD, since the filleting can be performed directly on the mesh. This solution can be

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faster, since a mesh, unlike CAD, has no holes or surface overlaps, which facilitates the
filleting.
Meshing Criteria Definition
The meshing is controlled by: Algorithm type, Size of elements, Chordal error, Angle
criterion and Automatic remeshing parameters. For more details please read the section
DeltaMESH.
The rules for meshing are stored in strategies and a strategy is selected when importing
a CAD model. Some strategies are preset and the recommended strategy for meshing
the tools for a bending or hydroforming simulation is the Validation strategy; (the
defaults one for project of type AutoStamp).
For most cases, the following meshing rules are recommended:
-
Chordal error: 0.15 mm.
Angle criterion: 15 for a calculation without springback or 7.5 for a springback

calculation.
Minimum element size: between 0.1 and 0.5 mm.
Maximum element size: 30 mm.
The meshing can be very heterogeneous.
Very elongated elements are accepted.
3-node or 4-node elements can be used.
It is common to end up with several thousands of elements for the meshing of the initial
tool.
In the Validation strategy, the following parameters are set:
Algorithm is Parametric by default.
Activation of the quadrangular surfaces detection with a Density variation
coefficient equal to 1.2.
Minimum element size is 0.1 by default.
Maximum element size is 30 by default.
Chordal error / Maximum distance is 0.15 mm by default.
Angle criteria / Maximal angle is 15 by default.
Automatic remeshing activated by default
Note:
meshing strategies can be modified in the Customize menu, to best fit the cases
usually meshed by the user.
Initial Tool Meshing Quality Control
The user is strongly advised to avoid free or multiple edges inside the mesh, since their
presence could not only impede the execution of an offset during the generation of
tools, but also affect the results accuracy if the holes or overlaps reach 10% of the tube

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thickness. Moreover, the user must check that there are no undercuts in the mesh. Even
if the initial CAD is free of undercut, the mesh can induce undercut in non-planar
vertical parts. For example in the curved vertical surface, if the discretisations on the top
and bottom lines of the surface do not coincide, there will unavoidably be some
undercut elements.
Top view:
A
Cross section AA:
Edges on
bottom line
CAD
CAD
A
Edges on
the top line
Mesh
the Chordal error. To eliminate or reduce the undercut reduce the Chordal error during
the meshing process.
To assure the mesh quality, the angles between the normals of the neighboring shells
(Mesh Quality / Shell joining angle / Angle between shells contour plot) should be
checked; they must not exceed 20 for the fillets (10 if a springback calculation is
planned), and 30 for the rest.
Mesh Orientation
Be careful of the contact type used in the process. There are several contact types
available in the program, some of them have a dependency on the mesh orientation
(penalty, Lagrangian and implicit contacts).
Penalty, Lagrangian and implicit contact
If the penalty contact will be used, the user has to orient the normals of the tool
elements consistently into one direction such that they define the contact surfaces of the
tools. The normals must point towards the blank.
Accurate contact
With Accurate contact, the mesh orientation does not need to be worried. Implicit
gravity simulation uses a specific contact that needs the mesh orientation.
How to proceed
The procedure for importing the tool is as follow:
-
Import tools CAD.

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Select the CAD file(s) corresponding to the tool
Select the Meshing strategy, which should be Validation Check/modify the

Meshing size. It is linked to the size of the model and will be used for for all the
tolerances of CAD and mesh cleaning (joining tolerance, removal of thin
surfaces )
Import & Transfer or Import and Check:
If you select Import and Check, the model will be imported and meshed inside a
DeltaMESH module. For more details please read the section DeltaMESH. After checking
and remeshing, you transfer then the mesh to the setup using the Update setup
functionality:
Tools are designed in TUBEMAKER:

When the bending tools have been created in the TUBEMAKER module it should be
transferred to the set-up, using the Transfer to Bending functionality (icon
in the
TUBEMAKER toolbar), or using the Update setup functionality with the Design->
Tube bending setup rules :

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For the first transfer a Workflow transfer rules menu appears. It has to be check and
design of the process and the simulation) see the Iteration on Design and Stamping
feasibility chapter.
Initial tube is imported:

The(initial) tube can be imported through one of the available translators (Nastran,
Patran, Ideas) or from a CAD file as any other tool.
Initial tube has been built in the TubeMaker module:

The tube is then proposed at the transfer with the tools and has to be selected (replace
content of action).
The RollForming feature was used in the TubeMaker module:
The results of the rollforming estimation (on thickness and strain) have been exported in
a mapping file. See the section Tube Design Module for details. The Import mapping
attribute has to be set in the setup, pointing on this mapping file of the inverse
rollforming estimation.

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Tube is created in the setup module using the Tube editor:

The tube mesh can be created using the Tube Editor menu.
The Tube Editor allows to:

-
Create (and then modify) an object which will

be in the tube group.
Build (and replace) the mesh of the object

using the tube geometric definitions (radii,
length, position) and mesh size.
Set material data of the tube:
the data are

available (and retrieved) in the macros.

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Tube Bending Macros

There are two different macros for tube bending in the 2008 release:
-
Macro for 1 bend
The standard macro for simulation of 1 bend
Contains all the needed tools, incl. mandrel and 3 mandrel balls
Macro for 2 bends:
The standard macro for 2 bends
Contains all the needed tools, incl. mandrel and 3 mandrel balls
Separate bend and clamp dies for the 2 bends
Contains possibility to use freeze objects to speed up the calculation time
The above macros include:

-
Bending and feeding stages.
Autopositioning of the tube on the inner clamp/bend/wiper die, and the outer
clamp/pressure die on the tube.
Autopositioning of the piston/booster the tube.
Notes :
Rotation centres for the bend and the inner clamp dies need to be set manually.
When bending design was performed in Tubemaker, all important parameters
for definition of bending movement can be read from textfile, which was saved
during bending tools creation (see PAM-Tubemaker chapter)
Links between the mandrel balls need to be set manually.

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Macro for tube bending
Tube Macro Builder

If bending design was performed in Tubemaker, appropriate bending macros can be
filled in automatically by using the Tube Macro Builder.
Initialization button in Set-up dialog and Tube Macro Builder

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Based on data, which were used in Tubemaker during the bending design, the Builder
will set up all necessary parameters in the bending macro for each clamping, bending
and feeding operation, which will be performed in real process. The user has to define
only several process parameters like selecting the appropriate bending curve, rotational
speed of bending die, feeding speed of the pistons and ev. pressure die speed in % of the
tangential velocity of bending die. Those parameters have to be set in the Tube macro
builder dialog before opening the macro. In the macro itself (open by selecting the
Process button) all parameters will be filled in automatically, but the user should check
the material definition (usually missing), the pre-defined curves with forces and
pressures and all process parameter values. Applying the macro will create input for
bending simulation.
More about macros see Customization chapter.

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TUBE HYDROFORMING
There are two main methods to calculate tube hydroforming using AUTOSTAMP,
pressure controlled and using fluid cells. The choice depends on the available data. It is
also possible to do a fluid cell calculation using a pressure limitation to prevent
uncontrolled increase of the pressure.
Moreover, the piston feedings can be defined by the user or automatically computed in
order to minimize wrinkling or cracks on the tube.
Several Possibilities to Start Tube Hydroforming Calculations

Tube and tools have to be imported in the setup. Different possibilities are available for
the tools and for the initial tube, as results of a bending process (occurring before the
hydroforming stage):
Tools are imported (user-defined profile):

In that case the tools have to be imported and meshed. The profile shape does not have
to be circular, and can also consist of more than one closed profile.
CAD Design
To do the simulation the user first needs the CAD surface of the tools. Please refer to
the DeltaMESH section for specific details on export options for each CAD system.
This CAD will be subsequently used to perform the meshing of the toolsIn order to
obtain realistic results, the tools used in the simulation, which are represented by
meshes, must be completely filleted as they are in reality. A sharp edge leads to a likely
rupture of the tube, just as in reality. However, all fillets do not need to be created in the
CAD, since the filleting can be performed directly on the mesh. This solution can be
faster, since a mesh, unlike CAD, has no holes or surface overlaps, which facilitates the
filleting.

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Meshing Criteria Definition
The meshing is controlled by: Algorithm type, Size of elements, Chordal error, Angle
criterion and Automatic remeshing parameters. For more details please read the section
DeltaMESH.
The rules for meshing are stored in strategies and a strategy is selected when importing
a CAD model. Some strategies are preset and the recommended strategy for meshing
the tools for a bending or hydroforming simulation is the Validation strategy the
defaults one for project of type AutoStamp.
For most cases, the following meshing rules are recommended:
-
Chordal error: 0.15 mm.
Angle criterion: 15 for a calculation without springback or 7.5 for a springback

calculation.
Minimum element size: between 0.1 and 0.5 mm.
Maximum element size: 30 mm.
The meshing can be very heterogeneous.
Very elongated elements are accepted.
3-node or 4-node elements can be used.
It is common to end up with several thousands of elements for the meshing of the initial
tool.
In the Validation strategy, the following parameters are set:
Algorithm is Parametric by default.
Activation of the quadrangular surfaces detection with a Density variation
coefficient equal to 1.2.
Minimum element size is 0.1 by default.
Maximum element size is 30 by default.
Chordal error / Maximum distance is 0.15 mm by default.
Angle criteria / Maximal angle is 15 by default.
Automatic remeshing activated by default
Note:
meshing strategies can be modified in the Customize menu, to fit the best to the
cases usually meshed by the user.
Initial Tool Meshing Quality Control
The user is strongly advised to avoid free or multiple edges inside the mesh, since their
presence could not only impede the execution of an offset during the generation of
tools, but also affect the results accuracy if the holes or overlaps reach 10% of the tube
thickness. Moreover, the user must check that there are no undercuts in the mesh. Even
if the initial CAD is free of undercut, the mesh can induce undercut in non-planar
vertical parts. For example in the curved vertical surface, if the discretisations on the top

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and bottom lines of the surface do not coincide, there will unavoidably be some
undercut elements.
Top view:
A
Cross section AA:
Edges on
bottom line
CAD
CAD
A
Mesh
Edges on
the top line
the Chordal error. To eliminate or reduce the undercut reduce the Chordal error during
the meshing process.
To assure the mesh quality, the angles between the normals of the neighboring shells
(Mesh Quality / Shell joining angle / Angle between shells contour plot) should be
checked; they must not exceed 20 for the fillets (10 if a springback calculation is
planned), and 30 for the rest.
Mesh Orientation
Be careful of the contact type used in the process. There are several contact types
available in the program, some of them have a dependency on the mesh orientation
(penalty, Lagrangian and implicit contacts).
Penalty, Lagrangian and implicit contact
If the penalty contact will be used, the user has to orient the normals of the tool
elements consistently into one direction such that they define the contact surfaces of the
tools. The normals must point towards the blank.
Accurate contact
With Accurate contact, the mesh orientation does not need to be worried. Implicit
gravity simulation uses a specific contact that needs the mesh orientation.
How to proceed
The procedure for importing the tool is as follow:
-
Import tools CAD.

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Select the CAD file(s) corresponding to the tool
Select the Meshing strategy, which should be Validation Check/modify the

Meshing size. It is linked to the size of the model and will be used for for all the
tolerances of CAD and mesh cleaning (joining tolerance, removal of thin
surfaces )
Import & Transfer or Import and Check:
If you select Import and Check, the model will be imported and meshed inside a
DeltaMESH module. For more details please read the section DeltaMESH. After checking
and remeshing, you transfer then the mesh to the setup using the Update setup
functionality:
Tools are designed in TUBEMAKER:

When the hydro forming tools have been created in the TUBEMAKER module it
should be transferred to the set-up, using the Transfer to Hydroforming functionality
(icon
in the TUBEMAKER toolbar), or using the Update setup functionality with
the Design-> Tube hydroforming setup rules :

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For the first transfer a Workflow transfer rules menu appears. It has to be checked and
design of the process and the simulation) see the Iteration on Design and Stamping
feasibility chapter.
Notice that if a tube bending process has been previously defined inside the project
(with a previous TUBEMAKER transfer to setup for instance), this setup will be
completed. Another solution to have independent setup for bending and hydroforming
- is to save the tube bending project (with all its modules) as a new hydroforming
project and then, transfer into setup the tools for the hydroforming process. This save as
functionality is available in the 3D view:

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Tube is the results of an analytic computation of the tube bending:

In the setup, the simplified tube bending method may be used to generate straight or
bent tubes with a circular profile. This functionality provides a simplified approach to
create a bent tube. It gives a fast estimation of the thickness distribution of the bent tube
using an analytic method. This tube can be used with or without the thickness
distribution applied to the analytic calculation.
How to proceed:
It is called from the item Simplified tube bending item in the Process menu.
Tube Definition
The tube is defined with:

-
a 3D curve, that defines the geometry of the tube,
the tube radius,
the tube thickness,
the Lankford coefficient of the tube material,

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the element edge size. The optimal value depends on tube radius.
The following assumptions are made to generate the mesh:

-
The radius of the tube is constant,
The length of the tube is constant,
Sections remain orthogonal to the center line.
3D curve creation
The 3D curve can be imported from an existing CAD definition or created in the
GUI, with the standard 3D curve editor.. A direct access for creating a new curve is
proposed in the dialog with the button
..
Tube Analysis
The thickness distribution can be analyzed; it is automatically affected to the tube in the
setup for the next simulation.
Tube is the results of an inverse computation of the tube bending:

The results of the inverse simulation are imported from a mapping file. See the section
Bending simulation feasibility for details on the inverse simulation. The Import
mapping attribute has to be set in the setup, pointing on the mapping file of the inverse
computation.

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Tube is straight and has been built in the TubeMaker module using
the RollForming feature:
The results of the rollforming estimation (on thickness and strain) have been exported in
a mapping file. See the section Tube Design Module for details. The Import mapping
attribute has to be set in the setup, pointing on this mapping file of the inverse
rollforming estimation.
Tube is the results of an accurate computation of the tube bending:

In that case, the results of previous simulation are picked through the Import
Computed Model.
Tube is created in the setup module using the Tube editor:

The tube mesh can be created using the Tube Editor menu.

