Metal Cutting
This LS-DYNA example shows the bulk metal cutting process using the Element Free Galerkin Method (EFG).
https://www.dynaexamples.com/efg/metal-cutting
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Metal Cutting
This LS-DYNA example shows the bulk metal cutting process using the Element Free Galerkin Method (EFG).
Watch animated result on YouTube
*BOUNDARY_PRESCRIBED_MOTION_RIGID *CONSTRAINED_GLOBAL *CONTACT_FORMING_SURFACE_TO_SURFACE_MORTAR *CONTROL_ACCURACY *CONTROL_ADAPTIVE *CONTROL_CONTACT *CONTROL_ENERGY *CONTROL_HOURGLASS *CONTROL_IMPLICIT_AUTO *CONTROL_IMPLICIT_DYNAMICS *CONTROL_IMPLICIT_GENERAL *CONTROL_IMPLICIT_SOLUTION *CONTROL_MPP_IO_NODUMP *CONTROL_OUTPUT *CONTROL_REMESHING_EFG *CONTROL_RIGID *CONTROL_SOLID *CONTROL_TERMINATION *DATABASE_BINARY_D3PLOT *DATABASE_BINARY_INTFOR *DATABASE_BNDOUT *DATABASE_FORMAT *DATABASE_GLSTAT *DATABASE_MATSUM *DATABASE_RBDOUT *DATABASE_RCFORC *DATABASE_SLEOUT *DEFINE_CURVE *DEFINE_CURVE_SMOOTH_TITLE *ELEMENT_SHELL *ELEMENT_SOLID *END *INCLUDE *KEYWORD 200M *MAT_PIECEWISE_LINEAR_PLASTICITY_TITLE *MAT_RIGID *NODE *PARAMETER *PART *SECTION_SHELL *SECTION_SOLID_EFG *TITLE
$-----------------------------------------------------------------------------
$
$ Example provided by Dr. Nils Karajan (DYNAmore)
$
$ E-Mail: info@dynamore.de
$ Web: http://www.dynamore.de
$
$ Copyright, 2015 DYNAmore GmbH
$ Copying for non-commercial usage allowed if
$ copy bears this notice completely.
$
$X PROJEKT: EFG simulation: cutting/bulk forming
$X------------------------------------------------------------------------------
$X
$X 1. Run file as is.
$X Requires LS-DYNA MPP R8.0.0 (or higher) with double precision
$X
$X------------------------------------------------------------------------------
$# UNITS: ton / mm / s / N / MPa / Nmm (mJ)
$X------------------------------------------------------------------------------
$
*KEYWORD 200M
*TITLE
EFG Local Adaptivity
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ PARAMETER DEFINITION $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*PARAMETER
$ PRMR1 VAL1
R tend 3.0e-2
R dtout 3.0e-4
$
R dtimpl 2.0e-4
$
$- Adaprive frequency
R dtadpf 1.0e-3
$
$- Adaptive mesh size
R rmin 0.15
R rmax 2.25
R adpene 0.3
$- Tool travel
R dist 9.0
$
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ CONTROL CARDS (GENERAL) $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*CONTROL_TERMINATION
$# endtim endcyc dtmin endeng endmas
&tend
$
$---
$
*CONTROL_IMPLICIT_DYNAMICS
$# imass gamma beta tdybir tdydth tdybur irate
$# DYNAMIC SIMULATION
1
$# DYNAMIC SIMULATION WITH CONVERGENCE PROBLEMS
$ 1 0.6 0.38
*CONTROL_IMPLICIT_GENERAL
$ imflag dt0 imform nsbs igs cnstn form zero_v
1&dtimpl/6.
