Manual Pam Stamp
description
Transcript of Manual Pam Stamp
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PAM-STAMP 2G 2012 Users Guide
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October 2012
GR/PAST/12/03/00/A
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.
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PAM-STAMP 2G 2012 i USERS GUIDE 2012 ESI Group (released: Oct-12)
CONTENTS
CONTENTS
ABOUT THIS DOCUMENT 1 Attributes /Functionalities Chapters -------------------------------------------------- 1
INTRODUCTION 5 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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CONTENTS
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 (PAM-DIEMAKER) --------------------------------------------------------------------------- 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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CONTENTS
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
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USERS GUIDE iv PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group
CONTENTS
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PAM-STAMP 2G 2012 1 USERS GUIDE 2012 ESI Group (released: Oct-12)
ABOUT THIS DOCUMENT Attributes /Functionalities Chapters
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 Standard Forming
Analysis entities
556
Aquadraw Simulation Concepts Fluid Cell
209
Autopositioning Simulation methodology for Standard Forming
Process setup 557
Behavior Simulation methodology for
Specific Processes
Gas Springs 777
Blank Meshing Simulation methodology for Standard Forming
Evaluation of the tool design
545
Simulation methodology for Specific Processes
Optimization 706
Boundary Condition on points
Simulation concepts Kinematics 200 Simulation methodology for Specific Processes
Springback measurement
725
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USERS GUIDE 2 PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group
ABOUT THIS DOCUMENT Attributes /Functionalities Chapters
Cartesian kinematics Simulation concepts Kinematics 200 Contact Simulation concepts Contact and
Friction 175
Cooling Channel Simulation methodology for Specific Processes
HotForming 609
CPU Control Finite element and numerical models
Time Step & Increments
59
Damage Finite element and numerical models
EWK Rupture Model
137
Drawbead Forces Simulation concepts Drawbead 237
Drawbead definition
Simulation concepts Drawbead 237
DMP Simulation concepts DMP 266 Simulation for Specific Processes
Rollhemming 631
Dynamic Freeze Simulation concepts Kinematics 204
Simulation for Specific Processes /
Rollhemming 631
Element elimination Analysis tools / Solver analysis tools
368
Fluid Cell Simulation concepts / Fluid Cell 209
Follower force Simulation concepts / Force & Pressure
207
Simulation for Specific Processes
Rollhemming
Force Simulation concepts Force & Pressure 206 Freeze Simulation concepts Kinematics 203
Gravity Simulation methodology for Standard Forming
Process setup 557
Finite element and numerical models
Algorithms
45
Gluing Contact Simulation concepts Contact and Friction
175
Kinematic Path Simulation for Specific Processes
Rollhemming 631
Ironing Simulation for Specific Processes
Simulation with Ironing-TTS Element
774
Mapping Simulation concepts Mapping 311 Mesh
Simulation methodology for Standard Forming
process setup 557
Multi body system Simulation concepts Rigid Body 217 Simulation for Specific Processes
Rollhemming 631
Optimization Simulation for Specific Processes
Optimization 706
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ABOUT THIS DOCUMENT Attributes /Functionalities Chapters
Path Definition
Simulation for Specific Processes
Rollhemming 631
Phase transformation Simulation for Numerical Models
Metallurgical material option
163
Picking Simulation concepts Picking 261
Press Force Analysis Simulation methodology for Specific Processes
Press Force analysis
760
Pressure Simulation concepts Force & Pressure 206 Quenching Simulation methodology for
Specific Processes
HotForming 590
Refinement Simulation concepts Adaptive meshing
264
Rigid Body Simulation concepts Rigid body 217 Robot Components Simulation for Specific
Processes
Rollhemming 631
Rotational kinematics Simulation concepts Kinematics 200
Solver Manager Product startup Solver configuration
32
Springback Simulation methodology for Specific Processes
Springback measurement
725
Substructure
Simulation concepts Substructure 303 Simulation methodology for Specific Processes
Surface defect analysis
504
Symmetry Plane
Simulation concepts Symmetry plane 259
Thermal properties Finite element and numerical models
Thermal material option
Simulation methodology for Specific Processes
Hotforming 590
Trimming Simulation methodology for Standard Forming
Process setup 557
User-Defined Simulation concepts User Defined Attribute
130
Values scaling Simulation concepts Picking 261
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INTRODUCTION PAM-STAMP 2G Overview
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:
Rollhemming
Hotforming
Super Plastic forming
Hydro forming
Tube forming
The Stamp Toolkit enables the customization of all
processes like Rubber pad
forming or stretch forming.
