Dynaform DF5 9 2 1 trim line development training manual

In the Blank Generator/Outline, click the Import button to import the blank outline, as illustrated in Figure 1.7... Click the Select line button in Blank Generator/Outline to select th

eta/DYNAFORM Trim Line Development

Training Manual

Version 5.9.2.1

Engineering Technology Associates, Inc

1133 E Maple Road, Suite 200

Troy, MI 48083

Fax: +1 (248) 729 3020 Email: support@eta.com

Engineering Technology Associates, Inc., ETA, the ETA logo, and eta/DYNAFORM are the registered trademarks of Engineering Technology Associates, Inc All other trademarks or names are the property

of the respective owners

INTRODUCTION

Welcome to the eta/DYNAFORM 5.9.2.1 Trim Line Development Training Manual Trim Line Development uses iterative approach to develop a trim line that will match the targeted trim line The workflow of iterative Trim Line Development is illustrated in Figure 1

Figure 1 Trim Line Development Workflow

This manual details a step-by-step Trim Line Development process through AutoSetup/sheet metal forming

TABLE OF CONTENTS

I Start eta/DYNAFORM 5.9.2.1··· 7

I New Sheet Forming Setup ··· 7

II General ··· 8

III Blank Definition ··· 8

IV Blank Material and Property Definition ··· 13

V Tools Definition ··· 13

VI Tools Positioning ··· 21

VII Process Definition ··· 23

VIII.Control Parameters ··· 25

IX Add the Second Stage (OP20) ··· 25

X Process Definition (OP20) ··· 26

XI Control Parameters (OP20) ··· 28

XII Add the Third Stage (OP30) ··· 28

XIII.Tool Definition (OP30) ··· 29

XIV.Tools Positioning (OP30) ··· 37

XV Process Definition (OP30) ··· 38

XVI.Control Parameters (OP30) ··· 40

XVII Animation ··· 40

XVIII Trim Line Development Setup ··· 42

I Compare the new trim line and the old trim line ··· 46

II Compare the forming result with the target line ··· 47

Example 1 Trim Line Development

Create an eta/DYNAFORM Database

I Start eta/DYNAFORM 5.9.2.1

For workstation/Linux users, enter the command “df5921” (default) from a UNIX shell For PC users,

double click the eta/DYNAFORM icon from the desktop

After starting eta/DYNAFORM, a default database Untitled.df is created The user needs to import

CAD or CAE model to the database to start working

Users can save the database to the designated working directory Go to FileSave as, type

“Trim_Line_Development”, and click Save to dismiss the dialogue window

Figure 1.1 Open file dialog box

AUTO SETUP

Click Sheet Forming option from AutoSetup menu to display Sheet Forming Setup

Figure 1.2 AutoSetup menu

I New Sheet Forming Setup

The New Sheet Forming dialog box appears for the user to define the basic setup parameters, as

illustrated in Figure 1.3

Figure 1.3 Sheet Forming Setup dialog box

1 Input blank thickness: 2.5 (mm)

2 Select process type: Single Action

3 Select original die face: Upper

4 Click OK to display the Sheet Forming interface

II General

Enter General interface, See Figure 1.4

Figure 1.4 General interface

III Blank Definition

1 First, click Blank tab to display the blank definition interface

2 Then, click Define geometry button from Geometry field in the blank definition interface

See Figure 1.5

Figure 1.5 Define blank

3 The Blank Generator dialog box illustrated in Figure 1.6 is displayed

Figure 1.6 Blank generator dialog box

4 In the Blank Generator/Outline, click the Import button to import the blank outline, as

illustrated in Figure 1.7

Figure 1.7 Blank Outline

5 Go to the training files located Locate the file: blank_outline.igs, and import it Click OK

to dismiss the Import File dialogue window

Figure 1.8 Import Blank Outline

6 Click the Select line button in Blank Generator/Outline to select the imported blank

outline, as illustrated in Figure 1.9

Figure 1.9 Define Blank Outline

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

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

Figure 1.10 Blank Mesh

9 Change Element Size to 8mm

Figure 1.11 Mesh Size

10 After you have entered the value, press OK, and the program will automatically save the created blank mesh as another BLK part Compare your mesh with the following picture

