SPECIAL FEATURES OF ETA/DYNAFORM 5.9.2.1 INCLUDE: A process-oriented module - AUTOSETUP The AutoSetup module consists of Preparation, Sheet Forming, Blank/Trim Line Development, Hot Fo
Trang 1eta/DYNAFORM
User’s Manual
Version 5.9.2.1
Engineering Technology Associates, Inc
1133 E Maple Road, Suite 200
Troy, MI 48083-2896
Phone: +1 (248) 729 3010
Support: +1 (800) 382 3362
Fax: +1 (248) 729 3020
Trang 2©1998-2014 Engineering Technology Associates, Inc All rights reserved
Trang 3TABLE OF CONTENTS
INTRODUCTION ··· 1
CHAPTER 1 STRUCTURAL OVERVIEW ··· 9
1.1 MENU BAR ··· 9
1.2 ICON BAR ··· 10
1.3 DISPLAY WINDOW ··· 13
1.4 DISPLAY OPTIONS ··· 14
1.5 MOUSE FUNCTIONS ··· 17
1.6 SPECIFICATIONS ··· 18
1.7 GEOMETRY DATA ··· 18
1.8 RECOMMENDED NAMING CONVENTION ··· 19
1.9 DIALOG BOXES ··· 20
1.10 PROPERTY TABLES ··· 20
1.11 CONFIGURATION FILE ··· 21
CHAPTER 2 GETTING STARTED ··· 25
2.1 GETTING STARTED ··· 25
2.2 STARTING WITH CAD DATA ··· 25
2.2.1 STARTING WITH CAD SURFACE DATA ··· 25
2.2.2 STARTING WITH CAD LINE DATA ··· 25
2.3 GETTING STARTED WITH MODEL DATA (NASTRAN, LS-DYNA, etc.) ··· 26
2.4 GETTING STARTED FROM SCRATCH ··· 26
2.5 LOCAL COORDINATE SYSTEM ··· 27
2.6 SHORTCUT KEY ··· 29
CHAPTER 3 FILE MANAGER ··· 31
3.1 NEW ··· 31
3.2 OPEN (CTRL+O) ··· 32
3.3 RESTART ··· 32
3.4 SAVE ··· 33
3.5 SAVE AS ··· 33
3.6 IMPORT (F3) ··· 34
3.7 EXPORT (SHIFT+F3)··· 34
3.8 SUBMIT DYNA FROM INPUT DECK ··· 35
3.9 RUN DYNA RESTART ··· 35
3.10 PRINT SETUP ··· 35
3.10.1 PAPER ··· 36
3.10.2 PRINTER ··· 36
3.10.3 ORIENTATION ··· 37
3.10.4 QUALITY ··· 37
3.10.5 OPTION ··· 37
3.10.6 NO OF COPIES ··· 38
Trang 43.12 RECENT FILES ··· 38
3.13 EXIT (CTRL+X) ··· 38
CHAPTER 4 PART CONTROL ··· 39
4.1 CREATE PART (CTRL+P) ··· 39
4.2 EDIT PART ··· 40
4.2.1 MODIFY PART ··· 41
4.2.2 DELETE PART ··· 41
4.3 DELETE ··· 41
4.4 ADD…TO PART ··· 42
4.4.1 ADD LINE ··· 43
4.4.2 ADD ELEMENT··· 44
4.4.3 ADD SURFACE ··· 48
4.4.4 SELECT THE TARGET PART ··· 48
4.5 TURN PART ON/OFF ··· 49
4.6 CURRENT PART ··· 50
4.7 SEPARATE PART ··· 50
4.8 TRANSPARENT ··· 50
4.9 SUMMARY ··· 50
CHAPTER 5 PREPROCESS ··· 53
5.1 LINE (CTRL+L) ··· 53
5.1.1 CREATE LINE ··· 54
5.1.2 CREATE ARC ··· 58
5.1.3 CREATE SPLINE ··· 59
5.1.4 SHORTEST CURVE ··· 59
5.1.5 BOUNDARY LINE ··· 61
5.1.6 S-LINE ··· 62
5.1.7 SECTION LINE ··· 63
5.1.8 SECTION THROUGH LINE ··· 68
5.1.9 BRIDGE LINE ··· 68
5.1.10 DELETE LINE ··· 69
5.1.11 MODIFY LINE ··· 70
5.1.12 SPLIT LINE ··· 71
5.1.13 COMBINE LINE ··· 75
5.1.14 EXTEND LINE ··· 76
5.1.15 EDIT LINE ··· 76
5.1.16 RESPACE LINE ··· 83
5.1.17 REVERSE LINE DIRECTION ··· 84
5.1.18 TRANSFORM LINE ··· 84
5.1.19 OFFSET LINE ··· 90
5.1.20 PROJECT LINE ··· 91
Trang 55.1.21 SHOW LINE ··· 91
5.2 SURFACE (CTRL+S) ··· 92
5.2.1 CREATE 2L ··· 93
5.2.2 CREATE 3L ··· 94
5.2.3 CREATE 4L ··· 94
5.2.4 REVOLUTION SURFACE ··· 94
5.2.5 SWEEP SURFACE ··· 94
5.2.6 SKIN SURFACE ··· 95
5.2.7 GENERATE MIDDLE SURFACE ··· 95
5.2.8 SEPARATE SURFACE ··· 98
5.2.9 MESH TO SURFACE ··· 100
5.2.10 SURFACE INTERSECT ··· 102
5.2.11 SURFACE SPLIT ··· 102
5.2.12 DELETE SURFACE ··· 104
5.2.13 TRIM SURFACE ··· 104
5.2.14 UNTRIM SURFACE ··· 106
5.2.15 EXTEND SURFACE ··· 106
5.2.16 TRANSFORM SURFACE ··· 107
5.2.17 OFFSET SURFACE ··· 107
5.2.18 RESPACE U-V LINE ··· 108
5.2.19 REVERSE NORMAL ··· 109
5.2.20 REMOVE HOLE ··· 109
5.2.21 BOUNDARY LINE ··· 109
5.2.22 CHECK DUPLICATE SURFACE ··· 109
5.2.23 CHECK SURFACE ··· 110
5.2.24 SHOW SURFACE ··· 114
5.3 ELEMENT (CTRL+E) ··· 115
5.3.1 2 LINE MESH ··· 117
5.3.2 3 LINE MESH ··· 118
5.3.3 4 LINE MESH ··· 118
5.3.4 SURFACE MESH ··· 119
5.3.5 LINE MESH ··· 124
5.3.6 2 LINE POINT MESH ··· 126
5.3.7 DRAG MESH ··· 127
5.3.8 CREATE ELEMENT ··· 127
5.3.9 DELETE ELEMENT ··· 129
5.3.10 ELEMENT TRIMMING ··· 129
5.3.11 ELEMENT LANCING ··· 132
5.3.12 COARSE ELEMENT ··· 135
5.3.13 SPLIT ELEMENT ··· 135
5.3.14 PROJECT ELEMENT ··· 137
5.3.15 TRANSFORM ELEMENT ··· 137
5.3.16 OFFSET ELEMENT ··· 138
5.3.17 MODIFY ELEMENT ··· 139
5.3.18 AUTO REPAIR ··· 140
Trang 65.3.23 IDENTIFY ELEMENT ··· 143
5.3.24 FIND ELEMENT ··· 143
5.4 NODE (CTRL+N) ··· 143
5.4.1 CREATE NODE ··· 144
5.4.2 ADD NODES BETWEEN TWO NODES/POINTS ··· 145
5.4.3 DELETE UNREFERENCED NODES ··· 145
5.4.4 TRANSFORM NODE ··· 146
5.4.5 MOVE NODE ··· 147
5.4.6 ALIGN NODE ··· 148
5.4.7 PROJECT NODE ··· 148
5.4.8 CHECK DUPLICATE NODES ··· 149
5.4.9 CHECK COINCIDENT NODES ··· 150
5.4.10 PART CONNECT ··· 150
5.4.11 COMPACT NODE ··· 150
5.4.12 CHANGE NODE NUMBER ··· 150
5.4.13 RENUMBER NODES ··· 151
5.4.14 DISTANCE BETWEEN NODES/POINTS ··· 151
5.4.15 IDENTIFY NODE/POINT ··· 152
5.4.16 FIND NODE ··· 152
5.5 MODEL CHECK / REPAIR (CTRL+R) ··· 152
5.5.1 MODEL CHECK ··· 153
5.5.2 MODEL REPAIR ··· 162
CHAPTER 6 BLANK SIZE ENGINEERING ··· 166
6.1 PREPARATION ··· 166
6.1.1 PREPARATION MENU ··· 175
6.1.2 TOOL LIST ··· 177
6.1.3 GEO&MAT ··· 178
6.1.4 MESH ··· 196
6.1.5 SYMMETRY/DOUBLE-ATTACHED ··· 214
6.1.6 TIPPING ··· 225
6.1.7 BOUNDARY FILL ··· 238
6.2 MSTEP ··· 261
6.2.1 TOOL DEFINITION ··· 261
6.2.2 ADVANCED ··· 262
6.2.3 MATERIAL ··· 266
6.2.4 FORMABILITY REPORT ··· 267
6.3 OUTLINE ··· 275
6.3.1 OUTLINE LIST··· 276
6.3.2 ORGANIZE ··· 276
6.3.3 EDIT ··· 276
6.4 NESTING ··· 283
Trang 76.4.1 ONE-UP NESTING ··· 288
6.4.2 TWO-UP NESTING ··· 308
6.4.3 TWO-PAIR NESTING ··· 313
6.4.4 MIRROR NESTING ··· 314
6.4.5 MULTIPLE NESTING ··· 314
6.4.6 RECTANGLE NESTING ··· 316
6.4.7 PARALLEL NESTING ··· 320
6.4.8 ISOSCELES-TRAPEZOID NESTING ··· 321
6.4.9 TRAPEZOID NESTING ··· 322
6.4.10 ARC NESTING ··· 323
6.5 BLANK SIZE ESTIMATE ··· 324
6.6 UNFOLD ··· 327
6.7 TRIM LINE ··· 328
6.7.1 DEFINE SHEET MAT ··· 329
6.7.2 ADVANCED ··· 330
6.8 BATCH MSTEP ··· 332
6.9 BATCH BSE ··· 335
CHAPTER 7 DIE EVALUATION ··· 337
7.1 PREPARATION ··· 337
7.1.1 PREPARATION MENU ··· 338
7.1.2 TOOL LIST ··· 341
7.1.3 GEOMETRY ··· 342
7.1.4 MESH ··· 357
7.1.5 SYMMETRY/DOUBLE-ATTACHED ··· 374
7.1.6 TIPPING ··· 385
7.1.7 BOUNDARY FILL ··· 396
7.2 BINDER ··· 419
7.2.1 CREATE ··· 420
7.2.2 BINDER TOOL ··· 435
7.2.3 MODIFY ··· 442
7.2.4 PART ON BINDER ··· 454
7.2.5 BUTTERFLY ··· 457
7.2.6 DIE TRIM ··· 459
7.2.7 ADVANCED ··· 463
7.3 MODIFICATION ··· 465
7.3.1 DIAMOND ··· 465
7.3.2 RIB ··· 469
7.3.3 ELEMENT MORPH ··· 473
7.3.4 EMBOSSMENT ··· 477
7.3.5 DRAW BAR ··· 481
7.3.6 DRAW BEAD TRIM ··· 486
7.3.7 LASER TRIM ··· 487
7.3.8 GEOMETRY DRAW BEAD ··· 488
7.3.9 BINDER TRIM ··· 488
7.4 TRIM CHECK ··· 488
Trang 87.4.5 CURVE EDITOR ··· 506
7.5 DIE DESIGN CHECK ··· 513
7.6 DIE SIMULATION ··· 514
7.6.1 INCSOLVER INTRODUCTION··· 514
7.6.2 INCSOLVER FUNCTIONS ··· 514
7.6.3 HELPFUL TIPS ··· 537
7.6.4 REFERENCE ··· 539
CHAPTER 8 AUTO SETUP ··· 540
8.1 PREPARATION ··· 540
