PNNL-13501 - Pacific Northwest National Laboratory

The three problems were built on one another and
demonstrate the ability to simulate a sequential metal
forming/joining process using simple finite element
models that include the features of larger industrial
manufacturing problems. The three test problems used to
demonstrate research outcomes are described below.
Results and Accomplishments
In keeping with the four focus areas, the results and
accomplishments of this effort are presented below,
followed by a description of the results obtained from the
three test problems that demonstrate the capabilities of the
integrated suite of tools.
Engineering Data Representation
We extended the use of Exodus as a common data format
and provided the capability to store stress/strain data in
addition to deformed geometry and thickness.
We also developed data transformation tools to convert
between the Exodus-based common data format and the
following commercial finite element codes:
• MARC Analysis (output format)
• MARC Analysis (input format)
• PAM-CRASH (input format)
Last, we developed and extended of a number of MARC
“user routines” to ensure that the appropriate data was
accessible to enable the appropriate transformations.
Remeshing/Remapping Capability
We explored the use of commercial remeshing tools
(e.g., Hypermesh) to provide required remeshing
capability with the idea of adding a remapping capability
through some other means. This effort was abandoned
when a NWGrid-based remeshing and remapping
capability appeared feasible.
We also developed data transformation tools to support
translation between common data format and formats
used by NWGrid.
Last, we integrated NWGrid-based remesh/remap
capability into an IMS tool suite to provide the capability
required for the demonstration of test problems 2 and 3
(see below).
180 FY 2000 Laboratory Directed Research and Development Annual Report
Data Pedigree Representation
We defined data representations (object representations)
for information that must be captured as part of a data
pedigree during multistep finite element simulation
efforts.
We also explored similar data pedigree efforts on other
projects, including ARM, the regional climate modeling,
Ecce, and the DOE 2000 projects and collaborated with
CPSE projects on the use of WebDAV technologies for
storage of result sets and data pedigree information.
We designed and completed a “model transformation
tool” to invoke data transformation tools and gather
pedigree information from users.
High Performance Computing
We demonstrated that the CDF-to-PAM-CRASH data
transformation tool works for simulations run on the
Zodiac. Currently, we are building on the accomplishments
in these four areas, three test problems were
undertaken to demonstrate the integrated modeling and
simulation capabilities provided.
Test Problem 1—Analysis Restart
The first test problem simulated a two-step stretchforming
of sheet metal between a spherical punch and a
cylindrical die (see Figure 1). At the completion of this
step, the common data format had the capability to store
stress/ strain data, data transformation tools were
completed to convert between the common data format
and Marc input and output formats and, subroutines were
written to transform the model data from the local shell
element system to the global coordinate system for
storage in the Exodus common data format.
Since the element results are based on the shape and
orientation of each element, the element coordinates and
their shape functions were used to perform the data
transformations for each individual element. Figure 2
shows the detailed multiple data transformation steps
associated with this process and the data translators
that were developed to execute this example problem.
This example problem performs a restart analysis
without saving the standard MARC restart file. It
provides, a demonstration of the capability to save
results from MARC into the common data format and