Dynaform DF5 9 2 1 die simulation training manual

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eta/D YNAFORM Die Simulation Training Manual Version 5.9.2.1 efa

Engineering Technology Associates, Inc

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respective owners

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TABLE OF CONTENTS

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

I Creating an eta/Dynaform Database and Analysis Setup

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

Il Meshing DIe

Ill Mesh Check and Reparr

SLIMULATION SE TUP

I Die Simulation Interface

II Define Tools

III Define and Mesh Blank

IV Defining the Blank Material

V Define Tool Control VỊ Define Drawbead VH Submit Job ._ ._ ._ ._ ._ ._ ._ oe oe oe POST PROCESSING (with eta/POST) I Reading the Results File into the Post Processor

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Tl Animating FLD -cẶẶĂĂssse sec IH Plotting Single Frames - «55555 << <<< s52 IV Check the forming Result of FLD .-

V Check the forming Result of THICKNESS e& e& e& e& e& e& e& _ đˆ, _ đˆ, _ đˆ, _ đˆ, _ đˆ, ere eee eee eee re ey ere eee eee eee re ey ere eee eee eee re ey “{ “{ “{ “{ “{ “{ “{ “{ “{ “{ “{ “{ . Terre eee eee eee ee Terre eee eee eee ee Terre eee eee eee ee Terre eee eee eee ee _& _ . _ ._ ._ ._ . _ ._“Ÿ ._ ._ ._ eee eee eee eee eee eee ee eee @ @ _ ._ .@ _ ._ ._ .@ @

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INTRODUCTION

Welcome to the eta/DYNAFORM 5.9.2.1 Die Simulation Training Manual The eta/DYNAFORM is the unified version of the DY NAFORM-PC and UNIX platforms

This manual details a step-by-step quick Simulation process through the Die Simulation interface process Users should take the time to learn these setup processes as it is different from the traditional setup process, such as AutoSetup

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

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

Note: This manual is intended for the application of all eta/DYNAFORM platforms Platform interfaces may vary slightly due to different operating system requirements This may cause some minor visual discrepancies in the interface screen shots and your version of eta/DYNAFORM that should be ignored

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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/D YNAFORMS.9.2.1

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

eta/DYNAFORM from the program group

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

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

ET = x

Savein: | }) Die_Simuiation >| © @ ek Ee

Name + | -| Date modified _|~| Type |«|[sze — |«|

No items match your search Recent Places = Desktop _ = Libraries = Computer a Network File name: |Die_Simulation | x L_seve_| = Save as type: | database (.d) 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 Defined

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DATABASE MANIPULATION 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 IGES (*.igs, *.iges) 10 NX (*.prt)

2 VDA (*.vda, *.vdas) 11 PROE (*.prt, *.asm) 3 LINEDATA (*.lin) 12 INVENTOR (*.ipt) 4 DXF (*dxf) 13 Parasolid (*.x_t)

5 STL (* stl 14 SolidWorks (*.sldprt; *.sldasm)

6 ACIS (*.sat) 15 LSDYNA (*.dyn, *.mod, *.k) 7 CATIA4 (*.model) 16 NASTRAN (*.dat; *nas)

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

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TOOL PREPARATION

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

I Import Die Geometry

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

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File name: Die_upper igs xị | OK |

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

Iv Lines IV Surfaces [ˆ AllFiles Cancel |

[ˆ Auto Mesh Mesh Param | A 4 After reading in the data file, verify the display looks the same as the illustration shown below Y L ETA/DYNAFORM

II Meshing Die

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

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TOOL PREPARATION

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

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

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

6 Save the database

III Mesh Check and Repair

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

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

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As shown above, the Model 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 Tool Preparation/Mesh dialogue A new dialogue will be displayed

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

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

“Is normal direction acceptable?”

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TOOL PREPARATION eta/DYNAFORH Question Is normal direction acceptable? Si al Deccccccccccccccscscccscseeed z YY X ETf/DYNAF DRH

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

4 Now that the Die part elements are consistent

= j ——

Display Model Boundary

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

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

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

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

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

3 Check for overlapping elements Delete the duplicate elements if they were found 4 Save your database

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DIE SIMULATION SETUP

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

I Die Simulation Interface

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

File Parts | BSE Ez] AutoSetup QuickSetup UserSetup SCP | OP | PostProcess Option Utilities View Help Preparation Binder Modification Trim Check Die Design Check Die Simulation

2 As shown in the following the Die Simulation 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 Upper tool Die Simulation Draw Type Single action (Inverted draw) Vv | Upper Tool Available vị Upper Tool — Blank Parameters Part Material Thickness -— Tool Control

Tool Travel Velocity: {5000.00

Binder Close Velocity: |2000.00 [ Lower Binder Force:

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II Define Tools

To define the Upper Tool:

1 Click the Upper Tool button, and then select the Select Part button from the Define Tool dialog window Define Upper Tool Include Part List Define Tool Tool Mesh

Mesh Check/Repair Add | Remowe | Display |

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

The elements on binder surface are excluded

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5 The Upper Tool is defined Click E