8.1.1 MENU ··· 541
8.1.2 TOOL LIST ··· 542
8.1.3 GEOMETRY ··· 542
8.1.4 MESH ··· 551
8.2 BLANK GENERATOR ··· 560
8.2.1 OPERATION ··· 561
8.2.2 MESH TYPE ··· 562
8.2.3 PARTS ··· 578
8.2.4 OUTLINE ··· 579
8.2.5 MESH EDIT ··· 589
8.3 SHEET FORMING ··· 592
8.3.1 NEW SIMULATION ··· 593
8.3.2 MENU ··· 596
8.3.3 STAGE SETUP ··· 601
8.3.4 FORMING ··· 602
8.3.5 GRAVITY ··· 681
8.3.6 TRIMMING ··· 688
8.3.7 SPRINGBACK ··· 692
8.3.8 COOLING ··· 700
8.3.9 ANNEALING ··· 701
8.4 BLANK/TRIM LINE DEVELOPMENT ··· 702
8.4.1 BLANK DEVELOPMENT ··· 703
8.4.2 TRIM LINE DEVELOPMENT ··· 705
8.5 HOT FORMING ··· 707
8.5.1 FORMING ··· 707
8.5.2 GRAVITY LOADING ··· 715
8.5.3 PRESS HARDENING ··· 716
8.6 TUBE BENDING/ FORMING ··· 717
8.6.1 ROTARY BENDING··· 717
8.6.2 TUBE FORMING ··· 736
8.7 ROLLER HEMMING ··· 745
8.7.1 GENERAL ··· 746
Trang 98.7.2 OUTER PANEL ··· 747
8.7.3 INNER PANEL ··· 751
8.7.4 TOOLS ··· 753
8.7.5 PROCESS ··· 755
8.7.6 CONTROL ··· 760
8.8 SUPERPLASTIC FORMING ··· 761
8.8.1 PROCESS ··· 761
8.9 STRETCH FORMING ··· 763
8.9.1 TRANSVERSAL BULLNOSE ··· 763
8.9.2 TRANSVERSAL WRAP ··· 789
8.9.3 LONGITUDINAL ··· 814
8.10 LS-OPT OPTIMIZATION ··· 840
8.10.1 VARIABLE DEFINITION ··· 842
8.10.2 RESPONSE DEFINITION ··· 842
8.10.3 METHODS DEFINITION ··· 845
8.11 LS-OPT VIEWER ··· 847
CHAPTER 9 QUICK SETUP ··· 848
9.1 QUICK SETUP GUI··· 848
9.2 GRAVITY LOADING ··· 849
9.2.1 TOOL AND BLANK DEFINITION ··· 851
9.2.2 BLANK PARAMETERS ··· 854
9.2.3 GRAVITY LOADING PROCEDURE ··· 855
9.3 DRAW DIE ··· 855
9.3.1 TOOL AND BLANK DEFINITION ··· 857
9.3.2 TOOL CONTROL ··· 857
9.3.3 ADVANCED ··· 858
9.3.4 THE QUICKSETUP/DRAW DIE PROCEDURE ··· 859
9.4 SPRINGBACK ··· 859
9.4.1 THE QUICK SETUP/SPRINGBACK PROCEDURE ··· 861
CHAPTER 10 USER SETUP ··· 863
10.1 ANALYSIS CONFIGURATION ··· 863
10.2 DEFINE TOOLS (CTRL+T) ··· 866
10.2.1 TOOLS SETUP ··· 867
10.2.2 ADD (PART) ··· 868
10.2.3 REMOVE (PART) ··· 868
10.2.4 DISPLAY (TOOL) ··· 868
10.2.5 DEFINE CONTACT ··· 868
10.2.6 DEFINE LOAD CURVE ··· 870
10.2.7 GENERATE TOOL FROM MATING TOOLS ··· 874
10.3 DRAW BEAD ··· 875
10.3.1 LINE BEAD ··· 875
10.3.2 GEOMETRY BEAD ··· 898
10.4 GUIDE PIN ··· 903
10.4.1 LOCATOR ONE ··· 906
Trang 1010.6 DEFINE BLANK (CTRL+B) ··· 908
10.7 MATERIAL ··· 909
10.7.1 NEW (MATERIAL) ··· 910
10.7.2 MODIFY (MATERIAL) ··· 911
10.7.3 DELETE (MATERIAL) ··· 911
10.7.4 IMPORT ··· 911
10.7.5 EXPORT ··· 912
10.7.6 MATERIAL LIBRARY ··· 912
10.8 PROPERTY ··· 913
10.8.1 NEW ··· 914
10.9 BLANK OPERATION ··· 914
10.9.1 BLANK AUTO POSITION ··· 915
10.9.2 BLANK MAPPING ··· 915
10.9.3 RESULT MAPPING ··· 916
10.9.4 DYNAIN CONTOUR ··· 917
10.9.5 ANNEAL ··· 918
10.9.6 MAPPING SOLID ··· 918
10.9.7 TRIM ··· 919
10.9.8 TIP ··· 921
10.9.9 TAILOR WELDED ··· 921
10.9.10 LANCING ··· 921
10.10 NODE/ELEMENT SET ··· 922
10.11 BOUNDARY CONDITIONS ··· 923
10.11.1 LOADING OPTIONS ··· 923
10.11.2 CONSTRAINTS ··· 926
10.11.3 INITIAL VELOCITY ··· 929
10.11.4 RIGID BODY STOPPER ··· 930
10.11.5 EXPORT ··· 932
10.12 POSITION TOOLS ··· 932
10.12.1 AUTO POSITION ··· 932
10.12.2 MOVE TOOL ··· 932
10.12.3 MIN (MINIMUM) DISTANCE ··· 933
10.13 TOOLS ON/OFF ··· 934
10.14 ANIMATE ··· 935
10.15 SUMMARY ··· 936
10.16 LS-DYNA (CTRL+A) ··· 937
10.16.1 ANALYSIS TYPE ··· 938
10.16.2 GRAVITY LOAD ··· 941
10.16.3 DYNAIN OUTPUT ··· 941
10.16.4 SPRINGBACK (SEAMLESS) ··· 942
10.16.5 POP LINE ··· 942
Trang 1110.16.6 ADAPTIVE MESH (toggle) ··· 943
10.16.7 DEFINED TOOLS ONLY (toggle) ··· 944
10.16.8 COARSENING ··· 944
10.16.9 OUTPUT CONTROL ··· 944
10.16.10 SPECIFY OUTPUT FILE NAME ··· 944
10.16.11 SPECIFY JOB ID (toggle) ··· 944
10.16.12 SPECIFY MEMORY (toggle) ··· 945
10.16.13 SPECIFY TITLE ··· 945
10.16.14 TERMINATION TIME ··· 945
10.16.15 DYNA SOLVER PRECISION ··· 945
10.17 LS-DYNA (SPRINGBACK) ··· 946
10.18 LS-DYNA (GRAVITY LOADING) ··· 947
10.19 MSTEP ··· 948
CHAPTER 11 SPRINGBACK COMPENSATION PROCESS ··· 949
11.1 COMPENSATION ··· 950
11.2 UNDERCUT CHECK ··· 954
11.3 TOPOLOGY REPAIR ··· 955
11.4 MORPHING ··· 955
11.4.1 MORPHING BY INTERIOR ELEMENT ··· 956
11.4.2 MORPHING BY ELEMENT EDGE ··· 957
11.4.3 MORPHING BY ELEMENT CORNER ··· 958
11.4.4 MORPHING BY EDGE QUADRATIC ··· 958
11.5 SURFACE MAPPING ··· 958
11.6 BEST FIT ··· 960
11.7 DEVIATION CHECK ··· 962
CHAPTER 12 OPTIMIZATION ··· 963
12.1 INCSOLVER ··· 963
12.2 OPTIMIZATION ··· 963
12.2.1 VARIABLE DEFINITION ··· 964
12.2.2 RESPONSE DEFINITION ··· 965
12.3 RESULT VIEWER ··· 971
12.3.1 BEST RESULTS ··· 972
12.3.2 GRAPH ··· 973
12.3.3 BEST PRACTICE ··· 975
CHAPTER 13 DIE SYSTEM ANALYSIS ··· 978
13.1 DIE STRUCTURAL INTEGRITY ··· 978
13.2 SCRAP SHEDDING REMOVAL ··· 978
13.2.1 TOOL BAR ··· 979
13.2.2 TOOL DEFINITION GUI ··· 982
13.2.3 SETUP ··· 983
13.2.4 SUBMIT JOB ··· 1001
13.3 SHEET METAL TRANSFER HANDLING ··· 1001
13.3.1 TOOL DEFINITION GUI ··· 1002
Trang 1214.1 ETA/POST ··· 1016
14.2 VERSION··· 1016
CHAPTER 15 OPTION ··· 1017
15.1 MESH CONTROL ··· 1017
15.1.1 AUTO SURFACE MESH (toggle)··· 1018
15.1.2 AUTO PLATE NORMAL (toggle) ··· 1018
15.1.3 USE CONTROL POINTS (toggle) ··· 1018
15.1.4 NO BIAS MESH ··· 1018
15.1.5 EDGE BIAS MESH ··· 1019
15.1.6 CORNER BIAS MESH ··· 1019
15.1.7 PLATE ELEMENT TYPE ··· 1020
15.1.8 LINE MESH METHOD ··· 1020
15.2 FILE OPTION ··· 1020
15.3 SYSTEM LANGUAGE ··· 1022
15.4 MATERIAL LIBRARY ··· 1023
15.5 DRAW BEAD SHAPE LIBRARY··· 1024
15.6 EDIT DEFAULT CONFIG ··· 1025
15.7 LEFT MENU (toggle) ··· 1026
15.8 SHOW ICON TIPS (toggle) ··· 1027
CHAPTER 16 UTILITIES ··· 1028
16.1 ANGLE BETWEEN LINES ··· 1028
16.2 DISTANCE BETWEEN POINTS/NODES··· 1029
16.3 RADIUS THROUGH 3POINTS/3NODES ··· 1030
16.4 AREA OF SELECTED ELEMENTS ··· 1030
16.5 LENGTH OF LINE ··· 1030
16.6 SECTION CUT ··· 1031
16.7 DRAW ARROW ··· 1031
16.8 DEFINE TITLE ··· 1031
16.9 LABEL DIMENSION ··· 1032
16.10 IDENTIFY NODE/POINT ··· 1032
16.11 IDENTIFY ELEMENT ··· 1032
16.12 FIND ELEMENT ··· 1032
16.13 FIND NODE ··· 1032
16.14 LOAD CURVE ··· 1033
16.14.1 CREATE CURVE ··· 1033
16.14.2 DELETE LOAD CURVE ··· 1034
16.14.3 LIST LOAD CURVE ··· 1035
16.14.4 MODIFY LOAD CURVE ··· 1035
16.14.5 READ CURVE DATA ··· 1037
16.14.6 RENUMBER LOAD CURVE ··· 1040
Trang 1316.14.7 RENAME CURVE ··· 1040
16.14.8 SHOW LOAD CURVE ··· 1041
16.14.9 D3PLOT CURVE ··· 1046
16.14.10 BLANK HOLD CURVE ··· 1048
16.15 SHOW LINE ··· 1048
16.16 SHOW SURFACE ··· 1048
16.17 COORDINATE SYSTEM ··· 1048
16.17.1 CREATE COORDINATE SYSTEM ··· 1049
16.17.2 DELETE COORDINATE SYSTEM ··· 1051
16.17.3 COPY COORDINATE SYSTEM ··· 1052
16.17.4 MODIFY COORDINATE SYSTEM ··· 1052
16.17.5 CURRENT COORDINATE SYSTEM ··· 1053
16.17.6 IDENTIFY COORDINATE SYSTEM ··· 1053
16.17.7 LCS LCS ENT TRANSFORM ··· 1053
16.18 DATABASE STATISTIC ··· 1054