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The Surface Blank editor allows the user to:

-
Create (and then modify) an object

which will be in the tube group.
Build (and replace) the mesh of the

object using the tube geometric
definitions (radii, length, position) and
mesh size.
Set material data of the tube: the data are

available (and retrieved) in the macros.
Tube is imported:
The tube can be imported through one of the available translators (Nastran, Patran,
Ideas) or from a CAD file as any other tool.
Tube Hydroforming Macros

There are six different macros for tube hydroforming in the 2008 release:
-
Standard macros:
Pressure defined, single integration, see picture below
Fluid cell defined, single integration
Use these macros for first check, and for parts that are not complex.
-
More accurate macros:
Pressure defined, full integration
Fluid cell defined, full integration
More accurate than the standard macros, but significantly higher CPU-time. Use
these macros if problems occur using standard macros, for final check and for all
complex parts.
Advanced macros:
Pressure defined with vertical punches, full integration

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Fluid cell defined with vertical punches, full integration

Use these macros if vertical punches have to be used. The macros set the integration to
full, assuming complex parts if vertical punches are necessary.
All the above macros include:
-
Closing, Forming and springback stages.
Definition for upper and lower tool as well as left and right axial tool.
Autopositioning of the tube on the lower tool, and the upper tool on the tube. The
upper and lower tools should be closed when the calculation starts.
Autopositioning of the left and right axial tools on the tube.
Macro for tube hydroforming, pressure defined

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Predefined Values in the Macros:

-
Closing speed: -3 m/s

Closing is normally a critical operation when it comes to process acceleration using
the explicit FE-method. Using a higher speed for closing than the predefined brings
up the risk of dynamic effects. For large parts, it can be necessary to reduce the
closing speed to -2 m/s.
Maximal refinement:
To keep one macro fast, the refinement for the single integration is set to 2, whilst
for the accurate macro, the refinement is set to 3. The impact on calculation times is
significant.
2 for single integration
3 for full integration
Friction: 0.08
Contact acceleration: 1
In the calibration phase, the risk of nodes penetrating the tool is high, therefore the
contact acceleration is set to 1. The impact on calculation times in comparison to an
acceleration factor of 10 is approximately 5-10 %, but this allows higher calculation
speeds.
Stop time: 1 ms
This needs to be modified by the user. Normally an acceleration factor of 1000 to
5000 is ok for the hydroforming stage of the calculation. For the calibration part,
acceleration factors of up to 10000 may be used. This means that if a process-step
takes 1 s in real life, the calculation time can be set to 1 ms.
Thickness: 1
Maximal volume flow velocity: 4

This value is set to define part explosion due to too high volume flow.
Additional Preparations Before Doing a Hydroforming

Calculation
-
At least upper and lower tools (and axial tools and vertical punches) have to be
imported.
Define closing frame.
Define the frame for every additional tool (axial & vertical).

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DELTAMESH
INTRODUCTION
Presentation
DeltaMESH is an automatic meshing tool suited to stamping simulations and fully
integrated into PAM-STAMP 2G. It is optimized to generate meshes very quickly from
retrieved CAD models of the stamping tools, without performing intermediate
operations to modify CAD surface models. Indeed, it can even process geometrically
imperfect models automatically.
DeltaMESH does not require specialized knowledge of meshing. It is therefore very
simple and easy to use, for users who are experts in stamping techniques but not in
meshing.
Technical advantages of DeltaMESH

In this part, we will present the main technical advantages of DeltaMESH.
-
High performance functions carrying out retrieval and automatic correction of

geometric models from a large number of CAD systems.
Highly effective functions performing automatic merging (or joining) of adjacent

surface edges to obtain the clean parts topology for perfectly connected meshes (no
gaps or overlaps), a guarantee of vital reliability for the simulation.
Automatic mesh density check to ensure that the meshes are adapted to the
required precision for stamping simulation, by generating the minimum number of
elements.
Specific meshing algorithms capable of delivering the density variations imposed

for precise representation of tools, and simultaneously preserving high element
shape quality in areas where it is necessary.
Overall efficiency of a discipline-specific software, enabling users to obtain the

required result much faster than with general software.
The organizational advantages are as follows:

-
You are able to carry out all meshing operations in the PAM-STAMP2G graphic
environment (used for the whole simulation), and do not have to learn to use other
user interface devoted to meshing only.
No duplication or modification of the original CAD model by using another

modeler specific to an interactive meshing software. The master model is always
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generated by the original CAD software and evolves if necessary within this
software (guarantees consistent geometric data).
-
Very low training costs, since all the functions are automated and do not require
special meshing expertise.
Very low operating costs, because time spent on meshing is minimized by

extensive automation.
Organization of the manual

You do not need to read all the subsections to start meshing with DeltaMESH.
To get started quickly, it is recommended to read these paragraphs in the following
order:
-
Subsection The main stages in Meshing a CAD Model which briefly describes the
different stages, from a CAD model to a mesh.
Subsection Messing session, which describes how to access DeltaMESH

functions.
The following topics will be useful, as users gradually seek answers to more specific
questions:
-
The beginning of subsection Recommendations for Surfacic CAD Model Exchange

from CAD Systems to DeltaMESH, which defines the type of CAD models to
mesh.
The paragraphs in subsection Interface Option for Different CAD systems devoted
to the CAD systems used, describing the output interface options to apply in order
to get the best result.
Subsections Importing the CAD Model, Topological Joining of the Geometrical

Model, Meshing the Topological Model for explanations of the main functions'
parameters.
Subsection Other DeltaMESH Actions for the complementary functions.
The Main Stages in Meshing a CAD Model

Importing the CAD Model
Using CAD surfacic geometry defined in an IGES or VDA format file, DeltaMESH
automatically constructs a geometric model, after filtering and correction. The latter
operations eliminate minor defects or details that you do not want to see during
meshing.
At the end of this phase, you can view the elementary surfaces created (they are not
yet connected together) and the independent 3D curves.
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Construction of a Topological Geometric Model

This operation enables you to join the areas of the model that you subsequently want to
mesh continuously, i.e. with common sides of elements between adjacent surfaces. This
operation consists in automatically recognizing adjacent surface edges according to
user-defined tolerance criteria. Some geometrical and topological treatments are made
to remove thin surfaces, overlaps, double surfaces. This step is very important to obtain
a mesh of a good quality. The common boundaries of adjacent surfaces will have the
same discretization and this ensures the mesh continuity along boundaries and then, on
the whole model.
At the end of this phase you can view the surface free/multiple edges of the
topological model constituted in this way.
Definition of the Discretization Criteria and Mesh Generation

Using a few parameters, DeltaMESH can automatically define consistent and optimum
distribution of the discretization criteria.
If necessary, the discretization criteria can be applied to groups of geometric entities.
These criteria include:
mesh type (regular, progressive, uniform),
minimum and maximum element sizes,
mesh size progression factor,
chordal error in relation to the geometry,
angle between two adjacent elements.
At the end of this phase, the user can view the mesh, the mesh free/multiple edges and
the different geometric quality criteria of the elements:
internal angles of an element,
area,
warping (for quadrangles),
undercuts
junction angles
etc.
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CAD MODEL EXCHANGE FROM CAD SYSTEMS

TO DELTAMESH
Description of the CAD Model
Type of surfacic model
DeltaMESH uses a surfacic model imported via the IGES or VDA translators.
The surfacic model must consist solely of "definitive surfaces" describing the exact
shape of the part to mesh. This means the following data are not interpreted by
DeltaMESH:
-
dimensioning symbols,
model comprising construction surfaces that are not trimmed by curves,
wireframe model without the surfaces,
CSG solid model, (solid modelers provide functionalities to extract and transfer the
part's external surfaces).
DeltaMESH interprets the types of surfaces most commonly used in surfacic CAD
systems, i.e. Bezier, Bsplines, NURBS trimmed surfaces, analytical surfaces (cylinder,
sphere, plane, cone, etc.) and special surfaces (ruled, offset surfaces).
However, it is always recommended to use Bspline/NURBS representation by following
the options indicated in subsection Interface Options for Different CAD Systems.
Thus, analytical and special surfaces from CAD system will be transformed in NURBS
entities.
In fact, the NURBS representations are geometrically perfect whereas the representation
of analytical and special entities can be a source of errors (angle expressed in
radians instead of degrees, wrong direction of rotation, )
Note:
In some software products it is necessary to use transformation functions before

using the IGES or VDA translators.
See Interface Options for Different CAD Systems.
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Quality of the model

Generalities
Although DeltaMESH has functions that automatically clean up geometric defects, it is

important to first verify the surfacic models provided in the CAD software (regardless
of the CAD software used). The following checks should be carried out in particular:
-
Connectivity test between surfaces (free edges) to avoid as much as possible the
connection problems between surface edges and therefore eliminate the need for
merging nodes and elements after meshing by DeltaMESH.
Detection of "duplicated" surfaces (identical and completely superimposed).
Detection of substantial surface overlaps or superimposing.
No twisted surfaces, so that the mesh is as regular as possible.
Detection of surfaces with very irregular and/or distorted iso-parametric curves.
Detection of "turn back points" or loops on the surface trimmed by curves, which
would make meshing very difficult or could generate a large number of elements.
Illustration of Anomalies
In this subsection, we will illustrate some specific geometrical anomalies that could be
present in the original CAD model if the surfacic model is not checked before the
export.
As we said, these geometrical defects can be easily detected and corrected with the
internal checking tools present in the CAD systems. These problems cannot be
corrected easily by DeltaMESH (for example using the joining tools) because they are
generally too big:
-
Overlaps.
First illustration of a very important geometrical overlap
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Second illustration of a very important geometrical overlap
Highly irregular surfaces.
Illustration of a twisted surface
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Illustration of too big a gap
Non-uniform parameterization of the original surface.
Illustration of the influence of the surface definition
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Definition of the areas

For stamping simulations, it is recommended to define the three following areas for the
die:
-
the blank holder surface,
the die entry fillet,
the rest of the model (also called "die bottom").
Other areas can also be defined depending on specific needs.

You can assign different meshing criteria to each area and/or give priority to meshing of
important areas (die entry fillet, etc.).
Although these areas can be defined by selecting the geometric entities in DeltaMESH
(then grouped in objects), it is better to group the surfaces of these different areas in the
CAD software using the usual commands (concept of group, set, layer, color, etc.).
The two methods for transferring these groups to DeltaMESH are described as follows:
-
The whole model including different areas can be transferred by the CAD system in
a single file containing :
Group entities ("402 form 7" entities for IGES files, "GROUP" entities for VDA
files,)
Group defined by the Level field of IGES entities
Group defined by the Color field of IGES entities.
The selected areas can be transferred by the CAD system in several different files.
Each file will correspond to a group of surfaces or a group of curves.
Interpreted CAD Entities

List of IGES entities interpreted by DeltaMESH
These entities are defined in the IGES standard Version 5.3.
The list of entities interpreted by DeltaMESH is given in the following table.
The description is in most cases the one used in the translation report files in CAD
software.
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IGES Entities (v 5.3) processed by DeltaMESH
IGES type
Description
Referenced entities
Curve entities
100
102
Circular Arc (or Circle)

Composite Curve
100, 104, 106, 110,

112, 126, 130, 102
104
Conic Arc (ellipse, hyperbola,

parabola)
106 Form 1, 2, 3 Copious Data (polyline)
110
Line (defined by 2 points)
112
Parametric Spline Curve
126
Rational BSpline Curve (NURBS)
130
Offset Curve
Surface entities
114
118
120
122
128
140
Parametric Spline Surface

Ruled Surface
Surface of revolution
Tabulated Cylinder
Rational BSpline Surface (NURBS)
(108, 114, 118, 120,
Offset Surface
122, 128, 140)
Trimmed surface entities

142
Curve on Surface
144
Trimmed Surface
(100,102,104,106,110,
112,126, 130),
(108, 114, 118, 120,
122, 128, 140)
142, (108, 114, 118,
120, 122, 128, 140)
Group entities
402 Form 7
Associativity Instance - Group
(100,102,104,106,110,
112,126, 130),
(114, 118, 120, 122,
128, 140,144), 402
Miscellaneous entities
108 Form 0, 1
124 Form 0, 1
Plane
Transformation Matrix
All geometric entities
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Below are a number of recommendations concerning the options to choose when

generating IGES files. These options are listed for several CAD software products in the
subsection Interface Options for Different CAD Systems . For other software
products, refer to the documentation for their IGES interface.
-
It is recommended to transform analytical entities and entities specific to certain

CAD software products into BSpline/NURBS or Parametric representation (this
transformation is geometrically exact). This is performed automatically by choosing
the right option in the CAD software output interface (usually, in recent CAD
software it is sufficient to select an option called "Transform all curves as NURBS
(126 entity)" and "Transform all surfaces as NURBS (128 entity)").
For "trimmed surfaces", choose the "trimmed surface" option (entities 144 and
142) and do not select the "bounded surface" option (entities 143 and 141).
Therefore, the following entities must be transformed and must not be present in the
IGES file (examine the "translation report" generated by the CAD software).
IGES entities not translated by DeltaMESH (must be transformed beforehand)
IGES type
Description
IGES type
Description
141
Boundary
143
Bounded Surface
If possible, give preference to a BSpline/NURBS representation (entities 128, 126)

rather than a "Parametric representation" (entities 114, 112)
For solid modelers, extract the model's external surfaces (automatic function or
interface option). For example, the following entities serve no purpose and will be
ignored:
150 to 168:
Construction Solid Geometry entities
180 to 184 and 430:
Structural CSG entities
If possible, transfer only geometric entities (no dimensioning entities, drawing

entities, etc.). For example, the following entities serve no purpose and will be
ignored:
116:
Point entity
202 to 230:
Annotation entities
132, 134, 136, 138, 146, 148:
FEM entities
302 to 422:
Structure entities except entity

402 form 7, used to denote groups of
surfaces or curves.
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List of VDA entities interpreted by DeltaMESH

These entities are defined by standard VDAFS release 2.2.
The list of entities interpreted by DeltaMESH is given in the table below. The
description is in most cases the one used in the translation report files (.log) in CAD
software products.
VDAFS (v2.2) entities interpreted by DeltaMESH
VDA type
Description
Referenced entities
Curve entities
CIRCLE
CURVE
Circle / Circular Arc

Parametric Curve
Surface entities
SURF
Parametric Surface
Trimmed Surface entities

CONS
Curve on Surface
FACE
Trimmed Surface
CURVE, SURF
SURF, CONS
Group entities
GROUP
Group
(SURF,FACE), (CURVE,CIRCLE), GROUP
There are less recommendations for VDA files generation than for IGES files because
the VDAFS covers a limited number of entities (no analytical entities, no drawing
entities, etc.). However the following points must be checked:
-
For the surfacic model, try not to transfer isolated points or curves. For example,
the following entities serve no purpose and will be ignored:
POINT :
Point entity
PSET :
Point Sequence entity
MDI
Point Vector Sequence entity (Master dimension)
The present version of DeltaMESH does not support the following entities, which
will therefore be ignored:
TOP
Topology of Surface entity
TMAT :
Transformation Matrix entity
TLIST :
Transformation List entity
Notes:
The VDAFS standard should not be confused with the VDAIS standard.
VDAIS is a restricted version of the IGES standard containing a number of

geometric entities more or less equivalent to those used in VDAFS.
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A VDAIS file must therefore be imported using the DeltaMESH IGES option
(file suffix must be .igs) using the recommendations given in the above
paragraphs).
Interface Options for Different CAD Systems

In the paragraphs below, the different options to use when generating IGES or VDA
files are given for the main CAD software products. These options may change when
new software releases become available; it is therefore recommended to refer first to the
CAD software manuals.
If your software is not mentioned in this manual, we recommend you find the
equivalent functions and check the types of entities generated compared to those
imported by DeltaMESH. The translation reports produced by CAD software will help
to do this.
Preparation of geometry in AutoCAD

Definition and verification of the geometric model
Refer to the general recommendations in subsections from Description of the CAD
Model to Interpreted CAD Entities.
The groups of surfaces defining different areas (Die entry fillet, Blank holder surface,
Rest of the part, etc.) can be saved in a single CAD file (IGES 402 form 7 or
VDA GROUP entities) using the GROUP Command in AutoCAD.
Each group of surfaces can also be saved in a different CAD file. DeltaMESH will
create a group each time a file is imported. The global model will be made of all these
groups.
IGES interface parameters

Press the Edit Options button in the Autodesk IGES Translator - IGESOUT window. The
IGESOUT Options Editor window is then displayed, enabling you to define the following
export parameters:
-
In the IGESOUT Structure Options dialog box (button Structure)

Map Groups :
Unordered (402 :7) (default value)
(output_groups = 1)
In the IGESOUT Geometry Options dialog box (button Geometry)

3D Solid Part Mapping : Surfaces
(default value)
(brepout_mapping = 2)
Trimmed Surface Mapping : Trimmed Surface (144) (instead of Bounded
surfaces 143)
(trimmed_surface_mapping = 1)
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In the IGESOUT Miscellaneous Options dialog box (button Miscellaneous)

Generate Log File :
ON (default value)
(logging = 1)
These parameters can be saved (Save As button in the IGESOUT Options Editor
window ) in a file (e.g. DeltaMESH_options) so that they can be recovered easily
when required for execution (Options File button in the
Autodesk IGES Translator - IGESOUT window).
VDA interface parameters

No parameters are required for DeltaMESH (see subsection List of VDA entities
interpreted by DeltaMESH).
Preparation of geometry in CADDS

Refer to the general recommendations in subsections from Description of the CAD
Model to Interpreted CAD Entities
The DEBUG Solid command is used to verify free edges in particular.
Rest of the part, etc.) can be saved in a single CAD file (IGES 402 form 7 or VDA
GROUP entities) by using the Relation entity concept (type 87) in CADDS.
However we recommend you use the second method, i.e. grouping the surfaces in
several files (one for each PART).
groups.