Figure 1.12 Blank Mesh Result

11 Click the Exit button to return to the blank definition interface Now, the color of Blank tab

is changed from RED to BLACK See Figure 1.13

Figure 1.13 Defined Blank

IV Blank Material and Property Definition

Once the BLANK part is defined, user needs to define a material for the blank

The user can create a new material, edit the selected material, or import the existed material In this

case, the existed material will be imported

1 Click the None button, Material definition dialog pops up, as illustrated in Figure 1.14

Figure 1.14 Material Definition

2 Select a material from Material Library Click Material Library button, select AA5182 (36)

in United States standard, as illustrated in Figure 1.15

Figure 1.15 Material Library

3 Click OK to exit the Material definition

V Tools Definition

Define Die Tool

1 Click Tools tab to display tool definition interface

2 Based on the defined process, three standard tools: die, punch and binder, are listed at the left side of the tool definition interface You can continue with definition of each tool By default, the die interface is displayed

3 Click the Define geometry button to assign a part as die See Figure 1.16

Figure 1.16 Die definition

4 Click FileImport in the preparation dialog box, as illustrated in Figure 1.17

Figure 1.17 Preparation

5 Go to the training files located Locate the file: OP10_Die.igs, as illustrated in Figure 1.18 Click OK to import it and dismiss the Import File dialogue window

Figure 1.18 Import Die Geometry

6 Now, the die has been defined and the font color of die is changed to BLACK See Figure

1.19

Figure 1.19 Die definition interface

7 Click Mesh tab, click Surface Mesh icon, as illustrated in Figure 1.20

Figure 1.20 Mesh tab

8 Select Tool Mesh, input 10 for Max Size, as illustrated in Figure 1.21

Figure 1.21 Mesh size

9 All surfaces of Die will automatically be selected Click Apply button

10 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

Figure 1.22 Mesh of Die

Define Punch Tool

1 Select punch located at the left side of tools list to display punch definition interface

2 Click MeshOrganizeCopy elements icon illustrated in Figure 1.23

Figure 1.23 Preparation

3 Click Select button to select copied element, as illustrated in Figure 1.24

Figure 1.24 Copy Elements dialog box

4 Click the Displayed button in the Select Elements dialog box to select all elements Toggle

on the Exclude option and select the elements on binder surface using Select by surface As

illustrated in Figure 1.26, the elements on binder surface are excluded

Figure 1.25 Select elements

Figure 1.26 Highlighted elements

5 Click OK button to return Copy Elements dialog box Now, the Apply button is activated

See Figure 1.27

6 Click Apply button to copy selected elements to a new part See Figure 1.28

Figure 1.27 Copy Elements dialog box

Figure 1.28 Copied elements

7 Click Exit button to return to the tool definition interface The font color of punch is also changed to BLACK It means the punch has been defined

Define Binder Tool

1 Click binder located at the left side of tool definition interface to display the binder definition interface Toggle off Punch, and Toggle on Die, as illustrated in Figure 1.29

Figure 1.29 Binder definition

2 Click MeshOrganizeCopy elements icon, following by clicking the Select button to

select the elements to be copied to binder

3 Switch to Surface function provided in Select Elements dialog box and select the binder

surface The program prompts 909 elements have been selected, as illustrated in Figure 1.30

Figure 1.30 Select elements for Binder

4 Click OK button to exit the Select Elements dialog box Click Apply button to copy

elements in the Copy Elements dialog box All selected elements are automatically copied to

a new part, as illustrated in Figure 1.31 Click Exit to dismiss the Copy Elements dialog box

Figure 1.31 Copied Elements

5 The font color of all the tool names has been changed from red to black It means that all the tools have been defined, as illustrated in Figure 1.32

Figure 1.32 Tool Preparation

6 Click the Exit button to return to the Sheet Forming Setup interface The font color of all the

tool names has been changed to black See Figure 1.33

Figure 1.33 Tool Definition

VI Tools Positioning

After defining all tools, the user needs to position the relative position of tools for the OP10 stamping operation The tool positioning operation must be carried out each time the user sets up a stamping simulation model Otherwise, the user may not obtain correct stamping simulation setup

The tool position is related to the working direction of each tool Therefore, you need to carefully check the working direction prior to positioning the tools If the process template is chosen, the default working direction is selected You can also define special working direction manually