CHAPTER 17 VIEW OPTIONS ··· 1057
17.1 COLOR MAP ··· 1057
17.2 ROTATION ··· 1058
17.3 LIGHT··· 1059
17.4 BACKGROUND COLOR ··· 1060
17.5 DEFINE ROTATION CENTER ··· 1062
17.6 PLOT SHELL ELEMENT AS SOLID ··· 1062
17.7 USER VIEW ··· 1062
17.8 TRUE VIEW ··· 1064
17.9 EXPLODED VIEW ··· 1064
17.10 LABEL NODES (toggle) ··· 1065
17.11 LABEL ELEMENTS (toggle) ··· 1065
17.12 PLATE NORMAL (COLOR) (toggle) ··· 1065
17.13 SHADING MODE ··· 1065
17.14 SHADING QUALITY ··· 1066
17.15 SCALE ACTIVE WINDOW ··· 1066
APPENDIX A HARDWARE AND SOFTWARE REQUIREMENTS ··· 1067
APPENDIX B SUPPORTED IGES ENTITY TYPES ··· 1068
APPENDIX C CURVE FILE FORMAT EXAMPLE ··· 1069
APPENDIX D FORMAT SPECIFICATIONS FOR LS-DYNA INPUT DECK ·· 1070
FINAL NOTES ··· 1072
Trang 15INTRODUCTION
eta/DYNAFORM is an LS-DYNA-based sheet metal forming simulation solution package developed
by Engineering Technology Associates, Inc The specialty CAE software combines the sheet forming analysis power of LS-DYNA Versions 971 with the streamlined pre- and post-processor functions These analysis codes and interactive functions are uniquely integrated to service the sheet metal forming industry in tooling design and development, which helps designers reduce tooling development time and tryout lead-time With its superior usability and intelligent tools, eta/DYNAFORM can easily solve all kinds of sheet forming problems The program also maximizes traditional CAE techniques to reduce prototyping costs and lead time for product development
eta/DYNAFORM’s analysis engine is LS-DYNA, which is developed and currently supported by the Livermore Software Technology Corporation (LSTC) of Livermore, California It is a general purpose, non-linear, dynamic, finite element analysis code utilizing explicit and implicit capabilities for solving fluid and solid structural problems The code has been developed for applications such as automobile crashworthiness, occupant safety, underwater explosion, and sheet metal forming
The bottleneck of the metal forming development cycle is the hard tooling design lead-time The eta/DYNAFORM CAE approach simulates this tooling process and thereby reduces the tooling tryout time and the associated cost for producing high quality stamped parts eta/DYNAFORM effectively
simulates the four major design concerns in the tooling process: Binder Wrap, Draw Die, Springback, and Multiple Stage Tooling These simulations enable engineers to conduct feasibility studies of a
product design early in the design cycle
eta/DYNAFORM features well-defined tooling surface data to predict the performance of a stamping
for areas such as Tearing, Wrinkling, and Thinning, in addition to predicting Skid Mark and
Springback effects
Multi-Platform:
eta/DYNAFORM is available for all UNIX workstation platforms including DEC(Alpha), HP, IBM, SUN, and SGI It is available on PC for Windows XP operating systems and above For Linux, the Red Hat Enterprise Linux 5 and above is supported
SPECIAL FEATURES OF ETA/DYNAFORM 5.9.2.1 INCLUDE:
A process-oriented module - AUTOSETUP
The AutoSetup module consists of Preparation, Sheet Forming, Blank/Trim Line Development, Hot Forming, Tube Rotary Bending, Tube Forming, Roller Hemming, Superplastic Forming, Stretch Forming and LS-OPT Optimization The Preparation module is used to prepare the necessary tools for the analysis model; Sheet Forming completes various setups for blank forming analysis, including laser tailor-welded blank, laminated sheet, hydroforming and multi-stage forming; Blank/Trim Line Development uses iterative approach to develop a blank outline/trimline to match the target line; Hot Forming sets up full process: Gravity, Hot Forming and Press Hardening; Tube Forming sets up hydroforming for tube; Rotary Bending performs multi-stage bending simulation on tube; Roller Hemming sets up simulation for robot roller hemming process; Superplastic Forming provides a quick setup interface for superplastic forming simulation; Stretch Forming is mainly used to simulate the forming of aircraft skin parts; LS-OPT optimization is mainly used to optimize the Blank outline, Lubricant, Binder Press and Line Bead Force
Trang 16and enables users to easily set up all types of simulation The sheet forming module combines the merits of user setup power and quick and easy setup It provides a perfect combination of function and operation while avoiding the traditional disadvantages of difficulty in usage and single quick setting function
In the sheet forming module, the user can define stamping direction, welded blank simulation, hydroforming simulation, multi-stage simulation and trimming In addition, thermal forming and cooling simulations are also added to sheet forming The enhanced material library in AutoSetup module allows the user to add the standard material library for corporations to the program interface for easier selection of common used materials
Blank Development use iterative approach to develop a blank outline, where the final result matches the defined target line
Trim Line Development use iterative approach to develop a trim line in the trimming stage, where the final result matches the defined target line
The Hot Forming technology is used to solve various problems for the wide application of high strength steel forming It provides a user-friendly interface to perform complex hot forming setup Tube rotary bending is a setup module for tube bending analysis and it is completely in accordance with the practical process With the user-friendly interface, the user may define a bending axis for arbitrary axis bending, and perform multi-step rotary bending simulation and tubular springback simulation This module is also equipped with functional modeling for the user to directly create tube and the meshes of various tools for new simulation, which may greatly reduce the setup time and improve modeling efficiency
The tube forming module is used to set the internal high pressure for forming Multiple stage analysis including springback can be performed The user can adopt the hydraulic mechanism by Pressure and Volume, and specify a detailed pressure curve The settings for tube forming are similar
to blank hydro forming, which makes it easier to grasp the operating process
Roller hemming is a setup module for rolling analysis With the user-friendly interface, the user can define or select a line as its orbit to make the roller move along specified path
The superplastic forming module is used to analyze capabilities of sheet forming in superplastic temperature range and under specified pressure It provides a complete scheme for superplastic forming
