DF5.9.2.1_OP_Trainin..
Contents
1. Lower Binder Force Lance 0 Trim 0 Advanced Help Apply Unde Preview Submit Job e por Eyit HI DEFINE TOOLS The parts LOWTOOL and BINDER are meshed and can be defined as the Binder and Lower Tool respectively To define the Binder 1 Click the Binder button and then select the Select Part button from the Define Tool dialog window eta DYNAFORM Training Manual 21 INCSOLVER SETUP Define Tool I Mesh Check Repair EXIT DONE ABORT 2 Add from the Define Binder window Define Binder Display 3 Select the part name from the part list BINDER 22 eta DYNAFORM Training Manual INCSOLVER SETUP Select Part Select by Cursor select by Name BLANK Exclude Total selected 1 Displayed All Parts Reject Last Part Repeat the same procedure to define the Lower Tool Once both tools have been defined the color in the INCSolver window will be changed to green as shown in the following picture eta DYNAFORM Training Manual 23 INCSOLVER SETUP INCSolver OO Draw Type single action Inverted draw Lower Tool Available Blank Part Material Thickness I Blank Parameters Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Lower Binder Force Lance 0 Trim 0 Advanced Help Apply Undi Preview Submit Job e por Eyit IV DEFINING THE BLANK MATERIAL AND TOOL CONTROL Click the Blank button fro2. 5 000 Delete Modify Show C Draw Bead M Lock Force Percentage Color by Property he Nodes l Define Box Size 100 l Show Box eta DYNAFORM Training Manual 31 INCSOLVER SETUP 32 58 83 15 58 83 14 56 0 Bb 50 0 V 83 58 87 58 83 10 50 0 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 Lock tool Part _BNDRO000 Remove Once the sheet is defined the program will calculate the full lock force We can set force Percentage for each draw bead respectively according to the flowing condition of material Select the first drawbead and input the percentage 40 eta DYNAFORM Training Manual INCSOLVER SETUP File I List by Property Current Referto LinelD 31 50 05 Drawbd 9 50 05 Drawbd 10 50 0 Drawbd 11 50 C Drawbd 12 50 0 Drawbd 13 50 C Drawbd 14 50 0 15 50 16 50 07 Type Constant Force w Force 51 1 436 Default Percentage 140 0 Lock Force Definition k Add Delete Modify J l Draw Bead W Lock Force Percentage Color by Property he Nodes l Define Box Size 200 l Show Box 7 Repeat the above operations to set force percentage for each drawbead respectively Percentages for all drawbeads are set to 40 8 Click Exit to exit the Drawbead dial
3. Some regions are crack and it is unacceptable in actual engineering Then next step is to Proceed to section Optimization with SHERPA for optimization 40 eta DYNAFORM Training Manual POST PROCESSING with eta POST Hama Deform Operation Undeform Scale Factor E 0 Frames Single Frame Y Reset 44 961548 a 38 921021 34 960083 28 055542 24 961914 19 961792 17 193237 14 963379 9 963562 6 356873 4 960083 2 961914 0 962036 0 000000 10 32 Frames Second 20 m Y ETA POST CHECKING FRAME 29 CHECKING FRAME 30 CHECKING FRAME 31 CHECKING FRAME 32 COMMAND COMPLETED Shade MV Smooth Shade Material Color Fill Color Element Edge Shrink Hidden Surface Plate Normal M Background FRAME 32 STROKE 0 000000 FLD middle layer CRACK RISK OF CRACK PART BLANK 1 3 Dey s SAFE WRINKLE DENCY RINKLE SEVERE WRINKLE INSUFFICIENT STRETCH ETA POST eta DYNAFORM Training Manual 4 OPTIMIZATION OPTIMIZATION As shown above the forming result is not good and we need to modify the forming parameters to get a better result In the forming process the line bead force is an important factor So in this case we mainly illustrate how to optimize the drawbead and the blank outline lubricant binder press force are similar with that of the drawbead Before entering the Optimization interface the user should complete the formin
4. r etc from FLD Curve Option 4 Select Edit FLD Window to define location of FLD plot on the display window 5 Click Play button and the animation will begin 6 Click Stop button 38 eta DYNAFORM Training Manual POST PROCESSING with eta POST MIDDLE 4 J E j L UT Fu LI LI CS Go I j Ce oo tal J L Li M I I F a Li J en th e to E LT oo J I I LT yo am 1 co i LT Ci Iw 1 i 130 31 1 i 1 ho hi Em Els can co 1O 104 1 11 HI PLOTTING SINGLE FRAMES Sometimes it is more convenient to view single frames rather than the entire animation To do this select Single Frame from the Frame combo box Then select with your mouse the frame you would like to view from the frame list Users can also drag the slider of frame number to select the frame accordingly eta DYNAFORM Training Manual 39 POST PROCESSING with eta POST Frames Single Frame q 274 953339 d 250 733780 de 219 439987 4 158 149946 5 156 8656247 6 130 310913 de 125 790923 o 124 962200 g 114 967712 10 104 101074 11 99 963867 12 93 241021 From 1 To 32 P Il H dll Frame Mumber 1 mer FramEesiSecond 20 IV CHECK THE FORMING RESULT In this step we check the forming result based on the FLD plotting Turn off all parts except BLANK part and then plot the last frame as shown below The formed result will be displayed as shown below
5. the crack split area is significantly reduced as shown on the forming limit diagram FLD eta DYNAFORM Training Manual 53 MORE ABOUT eta DYNAFORM 5 9 2 1 MORE ABOUT eta DYNAFORM 5 9 2 1 The eta DYNAFORM 5 9 2 1 configuration file is located under both the installation directory and My Documents directory Inside the eta DYNAFORM 5 9 2 1 installation directory there is a file called dynaformdefault config Many key default parameters are included in this file When the user opens eta DYNAFORM 5 9 2 1 for the first time the program will automatically create a file called dynaformdefault config under My Documents directory The configuration file locates in the My Documents directory of the current user s PC for example C Documents and Settings Andy My Documents ETA DynaformS 9 2 Windows XP C Users Andy My Documents ETA Dynaform5S 9 2 Windows 7 The user can open this file and change these default parameters or click Option gt Edit Default Config from Menu bar to edit these default parameters in the dialog box The modified default values in the dialog box will be saved in the configuration file under My Documents directory The configuration file under My Documents directory will take precedence over the one under the installation directory For UNIX Linux users the dynaformdefault config file is located under both the installation directory and the user s home directory home Andy ETA Dynaform5 9 2 The dynaformdefault co