1 Click the Positioning button located at the lower left corner of the tool definition interface

to display the Positioning dialog box

2 Select binder as the Blank’s reference tool Put die on blank The die and the blank will be

moved to a new position and the corresponding distance values will display in each edit box,

as illustrated in Figure 1.34

Figure 1.34 Tool positioning dialog box

3 Click F button The program will auto move the binder The position of die and the blank

will be updated with the relative position, as illustrated in Figure 1.35

Figure 1.35 Position Binder

4 Click OK button to save the current position of tools and blank(s), and return to the Sheet

Forming interface

Figure 1.36 The relative position of tools and blank after positioning

Note: After positioning, the relative position of tools and blanks is displayed on the screen However, you may follow by clicking the Reset button in the Positioning dialog box to set the tools and

blank(s) back to its original position

VII Process Definition

The Process definition is utilized to set up process parameters of the current simulation such as time required for every process, tooling speed, binder force and so on The parameters listed in process definition interface depend on the pre-selected process template, including type of simulation and process

In this example, the type of simulation and process is Sheet Forming and Single Action, respectively

Therefore, two default processes are listed in the process definition interface: closing and drawing process

You can click Process tab of the main interface to enter process definition interface You only need to

check your setting with Figure 1.38 Next, follow the steps listed below:

1 Select closing process from the list located at left side of the interface as the current process

Verify the default setting of closing stage is similar to Figure 1.37

2 Select drawing process from the list located at left side of the interface as the current process

Verify the default setting of drawing stage is similar to Figure 1.38

Figure 1.37 closing definition

Figure 1.38 drawing definition

VIII Control Parameters

For different model sizes and mesh sizes, the control parameters are different In this case, we suggest the following parameter

Figure 1.39 Control parameters

IX Add the Second Stage (OP20)

1 Click button to display the Stage setup interface illustrated in Figure 1.47

Figure 1.40 Stage setup

2 Click New button to add a new stage The New process stage dialog box illustrated in Figure

1.48 appears

3 Select Trimming from the drop-down list of Type, select Insert after and click OK to exit

Figure 1.41 New process stage dialog box

4 The new stage OP20 has been created, as illustrated in Figure 1.42

Figure 1.42 OP20 trimming

X Process Definition (OP20)

Click Process tab of the main interface to enter process definition interface

1 Click the Import button to import the trim line, as illustrated in Figure 1.43

Figure 1.43 Trimming Process

2 Go to the training files located Locate the file: OP20_Trim_Line.igs, and import it, as illustrated in Figure 1.44 Click OK to dismiss the Import File dialogue window

Figure 1.44 Import Trim Line

3 The imported line will be defined as trim line, as illustrated in Figure 1.45

Figure 1.45 Defined trim line

XI Control Parameters (OP20)

For different model sizes and mesh sizes, the control parameters are different In this case, we suggest the following parameter

Figure 1.46 Control parameters

XII Add the Third Stage (OP30)

1 Click button to display the Stage setup interface illustrated in Figure 1.47

Figure 1.47 Stage setup

2 Click New button to add a new stage The New process stage dialog box illustrated in Figure 1.47

3 Select Single action from the drop-down list of Type, select Insert after and click OK to exit, as illustrated in Figure 1.48

Figure 1.48 New process stage dialog box

4 The new stage OP30 has been created, as illustrated in Figure 1.49

Figure 1.49 OP30

XIII Tool Definition (OP30)

Define Die Tool

1 Click Tools tab to display tool definition interface

2 Based on the defined process, three standard tools: die, punch and binder, are listed at the left side of the tool definition interface You can continue with definition of each tool By default, the die interface is displayed

3 Click the Define geometry button to assign a part as die See Figure 1.50

Figure 1.50 Die definition

4 Select 30_die Click FileImport in the preparation dialog box, as illustrated in Figure 1.51

Figure 1.51 Preparation

5 Go to the training files located Locate the file: OP30_Die.igs, as illustrated in Figure 1.52 Click OK to import it and dismiss the Import File dialogue window

Figure 1.52 Import Die Geometry

6 Now, the die has been defined and the font color of die is changed to BLACK See Figure

1.53

Figure 1.53 Die definition interface

7 Click Mesh tab, click Surface Mesh icon, as illustrated in Figure 1.54

Figure 1.54 Mesh tab

8 Select Tool Mesh, input 10 for Max Size, as illustrated in Figure 1.55

Figure 1.55 Mesh size

9 All surfaces of Die will automatically be selected Click Apply button

10 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

Figure 1.56 Mesh of Die

Define Punch Tool

1 Select 30_punch located at the left side of tools list to display punch definition interface

2 Click MeshOrganizeCopy elements icon illustrated in Figure 1.57

Figure 1.57 Preparation

3 Click Select button to select copied element, as illustrated in Figure 1.58

Figure 1.58 Copy Elements dialog box

4 Click the Displayed button in the Select Elements dialog box to select all elements Toggle on the Exclude option and select the elements on binder surface using Select by surface As