The stretch forming can be divided into Transversal Bullnose, Transversal Wrap and Longitudinal according to different stretching machine types and technology types In addition, default stretch forming simulation settings are provided for each type of stretch forming according to different parameters of the stretching machines
LS-OPT optimization is mainly used to optimize the Blank outline, Lubricant, Binder Press and Line Bead Force The user only needs to do simple set-ups, and the program will automatically calculate an optimized and proper parameter value, which allows the user to refer to the result for optimized parameter
The major improvements include:
• Added a new function ‘Auto-Position’, to automatically position the blank and tools for multi-stages
• Added the ability to position models with vertical walls
Trang 17• Added the ability to calculate the binder travel by automatically filling the binder
• Add the ability to support multi-stages in Blank Development
• Added the ability in ‘Blank Development’ for half of the blank
• Added the ability in ‘Blank Development’, to support a blank which is not in X-Y plane
• Added a new function ‘Trim Line Development’, using iterative approach to develop a trim line in the trimming stage, where the final result matches the defined target line
• Improved the parameters of the ‘Accurate’ and ‘Fast option’ in the Control page of ‘Sheet Forming’
• Added the ability to show the rotate center when transform blank in multi-stages
• Added the ability to auto move the blank to the current stage when displays the preview animation
• Added the ability to automatically move the blank to the current stage when switching to another stage
• Added the ability to tip the blank around the specified rotate center in Tool Position
• Added the ability to export and import the result of the theoretical equation in ‘Line Bead’
• Added the ability to allow the user to set the specific material’s relation between the draw bead shape and full lock force percentage in the ‘Draw Bead Shape Library’
• Added the import function in the Trimming stage, allowing the user to import a trim line
• Added a function “Replace current tool function’ in Preparation, allowing the user to import the tool geometry to replace geometry and elements of the selected tool
• Added rubber materials:
*MAT_027/*MAT_MOONEY-RIVLIN_RUBBER;
*MAT_077_O/*MAT_OGDEN_RUBBER;
*MAT_127/*MAT_ARRUDA_BOYCE_RUBBER
• Added the ability to support Pre-Bending in Gravity
• Added the ability to run a gravity simulation by specifying the height from the ground
• Restored ‘Stroke vs Force’ in the ‘Process’ dialog in ‘AutoSetup’
• The new ‘Hot Forming’ module was added in AutoSetup, removing thermal analysis from
‘Sheet Forming’
• Added the ability to support full process of Hot Forming: Gravity, Hot Forming and Press Hardening
• Added the ability to support the thermal gravity loading simulation
• Added the ability to support thermal thick shells for the tools (TSHELL=1)
• Changed the default friction coefficient to 0.46 for hot forming
• Added the ability to define the initial temperature for both the blank and the tools
• Added the ability to support *DEFINE_TABLE_3D for *MAT_106/*MAT_244
• Combined ‘Tube Forming’ and ‘Tube Rotary Bending’ into one menu ‘Tube Bending/Forming’
Trang 18• Added the ability to preview the tube bending process in ‘Tube Rotary Bending’
• Added the ability to preview the tools movement in ‘Tube Rotary Bending’
• Added the ability to use the solid elements tube for ‘Tube Forming’
• Added a new ‘Tube Generator’ to create tube with defined parameters in ‘Tube Forming’
• Improved the 2D trimming and 3D trimming in Utility Batch
• Fixed a bug in Refine Mesh in Utility Batch
• Added the ability to save the SPC in trimming result for Utility Batch
• Added the ability to refine mesh in Lancing of Utility Batch
• Added the ability to trim the tailor welded blank in Utility Batch
Blank Generator
The Blank Generator is used to generate the blank needed in the forming analysis It allows the user to import the blank surface or blank outline generated by external tool software Alternatively, the user can also directly import the blank outline generated with BSE module Meanwhile, the Blank Generator also provides the Generate and Edit function for the powerful blank outline, which allows the user to plot and modify the blank outline conveniently Various mesh generation tools are also provided by the Blank Generator, which is used to generate the blank mesh needed in different analyses, including shell elements, thick shell elements and solid elements It allows the user to define and edit tailor welded blanks and auxiliary holes quickly and easily The Blank Generator integrates the curve, surface and mesh tools into one, which greatly satisfies the blank design for the forming analysis
The major improvements include:
• Added the ability to create solid elements for a taper blank
• Added the ability to calculate the blank mesh size with the selected fillet surface
• Added the ability to create the blank outline with the selected blank surfaces
• Added the ability to create two laminated blanks
• Added the ability to support the positioning for the two laminated blanks onto the tools
• Added the ability to change the boundary nodes number by dragging the mouse in ‘Part Mesh’
• Added the ability to create a tailor welded blank in Quick Setup
• Added the function to create 6 lines and 8 lines solid mesh
Updated Drawbead function
This module contains “Line Bead” and “Geometry Bead”, which can be easily converted to each other The user may define the drawbead curve through selection, import, create and also define the lock force of a drawbead using four methods.One of the methods is to calculate drawbead force according
to section shape, which is very convenient, and the defined section shape is relating to the geometry bead The line bead can be imported and exported.All operations in drawbead generation, including
Trang 19property definition, modification and project can be easily performed without advanced training.Geometry bead is utilized to create geometry bead mesh according to the defined section shape It automatically reads in the information of line bead for the creation of geometry mesh model The user may also import the curve directly to define geometry bead High quality surfaces will also be generated when generating mesh model
The major improvements include:
• Added the ability to export and import the result of the theoretical equation in ‘Line Bead’
