Chapter 3.

9: Break Forming

3.9 Break Forming


Summary 2

Chapter Overview 3
 Detailed Session Description of Break Forming 4

Run Job and View Results 9

Discussion 13
 Modeling Tips 14

Input Files 15
 Animation 16
3.9-2 Marc User’s Guide
Summary

Summary

Title Break forming of a metal bracket

Problem features Contact and metal forming - click here for interactive preview
Geometry Grid Spacing 0.1 in v=0.4

u=1

Z X

0.6
Material properties E = 30x106 Psi,  = 0.3,  = 5x10 4  1 +  p 
Analysis type Static with elastic plastic material behavior
Boundary conditions Ux = 0 at center nodes, cylindrical rigid body bends metal sheet

Element type Plane strain element type 11

FE results Punch load verses stroke
job1
Force Y cbody2 (x1000)
1.289 28 26
27 25
3029
3231
33 8
34
50 373635 242322 12019
1817
161 5 9
38 1 4
1312
1110
39
40
41
42
43
44
45
48 46 765
4 32
49 47 1

0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)
 CHAPTER 3.9 3.9-3
Break Forming

Chapter Overview
A flat sheet is formed into an angled bracket by punching it though a hole in a table using the
contact option.
Inc: 50 Inc: 70
Time: 5.000e-001 Time: 1.000e+000

4.600e-001 4.600e-001

4.140e-001 4.140e-001

3.680e-001 3.680e-001

3.220e-001 3.220e-001

2.759e-001 2.759e-001

2.299e-001 2.299e-001

1.839e-001 1.839e-001

1.379e-001 1.379e-001
Y
9.184e-002 9.184e-002

4.581e-002 4.581e-002
Z X
-2.149e-004 Y -2.149e-004 Y

Z X Z X
lcase1 lcase2
Total Equivalent Plastic Strain 1 Total Equivalent Plastic Strain 1

Figure 3.9-1 Punching Examples

The cylindrical punch drives the sheet down into the hole of the table to a total stroke of 0.3”. The punch
then returns to its original position. The material is elastic plastic with workhardening.
A B
job1
Force Y cbody2 (x1000)
1.289 28 26
27 25
3029 Equivalent Von Mises Stress Node 63
333231 8 100000
3534
36 242322 12019
1817
50 37
38
1615
141312
11
9
10 Strength
39
40
41
42
43
44
80000
45
48 46 765
4 32
49 47 1

60000

40000 Elastic Unload

20000

0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0 0
-3 0 0.0 0.2 0.4 0.6 0.8 1.0
Pos Y cbody2 (x.1) 1
Total Equivalent Plastic Strain

Figure 3.9-2 (A) Vertical Punch Load versus Stroke (B) Stress versus Plastic Strain

At the bottom of the stroke, the total plastic strain is nearly 45%. The vertical punch force is plotted
versus its vertical position. This force rises quickly, hardens though about half of the stroke, then softens
near the end of the stroke. Upon lifting the punch, the punch force drops rapidly and the sheet has very
little springback.
The stress-plastic strain response of a point in the sheet under the punch is plotted and shown to overlay
the material data. This workshop problem exemplifies how every point in the sheet must follow the
material’s constitutive behavior as well as being in equilibrium throughout the deformation. The vertical
line in the history plot to the right is the elastic unloading of this point in the sheet.
This is a break forming problem where a punch indents a sheet over a table to make an bracket.
The problem geometry is shown below:
3.9-4 Marc User’s Guide
Detailed Session Description of Break Forming

Grid Spacing 0.1 in v=0.4

u=1

Grid spacing 0.1" X 0.1"

Figure 3.9-3 Break Forming Geometry Problem

Detailed Session Description of Break Forming

MESH GENERATION
COORDINATE SYSTEM SET: GRID ON
V DOMAIN
-.7 .4
FILL
RETURN
CURVES ADD (pick indicated points on grid)
POINT (1,0,0), POINT(.3,0,0)
POINT(.3,0,0), POINT(.3,-.6,0)
POINT(.3,-.6,0), POINT(-.3,-.6,0)
POINT(-.3,-.6,0), POINT(-.3,0,0)
POINT(-.3,0,0), POINT(-1,0,0)
CURVE TYPE
FILLET
RETURN
CURVES ADD
radius (right horizontal curve, right vertical curve)
0.1
radius (left vertical curve, left horizontal curve)
0.1
CURVE TYPE
CIRCLES: CENTER/RADIUS
RETURN
CURVES ADD
0 .2 0
.1
ELEMENTS ADD (pick points on grid)
 CHAPTER 3.9 3.9-5
Break Forming

NODE (-.9,0,0), NODE(.9,0,0)