6. the left side of the Element s button as below topat BINDER Apply Close 10 Click Apply and all selected elements are moved into BINDER 11 Turn on only BINDER and display the part using Top view The program displays the result as the following If the result differs repeat the above steps eta DYNAFORM Training Manual 19 INCSOLVER SETUP ETA OYHAPORA 12 Save the changes Il INCSOLVER INTERFACE 1 Select the OP menu OP INCSolver fF f ie ere Tift T i si ah a i Tt oe oor bee Ifggeds tf F it oe E i oanh a ETU ea i i f IJ I f a f dE I NARR El dpa kchik 1 ia TIRAR HiHi i J oT aren LD H pitti File Parts BSE D Eval AutoSetup QuickSetup UserSetup SCP ES PostProcess Option Utilities View Help INCSolver Optimization Result Viewer 2 As shown in the following the INCSolver menu the undefined tools are highlighted in red The user needs to select the draw type and available tool first In this application the draw type is Single action or Inverted draw The available tool is the lower tool 3 Define the blank and tools by clicking the appropriate buttons 20 eta DYNAFORM Training Manual INCSOLVER SETUP INCSolver OO Draw Type single action Inverted draw Lower Tool Available Blank Blank Parameters I Part Material Thickness Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00
7. INC Drawbd_9 Deper INC Dravbd 1 INC_Drawbd_10 Deper w INC_Drawbd_4 INC _Drawbd_11 Deper w INC_Drawbd_4 40 0 INC_Drawbd_12 Deper INC_Drawbd_4 40 0 INC Dravbd 13 Deper INC_Drawbd_1 40 0 INC Dravbd 14 Deper VlINC Drambd 4 40 0 INC Draubd 15 Contir vl5 80 40 0 INC Dravbd 16 j Deper w l INC Drawbd_5 40 0 Hel Te i i 4 Change the variable range The range is the multiple of 5 to 5 80 5 The baseline is just the defined bead force value in INCSolver and it is not modified here HI DEFINING RESPONSES When variable definition has been completed we need to define the responses for variables The Response is the output file which includes the variable performance Aa eta DYNAFORM Training Manual OPTIMIZATION Responses Global RiskofCrack Add ar WrinkleTendency Remove Wrinkle SevereWrinkle ae Insuf Stretch Thinning Add C Crack T 1e 007 C Safe Allowable Thinning 120 0 MM Active 1 Select Crack and Safe from the Responses list For the simulation we mainly focus on the Crack and Wrinkle like Performance in output file 2 Click the Add button to add these two responses as the Objective Use the default option and normalizing factor This operation will build the link between variable and response 3 Click the Add button below to add Constraints for responses Set the Safe constraint Limit to 99 and others just use the de
8. rrr 16 I Detinethe Binder fromthe Lower TOOlmcenaiaamnsmssssmesatsessasansmssontasmtasm mans mesa 16 DE INC SOR ERC IC El ICE tecessoopiemttamemoam st mmesmntam as asttan atac mtantasentatantetestattemta 20 IE De o omseostentesonesoseomemodsmsonest sions ysimynontysioyontosemenotostomen et 21 IV Defining the Blank Material and Tool Control cc ccccccccccceccceeeeeceeecaaeeeeeeeeseeeeeeeeeeeeeeeseeaeaaaaeeeeeees 24 Ne Deine DAW DE i ear E E E E E AE E E 28 ML SUD OIE JO D a E E E E T EE 34 FOST PROCESSING vith Cla POST cnniconiestiniticonnaininninunniennednerenceiin 36 I Reading the Results File into the Post ProcessoP cccccccccccccececccecceeeeeesssseeeeeeeceeeeeeeeeeeaeaeaeeeseees 36 uU Naa ea TTL a E E E E 38 HL Plone smoes E 39 IV Check the Oro Restless iei an a a a a a a ar a aa 40 OPO LC OM aaa ace sen sceitsvnecacesiswanetaveusasisoscseuisere ciueisucaesayseascasusersetasensceversaenessessaasestecsseiaeeases 42 I Entering Optimization Interface cece ccccccccccccceceeeeeeeeeeseeeeeeceeeeeeeeeeeeaaeaeeeeeseeeeeeeeeeeeeseeeeeaaaaaaeeeeeses 42 EL DC ano NO BCS sepr E E E tament tyemtquetammtmssmbbeem tema 43 DL Bonino TRS CONS oee E E inst tacte amat 44 EV UE OD n E del 45 Vs Review the Optimization Resi rsiccsicesiciacesaicdabetaiadiiatubad eae AEN EEE OEE a 46 VI Compare the optimized result with original result ccccccccccccccccccceeeeeeeeesseeeeeececeeeeeeeeeeeeaeeeeeessees 50 MOREABO
9. the eta DYNAFORM installation Locate two data files die lin and blank lin Then import both files and click OK to dismiss the Import File dialogue window eta DYNAFORM Training Manual I DATABASE MANIPULATION Pal nl X ETA DYNAPORA After reading in all of the data files verify the display looks the same as the illustration shown above The parts are displayed in the isometric view which is the default view setting of eta D YNAFORM Note Icons may appear different depending on platform Other functions on the Toolbar will be discussed further in the next section You can also refer to the eta DYNAFORM User s Manual for information about all of the Toolbar functions 2 Save the database to the designated working directory Go to Files Save as type optraining and click Save to dismiss the dialogue window 2 eta DYNAFORM Training Manual DATABASE MANIPULATION i Date modified T No items match your search Database Unit 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 Def