• Added the ability to allow the user to set the specific material’s relation between the draw bead shape and full lock force percentage in the ‘Draw Bead Shape Library’
SCP module
Springback Compensation Process (SCP) is used for die compensation of sprung sheet metal parts Springback is known to be a crucial issue for the sheet stamping industry The springback compensation based on finite element technology is utilized to alleviate the severity of springback phenomena SCP is used to modify the original die face in a direction opposite the springback and by a scaled magnitude generated from the springback simulation to ensure part dimensions fall within the tolerance of the intended part design after springback The SCP module in eta/DYNAFORM also provides some practical tools for the user to repair the compensated die face and improve the efficiency for die face design
Improved functionality of D-Eval module
The eta/DYNAFORM-D-Eval module, Die Evaluation, has been developed to generate Die to support early stage die design With the D-Eval module, the user can import the part model and complete the whole process design quickly The major improvements include:
• A new ‘Report’ function in ‘Die Simulation’ was added, allowing the user to generate a formability report and check the formability result
• Two new simulation types were added: ‘Single Spring Bend’ and ‘Double Spring Bend’
• Added the ability to deactivate the specified buttons
Enhanced BSE module
Blank Size Engineering (BSE) is used to generate the blank outline, product trim line and stock layout for the blank, which provides more concisely and more easily operated user interface for the user MSTEP is improved to estimate forming capabilities during the part design stage while allowing the user to predict the blank size quickly and precisely, and it gives the formability report of the product after solving The solving for the product trim line allows the user to obtain the trim line of complicated parts quickly The improved nesting function will optimize the nesting result For nesting
of complicated parts, the nesting result yields higher material utilization rate and more practical nesting pattern Batch MSTEP and Batch BSE modules allows the user to perform quick batch operations on multiple parts and output reports
The major improvements include:
• Added an Excel format option for the Nesting Report
• Added a default option for nodal result or element result with nodal result
• Added a default button in the Formability Report window, to recall the saved default configuration settings after making changes to the options for the specific cases
• Added the ability to tip the curve binder with the Sheet part
Trang 20• Added the ability to re-space the outline in ‘MSTEP’
Die System Analysis (DSA)
The Die System Analysis module provides a set of solutions for solving practical problems encountered in part production Finite Element Analysis is utilized to efficiently predict possible problems in a die design and within the die production line to optimize the design of the die structure and the production line This could greatly reduce tryout time and lower the development cost of new products The Die System Analysis module includes Die Structural Integrity (DSI), Scrap Shedding Removal (SSR) and Sheet Metal Transferring and Handling (SMTH) In all the analyses of the DSA module, the program provides simple graphic interfaces to guide the user through execution of complicated preparation and simulation processes
Enhanced Pre-processor functions
• Added the ability to refine mesh in ‘Element Trimming’ and ‘Element Lancing’
• Added the ability to select elements or surfaces by dragging window
• Added the ‘Expand’ function in ‘Tool Preparation’
• Improved the selection method in ‘Auto Fill’, where all the inner holes no longer selected by default Users must select the inner holes for filling
• Added the ability to split the line by UV-plane
• Added a new function ‘Check Free Surface’ to extract the free surfaces of the solid elements
to generate the shell elements
• Added the display option in ‘Deviation Check’, allowing the user to specify the range of deviation value
• Added the ability to turn off the mouser operation message
• Added the ability to print the read failure message from the log file
• Added the ability to save the defined mesh parameters in ‘Tool Mesh’
• Added the ability to display the node or the element result in Blank Operation/DYNAIN Contour
• Added a ‘Normal’ option in Position Tools/Min Distance, to measure the minimum distance between two selected tools in the normal direction
Enhanced Post-processor functions
• Fixed a bug in reading the dynain solid element data
• Fixed a bug in reading the d3plot hot forming history variables
• Added the ability to export ‘Contour Value’ as CSV file
• Added the ability to support minimum/maximum marks in element result contour plot
• Added undeformed shape color configure, accessed by File->Edit Default Config->DRAW SETTING
• Moved the menu item ‘Edit Default Config" from the ‘File’ menu to ‘Option’ menu
Trang 21• Added the EFLD function in the FLD dialog for the d3plot result
• Added a ‘Show Stone’ option in ‘Stoning’ dialog, plotting the current stone symbol when activated
• Added a ‘Show Mark’ option in the ‘Stoning’ function
• Set the default value of ‘Arrange List by Value’ (in List Table dialog) to ON
• Added ‘User Define Contour’ in the system configuration setting dialog When on, the current user defined contour setting will be saved to system home directory after exiting eta/Post
• Extended the opening file length limitation to 1024
• Added the ability to export the E3D file for the FAS result
• Fixed the temporary path problem when exporting pdf file
Enhanced Job Submitter functions
• Added the ability to submit a job with Job Submitter in DYNAFORM
• Added the ability to allow the user to define NCPU (No of CPUs) in AutoSetup
• Added the ability for the user to define IFORCE (interface force) in AutoSetup
• Added an option to delete the adaptdmp file
• Added an option to output d3dump or not
• Added the ability for different users to open multiple-processes of Job Submit
The step-by-step procedure guides users through the complete process and flow of tasks A new user can usually complete the training program and be ready to begin a production project in less than two hours
An Applications Manual discusses the basics of the sheet metal forming process and provides fundamental knowledge of tooling design and related topics to the user The following are typical examples of simulations that are included to demonstrate eta/DYNAFORM’s capabilities, features, and functions:
Case 1 NUMISHEET’2002 Fender Draw Simulation Case 2 Double Action of Solid Element Simulation Case 3 Springback and Springback Compensation Simulation Case 4 Tube Bending and Hydroforming Simulation
Case 5 Multi-StepRotary Bending These workshop examples enable users to fully understand general pre- and post-processing
Trang 22For further details about LS-DYNA, please refer to the LS-DYNA Keyword User’s Manual published
by the Livermore Software Technology Corporation (LSTC) of Livermore, California
Trang 23Chapter 1 STRUCTURAL OVERVIEW
eta/DYNAFORM is a complete Graphic User Interface (GUI) package operating on Windows (XP and above) and on UNIX/Linux based workstations (W/S) including IBM, HP, DEC-Alpha, SGI and SUN-SOLARIS platforms The model generation and input file preparation of a typical stamping simulation are performed in the eta/DYNAFORM preprocessor, while the stamping simulation result
is processed in eta/POST Please refer to the eta/POST User’s Manual for detailed information The solver, LS-DYNA can be executed on either local or remote server systems
eta/DYNAFORM is organized as a tree structure and is operated and controlled by the user-friendly GUI The environments are unified on both Windows and UNIX platforms
1.1 MENU BAR
Figure 1.1.1 eta/DYNAFORM menu
As illustrated in Figure 1.1.1, eta/DYNAFORM menus are selected by mouse pick and contain a wide variety of functions Descriptions for these functions are located in their respective sections
FILE MANAGER Imports/exports data to/from eta/DYNAFORM
PART CONTROL Organizes Parts (or layers)
BSE Blank Size Engineering includes a modified one-step-based unfolding
function, blank development and nesting function
D-Eval Die Evaluation provides tools to quickly derive a suite for Die
Simulation
AUTO SETUP The AutoSetup menu consists of Preparation, Sheet Forming, Rotary
Bending, Tube Forming, Roller Hemming and Superplastic Forming
QUICK SETUP
QuickSetup GUI is designed as a streamlined, user-friendly and fully automated interface It offers contact offset algorithm in the stamping simulation
USER SETUP
This module provides functions to create and edit line, surface, element and node geometry; check and repair mesh model; create, define and modify tooling; define blank, material and property Define the control parameters, boundary conditions, and submit job for analysis
Springback compensation analysis enables the parts after springback to meet the design requirements of final products
Trang 24DSA This module is utilized to analyze die structural strength and fatigue,
check scrap shedding and sheet metal transferring
POSTPROCESS Initiates eta/POST for post-processing analysis results
OPTION Contains various options to control the mesh criteria, file window
style, material library and language setup
UTILITIES Includes several supplemental functions for identifying entities,
measurement and load curve generation
VIEW Controls the display of the items and view angle on the screen
HELP Displays the version level, contact information and license
management for eta/DYNAFORM support and Online Help (F1)
1.2 ICON BAR
The icon bar is designed to provide the user easy access to the most commonly used functions of eta/DYNAFORM The user can click on these icons to activate the functions instead of browsing the various menus An illustration of the icon bar is shown in Figure 1.2.1
Figure 1.2.1 Icon bar
Trang 25to printing, the postscript driver must be initialized to accommodate eta/DYNAFORM software
TURN PARTS ON/OFF
Turns the selected parts ON or OFF The Turn Part On/Off dialog window is displayed to select parts
DELETE ALL UNREFERENCED NODES
Deletes all nodes that there are not associated to elements
Trang 26function, click once on the left mouse button This function can be initiated by simultaneously pressing the <CTRL> key, clicking, and holding the middle mouse button, followed by moving the mouse cursor Release the middle mouse button to dismiss the function
CURSOR ZOOM
This function enables the user to reduce or enlarge the apparent size of a model or selected region on the display screen To zoom to a selected region, select the Cursor Zoom button and position the mouse cursor at the desired region Then, click and hold the left mouse button, followed by moving the mouse cursor up or down Release the left mouse button to dismiss the function This function can be initiated by simultaneously pressing the <CTRL> key, clicking, and holding the right mouse button, following by moving the mouse cursor up or down Release the right mouse button to dismiss the function
WINDOW ZOOM
This function enables the user to enlarge the apparent size of a selected region of a model on the display screen The user defines the corners of the zoom window by positioning the cursor on the display screen Then, clicks the left mouse button and drags the cursor diagonally to obtain the desired window size The entities included in the zoom window will be fully displayed on the screen after the left mouse button is released
FREE HAND ZOOM
This function is similar to window zoom Instead of using a drag window, the user defines a free region by pressing the left mouse button and dragging the mouse cursor on the display screen The entities included in the defined region will be fully displayed on the screen after the left mouse button
is released
ACTIVE WINDOW
This command allows the user to isolate a portion of the displayed geometry/model for more detailed viewing or editing The user defines the region by dragging a window on the desired area eta/DYNAFORM displays the elements, lines, and surfaces within the window (volume in space) as active Other objects on the screen remain masked and inactive
Trang 28with the appropriate functions is displayed in this area
Display Control option is used to control the display of the model This group of commands will be displayed during an eta/DYNAFORM session
Display the eta/DYNAFORM prompts and messages It enables the user to copy the selected messages to the clipboard by pressing CTRL+C
Figure 1.3.1 Interface of eta/DYNAFORM
1.4 DISPLAY OPTIONS
The DISPLAY OPTIONS window, as illustrated in Figure 1.4.1, is located at the bottom right corner
of the display screen It displays the current part and contains the following commonly used functions
Trang 29Figure 1.4.1 Display Options
CURRENT PART