The methodology for generating IGES files is the one usually used in CADDS.
The PUTIGES command must be used, accompanied by the following options:
-
CV Translator v1.1
model (to only transfer the geometric model, not the drawing)
nurbs (to convert geometric entities into NURBS entities)
Notes:
Do not use the bound option
CV Translator v1.2.1 and v2.0

model
(to only transfer the geometric model, not the
drawing)
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nobounded
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(to convert geometric entities into Nurbs entities)

(to prohibit conversion into IGES 143 entities)
(avoids generation of properties)

We recommend you refer to the documentation for the VDA interface used with
CADDS, and to the general information about VDA given in paragraph List of VDA
entities interpreted by DeltaMESH.
Preparation of geometry in CATIA V4

Refer to the general recommendations in subsections Description of the CAD Model
and Interpreted CAD Entities.
GROUP entities) by using several CATIA SETs.
To create a SET in CATIA you must use the SETS/CREATE command and indicate the
SET's name (e.g. fillets).
groups.
Be careful with the No-Show CATIA entities, in particular construction entities, which
CATIA will transfer into the interface files. It is therefore recommended to check
which entities are present in the No-Show, and if necessary to delete them before
carrying out the transfer.
Before the transfer, it is recommended to check if the model is clean using CATIA's
cleaner, in particular for CATIA V3 models reconverted to CATIA V4. The cleaner is
available in input line mode (/CLN) or from Catutil using the CATCLN utility (for more
details refer to CATIA documentation).
Note:
Be careful when choosing the options with CATMOD utility, which is sometimes
used before the transfer in internal procedures set up in corporations.

The methodology for generating IGES files is the one usually used with CATIA
(CATIGE utility) (refer to the CATIA-IGES Reference Manual). It is usually performed
in one of the three ways:
-
From interactive CATIA, via the UTILITY function,
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From the Unix command line:
In alphanumeric mode by typing:
catutil
In X11-motif mode by typing:
catutil -l
catige -XM
From a shell script or a procedure installed on the site, using a parameter file. In
this case, it is recommended to check the options chosen in the procedure are the
options recommended for DeltaMESH.
The responses to the CATIA=>IGES interface are the default ones, except for
generation of analytical surfaces (CANONICAL: sphere, cylinder, cone, etc.) and
analytical curves (CONIC: ellipse, parabola, hyperbole, etc.) where the B-SPLINE
option must be chosen.
Among the different parameters, the important options to choose are given in the table
below.
Parameter
(panel mode)
Keyword
(parameter file)
Option
to choose
Comment
IGES VERSION
*IGESVRS (or *IVR)
V5.1
(default)
CONVERSION MODE
*IGESSTD (or *IGS)
STANDARD
(default)
CANONICAL TRANSFER *CANONICAL (or *CAN)
B-SPLINE
(instead of STANDARD)
CONIC TRANSFER
*CONIC (or *CON)
B-SPLINE
(instead of STANDARD)
SPLINE TRANSFER
*SPLINE (or *SPL)
B-SPLINE
(default)
MESSAGE LEVEL
*MSGLEVEL (or *MLV)
WARN
(instead of ERROR)
Notes:
It is preferable not to choose the VDAIS-OPTION option (*VDAISGEO or *VDG)
Verify the transfer report located by default in the CATIGE.out file (even if
the message "Successful operation" is displayed).

Several CATIA=>VDA interfaces are available. Some are developed and marketed by
external companies (e.g. IKOSS-CSS, IVM, etc.).
Normally, no specific parameters are required for DeltaMESH. We recommend you
refer to the documentation for these various interfaces, and to the general information
about VDA given in subsection List of VDA entities interpreted by DeltaMESH.
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Preparation of geometry in CATIA V5

The IGES export from CATIA V5 concerns the data contained in CATPart or
CATProduct document.
GROUP entities) by using several CATIA selection sets.
To create a selection set in CATIA you have just to point to the selected objects, rightclick to display the contextual menu, and select selection sets. In the Selection Sets
dialog box, you can enter the name for the selection (e.g. fillets) and click the Create
button.
However, each group of surfaces can also be saved in a different CAD file.
DeltaMESH will create a group each time a file is imported. The global model will be
made of all these groups.

In order to proceed to an IGES export of CATPart or CATProduct document, select
File -> Save as from the menu. The Save as dialog box is displayed. You can
specify the name of the iges file that will be created and set the .igs extension in the
Save as type field. Before to click on the Save button, you must customize the several
3D IGES export options (menu Tools -> Options -> IGES) (see the following figure).
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CATIA v5 IGES Export dialog box (DeltaMESHs recommended values)
The parameters of the CATIA v5 IGES interface must be defined as follows to generate
a file that can be interpreted by DeltaMESH:
-
Export - Curve and surface type: BSpline
Export - Representation mode:
Surface
Export - Show/NoShow:
Save only shown entities
activated
After the IGES exportation, a report file and an error file are generated. You can refer to
these documents to check the quality of the transfer.

Several CATIA=>VDA interfaces are available. Some are developed and marketed by
external companies (e.g. IKOSS-CSS, IVM, etc.).
Normally, no specific parameters are required for DeltaMESH. We recommend you
refer to the documentation for these various interfaces, and to the general information
about VDA given in subsection List of VDA entities interpreted by DeltaMESH.
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PAM-TFA interface parameters

In CATIA v5, it is possible to convert a CAD part file into a DeltaMESH geometrical
database. This operation is possible using Caav5 with PAM-TFA
Illustration of the Save as *dtc in Caav5 interface
It is very simple to use this interface. The user saves the model directly in DeltaMESH
file (*r.dtc). Then, the DeltaMESH geometrical database can be read directly into
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PAM-STAMP 2G. This method avoids using intermediate formats, which are often a
source of errors.
Preparation of geometry in SolidWorks

The IGES export from SolidWorks concerns the data contained in SLDPRT or
SLDASM document.
Before the transfer, it is recommended to check if the model is clean. The tool is
available in menu Tools -> Check (for more details refer to SolidWorks
documentation).

In order to proceed to an IGES export of SLDPRT or SLDASM document, select
Save as type field. Before to click on the Save button, you must customize the several
IGES export options (Options button-> IGES 5.3) (see the following figure).
SolidWorks IGES Export dialog box (DeltaMESHs recommended values)
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The parameters of the SolidWorks IGES interface must be defined as follows to

generate a file that can be interpreted by DeltaMESH:
-
Solid/Surface features IGES entities:
Trimmed Surface(type 144)
Solid/Surface features IGES wireframe (3D curves):
B-Splines (Entity type 126)
Surface reprensentation/System preferences:
NURBS
If you have orientation problem with assembly files, choose ALIAS instead of NURBS

SolidWorks VDA Export dialog box
Preparation of geometry in Cadceus

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To export the IGES file, first you must create an Exchange parameter files with the
external data exchanger.
Load CADCEUS exterior Data exchange (Start -> All Programs -> CADCEUS
V6 -> Data Exchange) and click to the button CFIO->IGES.
Select a file to be converted and click on Next.

Then click on the button Copy in the Exchange Parameters files group box, input a
file name and confirm the file creation.
Select the file and click on the Edit button
In the option tab control, the parameters must be defined as follows to generate a file
that can be interpreted by DeltaMESH:
-
B-Spline entity to Parametric Spline entity
= Yes
Rev Surface and Sweep Surf to Parametric Spline entity
= Yes
or directly in the command text box

-
IGES PUT
= A, K
Notes:
If both side are used to define the parameters, CADCEUS may have an error.
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or
CADCEUS Export parameters box (DeltaMESHs recommended values)
Added parameters are now available in both internal and external data exchanges with
the chosen name.
CADCEUS internal Export window
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CADCEUS external Export window
Preparation of geometry in VX CAD


In order to proceed to an IGES export of VX document, select File -> Save as from
the menu. The Save as dialog box is displayed. You can specify the name of the iges
file that will be created and set the .igs extension in the Save as type field. Before
clicking on the Save button, first customize the several IGES export options (Options)
(see the following figure).
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VX IGES Export dialog box (DeltaMESHs recommended values)
The parameters of the VX IGES interface must be defined as follows to generate a file
-
Geometry form
Spline
Spline
Nurb
Solids
Free Surface
Group
YES
Extract sub-curves
YES
Split closed surfaces
YES

The parameters of the VX VDA interface must be defined as follows to generate a file
-
UV curve
Curve
Surface
Tolerances
0.01 (default values)
Decimal places
15
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VX VDA Export dialog box
Preparation of geometry in EUCLID IS

Before activating the IGES or VDA interfaces, it is mandatory to use the
Surfaces; Modify Type/Class; Surface command with the following parameters:
-
Max. class
10
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Revolution patch yes
Patch //
yes
Planes -> exact
no
Trimming
yes
Results
surface
List deviations
no
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This command transforms all the surfaces into BEZIER surfaces, in particular the
analytical (cylinders, etc.) and offset surfaces.
The checks stipulated in subsection Description of the CAD Model must be
performed after the surface transformation operation using the following commands:
-
Surfaces; curves; free edges
Surfaces; control; a surface
connectivity
dimension
twisted patch
superimposed patch
orientation
which performs the following checks:
Rest of the part, etc.) can be saved in a single CAD file (entities IGES 402 form 7
or VDA GROUP) using several EUCLID SFR entities.
groups.

The parameters of the EUCLID IGES interface must be defined as follows to generate
a file that can be interpreted by DeltaMESH:
-
Mode
= 3D Exact
Broken
= Line (N110) + Composite curve (N102)
Bzier curve
= Rational B-Splines (N126 et 128)
Opacity
= YES
Length
=5
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The parameters of the EUCLID VDA interface must be defined as follows to generate a
file that can be interpreted by DeltaMESH:
-
Name
= Automatic
Display
= YES
FIGURE=>GROUP
= YES
Polygon
= Curve
Preparation of geometry in I-DEAS Master Series


In I-DEAS Master Series, it is possible to define several geometric areas in a single file
by using I-DEAS Group. These groups are exported to IGES Group entity (IGES 402
form 7) which are interpreted by DeltaMESH. Each group of surfaces can also be
saved in a different CAD file. DeltaMESH will create a group each time a file is
imported. The global model will be made of all these groups.
The export parameters are defined in the IGES Export dialog box by clicking the
Flavors button.
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The Edit IGES Export Flavors dialog box appears.
Then click the Types to export button.
Types to export to IGES dialog with DeltaMESH Recommended values
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In this dialog box :

-
The toggle Points must be deactivated
The toggle Groups must be activated (default value)
The toggle Curves/Edges must be activated (default value)
Convert to curve type:
choose 126:0 Non-Uniform Rational BSpline (NURBS)
(default value)
Convert Arcs to Conics:
deactivated (default value)
The toggle Surfaces must be activated (default value)
Convert to trimmed Surface Type:

Param Space curves option
select 144:0 Trimmed with 3D Model and 2D
Convert to Base surface Type: select 128:0 Non-Uniform Rational BSpline

(NURBS) option (default value)
Trim curves convert to:
choose 126:0 Non-Uniform Rational BSpline (NURBS)
(default value)
-
The toggle Solids must be deactivated
Maximum number of points per IGES Polyline:
Chord deviation tolerance:
Maximum Degrees of Curves and Surfaces:
choose 1000 (default value)
choose 0.01 (default value)

choose 0 (default value)

In I-DEAS, it is not possible to define several geometric areas in a single VDA file. It
will therefore be necessary to use several files to define the different areas to mesh.
These areas can de defined either by interactively selected sets of surfaces or as a
complete PART.
Preparation of geometry in INTERGRAPH I/EMS

GROUP entities) using the Graphic Group concept in I/EMS.
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groups.

Press the Flavor button in the I/IGES Preprocessor Options window, and choose the User
Def option in the small pull-down menu. The Preprocessor Output Options window is
displayed, enabling you to define the following export parameters:
-
Model Type:
Choose the Surfaces option
Dimensions:
Generate Color Definition Entity (314)
Crosshatching as Lines
Suppress Window/View Output
Verbose Log File:
ON
NURBS Curve as Polynomial Curve (112):
OFF
All Curves as NURBS (126):
ON
NURBS Surface as Polynomial Surface (114):
OFF
All Surfaces as NURBS (128):
ON
Trimmed Surfaces as 141/143:
OFF
Note:
...
means the choice has no importance.
These parameters can be saved (using the Save button) in a file (e.g.
DeltaMESH_options) specified in the File Name field so that they can be recovered
easily (using the Load button) when required.

The parameters must be defined in the I/VDAFS Preprocessor Options window. There
are no mandatory options, but for best results we recommend the following values:
-
Maximum Order:
VDAFS Version:
(default value)
Decimal Accuracy:
15
(default value)
Preparation of geometry in PowerSHAPE

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In PowerSHAPE, it is not possible to define several geometric areas in a single file

(IGES 402 form 7 or VDA GROUP entities). It will therefore be necessary to use
several files to define the different areas to mesh. These areas can be defined either by
interactively selected sets of surfaces or as a complete PART.