10. 01_ FORM FAS File Edit Tool Application Option Help Coia oi ISA CT c Deform Operation I Undeform Scale Factor fi 0 ab I i on amp wh dE BR 6 T EE 93 271118 82 404419 74 964722 ETA POST phai eae M Shade M Smooth Shade I Material Color COMMAND COMPLETED READ COLORBAR CONFIGURATION FILE T Fill Color Element Edge I Shrink PLEASE WAIT COMMAND COMPLETED I Hidden Surface Plate Normal MV Background VI COMPARE THE OPTIMIZED RESULT WITH ORIGINAL RESULT The next step is similar to the previous one about Post Processing We will introduce the main procedure to compare the optimized result with original one FLD Pick FLD from the result manipulation menu bar 50 eta DYNAFORM Training Manual Plotting Single frames eta DYNAFORM Training Manual All Frames V ha Cl LT Fa q LI 10 11 MIDDLE 4 l s LI La L cw 4 DM RE RE J mn oo oo oo Co Li ri I moc qu LS LM Fu LS LS ua LT LI Lil co i LT Li LT al bu rR PR H Pa i D 1 1 130 1 1 1 104 1 3 963867 OPTIMIZATION 51 OPTIMIZATION Frames Single Frame q 274 953339 d 250 733780 de 219 439987 4 158 149946 5 156 8656247 6 130 310913 de 125 790923 o 124 962200 g 114 967712 10 104 101074 11 99 963867 12 93 241021 From 1 To 32 Incr 1 P Il H dll Frame Mumber E FramesiSe
11. 6 Save your database 4 eta DYNAFORM Training Manual Name BLANK DATABASE MANIPULATION Name ILOWTOOL Color Note Designers often model only one surface of upper or lower die The other die face will offset from the mating surface In this case we suppose the surface is the lower tool And the upper tool will offset from the surface later So we give the part name LOWTOOL HI CURRENT PART All lines surfaces and elements which were created will automatically be placed into the current part When creating new lines surfaces or elements always make sure the desired part is set as current Note When auto meshing surfaces the user does have the option of assigning the created mesh to the parts that contain the individual surface data In other words you can keep the mesh in the original parts rather than have them all created in the current part This will be dealt with later 1 To change the current part click on the Current Part dialogue in the Display Options dialogue w Lines l Shrink Hidden w Surfaces Normal Fill Color w Elements w Nodes Shade Or select Parts Current on Menu bar Create tril P Edit Delete Add Ta Part Turn On Separate Transparent Summar 2 The Current Part dialogue window will be displayed eta DYNAFORM Training Manual 5 DATABASE MANIPULATION Current Part Select by Cursor 3 Similar to the Turn Part On Off window this window allows
12. 6000 Mode number is 4i 4h Again the eta D YNAFORM INCSolver interface is designed to help the user to quickly setup a standard draw simulation The user is encouraged to learn the traditional a more flexible way of setting up a draw simulation eta DYNAFORM Training Manual 35 POST PROCESSING with eta POST POST PROCESSING with eta POST The eta POST reads and processes all the available data in the d3plot file For more information about them please refer to efa post User s Manual In this case we will just read the fas file which is generated from INCSolver I READING THE RESULTS FILE INTO THE POST PROCESSOR To execute eta POST click Post Process from eta DYNAFORM menu bar The default path for eta POST is C Program Files Dynaform 5 9 2 1 In this directory double click the executable file EtaPostProcessor exe The eta POST can also be accessed from the programs listing under the start menu under eta DYNAFORM 5 9 2 1 The eta D YNAFORM Menu Bar D Eval AutoSetup QuickSetup UserSetup eee Option Utilities View Help 1 From the File menu of eta POST select Open The Open File dialogue will be displayed 36 eta DYNAFORM Training Manual POST PROCESSING with eta POST import Export Copy To Clipboard Print Print To File Reload Setting Uit Alt q dl H I sk Favorites Name Date modified Type Size EE Desktop optrainingO1 FORM FAS 2012 10 24 12 49 FAS File mi Downloads El Re
13. DYNAFORM Training Manual MESHING Select Line Select By Cursor I Exclude Part Reject There are 4 lines in the part BLANK Switch the way of Select Line to the fourth one Select the lines one by one by left clicking on them This Select Line dialogue window allows you to select the line s in different ways Place the cursor over each icon and button to identify its function 3 After selection Select OK to open BLANK MESH option dialog box 4 User can change tool radius to 3 This number reflects the tightest radii in the model The smaller the radii the finer the blank mesh a larger value will result in coarser mesh Blank mesh Shell ThickShell Solid Parameter Siz ToolRadius 3 00 Element Size 156 00 Thickness 1 OO OK Cancel 5 After you have entered the variable press OK and the program will automatically save the created blank mesh as another BLK part Compare your mesh with the following picture 6 Save the database eta DYNAFORM Training Manual MESHING el P a a EE a arrar Se ee el a edr id a a a a mt mt tt a ta a a a a a a a as a ll am ta a cata a at Data Est a gr ee dE eet ii El az re aTaTa zZ f in ETA DTHAPORA Il MESHING SURFACE DATA Most of the meshing done in eta DYNAFORM is carried out using the Surface Mesh function This function will automatically create a mesh base
14. Turn On Current Separate Transparent aummary ToPat BINDER J Apply Close 6 The Add To Part window appears as above Click the Element s button as shown above 7 The program displays the Select Elements window as shown in next page The easiest way to select all elements of the ring is to switch the view to the XY plane on the Tool Bar then select the Spread icon press and drag the left mouse button on the Angle Slider to set a small angle Since the Ring surface is flat set the smallest angle you can select e g 2 as one degree eta DYNAFORM Training Manual 17 INCSOLVER SETUP Select Elements 8 Click any element on the outer ring of LOWTOOL 18 eta DYNAFORM Training Manual INCSOLVER SETUP PATH tt Hi He FY aa a Re al Q KELIEN 4 t jill i COLL III ae Te op 23 gt K 4 j PTT TTP MV VVAARAR ARTA PEP TT EEUU PTV EL VULL Tt IX a a WO YEH WOT W Fae a EET ma BMGs nnan Anm EER SSRs ea NE ae ae E ROR SEERA See Lit iyi Tyr kee Y ETA DYNAFORM All elements in the flat area before an element angle change of larger than 2 degrees should be highlighted Compare your display to the preceding image If your results differ repeat the above steps to re select 9 Select OK on the Select Elements window You will find the number of elements 887 1s shown on