This function enables the user to set the current part It is very important to set the current part in the eta/DYNAFORM because most of the results generated from the different functions will be stored into the current part by default The user can click on button to change the current part After clicking the button, the system will pop up a Current Part dialog box, as illustrated in Figure 1.4.2 The user can choose one of the parts as the current part The current part name will be displayed in the text box to the right of the Current Part button
Figure 1.4.2 Current part dialog box
Trang 30Figure 1.4.3 Shrink Elements
NORMAL (toggle)
This function enables the user to display the normal direction of each element with an arrow at the center of the element and perpendicular to the surface of the element For a solid element, the arrow points toward the bottom surface of the element See Figure 1.4.4
Figure 1.4.4 Elements Normal
If the user toggles on the Plate Normal (Color) in the View menu, the direction of positive element normal will be displayed using part color and gray color for negative normal direction See Figure 1.4.5
Trang 31a) with arrows b) with colors
Figure 1.4.5 Display of elements normal direction
FILL COLOR (toggle)
The Fill Color function fills displayed elements with a designated color The function is unable to accurately represent the depth perspective of a model The displayed part may appear to warp or penetrate other parts However, the Fill Color command displays an accurate 3D model display of the parts when it is used in conjunction with the HIDE PLOT option
is used to cancel the last operation, such as creating a line, selecting nodes, surfaces, elements or coordinate system These three buttons can also be used with <CTRL>, <ALT> and
<CTRL>+<SHIFT> keys respectively for rotation, translation and scaling For complicated models, eta/DYNAFORM provides the point cloud mode and Feature Line mode to accelerate the model display
Control key Left button Middle button Right button
ALT Rotation (Point cloud) Translation (Point cloud) Scaling (Point cloud)
Trang 32LINES 150,000
LENGTH OF PART, MATERIAL,
The large version of eta/DYNAFORM has the following specifications for PC and UNIX/LINUX based workstations per database:
1.7 GEOMETRY DATA
eta/DYNAFORM directly reads in IGES, VDA, STEP and eta/DYNAFORM/FEMB geometry data
(line and surface) It also directly reads in CATIA4 & 5, Pro/E and NX files with native libraries
Trang 331.8 RECOMMENDED NAMING CONVENTION
The protocol for naming files during an eta/DYNAFORM session includes attaching suffixes that specify the file types to the file names The appropriate file names are listed in the options area of the display screen
Examples of suffixes include:
eta/DYNAFORM database file name: filename.df
eta/DYNAFORM geometry data file name: filename.lin
IGES geometry data file name: filename.igs or filename.iges
VDA surfaces data file name: filename.vda or filename.vdas
AutoCAD Data Exchange file name: filename.dxf
Stereo lithography file name: filename.stl
CATIA4 database file name: filename.model
CATIA5 database file name: filename.CATPart
Pro/E database file name: filename.prt or filename.asm
Inventor database file name: filename.ipt
Parasolid database file name: filename.x_t
SolidWorks database file name: filename.sldprt or filename.sldasm
NASTRAN input file name: filename.nas or filename.dat
LS-DYNA input file name: filename.dyn
LS-DYNA model file name: filename.mod
Trang 34Cancel is clicked The user may also select multiple files in the dialog box and click OK to import them to the database in sequence
This practice simplifies file name selection and organizes the user’s work directory
1.9 DIALOG BOXES
eta/DYNAFORM incorporates various dialog boxes to execute functions throughout the program
At the bottom of the dialog boxes there are buttons to execute, reject, reset the data or close the dialog box The functions of these buttons are listed below
the next step
OK Accept the data in the dialog box and forward the user to the next step
1.10 PROPERTY TABLES
The tables in eta/DYNAFORM allow the user to modify properties of materials, elements, draw beads, etc For example, the material window as shown in Figure 1.10.1 enables the user to edit material properties such as K, n, R00, R45, R90, etc
Trang 35Figure 1.10.1 Material Type 36 Window
DEFAULT – Set all fields to their default values
RESET – Reset the last altered field to its previous state
OK – Accept the currently displayed values and exit the table
CANCEL – Exit the table without entering any altered values
The data fields in the table can be edited using several different methods: 1 Click the mouse button to insert the cursor at a specific point in the data field 2 Click and hold the left mouse button, followed
by dragging the cursor to highlight a selected portion of the field 3 Double click left mouse button to highlight the entire data field Keystroke entry then inputs the new value New values will be recorded
in the table All the parameters are shown in deck At the bottom of the table the Default, Reset, OK,
and Cancel buttons allow the user to accept or reject the data
1.11 CONFIGURATION FILE
Four configuration files (dynaformdefault.config, dynaformhardcopydefault,
dynaform_menu.config and dynaform.ini) are created to set all the control parameters By default,
these files are located in the user's directory, for example, C:\Documents and Settings\Andy\
Application Data\ETA\Dynaform5.9.2 (Windows XP), C:\Users\Andy\AppData\Roaming\ETA\ Dynaform5.9.2 (Windows 7) The files are located in the user's home directory on UNIX/Linux, for example, /home/Andy/ETA/Dynaform5.9.2 The modification of the first three files may require
Trang 36“Keyword value permission key”
The user can modify the default settings of most parameters related to a stamping simulation
dynaformhardcopydefault controls the default print settings The format of each control parameter
is listed as the following:
“Keyword value”
The user can modify the default settings of most printing parameters
dynaform_menu.config controls the access privilege of the eta/DYNAFORM menu The format of
each control parameter is listed as the following:
“Keyword value”
The super-user can control whether the user is allowed to define the access privilege of the menu according to the command below:
Allow user to config menu: No <Yes or No> If Yes is selected, the user is allowed to define the
access privilege of the menu; otherwise, the defined access privilege of the menu is invalid
dynaform.ini is provided to save customized settings in the database or in the user’s home directory
The format of each parameter is listed as the following:
#DYNAFORM configure file
