Dynaform DF5 9 2 1 roller hemming training tutorial

Click AutoSetup menu and select Roller Hemming submenu See Figure 4.. Click BLANKMAT to define Outer panel material See Figure 10.. Click OK button to exit the Material dialog box See Fi

DYNAFORM 5.9.2.1 Training Tutorial

This tutorial illustrates how to setup roller hemming

simulation

2

Figure 1 Figure 2

I Open Database

1 Start eta/DYNAFORM

For PC users: double click the icon on desktop to start eta/DYNAFORM

For Linux and UNIX users: enter df591 in the command line and press Enter

button to start eta/DYNAFORM

2 Click File menu and select Open… submenu (See Figure 1)

3 Select the hemming.df and click Open to open the DF file (See Figure 2)

Figure 3

I Open Database

4

1 Click AutoSetup menu and select Roller Hemming submenu (See Figure 4)

2 Default title is untitled, change it to Roller Hemming (See Figure 5)

II Enter Roller Hemming

6

1 Click Outer panel page

2 Click Define geometry to enter Blank generator (See Figure 6)

3 Click Add part in blank generator (See Figure 7)

4 Select the part OUTER, FLANGE and click OK to exit (See Figure 8)

5 Click Exit to exit Blank generator (See Figure 9)

7

Figure 9 Figure 8

6 Click BLANKMAT to define Outer panel material (See Figure 10)

7 Click Material Library to select the material (See Figure 11)

8 Select the material: BH180 (See Figure 12)

9 Click OK button to exit the Material dialog box (See Figure 13)

Figure 10

10 Input OUTER Thickness: 0.8 (See Figure 14)

11 Use the same material parameter for FLANGE

Figure 14

9

IV Define Inner Panel

1 Click Inner panel page

2 Click Define geometry to Enter Preparation

3 Click Define tool icon in Preparation (See Figure 16)

4 Click Add part in Define geometry dialog box (See Figure 17)

5 Select the part INNER and click OK to exit (See Figure 18)

6 Click Exit to exit define geometry (See Figure 19)

7 Click Exit to exit Preparation

10

IV Define Inner Panel

Figure 16 Figure 17

11 Figure 15

8 Click BLANKMAT to define inner panel material (See Figure 20)

9 Click Material Library to select the material (See Figure 21)

10 Select the material: BH180 (See Figure 22)

11 Click OK button to exit the Material dialog box (See Figure23)

12

IV Define Inner Panel

Figure 20

Figure 21

12 Input INNER thickness: 0.8 (See Figure 24)

Figure 24

V Define Roller

1 Click Tools page

2 Select Roller as current tool

3 Click Define geometry to enter Preparation (See Figure 25)

4 Click Define tool icon in Preparation

5 Click Add part in Define geometry dialog box (See Figure 26)

6 Select the part PREROLL and click OK to exit (See Figure 27)

7 Click Exit to exit Define geometry dialog box (See Figure 28)

15

V Define Roller

Figure 25

16

V Define Roller

17

VI Define Hem Bed

1 Click Hem Bed as current tool in Preparation

2 Click Define tool icon in Preparation (See Figure 29)

3 Click Add part in Define geometry dialog box (See Figure 30)

4 Select the part HEMBED and click OK to exit (See Figure 31)

5 Click Exit to exit Define geometry dialog box (See Figure 32)

6 Click Exit to back setup

Figure 29

Figure 31

19

Figure 33

VII Define Trajectory

1 Click Process page

2 Click Edit to define roller trajectory (See Figure 33)

Figure 34

VII Define Trajectory

3 Click Create path in Define Roller dialog box (See Figure 34)

4 Click Element in Create Path dialog box (See Figure 35)

5 Select all FLANGE elements in select elements dialog box and click OK to exit (See Figure 36)

6 Click Start Node in Create Path dialog box (See Figure 37)

7 Select a node as start node in graphic displayed area (See Figure 38)

8 Click OK to exit (See Figure 39)

VII Define Trajectory

22

Figure 40

VII Define Trajectory

9 Click End Node in Create Path dialog box (See Figure 40)

10 Select a node as end node in graphic displayed area (See Figure 41)

11 Click OK to exit (See Figure 42)

VII Define Trajectory

12 Check the direction of roller trajectory (See Figure 43)

13 Toggle on Create Line to create the trajectory as a line (See Figure 44)

14 Click Apply to define the trajectory

24

15 Check the Rotate a (taper angle) and Rotate b (lead angle)

16 Check the velocity of roller

17 Click OK to exit Roller Define dialog box

Figure 45

Note: Use default value in this case

VII Define Trajectory

25

Figure 46

18 Toggle on Springback seamless if user want to run a springback after hemming

simulation (See Figure 46)

VII Define Trajectory

1 Click Outer panel tab

2 Click Edit to define SPCs (See Figure 47)

3 Select All and click New to select nodes (See Figure 48)

4 Select Near Line type

5 Select the line (create line when the definition of roller trajectory) in graphic

display area and click OK in Tolerance to Line dialog box (See Figure 49)

6 Click OK to exit Select Node dialog box (See Figure 50)

7 Click OK to exit SPCs dialog box (See Figure 51)

Figure 47

VIII Constraint

27

1 Click Inner panel tab

2 Click Edit to define SPCs (See Figure 52)

3 Click New to select nodes (See Figure 53)

4 Select some nodes in graphic display area (See Figure 54)

5 Click OK to exit Select Node dialog box (See Figure 55)

6 Click OK to exit SPCs dialog box (See Figure 56)

VIII Constraint

IX Define Control

1 Click Control tab

2 User can click button, the program will automatically calculate the time step

size according to material parameters and element size of outer panel and inner

panel

3 Set the time step as -1.2e-007 (See Figure 57)

4 User can toggle on Refining meshes to define refinement frequency and

refinement levels

Figure 57

32

1 Click Preview menu and Animation submenu (See Figure 58)

2 Click Play Button to show the animation, and user can also select the Individual

Frames option to display the incremental roller movement (See Figure 59)

Figure 58

Figure 59

33

1 Click Job  LS-DYNA Input Deck button (Figure 60)

2 The program popup a Save As dialog box, and click Save to output input deck

(Figure 61)

3 The input deck can be submitted to Job Submitter to run

Figure 60

Figure 61