15. UT eta DY NAFORM 59 2 Liisanne ia e aa 54 CONCE STON a E E E stein aden 55 eta DYNAFORM Training Manual MI INTRODUCTION Welcome to the eta DYNAFORM 5 9 2 1 Optimization Training Manual The eta DYNAFORM is the unified version of the DYNAFORM PC and UNIX platforms This manual is meant to give the user a basic understanding of finite element modeling for line bead optimization as well as displaying the optimization results It is by no means an exhaustive study of the optimization techniques and capabilities of eta DYNAFORM For more detailed study of eta DYNAFORM the user is urged to attend an eta DYNAFORM training seminar This manual details a step by step sheet metal optimization simulation process through the INCSolver interface process Users should take the time to learn these setup processes as it is different from the traditional setup process such as AutoSetup 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 Optimization is designed to adopt SHERPA through Red Cedar HEEDS s SDK as the optimization engine Build a Black Box solution with a set of simple Dialog Box for DYNAFORM u
16. cent Flaces Libraries El Documents di Music Ee Pictures ES Videos ll Computer El Local Disk C a Tool D ca Project E ca STONES F a Data G a Backup H GA dir_nli6 200 1 1 20 G Sink_dyna_1 200 1 G dir_nli 200 1 1 165 G dir_nli5 200 1 1 20 t dir ml 200 1 1 234 Aa File name optraining01_FORM FAS 2 Select INCSolver fas from the Files of Type list This option will allow you to read in the fas file Navigate to the directory where the result files were saved be sure you have the correct file of type selected pick the fas file and click Open as shown in the figure below eta DYNAFORM Training Manual 37 POST PROCESSING with eta POST TA Post Processor 1 8 1 E DF5 9_TestFiles Manual OP_Tutorial_ Manual OP_training Original_Result optraining01_ FORM FAS des ETA POST CHECKING FRAME 29 CHECKING FRAME 30 CHECKING FRAME 31 CHECKING FRAME 32 COMMAND COMPLETED 3 The fas file is now completely read in You are ready to process the results using the result manipulation menu bar as shown below Il ANIMATING FLD eta POST can animate deformation thickness FLD and various strain stress distribution of the blank In this case we mainly focus on the FLD To do this refer to the following examples FLD 1 Pick FLD from the result manipulation menu bar 2 Select Middle from the Current Component list 3 Set FLD parameters n t
17. cond 20 m Check the optimized forming result ETA Post Processor 1 8 1 E DF5 9_TestFiles Manual OP_Tutorial_Manual OP_training optraining_INC HEEDS_181 0 0ptcase01_FORM FAS Oo x File Edit Tool Application Option Help J SSL leo OR esi VILA Ll FRAME 32 STROKE 0 000000 CRACK FLD middle layer RISK OF CRACK V Element Result FLD Curve Option Edit FLD Window PART BLANK 1 SAFE WRINKLE TENDENCY List Value poten ff FLD Reversed Mapping SEVERE WRINKLE INSUFFICIENT E 44 964233 J A STRETCH 38 935425 34 960388 28 068542 24 960449 19 963196 17 199829 14 958740 9 962036 6 358276 4 963928 2 964233 0 961121 0 000000 T02 incr 1 ETA POST Frame speed 0 172 seconds Shade M Smooth Shade I Material Color COMMAND COMPLETED FLD PLOT I Fill Color Element Edge Shrink Frame speed 0 125 seconds i COMMAND COMPLETED Ji Hidden Surface Plate Normal V Background Compare the two results Original result 32 eta DYNAFORM Training Manual OPTIMIZATION FRAME 32 STROKE 0 000000 FLD middle layer CRACK RISK OF CRACK p PART BLANK 1 SAFE WRINKLE DENCY RINKLE SEVERE WRINKLE INSUFFICIENT STRETCH ETA POST Design optimization result Sw B FRAME 32 STROKE 0 000000 FLD middle layer OF CRACK PART BLANK 1 SAFE WRINKLE TENDENCY WRINKLE SEVERE WRINKLE INSUFFICIENT STRETCH ETA POST Conclusion After the Design Optimization
18. d on the provided surface data This is a very quick and easy way of meshing the tools 1 Turn off the part BLK and turn on the part LOWTOOL Set the part LOWTOOL as current 2 Select UserSetup Preprocess on Menu bar or click the SURFACE MESH button E H bar Analysis Configuration Frepr Define Tools CET Draw Bead P Guide Pin Blank Generator Define Blank CEEB Material Property Blank Operation Node Element Set Ctrl V 3 Select Surface Mesh from the Element tab as shown below eta DYNAFORM Training Manual 9 MESHING Preprocess l Label Elements C Shrink Elements 4 Inthe displayed Surface Mesh dialogue window default values will be used for all fields Note Chordal deviation controls the number of elements along the line surface curvature Angle controls the feature line Gap Tol controls whether two adjacent surfaces are connected 10 eta DYNAFORM Training Manual Surface Mesh Mesher wW Connected ll Untonnected C In Original Part l Boundary Check Refine Sharp Angle l Re mesh Parameters Max Size 30 00000 Min Size 0 50000 Chordal Dev 0 15000 Angle 20 00000 Gap Tolerance 2 50000 E lgnore Hole Size 0 00000 l Set By Select Surfaces MESHING Select Surfaces Select By Cursor Key in Surf Range OK Cancel 5 Choose the Select Surfac
19. es button from Surface Mesh dialogue 6 From the Select Surface dialogue choose the Displayed Surf icon Note All of the displayed surfaces will turn to white This verifies they have been selected This dialogue window allows you to select the surface s in different ways Place the cursor over each icon and button to identify its function 7 Click the Apply button on the Surface Mesh dialogue 8 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 eta DYNAFORM Training Manual 11 MESHING El ell x ETA DTHAPORA 9 Press Exit on the Surface Mesh dialogue to exit the function Now that we have all the parts 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 Save the changes 10 Save the database HI 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 UserSetup Preprocess Model Check Repair on the Menu bar 12 eta DYNAFORM Training Manual MESHING Preprocess Line Surt Elem Node Rep l Label Elements C Shrink Elements As shown above the Mode