NODE(.9,.1,0), NODE(-.9,.1.0)
SUBDIVIDE
DIVISIONS
30, 3, 1
ELEMENTS
ALL:EXISTING
RETURN
SWEEP
ALL
RETURN
RENUMBER
ALL
RETURN
COORDINATE SYS: SET GRID OFF
RETURN (twice)
BOUNDARY CONDITIONS
MECHANICAL
FIXED DISP
X=0
OK
NODES:ADD (pick nodes along x=0,)
MAIN
MATERIAL PROPERTIES
MATERIAL PROPERTIES
NEW
STANDARD
STRUCTURAL
E = 3E7
 = .3
OK
ELEMENTS ADD
ALL: EXISTING
TABLES
NEW
1 IND. VARIABLE
TABLE TYPE
3.9-6 Marc User’s Guide
Detailed Session Description of Break Forming

table1
F (x1e5)
1 11
10
9
8

0.5 1
0 1
V1

Figure 3.9-4 Flow Stress

eq_plastic_strain
OK
FORMULA
ENTER
5E4*(1+V1^.6) The equation describing the flow
4 .6
FIT stress is  y = 5 x 10  1. +  p 
NEW
1 IND. VARIABLE
TABLE TYPE time
OK
ADD POINT
0, 0, .5, -.3, 1, 0
FIT
SHOW MODEL
RETURN
 CHAPTER 3.9 3.9-7
Break Forming

table2
F (x.1)
0 1 3

-3 2

V1

Figure 3.9-5 Punch Position

STRUCTURAL
PLASTICITY (twice)
INITIAL YIELD STRESS
1
TABLE1
table1 (eq_plastic_strain)
OK (twice),
MAIN
CONTACT
CONTACT BODIES
DEFORMABLE
OK
ELEMENTS ADD
ALL:EXISTING
NEW
RIGID
POSITION PARAMS
Y=1
TABLE
table2 (time),
OK (twice)
3.9-8 Marc User’s Guide
Detailed Session Description of Break Forming

CURVE ADD (pick cylinder)

END LIST
ID CONTACT
NEW
CONTACT BODY TYPE RIGID
OK
CURVES ADD (pick all remaining curves)
END LIST
MAIN

cbody1

cbody2

cbody3

Z X

Figure 3.9-6 Identify Contact Bodies

LOADCASES
MECHANICAL
STATIC
LOADCASE TIME
.5
# OF STEPS
50
CONVERGENCE TESTING
DISPLACEMENTS
RELATIVE DISPLACEMETN TOLERANCE
0.001
OK (twice)
COPY
STATIC
LOADCASE TIME
.5
# OF STEPS
20
OK
MAIN
JOBS
NEW
MECHANICAL
PROPERTIES
ANALYSIS OPTIONS
LARGE STRAIN
OK
lcase1
 CHAPTER 3.9 3.9-9
Break Forming

lcase2
ANALYSIS DIMENSION: PLANE STRAIN
JOB RESULTS
EQUIVALENT VON MISES STRESS
TOTAL EQUIVALENT PLASTIC STRAIN
OK
CONTACT CONTROL
ADVANCED CONTACT CONTROL
SEPARATION FORCE
.1
OK
OK (thrice)
SAVE

Run Job and View Results

RUN
SUBMIT
MONITOR

Figure 3.9-7 Run Job Menu

OPEN POST FILE (RESUTLS MENU)

DEF ONLY
SCALAR
TOTAL EQUIVALENT PLASTIC STRAIN
CONTOUR BANDS
SKIP TO INCREMENT 50
3.9-10 Marc User’s Guide
Run Job and View Results

Inc: 50
Time: 5.000e-001

4.600e-001

4.140e-001

3.680e-001

3.220e-001

2.759e-001

2.299e-001

1.839e-001

1.379e-001

9.184e-002

4.581e-002

-2.149e-004 Y

Z X
lcase1
Total Equivalent Plastic Strain 1

Figure 3.9-8 Plastic Strain Plot at Increment 50

RESULTS
SKIP TO INCREMENT 70
Inc: 70
Time: 1.000e+000

4.600e-001

4.140e-001

3.680e-001

3.220e-001

2.759e-001

2.299e-001

1.839e-001

1.379e-001

9.184e-002

4.581e-002

-2.149e-004 Y

Z X
lcase2
Total Equivalent Plastic Strain 1

Figure 3.9-9 Plastic Strain Plot at Increment 70

 CHAPTER 3.9 3.9-11
Break Forming

RESULTS
HISTORY PLOT
SET LOCATIONS
n:63 # (pick bottom middle node n:63)
ALL INCS
ADD CURVES
GLOBAL
Pos Y cbody2
Force Y cbody2
FIT
job1
Force Y cbody2 (x1000)
1.289 28 26
27 25
3029
333231 8
3534
50 36 2423
22 12019
1817
16 9
37
38 1 5
1 4
1312
1110
39
40
41
42
43
44
45
48 46 765
4 32
49 47 1