To define the Binder: xit to exit Define Tool 7 bị ĐÓ NHẬT TIỂNG 7/7711 HA tH 22/1A i A i —— —

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

2 Click Add Elements from the Define Tool window

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Define Binder Include Part List Add | Remove Display | Add Elements || OK

3 Select the surfaces on binder surface by using Select by surface The elements on binder surface are selected Select Elements Select by Cursor xx| >|© Angle 0 mm Select by Range Done | Select by Part

Displayed All Elements

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4 The Binder is defined Click Exit to exit Define Tool

|

III Define and Mesh Blank 1 1 + 1 |

1 Click the Blank button to display Blank Generator dialog box TBS tale) — Draw Type Single action (Inverted draw) wv Upper Tool | Upper Tool Available X| Binder Close Velocity: }2000.00 — Blank Parameters Part Material Thickness - Tool Control

Tool Travel Velocity: |5000.00

[ Lower Binder Force:

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3 Go to the training files located Locate the file: Blank.igs, and import it Click OK to dismiss the Import File dialogue window Open xi Lookin: |), DIE_Smulaion_Model >| © er

* bead.igs 2013/7/2 10:47 IGES File 172 KB

Recent Places Ji blank.o:

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

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DIE SIMULATION SETUP Blank generator 7 User can change Element Size to 16 Blank mesh

8 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

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9 Save the database

IV Defining the Blank Material

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

The blank material can be selected from the Material Library under the material definition window 1 Click the MAT0000 button under Material text -— Draw Type Single action (Inverted draw) Vv |Upper Tool Available vị Upper Tool — Blank Parameters Part Material Thickness No Symmetry | ] BLK watoooo =|} [1.00 -— Tool Control Tool Travel Velocity: {5000.00

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

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

Apply | Exit |

2 Click the Material Library button to open the material lib

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DIE SIMULATION SETUP Hiaterial Library a United States | : Material = Material Library =) STEEL = Mild

3 Select BH180 from the Unite States standard Then exit Material definition dialog box 4 Input blank thickness: 0.8mm

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Die Simulation =— Draw Type | Single action (Inverted draw) vị | Upper Tool Available vị Upper Tool — Blank Parameters Part Material Thickness No Symmetry | ] BLK | BHi80 | | {0.80 ‘- Tool Control Tool Travel Velocity: {5000.00 Binder Close Velocity: |2000.00 [~ Lower Binder Force: TT Lower Binder Travel: Lance (0) | Trim (0) | Advanced | Help | Apply | Exit |

V Define Tool Control

1 Use the default Tool Travel Velocity and Binder Close Velocity

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

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DIE SIMULATION SETUP Die Simulation =— Draw Type | Single action (Inverted draw) X| Upper Tool | | Upper Tool Available Binder Close Velocity: |2000.00 — Blank Parameters Part Material Thickness No Symmetry | ] BLK | BHi80 | 0.80 —¬ Tool Control Tool Travel Velocity: {5000.00 lv Lower Binder Force: | 334000.00 I Lower Binder Travel: |õ5.00 Lance (0) | Trim (0) | Advanced | Help | Apply | Exit |

3 Select Apply, and the program will automatically create mating tools, position the tools and generate the corresponding travel curves

Select Preview to check the tooling motion

Compare your display with the illustration shown below

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STEP 18 PUNCH DIE BINDER TIME POS] = -589.438 POS] = 6.666 ~Ắ 7.5571H813F-0881 Binder Closure 2 4 ETA/DYNAFORA

VI Define Drawbead

Next step is to define the drawbead for the simulation analysis

1 Click the Drawbead button to open the Drawbead dialog box, as illustrated in the following figure Die Simulation — Draw Type | Single action (Inverted draw) vị Upper Tool | Upper Tool Available Ma Binder Close Velocity: }2000.00 — Blank Parameters Part Material Thickness No Symmetry | ] BLK | BH180 | [080 — Tool Control

Tool Travel Velocity: |5000.00

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Line Bead

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

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Lookin: | |}) DIE_Simulation_Model xị © er = eee 6 blank.igs 2014/5/7 16:10 IGESFile 1KB = * Die_upper.igs 2004/7/23 8:40 — IGESFile 9,161KB Desktop ree x Computer P x "1 Network Files oftype: J IGES("igs:"iges) xi [ All Files

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

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

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DIE SIMULATION SETUP BeadID | 1 | 2] 3 | 4/5 | 6 | 7 { 8 | 9 | 10] at | 12 | 13] 14] 15 | 16 | 17 | 18 | 19 | 20 | 21 | 22 Percentage | 32 | 32 | 22 | 22 | 35 | 35 | 25 | 25 | 25 | 25 | 25 | 25 | 33 | 33 | 22 | 33 | 22 | 35 | 35 | 33 | 25 | 25 (22.9%) + (22.0%) 2 (25.0%) 28 (33.0%) 3 (33.0%) ? (25.0%) (25.0%) 4 (ngon 00s(uosôZ) 22 (25.0%) U%) Lf (33.0%) 5.8%) - 8%)