optimization and modification
functionalities, like:
Die compensation combined with surface reconstruction
with iCapp PanelShop
Blank and trim line optimization
Morphing
Filleting with Deltamesh fillet
Substructuring for local iterations
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INTRODUCTION PAM-STAMP 2G Overview
dedicated analysis tools, like
Cosmetic defect analysis
Draw-in analysis
Reporting tools
dedicated material models, like:
Corus Vegter material Model
Matfem Crach material Model
Yoshida material Model
Ito-Goya material model
Superplastic material models
Environment
Common environment
All modules proposed within PAM-
STAMP 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.
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INTRODUCTION PAM-STAMP 2G Overview
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, user-
defined 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.
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INTRODUCTION PAM-STAMP 2G Overview
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 re-
engineering starts from an existing die
geometry (CAD or scanned data) and re-
creates 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.
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INTRODUCTION PAM-STAMP 2G Overview
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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INTRODUCTION PAM-STAMP 2G Overview
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 time-
consuming 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, rubber-
pad 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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INTRODUCTION PAM-STAMP 2G Overview
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 PAM-
SYSTEM, 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.
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INTRODUCTION PAM-STAMP 2G Overview
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
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INTRODUCTION PAM-STAMP 2G Overview
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 time-
steps. Generally, implicit increments are
large with respect to the explicit time-
steps.
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.
element
nodes
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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PRODUCT START UP ASCII Input
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.
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PRODUCT START UP ASCII Input
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.
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PRODUCT START UP ASCII Input
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.
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PRODUCT START UP Customization
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: 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.
- External tools: This allows the user to define links from within the GUI to external software tools, for example a calculator, or a spreadsheet etc.
- Keyboard: This allows the user to define shortcut keys, which can be assigned to any action, making routine work more efficient.
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PRODUCT START UP Customization
- Menu: 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 reset all windows and toolbar positions.
- Options: 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.
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PRODUCT START UP Customization
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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PRODUCT START UP Customization
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\
while on Unix this would be depending on the system that is used, e.g.:
/usr/local/
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.
One file per process macro-command.
- macro.ktf:
Definition of PAM-AUTOSTAMP tube hydroforming macro.
ASCII file.
One file per process macro-command.
- macro.ktb:
Definition of PAM-AUTOSTAMP tube bending macro.
ASCII file.
One file per process macro-command.
- macro.ksi:
Definition of PAM-INVERSE standard forming macro.
ASCII file.
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One file per process macro-command.
- macro.kti:
Definition of PAM-INVERSE tube bending macro.
ASCII file.
One file per process macro-command.
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 PAM-
TUBEMAKER)
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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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:
gn.pre.
- CAD meshing module, for each selected module:
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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USERS GUIDE 32 PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group
PRODUCT START UP Solver Manager Configuration
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 ]
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
#
##################################################
# #
# 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
default value : no script template
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
configuration file line : BATCH_COMMAND |
command line argument : -batchcmd
default value : batch
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
configuration file line : LIBRARY_VARIABLE |
command line argument : -libvariable
default value : DEFAULT
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 : LIBPATH and LD_LIBRARY_PATH are both set
- DIGITAL : LD_LIBRARY_PATH
Automatic setting of the linked library path environment variable on Unix/Linux systems
configuration file line : LIBRARY_PATH |
command line argument : -libpath
default value : NONE
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
configuration file line : MP_VARIABLE |
command line argument : -mpvariable
default value : NONE
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
configuration file line : SERVER_LOG_FILE |
command line argument : -output
default value : blank (no file)
is the full name of the log file (eg: /usr/tmp/solvermanager.log)
Port number on which the solver manager listens to requests
configuration file line : SERVER_PORT |
command line argument : -port
default value : 1201
is the port number on which the solver manager listens to the requests.