The following figures illustrate two existing versions of the PowerSHAPE IGES
interface. The difference between these versions concerns the export of 2D or/and 3D
trim curves. In the version 1, these curves can be converted as NURBS and in the
version 2, these curves can be converted as polylines. Be careful, these conversions are
incompatible.
PowerSHAPE IGES Interface Version1 Setting for DeltaMESH
PowerSHAPE IGES Interface Version2 Setting for DeltaMESH
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General setting:
The following values are valid for both PowerSHAPE IGES interface versions.
-
Surface trimming:
Choose option 2D and 3D
Offset:
Along surface normal
3D Curve Point coincident:
0.001 (default value)
3D Curve Approximation:
2D Parametric Curve Approx.:
3D Parametric Curve Approx.:
3D Surface Approximation:
Standard:
BSI
(default value)
Specific setting:
If we refer to the general recommendations described in subsection Type of surfacic

model, the Bspline/NURBS representation is always preferred, thus :
-
for the interface version 1, activate the two toggles Export 2D curves as NURBS and
Export 3D trim curves as NURBS
for the interface version 2, deactivate the 2 toggles Export 2D curves as polylines
and Export 3D trim curves as polylines

Preparation of geometry in Pro/ENGINEER

In Pro/ENGINEER it is not possible to define several geometric areas in a single file
(IGES 402 form 7 or VDA GROUP entities). It is therefore necessary to use
several files to define the different areas to mesh.

In the Export IGES dialog box (see below), the following parameters must be set:
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Wireframe Edges:
Surfaces:
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OFF
ON
Solids:
OFF
Shells:
OFF
Datum Curves and Points:

Customize layers:
OFF
DEFAULT
Quilts: ALL
Coordinate System: Default
Pro/ENGINEER Export IGES interface
The advanced export parameters are accessible by clicking the Options button. The
IGES export parameters must be set as follows:
Options
Value
Options
Value
Iges_clip_view_note
no_clip Iges_out_spl_sfrs_as_128:
yes
Iges_export_dwg_views
no
Iges_out_start_note
no
Iges_out_all_srfs_as
128
Iges_out_symbol_entity
no
Iges_out_assembly_default_mode flat
Iges_out_trim_curve_deviation DEFAULT
Iges_out_catia_gdt_width
no
Iges_out_trim_xyz
yes
Iges_out_catia_notes
no
Iges_out_trm_ srfs _as_143
no
Iges_out_dwg_color
no
Iges_zero_view_disp
All_views
Iges_out_dwg_line_font
no
Intf_out_as_bezier
yes
Iges_out_dwg_pnt_ent
no
Intf_out_max_bspl_degree
Iges_out_ent_as_bspline
true
Intf_out_blanked_entities
no
Iges_out_JAMAIS_compliant
no
Intf3d_out_extend_surfaces
no
Iges_out_mil_d_28000
no
Int3d_out_default_option
surfaces
Iges_out_spl_crvs_as_126
yes
The values in bold in the table above are different from the default values and must be
tuned.
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VDA interface parameters are set using the Interface; Export; Iges; Vda Config
command. The following parameter must be set:
-
Intf_out_blanked_entities
no
Preparation of geometry in STRIM 100

Before generating CAD files, we recommend you remove shell entities using the SPLIT
SHELLS ->FACES command.
It is possible to define several geometric areas in a single VDA file. STRIM transfers
these areas into GROUP (VDA) entities.
However STRIM does not create IGES group entities (402 form 7), in this case it will
be necessary to use several IGES files to define different areas.
There is no mandatory options in STRIM. But for best results, we recommend you
define or verify the following parameters in the PROFIL files used by STRIM (see
STRIM 3D CAD/CAM documentation):
-
user PROFIL file: STSETUP.DAT located in the STRMINIT directory,
group PROFIL file: STSETUP.DAT located in the STRMENVG directory,
or standard PROFIL file: STSETUP.FRA located in the STRMDATA directory.

The recommended parameters are as follows:
-
IGES_EXP < CREATE
(CR_126=1) (default value)
IGES_EXP < CREATE
(CR_128=1) (default value)
IGES_EXP < CONST_126
(MAXDEG=9)
(IORDER=2)
(MAXDEG=9)
(IORDER=2)

The recommended parameters are as follows:
-
VDA_EXP < CONST_CURVES (MAXDEG=9)
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VDA_EXP < CONST_CURVES (IORDER=2)
VDA_EXP < CONST_SURF
(MAXDEG=9)
VDA_EXP < CONST_SURF
(IORDER=2)
Preparation of geometry in TEBIS

It is possible to define several geometric areas in a single VDA file. In TEBIS these
areas are defined either by Layers or by Sets, then are transferred as VDA GROUP
entities (see the choice of VDA interface parameters).
However TEBIS does not create IGES group entities (402 form 7), and in this case it
will be necessary to use several IGES files to define the different areas.

The IGES output parameters are defined by the PUTVDAIS module. In TEBIS
release 3.1, the verbose level of error messages in the TEBIS output files is controlled
by a single parameter. It is recommended to use the detailed level.
-
Error list: 1
(error output for each IGES entity).
The command to use is therefore:

S: PUTVDAIS, 1

The VDA output parameters are defined by the PUTVDAFS module. In TEBIS
release 3.1, there are 4 parameters that must be set as follows:
-
Structure:
to transfer the LAYERS" into VDA-GROUP
to transfer the SETS into VDA-GROUP
Name:
0 or 1 (not important)
Error list:
(error output for each VDA entity).
Divide:
to divide face sides exhibiting large angles.
The command to use is therefore:

S: PUTVDAFS, 0 or 1, 0 or 1, 1, 1
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Preparation of geometry in Think 3

and Interpreted CAD Entities for more details.
It is much recommended to convert all the geometrical entities into NURBS with the
following thinkdesign command before exporting the CAD model:
Modify->Surface->Convert into NURBS

To export a thinkdesign model into IGES format that could be imported by
DeltaMESH, the IGES options must be customized.
To export in IGES format, select Save as in the File menu. The following dialog will
appear:
thinkdesign: the Save as dialog box
Choose the .igs option in the Type drop-down list, and click the Options button. The
following dialog box will appear.
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thinkdesign: the Advanced IGES options dialog box (DeltaMESHs recommended values)
Select Settings->Save->Advanced. There are 4 parameters that must be set as follow

(see the figure above):
-
Split closed faces/surfaces:
OFF
Map rational to not rational:
OFF
Map 143:0 to 144:0:
ON
Convert to NURBS
Arcs:
ON
After that, click the Settings button and save the new settings as the deltamesh settings.

The VDA output parameters are defined in the VDA Options dialog box available by
choosing the VDA type in the Save as dialog.
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thinkdesign: the Advanced VDA options dialog (DeltaMESHs recommended values)
The default value can be used to export into the VDA format, a format dedicated to
DeltaMESH.
Preparation of geometry in UNIGRAPHICS


The types of transfer of UNIGRAPHICS entities to IGES are defined by selecting
option 10 of the Preprocessing Options menu. The Preprocessor Entity Mapping menu
is then displayed. To choose the different types of entities, the following options must
be selected (... means the choice has no importance) :
1. Crosshatching
TO
...
2. Cone
TO
B-Surface
3. Cylinder
TO
B-Surface
4. Sphere
TO
B-Surface
5. Surface of Revolution
TO
B-Surface
6. Tabulated Cylinder
TO
B-Surface
7. Trimmed Surface
TO
Trimmed surface
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8. Periodic Surface
TO
Split Surfaces
9. Solid/Sheet Body
TO
Ungrouped geometry
10. Assembly
TO
...
11. Pattern
TO
...
12. UG Line Font
TO
...
13. UG Color Definition
TO
...
The types of surfacic entities to transfer are defined by selecting option 2 of the Entity
Selection menu. The Select Surfaces menu is then displayed, and the following options
must be selected:
1. Cylinder
ON
2. Cone
ON
3. Spheres
ON
4. Surface of Revolution
ON
5. Tabulated Cylinder
ON
6. Bounded Planes
ON
7. B-Surfaces
ON
8. Planes
OFF (1)
9. Offset Surfaces
ON (2)
10. All
11. None
(3)
Notes:
(1) Isolated planes must be replaced by standard B-surfaces.

(2) We recommend replacing Offset surfaces by standard B-Surfaces.
(3) If you only want to transfer curves into the IGES file (e.g. for drawbead lines),
you must select None to set all the surface types to OFF.
The types of curve entities to transfer are defined by selecting option 1 of the Entity
Selection menu. The Select Curves menu is then displayed. The following options must
be selected:
1. Points
OFF
2. Lines
ON
3. Arcs
ON
4. Conics
ON
5. B-Curves
ON
6. Solid Edges on Drawings OFF
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OFF
8. All
9. None
(1)
Note:
(1) If you only want to transfer surfaces into the IGES file, select None to set all the
curve types to OFF.
Preparation of geometry in Rhinoceros

Before the transfer, it is recommended to check if the model is clean. The tool is
available in the Analyze -> Diagnostics -> Check menu (for more details refer to
Rhinoceros documentation).

In order to proceed to an IGES export document (only the geometry is saved) select
Save as type field. After, click on the Save button, you must customize the IGES export
options (Edit Types button) (see the following figure) or select the right IGES type if
you ever have saved it.
Rhino IGES Export detailed option dialog box
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The IGES tolerance: In general, it should match the absolute tolerance setting in Rhino,
taking into account the possible unit conversion.
To create a new IGES export type, Click on the New button, set the following option
and click Close:
Rhino IGES Export dialog box (DeltaMESHs recommended values)
General:
-
IGES version:
5.3
Text file type:
CRFL (MS-DOS, Windows)

or LF (UNIX).
DeltaMESH reads indifferently both types of files on all platforms.
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Points and Curves:

-
Point objects:
106-2 (Layer point sets)
Max degree:
performance but other values are admissible.
3 is recommended for better
Composite curves as single B-spline:
NO
Use simple entities when possible:
NO
Fit rational curves:
YES
Clamp end knots:
YES
Surfaces:
-
Solids:
402-7 (Unordered group).
Polysurfaces:
Separate surfaces
Surfaces:
144
Use simple entities when possible:
NO
Fit rational surfaces:
NO
Clamp end knots:
YES
Split closed surfaces:
YES
Split bipolar surfaces:
YES
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Rhino VDA Export dialog box
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MESHING ACCESS
Standard mode
To start a session, first check that the CAD files are available, and then start the
application.
Create a project by selecting New -> Project in the Project menu, or by clicking the
button.
To access DeltaMESH direct import dialog:
-
click the
or click the
button in the Data set-up dialog box in an active DeltaMESH module

button in the 3D window meshing module and select import CAD
(direct)
or click the
button in the 3D window setup module and select import tools CAD
(automatic transfer to setup module)
or click the
button in the 3D window setup module and select import CAD for
(automatic transfer to design module).
reengineering or import CAD
Figure 6: DeltaMESH direct import window
Import, joining and meshing are executed by clicking the Import & Transfer or Import &
Check button.
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Import & Check: saves and opens a DeltaMESH module.

Import & Transfer: transfers directly the mesh to the setup or a design module without
any possibility of correction of the topological information and mesh except if Backup
in DeltaMESH module is activated. The geometry, the topological information and the
mesh are saved in a DeltaMESH module. It allows the user to return to the module for
any modifications keeping geometry, topological information or a part of the mesh. See
advanced mode section for more information.
Two parameters are available:
-
Size:
It is a factor size used to adapt mesh size to the part. The value depends on the
unit used in the CAD file and the size of the model. The default value is 1,
corresponding to a part size between 1 and 4 meters with millimeter as unit.
Strategy:
4 strategies included all meshing parameters are pre-defined,

corresponding to the use of the solver.
Feasibility
Validation
Springback
Algorithm
Parametric
Minimum
element size
0.1 x Size
Maximum
element size
30 x Size
30 x Size
30x Size
Chordal error
active
YES
Chordal error
follow iso
YES
Chordal error
max distance
0.15 x Size
0.15 x Size
YES
Angle criteria
follow iso
NO
15.
15.
Follow borders
10 x Size
0.1 x Size
Angle criteria
active
Angle criteria
max angle
Die compensation
0.1 x Size
7.5
7.5
YES
It is possible to add user defined strategies.

Import and Joining default parameters are used.
Refer to the Parameters chapter for more details about parameters.
The transfer menu from DeltaMESH module appears by a left-click on the
the 3D window.
button in
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It is possible to:
-
transfer the DeltaMESH module's mesh to the Setup (pre-processing) or to the

Design module
update an existing module with the DeltaMESH module's mesh
edit transfer rules
Advanced mode
DeltaMESH Module
A meshing session is started either by creating a DeltaMESH module or by activating a
previously created module. The list of created modules is present in the Meshing tree of
the Project tab.
-
To create a new DeltaMESH module, select New -> DeltaMESH Module in the
Project menu or select Add DeltaMESH module in the Meshing right-click menu.
In the Creation of new DeltaMESH module dialog, enter the project name.
-
To activate a previously created DeltaMESH module, double-click its name in the

explorer window.
A DeltaMESH module contains the geometry, the topological information and the mesh
for a specific part.
To access DeltaMESH advanced mode; select DeltaMESH -> Tool meshing in the
menu, click the
button in the Data set-up dialog box or click the
button in the 3D window meshing module and select import CAD (advanced).
Geometry
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If for a single part you need to store several strategies for importing the geometry,
joining and meshing, you must create several CAD modules.
A contextual menu can also appear by a right-click on the CAD module label. Several
options can be reached.
It is possible to:
-
activate a previous created module using Set as active module option (you can also
double-click on its name)
rename a previous created module with the Rename option,
copy all or part of a module (Geometry, Topology, Mesh) into a new CAD module
using the Save as option,
delete a previous created module using the Remove option.
The transfer menu appears by a left-click on
button in the 3D window.
It is possible to:
-
transfer the DeltaMESH module's mesh to the Setup (pre-processing) or to the

Design module
update an existing module with the DeltaMESH module's mesh
edit transfer rules
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DELTAMESH PARAMETERS
All parameters presented are available in the advanced mode. They are also used to
define default strategy adapted to the type of users part, to complete or to correct a
model.
The work is divided into three stages:
-
Import
Joining
Meshing
The three steps can be defined and run separately or jointly. We recommend you to
check each step and examine the output report displayed in the DeltaMESH console.
You can also access a more detailed report by clicking the
repair chapter for more details)
button (see Check &
Import
Presentation
In this stage the geometrical model is constructed from one or more CAD files in IGES
or VDA.
Note:
We can also import an existing PAM-STAMP 2G geometrical database

generated from CAAV5 and proceed directly to the other steps (joining and
meshing).
The CAD files can be imported one by one, or in groups. In all cases, the files must be
imported before the joining phase.
Each CAD file will be imported and "cleaned" depending on the following
characteristics:
-
the import tolerance of the CAD file,
which representation for faces boundaries was used when creating CAD file,
which geometry to mesh (surfaces and/or curves),
how the faces groups were defined when creating CAD file?
Depending on the import tolerance's value, DeltaMESH constructs a geometric model

using the following rules:
-
surfaces and/or curves smaller than the tolerance are eliminated,
curves smaller than the tolerance are eliminated from the contours of the
corresponding surfaces,
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successive tangent curves along a surface's contour are concatenated to form longer
curves,
surface contours are closed.
Elements will be grouped afterwards according to the created surface or curve groups.
Notes:
All the previous recommendations are not necessary for the PAM-STAMP 2G
geometrical format (*r.dtc file) because these recommendations are already
included in this format.
The r.dtc file can be obtained either from PAM-STAMP 2G or directly from
CAAv5.
Definition of Import Parameters