8 Click Exit to exit the Drawbead dialog box

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

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

e Advanced allows the user to change default parameters related to Die Simulation e Help brings some tips for the user about the Die Simulation

e Submit Job brings the user to the analysis menu e —= Exit will allow the user to exit the Die Simulation menu

VII Submit Job

After verifying the tool motion is correct, we can define the final parameters and run the analysis 1 Click the Submit Job button to display the Submit Job dialogue window shown below

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Die Simulation — Draw Type | Single action (Inverted draw) xị |Upper Tool Available vị Upper Tool — Blank Parameters Part Material Thickness No Symmetry | ] BLK | BH130 | 0.80

— Tool Control TC Long veentntntnteree

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

[_ Spring Back

# Lower Binder Travel: [65.00

Adaptive Level | 4 v |

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DIE SIMULATION SETUP J Job Submitter 2014 R1 =|El x! Solver: | eS | Q

LS-DYNA (S) [D:\Program Files\ETA\Dynaform 5.9.2\isdyna.exe | LS-DYNA Control Parameter:

LS-DYNA (D) [D:\Program Files\ETA\Dynaform 5.9.2\isdyna_d.exe - | Memory 500 MB WV Auto UTILITYBATCH [D:\Program Files\ETA\Dynaform 5.9.2\UtilityBatch.exe | No of CPUs (ncpu=) |1

MSTEP [D:\Program Files\ETA\Dynaform 5.9.2\MStep.exe | Pause between Jobs |2 Sec INCSolver [D:\Program Files\ETA\Dynaform 5.9.2\DEMS_SC.EXE | MPP Not use MPP |

E1 || | x ALL +| ý ped] Bea| eal ital submit Jos | Job Name Die_ Simulation.fin In Folder E\DF592_TestFiles\Application_ Ma Message

max Summary | IForce| Other Param 4]

|Command | FASTAMP320NO.328757879 "D:\Program Files\ETA\Dynaform 5.9.2" E\DF592_TestFiles\Application_Manual\Die_Simulation\Die_Simulation The INCSolver displays a DOS window, showing the status of the job You will notice that some model information is given The next step is to Proceed to section POST PROCESSING (with eta/POST) for post-processing EM ETA-1S/INCSolver DAT E CMM/DD/YY>: 5⁄88⁄2814 TIHE<CHH :HH:SS : 81 >: 16:68:54:11 am

Nonlinear Dynamic Explicit Method Solver¢CINCSolver> Engineering Technology Associates Inc.¢CETAD>

has developed a specialty Dynamic Non-linear

Transient Finite Element Program, INCSolver for sheet metal forming problen

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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 eta-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/DYNAFORM Menu Bar

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POST PROCESSING (with eta/POST) 'Sj Libraries LỀ\ Documents @) Music lee! Pictures #& Videos (1 Computer &, Local Disk (C:) za Tool (D:) a Local Disk (F:) (a Data (G:) a Bi =: | Die_Simulation01_FORM.FAS | [INCSolver (*fas) | | 7 4 2 Select Die Simulation01_FORM.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

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ETA/Post-Processor 1.8.1 - F:\DF592_ TestFiles\Application_Manual\Die_Simulation\Die_Simulation01_FORM.FAS

File Edit Tool Application Option Hep

Ele) 24) scala Galea) Bish Ole [eta lic) cal) | lll el el) 7 le] | Bole itae2y T Undeform Scale Factor fi 0 All Frames v 1 TỔ 25 E HE 1 » II m © H dl I› M Number Zz A ETA/POST CHECKING FRAME 28 “|| Shade M Smooth Shade [ Material Color #COMMAND COMPLETED ` #READ COLORBAR CONFIGURATION FILE T Fill Color [Element Edge I” Shrink PLEASE WATT = #COMMAND COMPLETED +]| Hidden Surface [Plate Normal‘ ¥ Background

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 LỊ | ZI#| 5 k]|LilLl II Animating FLD

eta/POST can animate deformation, FLD, thickness, and various strain/stress distribution of the blank To do

this, refer to the following examples FLD "+ 2

1 Pick FLD from the result manipulation menu bar 2 Select Middle from the Current Component list

3 Set FLD parameters (0, t, r, etc.) from FLD Curve Option

4 Select Edit FLD Window to define location of FLD plot on the display window 5 Click the Play button and the animation will begin

6 Click the Stop button

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III Plotting Single Frames

All Frames ` [se _ 2— ˆ ` 7— Dan 9 — 1120.330933 367 301331 340.7069700 316.594543 251.080429 185.562729 120.044540 64.789185 60.942017 54959473 53 920532 46897034 44957153 39877441 -

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

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1— 1120.330933 2 367301331 3 340.706970 316.594543 251.080429 185.562729 120.044540 64.789185 60.942017 54.959473 53.920532 46.897034 44957153

IV Check the forming Result of FLD

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 TRAME 20 STROKE: (10000001 FLD, middie layor PARI: BLANK 1 qu dS gt š§ § £ & § § | ee pc (ca LU ETA/POST

V Check the forming Result of THICKNESS

In this step, we check the forming result based on the THICKNESS and THINNING plotting 1 Pick THICKNESS from the result manipulation menu bar

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