#[keywords] value
#[FILE_DIALOG_STYLE]: 0 - WINDOWS style, 1 - UNIX STYLE
#[SYSTEM_LANGUAGE]: ENGLISH,CHINESE,JAPANESE,KOREAN and so on
#[AUTOBACKUPTIME]: <=0 - don't autobackup, >0 - backup time( minutes )
#[AUTORESTART]: 0 - don't autorestart, 1 - autorestart
Trang 37C:\Documents and Settings\Andy\My Documents\
Comment lines start with ‘#’
[FILE_DIALOG_STYLE] Determine the default style of file dialog There are two file dialog styles
(Windows and UNIX) under Option/File
[SYSTEM_LANGUAGE] Define the default language for the GUI eta/DYNAFORM currently
supports four types of languages There are Chinese, English, Japanese and Korean
[MATERIAL_LIB_TYPE] Define the default material library eta/DYNAFORM provides four
different standard material libraries
[FADE_BACKGROUND] Determine whether to show a faded gradient background for graphic
display area or not
[BACKGROUND_TOP_COLOR] When displaying the Fade Background, set a color for the top of
graphic display area If only a unique background is displayed, set a background color for the entire graphic display area The background color is in RGB format
[BACKGROUND_BOTTOM_COLOR] When displaying the Fade Background, set a color for the
Trang 38[LAST_IMPORT_PATH] When importing or exporting a database, eta/DYNAFORM will
automatically identify the last import or export database path
[LS-DYNA_SOLVER_S] When submitting to LS-DYNA for calculation directly after setting,
eta/DYNAFORM will search for the Single Precision Solver from this path
[LS-DYNA_SOLVER_D] When submitting to LS-DYNA for calculation directly after setup,
eta/DYNAFORM will search for the Double Precision Solver from this path
[ETA-POSTPROCESS] When switching from Pre-processor to Post-processor, eta/DYNAFORM
will search for the Post-processor from this path
[AUTOBACKUPFILE] Define the backup file name
[AUTOBACKUPTIME] Define the time interval between automatic backup files
[AUTORESTART] Post-process can be initiated directly from eta/DYNAFORM If the value is 1,
the database (*.df file) will be restarted automatically after eta/POST interface is closed
[LAST_DBFILE_NAME] Record the last opened database file
[MATERIAL_PATH] Specify the User Define Material path
Trang 39Chapter 2 GETTING STARTED
eta/DYNAFORM is organized into four major modules, a formability simulation module (FS), a blank size engineering module (BSE), a die evaluation module (D-Eval) and a die system analysis module (DSA) All modules can be executed independently from eta/DYNAFORM interface
2.1 GETTING STARTED
An eta/DYNAFORM session begins with one of the following scenarios:
1 The user provides CAD data (IGES, VDA, NX, CATIA or any other geometry data) that will
be translated and read directly into eta/DYNAFORM database
2 The user provides FE model data (e.g NASTRAN, LS-DYNA, etc.) that will be read directly into eta/DYNAFORM
3 CAD or FE model data are not provided The user begins with a blank database and generates or digitizes the line and surface data from a drawing
Note: An example of a method of supplying or generating data is outlined in Sections 2.2-2.4
Usually, a stamping simulation includes the following steps
2.2 STARTING WITH CAD DATA
The user begins a session by entering eta/DYNAFORM executable, such as “dynaform”, “df5921”, etc., at the UNIX prompt For Window/LINUX, the user can double click on the eta/DYNAFORM icon from the desktop or select eta/DYNAFORM from program menu Once the program is activated,
a default database named Untitled.df is created
2.2.1 STARTING WITH CAD SURFACE DATA
The user can read in surface data via the command File/Import The user can choose between IGES, VDA, Line data, NX, CATIA and other geometry file types
Note: If IGES is selected, files having the suffixes igs and iges will be listed in the menu area Please refer to Section 1.8 for more information about file types
If LINE DATA is selected, files having the suffix lin will be listed
2.2.2 STARTING WITH CAD LINE DATA
By using the line data, the user can create models via the UserSetup/Preprocess menu The functions
in this menu can be used to create a 2-, 3-, or 4-Line Mesh directly from the line data In addition, lines can be used to generate surfaces using the surface option menu (Surf) located in the UserSetup/Preprocess menu The created surfaces can be auto meshed via the Surface Mesh command found in the Element option menu (Elem) The line data can be imported to eta/DYNAFORM database using the File/Import command
Trang 401 To read an LS-DYNA (or other analysis code) data file into eta/DYNAFORM database, select File/Import
2 Select the button to the right of Files of Type: in the displayed dialog box and choose the desired file format from the drop down menu
3 Once the selection is made, the program will read the LS-DYNA input file into eta/DYNAFORM database
4 At this point, the display can be manipulated via the commands in the Menu Bar and the Display Options area
2.4 GETTING STARTED FROM SCRATCH
This section will help users getting started in eta/DYNAFORM when line data or FE model data is unavailable The user will typically generate his/her own line data according to the following procedure:
• Create a new part in the Parts menu
Lines or meshes cannot be created in an empty database, so a default part (PART000) is created by default in a new database
• Generate line data by its coordinates Refer to Section 5.1 for additional information on generating lines
1 Exit the Parts menu
2 Enter the UserSetup/Preprocess menu
3 Select the Create Line command
4 Select the LCS or ABS option for the coordinates in the current local or global coordinate system Refer to Section 2.5, Local Coordinate System
5 Select the XYZ or DXYZ option
If XYZ is selected, the keyed-in values of U, V, and W are the coordinates
If DXYZ is selected, the keyed-in values of DU, DV, and DW are increments from the previously created point
6 Key in the corresponding values in the field
7 Select Apply Input Value to confirm the values and create the point
The prompt asks for the coordinates until the user selects either OK or Cancel from the options area of the display screen
eta/DYNAFORM lines consist of multiple points Using the OK command will create
an end to a current line
Note: The user may continue to generate line data or execute the other CAD functions available in the Preprocess menu Generating FE model data from line data is described in Section 5.3, Element
Once the desired geometry has been created and meshed, the user can define each part as a specific tool (e.g a die, punch, upper/lower ring) via the UserSetup/Define Tools menu In the