Version of the communication with the GUIs protocol
configuration file line : SERVER_PROTOCOL_VERSION |
command line argument : not available by command line
default value : depends on the version of the solver manager (2 for v2.2)
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
configuration file line : TEMP_DIRECTORY |
command line argument : -tmpdir
default value : /usr/tmp
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
configuration file line : SAVE_LAUNCH_SCRIPT | YES / NO
command line argument : -savelaunchscript
default value : 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)
configuration file line : SOURCE_PROFILE | YES / NO
command line argument : -nosourceprofile
default value : YES
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]
configuration file line : FORCE_AUTOMOUNT | YES / NO
command line argument : -forceautomount
default value : 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]
configuration file line : SCRIPT_CLEANUP_DELAY |
command line argument : -scriptcleanupdelay
default value : 5 (seconds)
This option allows defining the delay (in seconds) before the solver manager deletes a
script it has just launched.
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PRODUCT START UP Solver Manager Configuration
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 ]
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
PAMPARAM_VAR2_LABEL="PAMPARAM_VAR2_VALUE";export PAMPARAM_VAR2_LABEL
PAMPARAM_VAR3_LABEL="PAMPARAM_VAR3_VALUE";export PAMPARAM_VAR3_LABEL
PAMPARAM_VAR4_LABEL="PAMPARAM_VAR4_VALUE";export PAMPARAM_VAR4_LABEL
PAMPARAM_VAR5_LABEL="PAMPARAM_VAR5_VALUE";export PAMPARAM_VAR5_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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USERS GUIDE 40 PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group
PRODUCT START UP Solver Manager Start
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
where is the directory where the solver manager executable
file is located.
- type the command:
nohup solvermanager.exe [-output ] > /dev/null &
where is the full path of the solver manager log file
(/usr/tmp/solvermanager.out for example)
The output 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:
/solvermanager.exe [-output ] > /dev/null &
where is the full path of the solver manager executable file
directory and is the full path of the solver manager log file
(/usr/tmp/solvermanager.out for example)
The output 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.
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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:
cd
where is the directory where the solver manager executable
file is located.
- type the command:
solvermanager.exe noservice -output
where is the full path of the solver manager log file
(/usr/tmp/solvermanager.out for example)
The output argument is optional (the user can also define the log
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:
cd
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PRODUCT START UP Solver Manager Start
where is the directory where the solver manager executable
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).
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PRODUCT START UP Solver Manager Activity
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).
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USERS GUIDE 44 PAM-STAMP 2G 2012 (released: Oct-12) 2012 ESI Group
PRODUCT START UP Calculation Stop
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 [-port ]
where is the process id of the calculation and is the port
number on which the solver manager listens to requests.
Note:
port is optional. If it is not specified, the default port is used.
This procedure is not available on Unix/Linux systems.
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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
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
k m
f(t),x,v,a
A linear damped spring system
The equilibrium equation of the spring system is:
nnnn fxkvcam ... ,
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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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
)x.ktf nn(.1
ma n
in case of no damping applied.
2/)n
T1-n
T(
VV
a2
1n
2
1n
n
nT
XXV
n1n
2
1n
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|)
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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
F
u
Rsolution
F(u)
1st Newton iteration
2nd Newton iteration
F
u
Rsolution
F(u)
1st Newton iteration
2nd 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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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
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|)
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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
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
u u1 u2
Fext
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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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
Default setting:
Default is 10 for springback and it is imposed to 2 for QUIKSTAMP PLUS.
Fext
F
u u1 u
1 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.
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
n
Initial configuration
(integration volume)
Current configuration
(or integration volume)
n+
1
Final configuration of previous increment
... : 00
dES
... : 11
nd
n
Total Lagrange Updated Lagrange Quasi-Euler
Advanced Implicit Implicit
... :
ndES
n
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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
New Options
Force convergence tolerance
|Fn|/Max(|Fi|)
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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 + d
2 = L0
2 with L0 imposed
arc length defined by user
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.
d
)(id
)0(d d
)0(dK )(idK
)0(int dF
)(int iF d
)1( id
L0
d
Limit Point
Post-Collapse
Objective Load
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FINITE ELEMENT AND NUMERICAL MODELS Algorithm
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