0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)

Figure 3.9-10 History Plot of Punch Force versus Stroke

3.9-12 Marc User’s Guide
Run Job and View Results

RESULTS
HISTORY PLOT
CLEAR CURVES
ALL INCS
ADD CURVES
ALL LOCATIONS
Total Equivalent Plastic Strain
Equivalent Von Mises Stress
FIT

100000 Equivalent Von Mises Stress Node 63

Strength

80000

60000

40000 Elastic Unload

20000

0
0.0 0.2 0.4 0.6 0.8 1.0
Total Equivalent Plastic Strain
Figure 3.9-11 Stress versus Plastic Strain Node 63
 CHAPTER 3.9 3.9-13
Break Forming

Discussion
Since the sheet will completely wrap around the rigid cylinder an the end of the bending, we can estimate
the strain assuming that the sheet completely surrounds the cylinder, and by knowing the strain, the stress
can also be estimated as shown in Figure 3.9-12.
r = 0.1

t = 0.1 εCD = CD – C’ D’
--------------------------
-
C’ D’
A’ B’ C’D’ = A’B’
A’ B’ = AB

C’ D’ εCD = CD – AB- = (---------------------------------

----------------------
rOC – r OA )θ rOC – r OA
= -------------------------
AB r OA θ rOA
O
εCD = 0.20 – 0.15 - = 0.05
-------------------------- ---------- = 1
---
0.15 0.15 3
σCD ∼ 5x10 3 ( 1 + ( 1 / 3) 0.6) = 75 Ksi
A B
θ
C D

Figure 3.9-12 Estimating the bending strain and stress in the center of the sheet

With the stresses estimated we can assume that a fully plastic hinge forms in the center of the sheet and
estimate the punch load as shown in Figure 3.9-13.
y

σ(y)

x M

y
M x
0.3
P/2 P/2

Figure 3.9-13 Estimating the bending moment and maximum punch load

The estimate for the maximum punch load, 1250 lbf, is very close to that found by the analysis as shown
in Figure 3.9-10 of 1289 lbf. Finally, although the final angle after spring back appears close to 90o, its
actual value is 84o, and the punch stroke should be slightly reduced to form a right angle after springback.
3.9-14 Marc User’s Guide
Modeling Tips

Modeling Tips
The punch force in Figure 3.9-10 has an abrupt jump at increment 50 which is caused by a new node
entering contact between the sheet and the rigid table. This can be improved by using segment to
segment contact and entered in the modeling under contact control; the comparison between node to
segment and segment to segment contact is shown in Figure 3.9-14.
JOBS
NEW
MECHANICAL
PROPERTIES
CONTACT CONTROL
METHOD: SEGMENT TO SEGMENT
OK (twice)
RUN, SUBMIT....
Segment to Segment Contact
Y (x1000) Force Y cbody2
Node to Segment Contact
1.289 28 26
27 2 5
313029
3332 28272625242322 1201918171615 8
35343332313029
36 242322 12019181716 1413 9
50 4544 40 37 3534 1514131211 0
46 4241 39383736
47 43 40 121110
48 41 987
49 42 654
50 43 32
44
48 4645 765
4 32
49 47 1

0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
0
-3 0
Pos Y cbody2 (x.1)
Inc: 50
Time: 5.000e-001
Contact Normal Force

8.587e+002 Node to Segment Contact Segment to Segment Contact

7.728e+002

6.869e+002

6.011e+002

5.152e+002

4.293e+002

3.435e+002

2.576e+002

1.717e+002

8.587e+001

0.000e+000 Y

Z X

Figure 3.9-14 Comparison of Node to Segment versus Segment to Segment Contact

 CHAPTER 3.9 3.9-15
Break Forming

Input Files
The files below are on your delivery media or they can be downloaded by your web browser by clicking
the links (file names) below.

File Description
s4.proc Mentat procedure file to run the above example

Also this problem can be automatically run from the HELP menu under DEMONSTRATIONS > RUN
A DEMO PROBLEM > CONTACT as shown below.
3.9-16 Marc User’s Guide
Animation

Animation
Click on the figure below to activate the video; it lasts about 10
minutes and explains how the steps above are done. Once the video is Close Floating Window
activated, a right click of the mouse will open the menu shown at the Full Screen Multimedia
right; you can switch to various screen sizes or stop the video by
disabling the content. Properties...
Disable Content