20. eta D Y NAFORM OP Training Manual Version 5 9 2 1 era Engineering Technology Associates Inc 1133 E Maple Road Suite 200 Troy MI 48083 Tel 248 729 3010 Fax 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 1998 2014 Engineering Technology Associates Inc All rights reserved TABLE OF CONTENTS TABLE OF CONTENTS SI CIRE TION cactus verindensspsavanaes E E IV DATABASE MANIPULATION sivectsssictctoasscxccccetencesttaccetaessatetonsscnscasecsneusiiacentuesseeatocticateneoedieusies 1 I Creating an eta DYNAFORM Database and Analysis Setup cccececcsssseecceeeeeceeeeeeaeseeesseseeeeeeeeees I IL Editing Parts tte EO I Oiceotesatesonmsmms som mass oaeiiecior esments st ANASO Ee EEREN 4 DOL COPC PANE ccc E E E E E A IEE E A EE A A EE I E EE A E E sateen EE A E 5 E G T ys mt taments 7 Es BI Meini esse A a E smdtiedteim tm t 7 I Meshing Surface Data ccccccsssssssssseeeeeeeeeeeeeeeeeeeaeeeeeeeseeeeeeeeeeeeeeeeeeeaaaaeeeeeseeseeeeeeeeeeeeeeeeeaaaaageeesees 9 TH Mesh Check And Repair ssi cistesssssicsososasvnssonisensndaabubasasbesanagsadenssonlneian wa tubsneubatnsaoeabuhadaabosbon geadebeaweiavante 12 NC IS De SETUP s error nr rrere mtr yr rrr rr ncr errr ae rrrrrnrrnr rrr rrerrren tyr rrr Ty rr Tren cr
21. fault setting 4 Use the default Thinning values 5 The Iterations are based on the number of defined variables There is a recommended number shown IV RUN THE JOB Having completed the above definitions of Variables Responses and control parameters next we will run job with INCSolver and SHERPA Heeds Firstly the user should have the license file of Dynaform and SHERPA They are different licenses Once the definition has been completed the Run button will be activated Click the Run button to submit the job The program will pop up the DOS window as shown below eta DYNAFORM Training Manual 45 OPTIMIZATION V c4 C PROGRA 1 ETA DYNAFO 1 9 DEMS_MC exe Forming Force 0 649534 BlankHolder Force 0 00000 Mass scalling factor 0 900000 Element number is 4025 Node number is 4140 Time Step Number 401 HMIN 1 0 700000 BlankHolder Velocity 0 00000 Die Velocity 72 9187 BlankHolder Stroke 0 350085E 01 Die Stroke 420 938 Forming Force 0 847704 BlankHolder Force 0 00000 Mass scalling factor 0 900000 Element number is 4025 Node number is 4140 Time Step Number 481 HMIN 1 0 700000 BlankHolder Velocity 0 00000 Die Velocity 87 4419 BlankHolder Stroke 0 350085E 01 Die Stroke 420 952 Forming Force 1 00914 BlankHolder Force 0 00000 Mass scalling factor 0 900000 Element number is 4025 Node number is 4140 Time Step Number 561 HMIN 1 0 700000 BlankHolder Velocity 0 00000 Die Velocity 110 808 BlankH
22. g of INCSolver The user can click the Optimization submenu located at the below of OP menu to display the interface File Parts BSE D Eval AutoSetup QuickSetup UserSetup SCP ES PostProcess Option Utilities View Help Optimization Result Viewer I ENTERING OPTIMIZAION INTERFACE Click Optimization in the menu bar then the program will pop up the Sheet Forming Optimization interface and prompt the user to define basic parameters 42 eta DYNAFORM Training Manual OPTIMIZATION Sheet Forming Optimization Source Blank_Outline Outer INCSolver formin Variable Range Formula Add Remove Drawbd_1 Drawbd_ Drawbd_3 m i z Responses Global Crack Normalizing Factor RiskofCrack Add Safe WrinkleTendency Remove Wrinkle severeWrinkle Insuf Stretch Thinning Constraint Add i Remove H Allowable Thinning 20 0 Ww Active No of Evaluations 246 0 Run Restart Result Exit 1 Once INCSolver forming setup is completed the forming stage will be shown on the Source list It will list all parameters which can be optimized The user is allowed to define the variable type range and baseline on the right frame shown above 2 Responses list all response objectives They are calculated based on the defined variables 3 No of Evaluation is also based on the defined variables 10 is the default value when you enter Optimiza
23. ined You can also refer to the eta DYNAFORM User s Manual for information about all of the Draw Type functions File Types Eta DYNAFORM has the ability to read the following types of input files 1 CATIA Em 7 CATIA4 model 16 NASTRAN dat nas 8 CATIAS CATPart CATProduct 17 ABAQUS inp 9 STEP stp step 18 DYNAIN dynain eta DYNAFORM Training Manual 3 DATABASE MANIPULATION If EDITING PARTS IN THE DATABASE The Edit Part command is used to edit part properties and delete parts Create Ctrl P Delete Add To Part Tur On Current Separate Transparent aummary 1 From the above menu click the Edit button The Edit Part dialogue will be displayed with a list of all the parts that are defined in the database The parts are listed with the part name and identification number From here you can modify the part name ID number and part color You can also delete parts from the database Select Color Name Cooavooo ID nn Name ID 2 Select the part C003V000 from the part list Change the Name by inputting BLANK in the field as shown below 3 Select the part C0O02V000 from the part list Change the Name by inputting LOWTOOL in the field as shown below 4 Once you have entered the new name LOWTOOL and selected the desired part color click on the Modify button located at the bottom left of the dialogue to make the changes 5 Click OK to end this operation
24. l Check Repair dialogue consists of several functions that enable the users to check the quality of mesh Only two of the functions are described in this training manual Please refer to eta DYNAFORM online help for information regarding to the remaining functions Auto Plate Normal ad 1 Click Auto Plate Normal from the Model Check Repair dialogue A new dialogue will be displayed 2 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 part LOWTOOL 3 An arrow will be displayed showing the normal direction of the selected element A prompt will ask Is normal direction acceptable eta DYNAFORM Question Is normal direction acceptable eta DYNAFORM Training Manual 13 MESHING zZ a hn r os ETA OYHAPORA Clicking Yes will check all elements and reorient the part as needed to the direction that is displayed Clicking No will check all elements and reorient as needed to the opposite of the direction that is displayed In other words click Yes if you want the normal to point in the direction of the displayed arrow or No if you want it to be the opposite As long as the normal direction of most elements in a part is consistent the program will accept that If half of the total element s normal is pointing upward and other half pointing downward the result will be flawed Note In this case we wil