To access the import parameters, the user must select a CAD file in the Meshing
dialogue box. Then the Import dialog appears where you can choose three different
formats of CAD file: Iges (.igs), Vda (.vda), or Deltamesh database (r.dtc).
The dialog detects automatically the extension.
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OR
After clicking the Open button, the Import parameters dialog appears, where you can set
various parameters that will influence the importation of CAD File:
-
Tolerance:
Defines the tolerance value for reading the CAD file (default value:
0.1). The tolerance value must be expressed in the length unit used in the CAD file.
It must be positive and its minimum value permitted by DeltaMESH depends on
the precision defined by the configuration parameter Reference space (see
subsection Model panel).
Notes:
The value of the tolerance used must be about the 10th of the size of the details
to represent (example: 0.1mm to represent details of 1mm).
The smaller the value of the tolerance, the higher the precision of the geometry,
but longer the geometrical processing.
Read IGES blanked entities:
This option is used to import or not blanked entities

defined in the IGES files. This parameter can be very useful with Catia v4 IGES
file, because it allows the user to filter entities present into the NO SHOW. If you
deactivate this parameter, the blanked entities (entities that belong to the NO
SHOW) will not be imported. By default, this toggle is activated.
Prefer 3D boundaries:
In IGES standard, a trimming curve entity (number 142) used

to describe surface boundaries, is defined both by its 3D representation and by its
2D parametric representation. In certain IGES file, these two curves
representations are inconsistent. This results in gaps between surfaces that are not
visible in the CAD software.
In fact, this problem is a translation error that occurs during IGES file creation. It
happens only with a few translators. The choice between these two representations
cannot be done automatically by DeltaMESH (by default, it uses the 2D
parametric representation). Only the user can choose.
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If this toggle is activated, the 3D boundary definition of faces will be preferred to

the other one. By default, this toggle is deactivated.
-
IGES preferred representation:
This functionality allows DeltaMESH choosing

automatically the better representation of the surface boundaries. When the surface
boundary representations in the 2D and 3D space are inconsistent (see more precise
explanations in the Prefer 3D boundaries definition), DeltaMESH will make some
projection tests to choose automatically the better representation to avoid a gap. By
default, this toggle is deactivated.
Surfaces:
3D Curves:
Entities:
IGES Level:
IGES Color:
This option is used to mesh a surfacic model and to generate triangular

and quadrangular elements (activated by default). This option can be
activated/deactivated simultaneously with 3D Curves option.
This option is used to mesh curves and to generate bar elements
(deactivated by default). This option can be activated/deactivated simultaneously
with Surfaces option.
This option takes (or not) into account the predefined groups in the CAD
file (IGES 402 FORM 7; VDA Group) (activated by default); and can be
activated/deactivated simultaneously with IGES Level and IGES Color options.
Some CAD software do not generate IGES group entities but use the
Level and/or Color fields in IGES entities definition for group representation
(often seen as layers in the content of a CAD system). If this check box is
activated, the groups predefined by the Level field (5th field of IGES entity) will
be read (deactivated by default).
If this check box is activated, the groups predefined by the Color field
(13th field of IGES entity) will be read (deactivated by default).
Click the Set button to apply the parameter setting to the chosen CAD file. The
parameter setting of each CAD file can be updated afterwards by double clicking
Parameters zone in the Import tab of the Meshing dialog box.
Click the Apply button to launch the DeltaMESH import session.
The order of CAD file importing is defined by the order in which the files are chosen. If
importing takes place in several stages, the application will ask whether to
Complete the model (add the geometry contained in the imported files), or to Delete the
existing model (the existing geometry will be replaced by the geometry contained in the
imported files).
Remarks on Importing Files and Groups

The CAD files must have the following suffixes to be imported by DeltaMESH:
-
.igs (in lower case) for IGES files,
.vda (in lower case) for VDA files,
*r.dtc (in lower case) for DeltaMESH geometrical database
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It is possible to mix several types of CAD form in an import operation, e.g.:

-
the blank holder surface in VDA format,
the die entry fillet in UNISURF format,
the rest (die bottom) in IGES format.
Note:
This capability is useful when it has proved impossible to transfer surfaces via a
CAD interface (e.g. IGES). Simply select these surfaces in the CAD system and
generate a file using another format (e.g. VDA). DeltaMESH can then import
this new file, by adding it to the previously imported geometric model.
Each time an import operation is executed, DeltaMESH creates one or more new
objects containing groups of surfaces and/or curves, depending on the number of group
entities defined in the file (see subsection Definition of the areas).
For groups containing other groups, only the highest level groups will be recognized by
DeltaMESH.
If the CAD file contains surfaces and/or curves not belonging to any group,
DeltaMESH creates one new group formed by the independent surfaces and another
new group formed by the independent 3D curves. This action is indicated in the
output file by the sentences: 25 patch(es) replaced by bounded faces and
Faces group number 2 created.
We recommend you use different files for surfaces (that define tools) and for 3D
curves (that define drawbead lines, cutting curves, ).
Joining
Presentation
In this phase, a topological model is automatically constructed from the geometrical
model created beforehand in the CAD file import phase.
The joining means reattaching surfaces and curves to obtain a continuous geometric
model. After this phase, most of the gaps and overlaps between surfaces and/or curves
will be eliminated automatically according to the values of the following two
parameters:
-
Joining tolerance:
This is the maximum permitted reattachment distance (gaps or

overlaps greater than this value will remain) that will be taken into account during
the first joining step.
Minimum Feature size:
This is the minimal size of the geometrical details that will

not be deleted during the joining session. All the geometrical details smaller than
this value will be erased.
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Definition of Joining Parameters

To access joining parameters, the user has
just to click the joining tab of the Meshing
dialog. This operation can be divided into
two parts:
-
Create the topological model
Complete an existing topological

model
Topological model creation
In general, for the first joining session, it is recommended to activate the Apply to all
objects option. All surfaces and 3D curves, if any, will be joined (the surfaces together
and the 3D curves together).
The joining parameters must then be specified, i.e.:
-
Joining tolerance:
(default value: 0.1
Minimal absolute joining tolerance used during joining session

mm).
This value is used during the first step (invisible for the user). This parameter makes
it possible to join generally 90% of the geometrical model without any degeneration
of the latter. This value must not be too high in order to keep the maximum details
for the next operations.
Minimum Feature size:
This is the minimal size of the geometrical details that will

not be deleted during the joining session. This value is used to join the remaining
free edges of the first step which the reattachment distance is lower than this value
Beyond this distance the sides of two surfaces will not be reattached
(default value: 0.5 mm),
Automatic deletion of thin surfaces:
This toggle makes it possible to

activate/deactivate the elimination of the thin surfaces and the correction of
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erroneous faces which present a thin zone that could induce a bad quality mesh. A
face is considered as a thin surface if its width is smaller than the Maximal width
value (default: activated, value: 0.25 mm).
-
Automatic deletion of duplicated surfaces: This
toggle permits to activate/deactivate

the detection and the elimination of the duplicated surfaces (default: activated).
Automatic deletion of geometrical overlaps:
Automatic holes filling: This toggle permits to detect or not the geometrical holes
according to the maximal diameter parameter value and to fill these holes by the
This toggle allows to activate/deactivate

the detection and the elimination of the overlaps according to the maximum gap
parameter value (default: activated).
creation of faces. Warning: only planned holes can be filled without any
degeneration of the geometry. This toggle is deactivated by default.
The joining session proceeds to a first joining with a very low joining value (0.1 by
default). This step is invisible for the user but makes it possible to join 90% of the
geometrical model and to prepare the topological model for the detection and the
elimination of the thin surfaces.
The joining operations will:
-
reattach the faces to obtain a continuous geometrical model,
automatically repair the faces that present a very thin zone (see the Figure 2)
DeltaMESH detects the thin zone on the

face. In the past, these zones generated
multiple edges after the joining session.
With the new algorithm, DeltaMESH

corrects the poor quality face and avoids
the creation of multiple edges.
Figure 2: Automatic treatment of surface with thin zones
detect and eliminate thin surfaces
For the elimination of the thin surfaces, DeltaMESH uses the value of the Maximal
width parameter. This parameter permits to complete the joining results obtained during
the first step and to detect and to eliminate the thin surfaces. The main advantage of this
functionality is to improve locally the mesh quality by eliminating the source of very
small elements generation.
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Before detection of thin surfaces
After detection, all surfaces are correctly

reattached.
Meshing without thin surfaces elimination
Meshing with thin surface elimination:

real improvement of the meshing quality
Advantages to eliminate the thin surfaces
detect and eliminate overlaps between faces according to the maximum distance
parameter value. This parameter gives the maximum distance, between 2 faces
which present an overlap, computed on the normal axis (see the Figure 3). When an
overlap is detected, DeltaMESH will redefined automatically the boundaries of the
faces in order to create a perfect geometrical connection (see the Figure 3).
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Illustration of the maximal gap parameter definition
Illustration of a geometrical overlap before

detection by DeltaMESH
Illustration of the geometrical correction

made by DeltaMESH
Figure 3: Automatic treatment of a geometrical overlap
detect and fill the geometrical holes according to the maximum size parameter
value. DeltaMESH will detect automatically the geometrical holes and create a new
surface to fill the hole (see the Figure 4).
Be careful, this first version of the hole filling function gives a good result only with
planned holes.
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This illustration presents a geometrical hole

due to a bad definition of a face.
With the new functionality of DeltaMESH,

this hole will be automatically detected
and filled. In this case, the boundary is
redefined without creating a new surface.
Figure 4: Automatic geometrical holes filling
After the joining session, you can display the eliminated thin surfaces and the
eliminated duplicated surfaces by selecting Show Thin surfaces and Show
Duplicated surfaces in the 3D View contextual menu.
It is also possible to join only a sub-set of surfaces and/or curves, e.g. when the punch
and die are different shaped tools. These selected entities will be either a group created
automatically when the CAD files are imported, or an object created beforehand by the
user using Selection tools.
Notes:
The Joining tolerance is only used during the first step of the joining session. Its
value must not be too great. Its default value is equal to the reading tolerance
value.
The value of the Minimal Feature Size parameter is expressed in the length unit
used for the model. It must be greater than the import tolerance value used for
the CAD file import phase.
For a CAD model without big defects, a value of 0.5 mm for the Minimal Feature
size is generally sufficient. However, it is not recommended to apply a value too
large to this parameter. The maximum value will be between 0.8 and 1.0 mm.
When you use a large value for the Minimal Feature Size, it is not recommended
to activate the elimination of the thin surfaces because it erases too many
geometrical details.
Complete an existing topological model
In certain cases, we must complete an existing topological model (see subsection

Execution of Joining and Checking) by processing a new joining session. In this case,
we can launch a new joining process with new joining parameters (e.g. Minimal Feature
size = 0.8 mm; Automatic deletion of thin surfaces = Off; Automatic deletion of
duplicated surfaces = On)
You will have the choice to complete the existing topological model or to create a new
topological model with these new joining parameters.
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If you choose the Complete mode, the following dialog will appear:
This dialog is displayed before proceeding to a new joining session in order to check the
parameter values.
The joining tolerance parameter is grayed because as we said, in the complete mode,
this parameter has no influence.
Just click OK to complete the topological model.
Meshing
Presentation
In this phase the discretization criteria (mesh density) are defined and the mesh of the
topological model (created in the joining phase) is generated. The discretization criteria
can be defined using:
-
the minimum and maximum sizes of the elements,
the maximum distance between the elements and the geometry (chordal error),
the maximum angle between two adjacent elements (angle criterion),
the type of meshing algorithm.
Continuity of the mesh between each surface is ensured automatically on the surface
edges where joining has been performed beforehand.
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Definition of Meshing Parameters

The meshing parameters are defined by
clicking the Meshing tab on the Meshing
dialog.
Meshing consists in defining the discretization criteria on the geometric entities

(surfaces and/or curves) and then automatically meshing these entities. The different
discretization criteria are:
-
the type of meshing algorithm (parametric, uniform, progressive),
the minimum and maximum sizes of elements,
the chordal error,
the angle criterion
The mesh density is computed locally on the geometric entities in conformity with these
different discretization criteria. Their respective effects can be combined on a single
geometric entity. The mesh obtained complies with the parameter requiring the highest
density, but without generating elements smaller than the minimum size or larger than
the maximum size (with a certain margin of error).
In any given module, the continuity of the mesh between two adjacent surfaces is
automatically ensured by repeating discretization of the edges of topologically adjacent
surfaces if they have already been meshed.
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Assign all criteria before meshing option

DeltaMESH can mesh a set of objects containing groups of surfaces using two different
methods, determined by the status of the Assign all criteria before meshing check box in
the Meshing tab.
- Assign all criteria before meshing check box is deactivated (recommended).
DeltaMESH computes the discretization criteria for each object and meshes it
immediately in the order defined in the Objects to mesh list. In this case, the
discretization used to mesh the surfaces of the first objects meshed is imposed on
the edges of the adjacent surfaces of the subsequently meshed objects. This method
makes it possible to prioritize the meshing of certain areas (fillets, blank holder
surface, etc.).
- Assign all criteria before meshing check box is activated.
DeltaMESH computes the discretization criteria for all the objects, and then meshes
them. In this case, the highest discretization level is imposed on edges common to
two adjacent surfaces belonging to two different objects, before meshing is
performed.
Note:
We recommend you to leave the Assign all criteria before meshing check box
deactivated, and prioritize meshing of important areas for simulation (in
particular the die entry fillet).
Type of meshing algorithm

DeltaMESH comprises several meshing algorithms that ensure the geometric
constraints of different areas automatically satisfied for the stamping simulation.
The following mesh generators are accessible in the Algorithm panel:
- Parametric: A regular mesh generator in the parametric space, which puts the
priority on compliance with the natural lines of CAD surfaces.
- Uniform: A free mesh generator in the 3D space that puts the priority on the shape
quality of the elements without constraints in relation to the parametric definition of
the surfaces. The size of the elements is uniform within each surface.
- Progressive: A free mesh generator in the 3D space that puts the priority on the
shape quality of the elements without constraints in relation to the parametric
definition of the surfaces. The size of the elements varies according to the
Progression ratio, which defines the size ratio between two adjacent elements.
The table below defines the advantages and disadvantages of each mesh generator.
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Type of
algorithm
Advantages
Disadvantages
Advice
PARAMETRIC
Follows and
preserves the
geometry
Possible to
elongate elements
in one direction
Regular shape of elements

