Dynaform DF5 9 2 1 die simulation training manual

| The meshing of the die part tool done in eta/DYNAFORM is carried out using the Surface Mesh function.. To accept the mesh, click the Yes button when prompted, ‘‘Accept Mesh?” in the S

eta/D YNAFORM Die Simulation

Training Manual

Version 5.9.2.1

efa

Engineering Technology Associates, Inc

1133 E Maple Road, Suite 200

respective owners

©1998-2014 Engineering Technology Associates, Inc All rights reserved

TABLE OF CONTENTS

TABLE OF CONTENTS

DATABASE MANIPUL.ATTIONN 2 55G 5 0 29 0 0.0000.000 0000 5000080000

I Creating an eta/Dynaform Database and Analysis Setup

OL PREPA RA TTIONN 0o G0 HT B000 0m00 I _ Import Die Geometry

Il Meshing DIe

Ill Mesh Check and Reparr

SLIMULATION SE TUP

I Die Simulation Interface

II Define Tools

III Define and Mesh Blank

IV Defining the Blank Material

V Define Tool Control

VỊ Define Drawbead

VH Submit Job

_ _ _ _ _ _ _ oe oe oe POST PROCESSING (with eta/POST) I Reading the Results File into the Post Processor

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V Check the forming Result of THICKNESS

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eta/DYNAFORM Training Manual

In Die Simulation, use INCSolver to do the sheet metal quick simulation analysis INCSolver is a nonlinear

transient dynamic finite element program using explicit scheme to solve equations of motion, commonly referenced as “incremental code” or “explicit code” INCSolver uses the SMP (Shared Memory Processing) computing scheme to take full advantage of multiple-CPU, multiple-core and multiple-thread configurations of latest computing platforms in Windows environment

Note: This manual is intended for the application of all eta/DYNAFORM platforms Platform interfaces may

vary slightly due to different operating system requirements This may cause some minor visual discrepancies in the interface screen shots and your version of eta/DYNAFORM that should be ignored

For PC users, double click the eta/DYNAFORM 5.9.2.1 (DF5921) icon from the desktop or choose

eta/DYNAFORM from the program group

After starting eta/DYNAFORM, a default database file Untitled.df is created Users can save the database to

the designated working directory Go to File™Save as, type “Die_Simulation”, and click Save to dismiss the dialogue window

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Click UserSetup®Analysis Configuration menu The default unit system for a new eta/DYNAFORM

database is mm, Newton, Second and Ton The default setting for draw type is double action (toggle draw) The user is able to change these default settings from the UserSetup* Analysis Configuration menu

Note: Draw Type should accord with press type in practice The parameters define the working direction of

default punch and die If you are not sure or operating new technique, you should select User Defined

Eta/DYNAFORM has the ability to read the following types of input files:

2 VDA (*.vda, *.vdas) 11 PROE (*.prt, *.asm)

3 LINEDATA (*.lin) 12 INVENTOR (*.ipt)

4 DXF (*dxf) 13 Parasolid (*.x_t)

6 ACIS (*.sat) 15 LSDYNA (*.dyn, *.mod, *.k)

7 CATIA4 (*.model) 16 NASTRAN (*.dat; *nas)

8 CATIAS (*.CATPart; *.CATProduct ) 17 ABAQUS_ (*inp)

TOOL PREPARATION

Tool Preparation is a very important step contributing to a successful simulation The tool will be imported and meshed in Tool Preparation

I Import Die Geometry

1 From the menu bar, select D-Eval* Preparation

File Parts | BSE Ez AutoSetup QuickSetup UserSetup SCP | oP | PostProcess Option Utilities View Help

Binder Modification Trim Check Die Design Check Die Simulation

2 From the menu of Preparation, select File» Import

Files oftype: |IGES ( igs:*iges) vị Import |

[ˆ Auto Mesh Mesh Param |

The meshing of the die part tool done in eta/DYNAFORM is carried out using the Surface Mesh function This function will automatically create a mesh based on the provided surface data This is a very quick and easy way of meshing the tools

1 Select Surface Mesh from the Mesh tab as shown below

TOOL PREPARATION

4 The mesh will be created and will be displayed in white To accept the mesh, click the Yes button when prompted, ‘‘Accept Mesh?” in the Surface Mesh dialogue Check your mesh with the mesh displayed below

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ETA/DYNAFORN

5 Press Exit on the Surface Mesh dialogue to exit the function

Now that we have the Die meshed, you can turn off the surfaces and lines by turning off Surfaces and Lines in the Display Option dialogue This makes it easier to view the mesh

6 Save the database

III Mesh Check and Repair

As the mesh has been created, its quality has to be checked to verify that there aren’t any defects that could cause potential problems in the simulation

All the utilities used for checking the mesh are located under the Tool Preparation™ Mesh» Edit

Auto Plate Normal ad

1 Click Auto Plate Normal from the Tool Preparation/Mesh dialogue A new dialogue will be displayed

The displayed dialogue prompts you to pick an element to check all the active parts or an individual part for element normal consistency Select an element on the Die part

An arrow will be displayed showing the normal direction of the selected element A prompt will ask

“Is normal direction acceptable?”

eta/DYNAFORM Training Manual

downward, the result will be flawed

4 Now that the Die part elements are consistent

= j ——

Display Model Boundary

This function will check the mesh for any gaps or holes, and highlight them so you can manually correct the problem