25. l offset upper tool from the lower tool by the normal direction So click Yes to make sure the normal to point in the direction of the displayed arrow 4 Now that the LOWTOOL elements are consistent check the rest of the parts in the database Turn off all the parts and turn each one at a time Check the normal direction and make sure it is consistent 5 Once all the normal directions are consistent turn on all of the parts and save the changes 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 Model Check dialogue window Minor gaps in the tool mesh are acceptable Blank mesh should not contain any gaps unless the blank is lanced or is designed with gaps Click the isometric view and make sure that your display looks like the following 14 eta DYNAFORM Training Manual MESHING 2 Y ETA OYNAFORN 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 2 ie x Y ETA DYNAT ORM 3 Check for overlapping elements and minimum element size Delete the duplicate elements if there were found 4 Save your database Save the changes to your initial database and make a note of
26. lculation results and list the corresponding Performance Variable and Response The user can select any one of the results and then click the View button and the program will automatically switch to eta Post to process the result When users view and accept the optimization result they are allowed to assign the drawbead value after the optimization to the drawbead defined in INCSolver by clicking the Apply button The result in the first line is selected as the optimization result by default In the Graph the user can check the defined responses related to variables Cycle and the Response Crack are selected as X Axis and Y Axis respectively and the program will display the relationship between Crack and Cycle as shown below eta DYNAFORM Training Manual OPTIMIZATION 3 26 DZ ra 104 130 6 Cycle and the Response Safe are selected as X Axis and Y Axis respectively and the program will display the relationship between Safe and Cycle as shown below Safe 3 26 of ra 104 136 7 Toggle on the Dynamic option and click on the ml icon and the program will show the relationship dynamically eta DYNAFORM Training Manual 49 OPTIMIZATION 8 Select the optimal result in the first line and click the View Best button and the program will automatically open the result in the Post Processer as shown below ETA Post Processor 1 8 1 E DF5 9_TestFiles Manual OP_Tutorial_Manual OP_training optraining_INC HEEDS 181 0 optcase
27. lver interface Save the changes Use the default Tool Travel Velocity and Binder Close Velocity Toggle on the Lower Binder Force and Lower Binder Travel and set the values as in the following figure Save the database Select Apply and the program will automatically create mating tools position the tools and generate the corresponding travel curves eta DYNAFORM Training Manual INCSOLVER SETUP INCSolver OO Draw Type single action Inverted draw Lower Tool Available T Lower Tool Blank Parameters Material Thickness No Symmetry i BLK HSS FENE 1 00 Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 he Lower Binder Travel afe DO Lance 0 Trim 0 Advanced Help Apply Unde review Submit Job epon Eyit 8 Select Preview to check the tooling motion 9 Compare your display with the illustration shown below eta DYNAFORM Training Manual 21 INCSOLVER SETUP STEP 28 TIME 2 5662643L 001 Binder Closure PUNCH POSI 512 253 DIE POSI 6 606 BINDER POSI 8 888 ToS wee et SRS Ere eee a NT RUA ds dites ant ETA DYNAF ORM V 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 28 eta DYNAFORM Training Manual INCSOLVER SETUP File T List by Property vem Bead Name Drawbd Use property of dra
28. m the INCSolver GUI and add the previously defined blank BLK the blank list The user needs to define the material and thickness For the blank thickness the user may enter the number in the thickness field In this case we will set it to 0 7mm The blank material can be selected from the Material Library under the material definition window In this case we will import the mat The Material Definition window will be shown as in the image below Click the Import button and select fender mat as in the below figure Then Click the Open button to import the material 24 eta DYNAFORM Training Manual INCSOLVER SETUP Material MATOOOO Date modified T Size hi 2012 10 23 15 28 Microsoft Office 2XB Computer ry T Network eta DYNAFORM Training Manual 25 INCSOLVER SETUP 26 4 The imported material will be shown as in the image below It lists all the parameters of the material Material Name Mass Density Young s Modulus Yield Stress Initial Strain Hardening Coef Hardening Exp Yield Rule Yield Exponent Roo R45 Click OK to use the imported material parameters following image Note ETA makes no guarantees as to the validity or accuracy of the generic material models in the material library Users should contact their material suppliers to determine material parameters To complete the material definition click OK from the material dialogue and return to the INCSo
29. nfig file located under the installation directory will take precedence over the one located in the user home directory 54 eta DYNAFORM Training Manual CONCLUSION CONCLUSION This concludes the training guide s basic overview of eta D YNAFORM 5 9 2 1 This manual is meant to give the user a basic understanding of finite element modeling for forming analysis as well as displaying the forming results It is by no means an exhaustive study of the simulation techniques and capabilities of eta DYNAFORM For more detailed study of eta DYNAFORM the user is urged to attend an eta D YNAFORM training seminar Please refer to the eta DYNAFORM User s Manuals and the LS DYNA Keyword User s Manuals for detailed explanation of individual functions and analysis settings eta DYNAFORM Training Manual 55