Insensitive to
geometric
defects
UNIFORM
PROGRESSIVE
Variable element
size
Regular shape of
elements
Sensitive to geometric
defects
The geometric lines

of surfaces are not
necessarily preserved.
Constant size of
elements on a surface
To be used mainly
for meshing tools.
To be used when the

PARAMETRIC mesh
generator cannot
generate a correct
mesh on a surface.
Increase the minimum

element size to avoid
generating too many
elements on large
surface.
Sensitive to small
geometric edges
propagating their size.
The geometric lines of

surfaces are not
necessarily preserved.
To be used with
caution when small
geometric edges are
present.
Increase the minimum

element size.
Notes:
If a surface and/or a curve cannot be meshed, it is possible to only generate this

entity's nodes by activating the Nodes only toggle (see subsection Solutions to
Complete a Mesh).
The free nodes will be loaded in the Others object in the Visibility tab. They can
be recovered in the preprocessor module and will be used to interactively
construct the missing elements.
Quadrangular surface detection function

The Quad surface detection toggle is used to activate a DeltaMESH function that
automatically detects surfaces with 3 or 4 sides. Once detected, these surfaces
automatically have priority for meshing. The generated mesh will follow lines parallel
to the surface sides, instead of lines parallel to the CAD surfaces' iso-parametric lines.
3 or 4-sided surfaces are detected using the following two configuration parameters (see
subsection Quad. Surface detection panel):
-
Corner limit angle:
Angle to detect the surface corners (10 by default).
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Notes:
This angles value must not be too small because too many corners would be
detected (and not enough 3 or 4-sided surfaces).
Neither must it be too large because false 3 or 4-sided surfaces would be

detected.
c> corner limit angle
c< corner limit angle

X
X : corners selected to describe the 4-sided surface ( c> corner limit angle 10)
: corner not selected to describe the 4-sided surface ( < corner limit angle 10)
c
Quad distortion angle:
Maximum distortion angle (default 40) of elements in

relation to a perfect quadrangle.
Note:
As this value is reduced, the number of selected 3 or 4-sided surfaces will

decrease.
Before meshing 3 or 4-sided surfaces, DeltaMESH will automatically propagate the

element densities computed on the different edges of these surfaces, to generate the
maximum number of quadrangular elements.
This propagation from one surface to another is controlled by the Density variation
parameter defining the maximum permitted progression in element size.
The density variation coefficient must be greater than 1.0. The higher the value, the
lesser the density propagated and the transitions between surfaces will be performed by
triangular elements. The coefficient may exceptionally be set to 1.0 if you wish to
maximize density propagation and obtain as many quadrangular elements as possible
(this will greatly increase the number of elements).
The progression in mesh density is also controlled by the Over discretization
configuration parameter (see subsection Quad. Surface detection panel), which
defines the type of density progression within each surface. When it is activated, more
elements are obtained within each surface (about 10%).
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Size criteria
The size criteria are defined in the Size panel.
The Maximum size parameter defines the maximum element size during meshing. If the
other criteria do not require a smaller size, the elements will take this maximum size.
The Minimum size parameter defines the minimum element size. This value will be
maintained as a priority to the other criteria that may create smaller elements.
The element size is computed as the distance between two nodes belonging to the same
edge. This size should not be confused with the size used by the solver to compute the
time step of the explicit computation (characteristic length).
The maximum size determines the elongation and warping of the generated elements. If
you want to improve these criteria, simply reduce the maximum size value (more
elements will be generated).
The size criteria must be expressed in the model's length unit. They must be positive
and greater than the precision value defined in the Reference space configuration
parameter (see subsection Model panel).
Note:
The minimum size must not be too large, otherwise discretization of small
surfaces, especially surfaces representing fillets, may not be regular.
Chordal error
The chordal criterion is defined in the Chordal error panel by clicking on the Active
check box.
It defines the maximum distance between
a point located in an element's plane and
the model's geometry that must be
preserved when meshing.
Maximum
distance from
the mesh to the
geometry
The chordal criterion value must be

entered in the model's length unit. It must
be positive and greater than the precision
value defined in the Reference space
configuration parameter (see subsection
Model panel).
By activating the Follow isoparametrics toggle it is possible to compute the chordal
error along the surface's iso-parametric curves, instead of on the surface itself. This
generates meshes whose discretization is uniform between the boundaries and the
surface interior.
Note: It may be useful to activate the Follow isoparametrics check box if you want to
obtain more elements and orient the mesh following iso-parametric lines in the plane
tangent to the surface.
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Angle criterion
The angle criterion is defined by clicking the Active check box in the Angle Criterion
panel.
The maximum angle parameter defines the
maximum angle between 2 adjacent elements
for meshing within the same surface and/or
the same 3D curve.
The angle criteria value must be defined in
degrees, and be greater than 0.
Max angle
betw. normals
of the 2
elements.
By activating the Follow iso-parametrics check box, it is possible to compute the angle
criterion along the surface's iso-parametric curves, instead of on the surface itself. This
produces meshes where discretization is uniform between the boundaries and surface
interior.
Notes:
It may be useful to activate this toggle if you want to obtain a more regular mesh
or if the surfaces have two important curvatures in two different directions.
It is recommend to keep deactivate this if a small angle value is used (less than
10).
Angle error on a surface in space
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Angle error with Follow iso-parametrics

option on a planar surface.
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MESH CHECK AND REPAIR

Import Check
We recommend you to examine the output report displayed in the DeltaMESH console.
In particular, this report gives the number of surfaces and/or 3D curves:
-
present in the CAD file,
created by DeltaMESH,
that are independent (not referenced by another entity),
eliminated because they are smaller than the import tolerance.
The output file recalls the import parameter used for each CAD files, gives the number
of imported surfaces and presents some advices in the case of a problematic import
status, as shown below in the output file example after the IGES file importing.
IMPORT SESSION
_______________________________________________________________________________
Import parameters:
______________________________________________________________________________
|
|
|
|
|
|
|
|
| Faces
| Curves | Prefer 3D |
|
CAD model
| Import tol | import | import | contours |
|_______________________________|____________|__________|__________|___________|
|
|
|
|
|
|
| deltacup_fillet.igs
|
0.1 |
YES
|
NO
|
NO
|
| deltacup_die.igs
|
0.1 |
YES
|
NO
|
NO
|
| deltacup_bh.igs
|
0.1 |
YES
|
NO
|
NO
|
|_______________________________|____________|__________|__________|___________|
Import results:
- 49 faces were imported in DeltaMESH
Import status: OK.
WARNING:
We have detected in the definition of some files, some inconsistencies between
2D and 3D faces boundaries representation. After joining session, if it
remains some amazing geometrical free edges, re-import the CAD model after
changing "Prefer 3D contours" parameter. The related files are:
- "deltacup_die.igs"
- "deltacup_bh.igs"
Cpu time (user+system) for the whole DeltaMESH session: 0.66 seconds
You can also access a more detailed report by clicking the

button. The CAD history
report gives some more precise information, as shown below in an extract of the CAD
history file after the IGES file importing.
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----------------------------------Summary of reading IGES file

----------------------------------Type
Entity
116
Point
144
Trimmed Parametric Surface
128
Rational B-Spline Surface
114
Parametric Spline Surface
118
Ruled Surface
120
Surface of Revolution
122
Tabulated Cylinder
140
Offset Surface
108
Plane
402 Associativity Instance(group)
1 predefined group(s)
25 patch(es) replaced by bounded faces
Faces group number 2 created
----------------------------------Type
Created Entities
----------------------------------Faces Group
1
Face
40
Edge
155
Vertex
216
-----------------------------------
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File
0
15
40
0
0
0
0
0
0
1
Created
0
15
40
0
0
0
0
0
0
1
Indepen.
0
15
25
0
0
0
0
0
0
1
< Toler.
0
0
0
0
0
0
0
0
0
0
Part 1
Part 2
It is very important to check the Part 1 called Summary of reading CAD file.
This part is divided into six columns.
-
The first column called Type indicates the name of the entities
The second column called Entity gives the description of the entity
The third column called File indicates the number of entities present in the CAD
file.
The fourth column Created gives the number of entities created by DeltaMESH
The fifth column Indepen. indicates the number of independent entities created by
DeltaMESH
The sixth column < Toler. gives the number of entities that have been eliminated
because they are smaller than CAD File reading tolerance
For example, in deltacup_die.igs file, there are 40 128 type entities (Rational
B-Spline Surface) present in the CAD file. 40 entities have been created by
DeltaMESH and among these ones, 25 are independent i.e. they are not referenced by
another entities (except 402 form7 groups). The 15 remaining ones are used as the
original untrimmed surfaces to obtain the 15 144 type entities.
Moreover, for each entity, we must check that:
number in 3rd column = (number in 4th column + number in 6th column)
This rule is true for all entities except for the 108 type entities (plan).
The Part 2 summarizes the total number of faces groups, faces, edges and vertices
created. We can also read the session time.
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If messages indicate that it was not possible to translate certain CAD entities, you must
check the CAD export options chosen in the CAD software (see the advice in
subsections Interpreted CAD Entities and Interface Options for Different CAD Systems).
If import problems arise, the user can re-import this CAD file in the original CAD
software from which it has been generated (preferably, in an empty project). This
permits to identify any problems that could have appeared during CAD file generation,
to solve them in the CAD system and to generate a new CAD file.
Joining check
After joining the mesh, the user should do several checks, as described more in details
below:
-
Display the eliminated surfaces
Check the surfaces free edges
Look at the output report
Eliminated surfaces
After the joining session, you can display the eliminated thin surfaces and the
eliminated duplicated surfaces by selecting Show / Thin surfaces and Show / Duplicated
surfaces in the 3D View contextual menu.
Surfaces free edges
After joining, the model's free edges can be viewed by selecting Show / Surface free
edges in the 3D View contextual menu.
If internal free/multiple edges remain after the first joining operation, additional joining
operations (iterative joining) can be performed to reduce their number. This is very fast
because iterative joining is only performed on the free/multiple edges left in the model.
(see RepairFAQ paragraph below)
Output report
We recommend you to examine the detailed report in the DeltaMESH console.
This report on the surfaces specifies:
-
the total number of geometric free/multiple edges,
the number of closed contours formed by free/multiple edges,
the number of open lists formed by free/multiple edges.
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If only one closed contour is listed, this means all the joined surfaces are connected,
and that this closed contour represents the external boundary of the tool.
Internal closed contours make it possible to visually detect duplicated surfaces,
substantially superimposed surfaces, isolated surfaces, and gaps in the model (surfaces
missing).
Final Mesh check

After meshing, the user should do several checks, as described more in details below:
-
check surfaces meshes when warnings have been written
Check the free and multiple edges
Check if undercut appears
Display the mesh quality contours
Look at the output report
If problems appear it is important to check also the import and the joining to understand
the origin of the problem and repair it easily.
Surfaces mesh with warning

It is recommended to check surface meshes when DeltaMESH indicates an information
message (WARxxx) in the report.
To locate the incriminated surface, simply choose the Surface entity type in the
Entity information dialog and enter the identifier indicated in the information message.
Then, the concerned surface is highlighted.
Free and multiple edges
It is useful to display the free and multiple edges of the mesh using the show toolbar.
We advise you to avoid free or multiple edges inside the mesh, since their presence
could not only impede the execution of an offset during the generation of tools, but also
affect the results accuracy if the holes or overlaps reach 10% of the blank thickness.
Undercut
Make sure that there are no undercuts in the mesh. Even if the initial CAD has no
undercut, the mesh can induce undercut in non-planar vertical parts. For example in the
curved vertical surface, if the discretizations on the top and bottom lines of the surface
do not coincide, there will unavoidably be some undercut elements.
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Top view:
A
Cross section AA:
Edges on
bottom line
CAD
CAD
A
Mesh
Edges on
the top line
the Chordal error.
The undercut area can be found using Analysis contour /Undercut. It displays the angle
or the critical areas (shown in red in the figure below) .
Undercut : 90
Safe :
> Threshold
Stamping
direction
Element
surface
Mesh quality contours

Other quality problems may appear because of a bad initial CAD data (overlapping of
surfaces, non trimmed surfaces) or a bad meshing.
The following Mesh Quality contours can be used to find the elements which are
warped, very thin or distorted.
-
the value is the angle between the average normals of these

two elements. If it exceeds 20 for the fillets (10 if a springback calculation is
planned), and 30 for the rest, that means that there can be a mesh problem like
overlapping or distorted element.
warping:
Area:
big warping can indicate a problem of mesh quality.
if the area of the elements is very small (0.01 mm), problems might appear
during offset.
if there is a very small angle in an element, problems could
occur during offset.

See the remeshing action chapter to correct easily this type of problem
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Iso parametric curves

It is possible to display surfaces with several iso-parametric curves in each U and V
direction (see subsection Visualization panel). This permits to understand in some cases
why the mesh is not good (generally due to a bad parameterization of the surface).
Output report
We recommend you examine the output report in the DeltaMESH console. Following
is an example output file after the meshing session.
_______________________________________________________________________________
MESHING SESSION
_______________________________________________________________________________
Meshing parameters:
Setting mesh type on a selection
- Mesh type
: PARAMETRIC
- Quadrangulars detection
: YES
Setting the size criterion on a selection
- Maximum size
: 30.000000
- Minimum size
: 0.100000
Setting the chordal error criterion on a selection
- Limit chordal error
: 0.150000
- Follow isoparametric curves : YES
Setting the angle criterion on a selection
- Limit angle
: 15.000000
Meshing of all surfaces, (force mesh generation activated)
Meshing Status: OK.
All of the 49 faces processed were meshed.
The resulted mesh is composed with 4002 elements and 3825 nodes.
The information indicated in the output file is very important. The meshing strategy is
recalled in it. In this example, the default values are used.
This report indicates:
-
the total number of meshed surfaces,
the number of nodes and elements generated,
if applicable, the error or information messages displayed during meshing.
In the above report, 49 surfaces are present in the topological model and all have been
meshed. The meshing Status is OK. This mesh is constituted with 3825 nodes and 4002
elements.
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Mesh Repair and FAQ

If import problem
-
The geometry does not look like the CAD geometry, there are many cylinders
and cones.
The IGES files are not exported from CAD software with the right option. Verify, you
have well choose 142/144 entities. See CAD model exchange from CAD systems to
DeltaMESH chapter for more details.
-
Some holes / free edges appear between surfaces.
It may come from inconsistent between 2D and 3D representation in the CAD file. Try
to use Prefer 3D boundaries or IGES preferred representation option during import.
If joining problem, if complex part