1 Select Display Model Boundary from the Tool Preparation/Mesh dialogue window

Minor gaps in the tool mesh are acceptable Click the isometric view and make sure that your display looks like the following

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2 Turn off all of the elements and nodes from the Display Options dialogue (Note: the boundary lines

are still displayed) This allows you to inspect any small gaps that might be difficult to see when the mesh is displayed The results are shown in the following picture

3 Check for overlapping elements Delete the duplicate elements if they were found

4 Save your database

DIE SIMULATION SETUP

DIE SIMULATION SETUP

In Die Simulation, use INCSolver to do the sheet metal simulation analysis Before simulation, it needs to define tools and blank

I Die Simulation Interface

1 Select the D-Eval menu, D-Eval® Die Simulation

File Parts | BSE Ez] AutoSetup QuickSetup UserSetup SCP | OP | PostProcess Option Utilities View Help

Preparation Binder Modification Trim Check Die Design Check

[ Lower Binder Travel:

II Define Tools

To define the Upper Tool:

1 Click the Upper Tool button, and then select the Select Part button from the Define Tool dialog

EXT | DONE | ABORT | Sa Sig

DIE SIMULATION SETUP

Select Elements Select by Cursor

Angle: 0

| Select by Range

r Exclude Total Selected 30469 RejectLastSelection |

OK Cancel |

4 Toggle on the Exclude option and select the surfaces on binder surface by using Select by surface

The elements on binder surface are excluded

5 The Upper Tool is defined Click E

To define the Binder:

I Click the Binder button, and then select the Select Part button from the Define Tool dialog window

2 Click Add Elements from the Define Tool window

DIE SIMULATION SETUP

3 Select the surfaces on binder surface by using Select by surface The elements on binder surface are

Displayed All Elements

[" Filter Filter Type

4 The Binder is defined Click Exit to exit Define Tool

III Define and Mesh Blank 1 1 + 1 |

1 Click the Blank button to display Blank Generator dialog box

[ Lower Binder Force:

[ Lower Binder Travel:

DIE SIMULATION SETUP

3 Go to the training files located Locate the file: Blank.igs, and import it Click OK to dismiss the Import File dialogue window

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5 After selection, click OK to exit Select Line dialog box

6 Click the BLANK MESH button to enter the Blank Mesh dialog box

DIE SIMULATION SETUP

Blank generator

7 User can change Element Size to 16

Blank mesh

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9 Save the database

IV Defining the Blank Material

The user needs to define the material and thickness For the blank thickness, enter the number in the thickness field In this case, we will set it to 0.8mm

The blank material can be selected from the Material Library under the material definition window

1 Click the MAT0000 button under Material text

Binder Close Velocity: |2000.00 [~ Lower Binder Force: |:

[ Lower Binder Travel:

Lance (0) | Trim (0) | Advanced | Help |

2 Click the Material Library button to open the material lib

DIE SIMULATION SETUP

Hiaterial Library a

United States | :

3 Select BH180 from the Unite States standard Then exit Material definition dialog box

4 Input blank thickness: 0.8mm

Die Simulation

| Single action (Inverted draw) vị | Upper Tool Available vị

1 Use the default Tool Travel Velocity and Binder Close Velocity

2 Toggle on the Lower Binder Force and Lower Binder Travel Set the valuel334000N for Lower Binder Force Set the value 65mm for Lower Binder Travel, as in the following figure

DIE SIMULATION SETUP

| Single action (Inverted draw)

Select Preview to check the tooling motion

Compare your display with the illustration shown below

STEP 18 PUNCH DIE BINDER

TIME POS] = -589.438 POS] = 6.666

VI Define Drawbead

Next step is to define the drawbead for the simulation analysis

1 Click the Drawbead button to open the Drawbead dialog box, as illustrated in the following figure

Die Simulation

— Draw Type

| Single action (Inverted draw)

Iv Lower Binder Force: [1334000.00

DIE SIMULATION SETUP

Line Bead

2 Click the Import button, as illustrated in the following figure

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Files oftype: J IGES("igs:"iges) xi

Use the default mesh parameters and click Apply to generate the line drawbead

Select all the Draw beads in the left side list Click Select in Lock tool and select BNDROOOO from

the Select Part list Click OK to exit Lock the drawbead to part BNDROOOO

DIE SIMULATION SETUP

8 Click Exit to exit the Drawbead dialog box

The followings are the description of other functions in the Die Simulation interface:

e Lance and Trim allows the user to define Lancing and Trimming stages

e Advanced allows the user to change default parameters related to Die Simulation

e Help brings some tips for the user about the Die Simulation

e Submit Job brings the user to the analysis menu

e —= Exit will allow the user to exit the Die Simulation menu

VII Submit Job

After verifying the tool motion is correct, we can define the final parameters and run the analysis

1 Click the Submit Job button to display the Submit Job dialogue window shown below

Binder Close Velocity: [2000.00 Iv Lower Binder Force: |1334000.00

[_ Spring Back

Adaptive Level | 4 v |

Lance (0) | Trim (0) | Advanced | Help | CPU | Multi v |

Undo | Preview | submit Job | Report | Exit | Submit | Close |

2 Toggle on Gravity Load to perform gravity loading analysis prior to Drawing analysis

3 Set the Adaptive level to 4 and Select Multi from the CPU type button, as shown below

¥ Gravity Load