30. og box The following are the description of other functions in the INCSolver interface Lance and Trim allows the user to define Lancing and Trimming stages Advanced allows the user to change default parameters related to INCSolver Help brings some tips for the user about the INCSolver simulation Submit Job brings the user to the analysis menu Report allows the user to check the formability report Exit will allow the user to exit the INCSolver menu eta DYNAFORM Training Manual 33 INCSOLVER SETUP VI SUBMIT JOB After verifying the tool motion is correct we can define the final parameters and run the analysis I Click Submit Job button to display the Submit Job dialogue window shown below Submit Job w Draw Die Spring Back Adaptive Level 4 vi CPU muri vi submit Close 2 Click the Submit button to run the job It is recommended that new users use the default control parameters For more information about them please refer to the INCSolver User s Manual JS Job Submitter 2014 R1 I 105 x a clajelel LS DYNA S D Program Files ETA Dynaform 5 9 2Usdyna exe LS DYNA Control Parameter LS DYNA D D Program Files ETA Dynaform 5 9 2 isdyna_d exe Memory 500 MB W Auto UTILITYBATCH D Program Files ETA Dynaform 5 9 2 UtilityBatch exe No of CPUs ncpu fal MSTEP D Program Files ETA Dynaform 5 9 2 MStep exe Pause between Jobs 2 Sec INCSolver D Program Files ETA D
31. older Stroke 0 350085E 01 Die Stroke 420 969 Forming Force 1 29301 BlankHolder Force 0 00000 Mass scalling factor 0 900000 Element number is 4025 Node number is 4140 The solver displays a DOS window showing the status of the job You will notice that more information about the model is given but the calculating time is hard to get Since we are using adaptive mesh and the model will re mesh for several times Also the number and speed of CPU influence it However it does give you a general idea REVIEW THE OPTIMIZATION RESULT After completing the optimization the program will return to the best value as shown below The next step 1s to check the result and compare the optimized result with the original result 46 eta DYNAFORM Training Manual OPTIMIZATION Sheet Forming Optimization Source Blank Outline Outer Range Formula oo vi 5 60 40 0 INC Dravbd 2 Contir BE 80 0 0 L Add b Drawbead INC Drawbd_3 De per w INC_Drawbd_ 40 0 Drawbd_1 Remove INC_Drawbd_4 Contir 5 80 0 0 Drawbd_2 INC_Drawbd_5 Contir BE 80 0 0 ic 7 INC Dravbd 6 Deper INC_Drawbd_2 40 0 a 1 UAW DrowhAd Pia line DirawhAi A An A hd Responses Variable INC Drawbd_1 ae NC Solver Crack RiskofCrack Safe WrinkleTendency Wrinkle severe rinkle Insuf Stretch Thinning Constraint Add C Crack Allowable Thinning 20 0 Ww Ac
32. sers mainly tool amp die designers to define the parameters and optimization objectives etc OP module combined INCSolver and SHERPA engine to optimize the blank outline lubricant binder press and line bead In this manual mainly introduce the drawbead optimization process The other optimization is similar 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 IV eta DYNAFORM Training Manual DATABASE MANIPULATION DATABASE MANIPULATION I CREATING AN ETA DYNAFORM DATABASE AND ANALYSIS SETUP Start eta DYNAFORM 5 9 2 1 For workstation Linux users enter the command df5921 default from a UNIX shell to start eta DYNAFORMS 9 2 1 For PC users double click the eta DYNAFORM 5 9 2 1 DF5921 icon from the desktop or choose eta D YNAFORM from the program group After starting eta DYNAFORM a default database file Untitled df is created Users will begin by importing CAD or CAE files to the current database Import files 1 From the menu bar select File Import Fe rama J Lo Files of type LINE DATA lin Import M AllFil Cancel Wes Cancel Change the file format to LINE DATA lin Go to the training files located in the CD provided along with
33. this file name We will use this file later in this training manual to perform INCSolver and Optimization with SHERPA This manual will first detail the INCSolver process then the Optimization with SHERPA Skip to the INCSolver of this manual if you are already familiar with the INCSolver interface and analysis setup procedure eta DYNAFORM Training Manual 15 INCSOLVER SETUP INCSOLVER SETUP Before entering the INCSolver interface we will need to separate the binder run out lower ring and punch upper tool from the lower tool This will allow the INCSolver to automatically generate the die from this run out This procedure is common to all INCSolver models that require a binder and punch I DEFINE THE BINDER FROM THE LOWER TOOL The next step is to separate the Binder from the LOWTOOL and Move Elements on Run out of LOWTOOL into Binder 1 Turn on LOWTOOL and turn off all other parts 2 Create a new part called Binder This part will hold the elements that we separate from the LOWTOOL Click Parts Create on Menu bar Add To Part Turn On Current Separate Transparent aummary 3 Enter BINDER in the name field Click OR to create the part Create Part Name BINDER ID 4 ok _Appiy cance 4 The part BINDER has been created and set as the current part automatically Click Parts Add To Part on Menu bar 16 eta DYNAFORM Training Manual INCSOLVER SETUP Create Ctrl P Edit Delete