If internal free/multiple edges remain after the first joining operation, additional joining
operations (iterative joining) can be performed to reduce their number. This is very fast
because iterative joining is only performed on the free/multiple edges left in the model.
The procedure to join together a complex model is as follows:
-
Perform an initial joining with the Apply to all objects toggle activated, using for
example the following setting parameters:
Joining tolerance = 0.1 mm
Minimum Feature size = 0.5 mm
Automatic deletion of thin surfaces = On
Automatic deletion of duplicated surfaces = On
Automatic deletion of geometrical overlaps = On
Automatic holes filling = Off
After the previous joining session, verify the model's free/multiple edges by
displaying them and by examining the detailed report. If there is only one contour
(the part's external edge), this means that the joining operation is complete. You can
stop the procedure.
Eliminate the unnecessary surfaces detected by the first joining (unwanted surfaces,
superimposed surfaces, construction plane, etc.) before starting complementary
joining.
Simply create an object containing all the correct surfaces by removing the
unnecessary surfaces. Then, this object will be used for subsequent iterative joining
operations.
Deactivate the Apply to all objects check box and perform a new joining session on
the previous created object, still using the same tolerance values. After clicking the
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button, a warning message is displayed. You can either delete the existing
topological entities or complete them.
You have to choose the Delete option in order to re-create a new topological model
from a clean object.
join
Check for free/multiple edges, and if there are any, complete the topological model
with a new joining session by increasing the tolerance value:
Minimum feature size = 0.8 mm
Automatic deletion of thin surfaces = Off
Automatic deletion of duplicated surfaces = On
Automatic deletion of geometrical overlaps = Off
Automatic holes filling = Off
Notes:
If you increase the minimum feature size value too much, there is a risk of
damaging the geometry and generating a much distorted mesh near to the defect
where joining have been forced. In this case it is preferable to keep a few
internal free edges and stitch the element nodes after meshing.
When you complete a topological model, it is recommended to deactivate the

elimination of thin surfaces because some important geometrical detail can be
erased using this function.
If meshing problem
If a problem appears during the mesh quality control, it must be repaired if accurate
contact is planned to be used (see Simulation methodology for high quality stamping
section).
-
Some surfaces are not trimmed or overlap others
Remove the problem surfaces from the object,(simply create an object containing all the
good surfaces by removing one of the not trimmed or overlapped surface) and do again
a joining and a meshing deactivating the Apply to all objects option.
-
Small surfaces overlaps others
Do again a joining and a meshing with a bigger value of maximum gap for Automatic
deletion of geometrical overlaps.
Or if the problem concern only very few elements, delete them and use
geometry/edition tools from nodes or elements, to eliminate the problematic element.
For instance, you can use the merge node to node option.
-
Elements are too warped, too thin or too distorted.
Make an automatic remeshing (see the remeshing action chapter for more details)
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Some fillets disappear or are degenerated
Reduce the Maximal width parameter of Automatic deletion of thin surfaces or disable
the function during the joining.
Advanced repair
General rules
To mesh non-deformable tools, it is preferable to use the Parametric mesh generator
because it produces a mesh that follows more closely the surfacic model of the tools.
Most of the elements that DeltaMESH creates are quadrangular and follow the
iso-parametric lines of the CAD geometry. This minimizes warping of the elements, and
the corresponding criteria are broadly satisfied provided the surfaces do not exhibit
themselves excessive warping (in which case a higher discretization level will minimize
the problem).
Elements can, if necessary, be highly elongated in one direction compared to the other,
to follow the geometry as closely as possible and simultaneously minimize the total
number of elements (in this case the elements are not very satisfactory with regard to
the standard shape criteria adopted in Finite Elements). This is not important for tool
meshing, and does not penalize the simulation results. However, if preferred, it is
possible to reduce the maximum size value, and reduce elongation of the elements.
The chordal error and angle criteria are complementary:
-
The chordal criterion ensures that the surface geometry is preserved when it
comprises large curvature radii.
The angle criterion sets a minimum discretization for small radii.
Note:
The numeric parameter values given in the paragraphs below have been defined
for automobile bodywork parts with sizes in the order of 1,000 to 2,000 mm.
They must be modified if the parts are of a different size or use a different unit of
measurement.
Special areas: die entry fillet, die bottom fillet, etc.

It is recommended to give priority to meshing these areas.
DeltaMESH will give priority to meshing these crucial areas (by specifying the
priorities and meshing these areas first). They will not be disrupted by the other areas,
thereby ensuring optimum quality.
The meshes in areas with a lower priority are then connected automatically to ensure
continuity (the layers of transition elements are then located in these areas, instead of in
the sensitive areas).
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To give priority to meshing these areas:

-
Deactivate the Apply to all objects check box in the Meshing dialog.
First select the object containing the surfaces of these areas and define the meshing
criteria (Meshing parameters dialog). Add the object to the list of Objects to mesh.
Then select the objects containing the others groups of surfaces, and define their
meshing criteria.
Do not activate the Assign all criteria before meshing check box.
The following meshing parameters are recommended for these areas:

-
Algorithm:
Parametric
The Quad. surface detection option
can be used to good effect in these areas to

generate the maximum number of quadrangular elements with a mesh as smooth as
possible.
-
Maximum size:
30 mm
Minimum size:
0.1 mm (do not assign a too large value to Minimum size, it
might reduce the regularity of the mesh).

-
Chordal error:
Angle error:
0.15 mm (identical to the value used for the other areas).
10 to 15. It is possible to use a lower value when you want to

show the curvatures very precisely (e.g. for a springback computation). In this case
we recommend you deactivate the Follow iso-parametrics check box.
Die internal area ("die bottom")and Blank holder surface

This is the part of the die located under the punch, whose mesh will be offset to
automatically create the mesh of the punch.
The recommended meshing parameters for this area are the same as those used for
priority areas. However, if you want to obtain less elements, you can:
-
Deactivate the toggle Follow iso-parametrics
Increase the Density variation parameter
Increase the Maximum Angle parameter (15)
Increase the Maximum size parameter (40 to 50 mm)
The blank holder is considered to be non-deformable. In this case the recommended

meshing parameters are the same as those used for the internal part of the die.
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Meshing the blank

The following meshing algorithms can be chosen to maximize the number of
quadrangular elements on the blank:
-
Parametric
when the iso-parametrics are regular and the blank sides are parallel to
these iso-parametrics,
Uniform
in other cases.
The Quad. surface detection option can be used to good effect when the overall blank
shape is rectangular or tubular (e.g. for hydroforming). A density progression
coefficient of 1.2 (exceptionally 1.0) will enable you to generate a mesh comprising
mostly quadrangular elements.
We recommend you only use size criteria and deactivate the angle and chordal criteria if
you want to achieve constant element size.
If necessary it may be useful to use the Barycentric smoothing function to increase the
"finite element quality" of the mesh (see subsection Barycentric Smoothing Action).
Solutions to Complete a Mesh

When the model is not meshed completely, DeltaMESH gives the list of identifiers of
non-meshed surfaces and/or curves in the DeltaMESH console.
The two main factors preventing a surface being meshed are:
-
discretization criteria incompatible with the size or geometry of this surface

(warping in particular),
CAD geometry comprising very substantial defects (surface edges comprising a

reversal point, very high surface curvature value, highly distorted iso-parametrics,
very irregular distribution of iso-parametrics, etc.).
In the text below, various strategies are presented for completing an initial mesh. They
should be used in the described order. To use these strategies, the mesh failed surfaces
must be grouped in an object.
Strategy 1
This strategy ensures mesh continuity.
Continue meshing of these surfaces within the same module in Complete mode:
1. Reduce the Maximum size criteria.
2. If (1) fails, deactivate the Angle and Chordal error criteria.
3. If (2) fails, use a Uniform mesh type (and increase the min. size slightly to avoid the
risk of generating a large number of small elements on the large surfaces).
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Strategy 2
This strategy ensures mesh continuity.
Start the meshing phase again with the problematic surfaces. In this way they will not
be affected by the meshing of adjacent surfaces.
1. Use the same criteria on these surfaces as in the initial mesh.
2. If (1) fails, reduce the Maximum size criteria on these surfaces.
3. If (2) fails, use a Uniform mesh type (and slightly increase the min. size).
If the strategy 2 succeeds, you can then restart meshing in Complete mode with the
initial criteria (since the "problematic" surfaces have now been meshed, DeltaMESH
will not mesh them again).
Strategy 3
This strategy does not preserve mesh continuity. Compared with strategy 2 it avoids
having to re-mesh the whole model, but requires interactive connecting of the mesh.
Therefore it must only be used if the number of surfaces to re-mesh is low and they are
small.
Copy the joined model into a new module, and only mesh the problematic surfaces.
1. Use the same criteria as in the initial mesh of the failed surfaces.
2. If (1) fails, reduce the Maximum size criteria for these surfaces.
3. If (2) fails, use a Uniform mesh type (and increase the minimum size slightly).
If the strategy 3 succeeds, the two meshes, both contained in a module, must be
interactively connected (with Edition -> Elements option in Geometry menu).
Strategy 4
This strategy does not generate a mesh. It only generates nodes on the non-meshed
surfaces.
In the module containing the initial mesh:
1. Keep the existing criteria and mesh with the Nodes only option activated.
2. If (1) fails, reduce the Maximum size criteria before meshing.
3. If (2) fails, use a Uniform mesh type before meshing.
If the strategy 4 succeeds, the generated free nodes are located in the Others object.
They can then be recovered in the preprocessor module to interactively generate the
missing elements using these nodes.
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THE REMESHING ACTION

Presentation
Remeshing is the fourth step of the DeltaMESH actions. It is an optional step. This
complementary action allows the user to improve the mesh quality whenever necessary.
Its process is very simple and useful.
The remeshing operation will detect automatically faces with a bad quality mesh due to
the presence of some erroneous surfaces in the CAD model. The faces detection is done
by applying three different element quality criteria. DeltaMESH will select these bad
mesh quality faces and also their adjacent ones. Their meshes will be deleted. Then, a
new meshing strategy specific to the erroneous surfaces can be applied. This post
meshing function reduces the time spent by the user to correct the mesh when the CAD
model contains some erroneous surfaces. Then, we can obtain directly and more quickly
a better mesh.
The following figures illustrate the interest of the remeshing (in this example, we have
specified Angle between elements to 30:
Before the remeshing, the maximal angle

between elements was about 41
After the automatic remeshing, the maximal

angle between elements is equal to 24.4
After the remeshing session, you can display the eventual remeshed surfaces by
selecting Show -> Remeshed surfaces in the 3D View contextual menu.
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The Remeshing Action
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Detection parameters
The detection of the invalid meshes depends on three different parameters values:
-
Angle between elements: 30
Warping:
15
Area:
0.001 (deactivated by default).
(activated by default);
(deactivated by default),
The Angle between elements threshold permits to detect the surfaces in which the angle
between element normals is greater than this threshold value (30 by default). However,
the faces situated along geometrical sharp edges will not be detected.
The Warping threshold permits to detect the surfaces in which the element warping is
greater than this value.
The Area threshold permits to detect the surfaces in which the element area is lower
than this value.
After the detection operation, DeltaMESH will delete the different selected meshes (the
invalid and their adjacent)
Remeshing parameters
The remeshing parameters definitions are given in the previous chapter (Meshing the
Topological model).
A toggle allows whether or not to apply two different meshing strategies for the invalid
meshes surfaces and their adjacent faces (see Figure 2 and Figure 3).
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Figure 2: Remeshing parameters dialog box
Figure 3: Interest of defining two different remeshing strategies
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Figure 3 illustrates the capability of defining two different meshing strategies for the
selected faces and their adjacency. For the main selected faces (darker shade), we
applied a 3D meshing algorithm (progressive). For their neighbours (lighter shade), we
used the default meshing strategy. A very localized modification is possible by applying
this strategy.
The default parameter values are as follow:
Faces detection criteria
Angle between elements
ON
value
30.0
Warping
OFF
value
15.0
Area
OFF
value
0.001
Same parameters for both faces
OFF
Meshing criteria
Selected faces
Adjacent faces
Algorithm
Progressive
Parametric
Progressive ratio
1.2
1.2
Quad. Surface detection
OFF
ON
Density variation
1.2
1.2
Minimum element size
0.1
0.1
Maximum element size
10.0
30.0
Active
ON
ON
Follow isoparmaetrics
ON
ON
Maximum distance
0.15
0.15
Active
ON
ON
Follow isoparmaetrics
ON
ON
Maximum distance
15.0
15.0
Algorithm
Size
Chrodal error
Angle crietria
By default, this fourth step is deactivated.

The remeshing parameters are defined by clicking the Remeshing tab on the Remeshing
dialog.
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It is possible (but not recommended) to mesh all the model's geometric entities (surfaces
and/or curves) in a single operation, by activating the Apply to all objects check box. In
this case it is sufficient to click the zone containing the parameters to display the
Meshing parameters dialog, and modify the default meshing parameters. Once
modified, these parameters will be applied to the whole model.
Execution and Checking

The remeshing can be executed by clicking the Mesh button in the remeshing dialog.
We recommend that you examine the output report in the DeltaMESH console.
Following is an example output file after the meshing session.
_______________________________________________________________________________
MESHING SESSION
_______________________________________________________________________________
Meshing parameters:
Setting mesh type on
- Mesh type
: PROGRESSIVE
: NO
Setting the size criterion on
- Maximum size
: 5.000000
- Minimum size
: 0.100000
Setting the chordal error criterion on
: 0.150000
Setting the angle criterion on
- Limit angle
: 10.000000
- Follow isoparametric curves : NO
Meshing of , (force mesh generation activated)
Setting mesh type on
- Mesh type
: PARAMETRIC
: NO
Setting the size criterion on
- Maximum size
: 5.000000
- Minimum size
: 0.100000
Setting the chordal error criterion on
: 0.150000
Setting the angle criterion on
- Limit angle
: 15.000000
Meshing of , (force mesh generation activated)
Remeshing strategy for the

main selected faces
Remeshing strategy for the

adajacent faces
Meshing Status: NO OK.