*CONTROL_IMPLICIT_AUTO
$ iauto iteopt itewin dtmin dtmax dtexp
1 20 4 &dtimpl
*CONTROL_IMPLICIT_SOLUTION
$ nsolvr ilimit maxref dctol ectol rctol lstol abstol
2 4 7 0.0010 0.01 1.0e-20
$ dnorm diverg istif nlprint nlnorm d3itctl cpchk
1 1 2
$ arcctl arcdir arclen arcmth arcdmp
$ lsmtd lsdir irad srad awgt sred
5
$
$---
$
*CONTROL_OUTPUT
$# npopt neecho nrefup iaccop opifs ipnint ikedit iflush
1 100
$# iprtf ierode tet10 msgmax ipcurv gmdt
2 50
*CONTROL_ENERGY
$# hgen rwen slnten rylen
2 2 2 2
*CONTROL_ACCURACY
$ osu inn pidosu iacc
1 4 1
*CONTROL_RIGID
$# lmf jntf orthmd partm sparse metalf plotel rbsms
0
*CONTROL_SOLID
$ esort fmatrix niptets swlocl
1 2 5
$# pm1 pm2 pm3 pm4 pm5 pm6 pm7 pm8 pm9 pm10
*CONTROL_HOURGLASS
$ IHQ QH
6
*CONTROL_MPP_IO_NODUMP
*CONTROL_CONTACT
$# slsfac rwpnal islchk shlthk penopt thkchg orien enmass
2.5
$# usrstr usrfrc nsbcs interm xpene ssthk ecdt tiedprj
$# sfric dfric edc vfc th th_sf pen_sf
$# ignore frceng skiprwg outseg spotstp spotdel spothin
$# isym nserod rwgaps rwgdth rwksf icov swradf ithoff
$# shledg pstiff ithcnt tdcnof ftall unused shltrw
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ CONTROL CARDS (ADAPTIVITY) $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*CONTROL_ADAPTIVE
$# adpfreq adptol adpopt maxlvl tbirth tdeath lcadp ioflag
&dtadpf 7 3
$# adpsize adpass ireflg adpene adpth memory orient maxel
1.0 0 0&adpene
$# ladpn90 ladpgh ncfred ladpcl adpctl cbirth cdeath lclvl
1
$# cnla
*CONTROL_REMESHING_EFG
$# rmin rmax vf_loss mfrac dt_min icurv iadp10 segang
&rmin &rmax
$# ivt iat iaat ier MonotoMsh
1 1 0 1
$# iat1 iat2 iat3
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ DATABASE CARDS $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*DATABASE_GLSTAT
$# dt binary lcur ioopt
&dtout 1
*DATABASE_MATSUM
$# dt binary lcur ioopt
&dtout 1
*DATABASE_BNDOUT
$# dt binary lcur ioopt
&dtout 1
*DATABASE_RBDOUT
$# dt binary lcur ioopt
&dtout 1
*DATABASE_RCFORC
$# dt binary lcur ioopt
&dtout 1
*DATABASE_SLEOUT
$# dt binary lcur ioopt
&dtout 1
*DATABASE_FORMAT
$# iform ibinary
1
*DATABASE_BINARY_D3PLOT
$# dt lcdt beam npltc psetid
&dtout
$# ioopt
*DATABASE_BINARY_INTFOR
$# dt lcdt beam npltc psetid
&dtout
$
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ PARTS / SECTION / MATERIALS $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*PART
Tool
$# pid secid mid eosid hgid grav adpopt tmid
2 2 2
*SECTION_SHELL
$# secid elform shrf nip propt qr/irid icomp setyp
2 2
$# t1 t2 t3 t4 nloc marea idof edgset
1.0
*MAT_RIGID
$# mid ro e pr n couple m alias
2 7.85E-9 2.10e+05 0.3
$# cmo con1 con2
1.0 4.0 7.0
$# lco or a1 a2 a3 v1 v2 v3
$
$---
$
*PART
Workpiece
$# pid secid mid eosid hgid grav adpopt tmid
3 3 3 2
*SECTION_SOLID_EFG
$# secid elform aet
3 41
$# dx dy dz ispline idila iebt idim(2) toldef
1.25 1.25 1.25 3 2
$# ips stime iken sf cmid ibr ds ecut
1
*MAT_PIECEWISE_LINEAR_PLASTICITY_TITLE
Material3_Band_plastisch
$# mid ro e pr sigy etan fail tdel
3 7.85E-9 2.10e+05 0.3 400.0
$# c p lcss lcsr vp
33 1
$# eps1 eps2 eps3 eps4 eps5 eps6 eps7 eps8
$# es1 es2 es3 es4 es5 es6 es7 es8
*DEFINE_CURVE
$# lcid sidr sfa sfo offa offo dattyp
33
$# a1 o1
0.000, 400.0
0.005, 450.0
0.020, 455.0
0.100, 600.0
0.200, 800.0
0.500,1000.0
1.000,1200.0
2.000,1400.0
3.000,1450.0
9.000,1500.0
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ CONTACT CARDS $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*CONTACT_FORMING_SURFACE_TO_SURFACE_MORTAR
$# ssid msid sstyp mstyp sboxid mboxid spr mpr
3 2 3 3
$# fs fd dc vc vdc penchk bt dt
0.1
$# sfs sfm sst mst sfst sfmt fsf vsf
$# soft sofscl lcidab maxpar sbopt depth bsort frcfrq
1
$# penmax thkopt shlthk snlog isym i2d3d sldthk sldstf
$# igap ignore dprfac dtstif flangl cid_rcf
5
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ BOUNARY CONDITIONS $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$
$--- Side Wall fixed
$
*CONSTRAINED_GLOBAL
$# tc rc dir x y z
7 7 1 3.0 5.0 5.0
$
$--- Bottom Support (normal only)
$
*CONSTRAINED_GLOBAL
$# tc rc dir x y z
3 7 3 10.0 7.0 0.0
$
$---
$
*BOUNDARY_PRESCRIBED_MOTION_RIGID
$# pid dof vad lcid sf vid death birth
2 3 1 -1.0
*DEFINE_CURVE_SMOOTH_TITLE
Prescribed Motion
$# lcid sidr dist tstart tend trise v0
1 &dist &tend &tend/6.0
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
$ $
$ ELEMENTS / NODES $
$ $
$---+----1----+----2----+----3----+----4----+----5----+----6----+----7----+----8
*INCLUDE
mesh.k
*END