34. tion interface 4 The user is allowed to set Thinning value IL DEFINING VARIABLES After entering the Sheet Forming Optimization interface the user needs to define the variables from the Source list In this case we will only optimize the Drawbead force eta DYNAFORM Training Manual 43 OPTIMIZATION Source El iNCSolver Variable NC Drambd 1 forming ssingle action Drawbead l Drawbd_1 NC Drambd 2 Dravbd 2 NC Dravbd 3 Dravbd 3 Remove NC Drambd 4 Contir B 80 40 0 Dravvbd 4 NC Drambd 5 Contir y s 80 40 0 dte INC Dravbd 6 W IW Dir 7 1 Select Drawbead under forming_ lt single_action gt in Source List 2 Click the Add button and then all defined drawbeads will be added to the Variable frame Danar w IR iraa Es Ann vi 3 Some Variables use the default variable type Continuous As for some drawbeads with the same numerical value we can define the relations of dependence between them by using Depend On The detailed variable setting is illustrated in the following figure Variable Type Range Formula Baseline INC_Drawbd_1 Contir 5 80 40 0 INC_Drawbd_2 Contir 5 80 40 0 INC_Drawbd_3 Deper Y INC Dravbd 2 40 0 INC Dravbd 4 Contir 5 80 40 0 INC_Drawbd_5 Contir ml 80 40 INC _Drawbd_6 TING Drawbd_ INC Drambd 7 Deper w lINC Dravbd 5 4 4 INC_Drawbd_8 Deper XJINC Dranba 2 400 4 4 UE
35. tive No of Evaluations 186 1 You will notice that the Result button is activated and the process status turns in red indicating the calculation is completed 2 The program provides two ways to review the result One is clicking the Result button on optimization GUI and the other is selecting Result Viewer from the OP submenu as shown below PostProcess Option Utilities View Help File Parts BSE D Eval AutoSetup QuickSetup OP INCSolver Optimization Result Viewer 3 After completing the optimization the Result button is activated Click the Result button to review the calculated result as shown below eta DYNAFORM Training Manual 47 48 OPTIMIZATION Best Results INC Drawbd_1 INC_Drawbd_ INC_Drawbd_3 INC_Drawbd_4 INC_Draw Performance 217 81 9406 10 99 81 8471 40 z Lo 181 818311 40 70 20 40 70 1817779 E 70 20 30 70 170 81673 40 s 20 40 s gt Apply Graph C Check by Performance Cycle 1 Performance 2 39161e 019 Cycle 2 Performance 2 72185e 015 Cycle 3 Performance 1 67452e 015 Cycle 4 Performance 1 02096e 017 Cycle 5 Performance 2 62166eE 015 Cycle 6 Performance 4 5159e 018 Cycle 7 Performance 3 7635e 01 7 Cycle 6 Performance 3 4566eE 016 da ml a TO Fa aa mana s A a dm ml ma a a EO ar d RE a y crak man a a mj pl Mi Best Practice Exit The program will automatically select the best five results from all ca
36. w bead Use default property Default Property no line defined Draw bead line Line amp Beam select import Create Spline Mesh Parameter amp By Distance 15 000 Uniform 15 Add 4 Chordal Devi 0 250 Max Length 5 000 Delete i Back Apply hlo dify F pp show l Draw Bead W Lock Force Percentage Color by Property M Nodes C Define BoxSizeioo C Show Box 2 Click the Import button as illustrated in the following figure Draw bead line Line s Beam select import Create Spline vi no line defined 3 Switch the file type to iges and select the drawbead file drawbead igs eta DYNAFORM Training Manual 29 INCSOLVER SETUP ee Wa HE Recent Places a Desktop Files of type IGES igs iges Import EC All Files 4 Use the default mesh parameters and click Apply to generate the line drawbead as shown in the figure below 30 eta DYNAFORM Training Manual INCSOLVER SETUP SS File List by Property vem Bead Name D rawbd Default Property Use default property Use property of draw bead w 16 lineis imported Draw bead line Line amp Beam select import Create Spline Mesh Parameter By Distance 1 5 000 Uniform HE Add Chordal Dewi 0 250 Max Length
37. ynaform 5 9 2 DEMS_SC EXE Not use MPP MPP LS plet Ei Submit Jobs anam ar Scher WSlages Memon Saus Message Summary Force OtherParam a optraining fin E DF592_ 1 APPLIC 1 0P INCSolver vi Mo The solver displays a DOS window showing the status of the job You will notice that some model information IS given After the program is completed Move the result into new directory named Original_Result Then next step is to Proceed to section POST PROCESSING with eta POST for post processing 34 eta DYNAFORM Training Manual INCSOLVER SETUP CE ETA 3S5 INCSolver i Transient Finite Element Frogram for sheet metal forming problen INCSolver ETA Add ii33 E Maple Rd Ste 266 Troy HI 48083 Wersion 590 Date START FASTAMP SOLUER FOR STAMPING FORMING THE INITAL BHF IS 4 88 Time Step Mumber 1 BlankHo Ider Velocity H HHBHHR BlankHo lder Stroke 35H085E 81 Forming Force 6 8600 Mass scalling factor 4 9660 Element number is 4625 Time Step Mumber si BlankHolder Velocity H HBHRHR BlankHolder Stroke 356085E 1 Forming Force 6 168938 Mass scalling fFactor 4 96 Element number is 4625 AY 31 2813 gt MULATION THE MAXIMUM COUNTER FORCE OF THE IMITAL DRAWBE HMIN 1 gt AH 76688 Die Uelocity 4 382576 Die Stroke 420 905 BlanEHolder Force 6 80600 Mode number is 4144 HMIN 1 gt 6 76068 Die Uelocity 14 8259 Die Stroke 420 906 BlankHolder Force 4
38. you to select the current part in different ways Place the cursor over each icon to identify its function 4 Set the part BLANK as current by selecting the part name from the Select by Name list that is displayed 5 Practice setting the current part 6 Turn off all of the parts except BLANK and set it as current 6 eta DYNAFORM Training Manual MESHING MESHING Meshing from surface or line data is a very important step contributing to a successful simulation There are many methods of creating mesh however in this exercise the Blank Generator and Surface Mesh will be used to generate meshes I BLANK MESHING Blank meshing is the most important mesh function since the accuracy of the forming results depends heavily upon the quality of blank mesh There is a special function for blank meshing 1 Select UserSetup Blank Generator Outline on Menu bar to open the Select Line option dialog box Analysis Configuration Preprocess LlefinE Tools Draw Bead sulde Fin Blank Generator Define Blank Material Property Blank Operation Node Element set Boundary Condition Position Tools Tools On off Animate SUMMary ME LS OYNA MS TEP Ctrl T P Corl 6 pr Ctrl Ctrl U pr pr CIA Blank generator Operation Mesh type Parts Outline Mesh ecit Geometry From BSE r Mesh Blank mesh 2 The Select Line dialogue window is shown as below eta
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