All of the 28 faces processed were meshed but the
following messages were generated:
- The mesh of some faces is incoherent. The faces are:
3088,
The resulted mesh is composed with 13998 elements and 12012 nodes.
The information indicated in the output file is very important. The meshing strategy is
recalled in it. In this example, the default values are used.
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This report indicates:

-
the total number of meshed surfaces,
the number of nodes and elements generated,
if applicable, the error or warning messages displayed during meshing.
In the above report, 28 surfaces have been selected and all have been meshed. The
meshing Status is NOT OK because one of these faces presents an incoherent mesh.
The identifier of this face is given in order to check it in the GUI.
This mesh is constituted with 12012 nodes and 13998 elements.
It is recommended to check surface meshes when DeltaMESH indicates a warning
message (WARxxx) in the report.
To locate the incriminated surface, simply choose the Surface entity type in the Entity
information dialog (appearing by choosing Information on Entities option of the
Analysis menu) and enter the identifier indicated in the warning message. Then, the
concerned surface is highlighted.
It is useful to display the free and multiple edges of the mesh by selecting the Show Free
edges and Show Multiple edges in the 3D View contextual menu.
The Contour tab in the Analysis toolbar gives access to the Mesh Quality menu enabling
you to display the element quality criteria.
It is possible to display surfaces with several iso-parametric curves in each U and V
direction (see subsection Visualization panel). This permits to understand in some
cases why the mesh is not good (generally due to a bad parameterization of the surface).
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THE MULTIPATCHING ACTION

Presentation
Multipatching is the new DeltaMESH tool that allows the user to improve the mesh
quality by modifying topologicaly the model automaticaly or manualy. Its process is
very simple and useful.
This action is made available by clicking the Multi-patch
dialog will then pop up.
button. The Multipatch
The multipatching operation will detect automatically surfaces containing faces near
borders with a bad quality, due to the presence of some erroneous surfaces in the CAD
model. The faces detection is done by applying different element quality criteria.
DeltaMESH will select these bad mesh quality faces and also their adjacent ones to
make connex surface groups. Each group is transformed into a multipatch and
considered as one surface. Treatments are done to mesh each multipatch without taking
internal borders into account. This post meshing function can also be done with users
defined groups
It is useful to correct thin surfaces packet, over cutting model, bad surface
parameterization, points
The following figures illustrate the interest of the multipatching:
Before the multipatching, the mesh contain

small and flat elements to respect CAD surface
borders.
After the automatic multipatching, an outline

disappears. Elements are regular
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Detection parameters
The detection of the invalid meshes depends on six different parameters values:
-
Angle between elements: 30
Warping:
15
Area:
0.001 (deactivated by default).
Size:
0.1 (activated by default).
Angle min.:
1. (deactivated by default).
Angle max.:
175. (deactivated by default).
(activated by default);
(deactivated by default),
The Angle between elements threshold permits to detect the surfaces in which the angle
between element normals is greater than this threshold value (30 by default). However,
the faces situated along geometrical sharp edges will not be detected.
The Warping threshold permits to detect the surfaces in which the element warping is
greater than this value.
The Area threshold permits to detect the surfaces in which the element area is lower
than this value.
The Size threshold permits to detect the surfaces in which the smallest element
dimension is lower than this value.
The Angle min. threshold permits to detect the surfaces in which the smallest angles
element is lower than this value.
The Angle max. threshold permits to detect the surfaces in which the bigest angles
element is upper than this value.
After the detection operation, DeltaMESH will creat the different multipatch and mesh
them
Multipatching parameter
The elimination parameter give the tolerance to remove nodes too close one another.
This coefficient, multiplied by minimum size mesh criteria represent the length under
which two nodes are merged.
Notes:
A value between 1 and 3 is correct and it is not recommended to exceed 5
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Figure 2: Automatic repatching parameters dialog box
Manual multipatching
Multipatching is also available after meshing from a users surfaces selection: a
multipatch is made for each object selected.
Two methodes are available:
-
surface is created by the interpolation of children surfaces. This method

give good results with a great amount of thin surfaces or bad parametrised
surface(s).
NURBS: A
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Before the multipatching, the model contain

many thin surfaces than impose many small
elements.
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New surfaces replace packet of thin surfaces

The mesh is less discretized and have a better
quality.
The group of face received treatment to eliminate small element present near
surface border. The group is consider like a new surface. Elements can cross
internal border.
Zone:
Notes:
Zone is the option used by the automatic multipatching.
For complex cases in which NURBS cant generate a multipatch, zone method is
automatically chosen.
All surfaces selected for a multipatch must be neighbor.
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Figure 4: Manual repatching parameters dialog box
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OTHER DELTAMESH ACTIONS

The different functions of DeltaMESH described in this paragraph help the user to
correct and improve interactively the meshing quality. The tools include:
-
Mesh delete tool
Barycentric smoothing tool
Eliminated surface restoring tool
Part splitting
Mesh Deletion
The deletion action is made available by clicking the
button of the CAD tab from
Data Set-up toolbar or by selecting DeltaMESH -> Mesh deletion from the Geometry
menu. This action gives access to the Delete mesh dialog.
This function is used to delete the mesh (elements, nodes, discretization criteria)
belonging to geometric entities (surfaces and/or curves), imported and meshed by
DeltaMESH. This will enable you to subsequently remesh these different entities using
other strategies (sizes, algorithm types, etc.) and obtain a new mesh.
This deletion action can be applied:
-
To a selection of surfaces and/or curves. You just have to select the surfaces and/or
curves that you want to delete the mesh.
To one or several groups. You just have to choose which group mesh will be deleted
by this action
To all the geometric entities (function previously available when starting meshing).
In this case, all the elements and nodes will be deleted (very quickly) and the next
mesh will be created using the topological model.
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The selected objects must contain geometric entities (surfaces and/or curves) and not
mesh entities (nodes and elements). DeltaMESH carries out the mesh deletion action
on geometric entities.
If the mesh is partially deleted, the nodes belonging to the surface edges will be deleted
only if the meshes of the adjacent surfaces are deleted simultaneously or did not exist.
The deletion function can also be used on entities (surfaces and/or curves) where
meshing has failed and therefore no elements or nodes have been created. The deletion
will make it possible to cancel the constraints accumulated on these entities by the
different meshing criteria. It will then be possible to mesh these entities with new
strategies (e.g. by increasing the size criteria) independently of the previous attempts to
mesh.
Barycentric Smoothing
This action is made available by clicking the Barycentric smoothing
button or by
selecting DeltaMESH -> Barycentric smoothing from the Geometry menu. The Smooth
This function is used to improve the finite element shape quality of the elements already
generated, using an algorithm that repositions the nodes.
Nodes belonging to the surface boundaries are not displaced. Only internal nodes are
displaced, and repositioned exactly on the CAD geometry.
This function can be used when better finite element shape quality is necessary:
-
On the mesh of the blank holder surface, if volume modeling of the blank holder is
chosen,
On the mesh of the blank.
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Notes:
This function must not be used on the mesh of die entry fillet and die bottom
areas, because after barycentric repositioning the alignment of the nodes on the
iso-parametrics is no longer preserved.
However, this function can be used on surfaces to improve the shape of elements
comprising angles that are too acute or too obtuse.
The number of iterations performed by the barycentric smoothing algorithm can be

defined in order to improve the quality iteratively. Three iterations are generally
sufficient.
Note:
The barycentric smoothing and repositioning operation on CAD geometry may

be costly in terms of CPU time when there are a large number of elements or the
CAD surfaces are complex. In this case it is preferable to leave the iterations
number at 1, and if necessary restart the barycentric smoothing operation when
the result has been examined.
Restore Eliminated Surface

This function permits to restore the surfaces that have been eliminated during the
joining session. These surfaces are either duplicated surfaces or thin surfaces. After the
joining session, these surfaces cannot be meshed because there are out of the
topological model. So, this tool permits to re-integrate the eliminated surfaces into the
topological model.
This action is made available by clicking the
Restore surfaces
button or by selecting
DeltaMESH -> Restore surfaces from the
Geometry menu. The Restore Surface dialog
will then pop up.

You can display the eliminated thin surfaces
and the eliminated duplicated surfaces by
selecting Show -> Thin surfaces and Show ->
Duplicated surfaces in the 3D View
contextual menu.
If you consider that DeltaMESH has
eliminated too many surfaces, you can select
them and restore them into the geometrical
model. To introduce them into the
topological model, you have to complete the
joining results (the thin/duplicated surfaces
toggles will be deactivated).
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Part Splitting
This action is made available by clicking the Part splitting
button. The Part splitting
This function is used to split the part with a curve. It is possible to separate the part in
two to apply two different mesh strategies (for hemming simulation for example), to
make a hole, to delete a piece of part or to improve the CAD model directly in
PamSTamp2G.
However this function is available after the import session or after the joining session, it
is recommended to use it after the joining session.
Notes:
If this function is used after the meshing session, meshing information will be
deleted.
The first field corresponds to the curve use. It is possible to use a curve present in the
model (imported by DeltaMESH for example) or to draw a new curve with the curve
manager.
Notes:
The curve used must be closed or must cross at least two surfaces borders.
The curve must not intersect itself
If the curve is too far from the model, some faces may not be cut.
The second filed is facultative. It indicate in witch object cutting faces are send. If
nothing is chosen, cutting faces replace original faces in their object.
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CONFIGURATION OF MESHING PARAMETERS

Click the Advanced parameters button situated on the Meshing dialog to display the
DeltaMESH parameters window containing the values of the various DeltaMESH
configuration parameters.
The roles of the various parameters are described below.
Parameters of the Geometry Tab
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Configuration of Meshing Parameters
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Visualization panel
Modification of the display parameters will take effect immediately. A DeltaMESH

session starts immediately once you have pressed the Enter key, in order to update the
model display. You can then close the window again.
-
Number of isoparam:
Number of iso-parametric curves to display the surfaces

(default value: 1). By increasing this value it is possible to estimate the shape of
surfaces more accurately and to detect surface parameter problems (iso-parametric
curves very close to the edges, not regularly spaced, etc.).
Geom. Discretization:
This value represents the chordal error used to show surfaces

(contours and iso-parametric curves) and curves (default value: 0.01). The lower
this value is, the more faithful the representation of surfaces and/or curves will be,
but the display time will also increase. (On workstations with graphic cards of
limited performance it may be worth increasing this value to display large models).
Model panel
Modifications of these parameters will take effect only when the subsequent mesh is
imported or joined.
-
Reference space:
Size of the space containing the CAD model (default

value: 4000) (in the automobile sector, 4,000 mm is a common value). The system's
precision will be calibrated according to this parameter. The minimum allowed
value for tolerances or dimensions specified in DeltaMESH (import tolerance,
joining tolerance, element size, etc.) is computed based on this parameter and is
equal to: Reference space x 10-5 (i.e. default value: 0.04).
Therefore it is very important to modify this parameter if the size of the relevant
part is far away from 4000, or if another unit of measurement is used (meter, m,
inch, etc.).
Joining panel
The following parameter is used by the joining algorithms.

-
Split surface edges:
Splitting status of surface edges for joining operations. If this

toggle is deactivated, joining will be performed without splitting the surface edges,
so that only surfaces with coinciding nodes will be joined. This toggle must only be
deactivated in very specific cases (activated by default).
Merge geometrical edges:
Merging status of surface edges for joining operations. If

this toggle is activated, joining will concatenated successive tangent curves along a
surfaces contour to form longer curves. This toggle must only be deactivated in
very specific cases (activated by default).
Parameters of Meshing Tab

The following parameters are used by the meshing algorithms to produce elements
complying with a given level of quality.
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Criteria panel
Max. warping angle: Maximum
permissible warping value for quadrangular

elements (default value: 10). During meshing, two adjacent triangles elements will
only be transformed into a quadrangle if the warping of the resulting quadrangle is
less than this value.
Merging triangle angle: Minimum
Max. validity angle: Maximum
Max. internal angle: Maximum
internal angle permitting two triangles elements to

be associated to form a quadrangle (default value: 60). During meshing, two
adjacent triangles will only be transformed into a quadrangle if the smallest internal
angle of the resulting quadrangle is less than this value.
angle between the normals of two adjacent elements
(default value: 135). A surface's mesh will be considered invalid (and will therefore
be rejected) if the angle between the normals of two adjacent elements is greater
than this value.
angle required inside an element (default value: 175).
Above this angle, diagonals will be swapped to attempt to satisfy this criterion.
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Min. internal angle:
Apply mesh criteria on borders:
Force center curvature node:
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Minimum angle required inside an element (default value: 1).
When this check box is activated (default value),

chordal error and angle criteria are also applied on surface border (with the same
meaning as follow isoparametric option). This option is useful to simplify the
mesh when borders respect is not important (mesh keep connected)
When this check box is activated, this enables
DeltaMESH to force node creation on borders curvatures center to obtain a better
mesh quality (default value: active). We recommend inactive it for very high
definition model to not slow meshing.
Force center curvature node deactivated
Force mesh generation: When
Elongation limitation: Parameter
Force center curvature node activated
this check box is activated, this enables you to force

meshing of a surface even if several elements do not comply with all the defined
quality criteria (default value: active). When this parameter is active, we recommend
you check surface meshing when an error is indicated in the report.
enabling you to activate limitation of element
elongation within a surface (default value: non active). When this toggle is active,
the maximum element elongation must be entered in the Limit field (default value:
3). This parameter must only be activated in special cases (mesh of blanks)
Quad. Surface detection panel
The following parameters are used to detect and mesh 3 or 4-sided surfaces (see
subsection Quadrangular surface detection function).
-
Corner limit angle:
Maximum value of the angle making it possible to detect corners

of 3 or 4-sided surfaces (default value: 10). A corner will be created if the external
angle of two consecutive curves is greater than this value.
Distortion angle:
Maximum angular distortion (default 40) of elements compared

to perfect quadrangles. If one of the angles is greater than this value, the surface will
not be selected as a 3 or 4-sided surface.
Over discretization:
Parameter concerning over-discretization of 3 or 4-sided surfaces

(default value: active). This parameter defines the type of density progression within
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each surface. If it is activated, a larger number of elements will be generated within the
surface (about 10%).
DELTAMESH
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PAM-STAMP 2G 2012

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Attributes /Functionalities Chapters -------------------------------------------------- 1

PAM-STAMP 2G Overview ------------------------------------------------------------ 5

ASCII Input ------------------------------------------------------------------------------- 15

FINITE ELEMENT AND NUMERICAL MODELS

Contact and Friction ------------------------------------------------------------------ 175

Rigid Body ------------------------------------------------------------------------------ 217

SIMULATION METHODOLOGY FOR DESIGN AND

Introduction ----------------------------------------------------------------------------- 397

SIMULATION METHODOLOGY FOR STANDARD

Introduction ----------------------------------------------------------------------------- 497

Creation of DRAWBEADS ---------------------------------------------------------- 547

SIMULATION METHODOLOGY FOR SPECIFIC

Tailored and Patchwork Blanks --------------------------------------------------- 567

SIMULATION METHODOLOGY FOR TUBE

Introduction ----------------------------------------------------------------------------- 789

Introduction ----------------------------------------------------------------------------- 855

ABOUT THIS DOCUMENT

Simulation methodology for Analysis entities

Simulation methodology for Process setup

Simulation methodology for Gas Springs

Simulation methodology for Evaluation of the

Simulation methodology for

ABOUT THIS DOCUMENT

Time Step &

Simulation for Specific

ABOUT THIS DOCUMENT

Force & Pressure

Simulation methodology for Process setup

Simulation for Specific

Simulation methodology for

Simulation methodology for Springback

Finite element and

ABOUT THIS DOCUMENT

PAM-DIEMAKER: for the design of the die

DELTAMESH: as meshing module

PAM-QUIKSTAMP: for feasibility analysis

PAM-AUTOSTAMP: for validation and optimization of sheet metal forming

PamStamp 2G v2012 proposes:

optimization and modification

Super Plastic forming

The Stamp Toolkit enables

Filleting with Deltamesh fillet

dedicated analysis tools, like

dedicated material models, like:

Cosmetic defect analysis

Corus Vegter material Model

Matfem Crach material Model

Yoshida material Model

Developed part blank shape estimation for costing purposes.

Very early feasibility studies on PART geometry, prior to die design

PAM-DIEMAKER can be used starting

Courtesy of SKODA Auto

Fully automatic surface mesher integrated into

Consecutive steps for import / joining /

Optional post-meshing operation:

DeltaMESH Stamping Inverse

Data Input File

Writing of the file

It is also possible to write the .att file

By default the option Write the

Mesh Input File

Writing of the file