Dynaform DF5 9 2 1 tube bending training tutorial

Click the Calculate button to calculate the tube center line See Figure 6.. Click the Create button to create the tube See Figure 14.. Click the OK button to exit the Material dialog bo

This tutorial illustrates how to set up multiple tube bending from the product geometry by automatically creating tube

mesh and tool mesh

2

Figure 1

1 Start eta/DYNAFORM

‒ For PC users: double click the icon on the desktop to start

eta/DYNAFORM

‒ For Linux and Unix users: enter df5921 in the command line and press the

Enter button to start eta/DYNAFORM

2 Click the menu File->Import to import the model file (See Figure 1)

3 Click the menu File->Save As

4 Enter bending1.df as the filename

5 Click the Save button to save the database

4

1 Click the menu AutoSetup->Tube Bending/Forming->Tube Rotary Bending

(See Figure 2)

2 Click the Define button (See Figure 3)

3 Click the Displayed button (See Figure 4)

4 All of the tube elements are selected (See Figure 5)

5 Click OK to exit the Select Elements dialog box

Figure 2

Figure 3

II Define the Geometry

5

II Define the Geometry

Figure 5

Figure 4

6

6 Key in the tube thickness: 1.0 mm

7 Click the Calculate button to calculate the

tube center line (See Figure 6)

8 The section perimeter is calculated (See

Figure 7)

9 The tube center line is calculated and

displayed in the graphic area (See Figure 8)

Figure 6

Figure 7

II Define the Geometry

7

Figure 8

II Define the Geometry

8

10 Modify the tube outer diameter: 60 mm

11 Click the Simplify button (See Figure 9)

Figure 9

II Define the Geometry

9

1 The bending parameters and tube parameters

are displayed in the Bending tab (See Figure 10)

2 Click No.3, the bending process is selected

3 Click the Delete button to delete No.3

4 Repeat step 2-3 to delete No.5 (It becomes No.4

after deleting No.3)

Figure 10 Figure 11

III Define the Bending Parameters

10

5 Change the radius to 100 (See Figure 12)

6 Click the Edit button

7 Drag the each control point to make the simplified line and arc coincide with

the center line (See Figure 13)

8 Click OK to exit the curve editor

Figure 13 Figure 12

III Define the Bending Parameters

11

9 Click the Create button to create the

tube (See Figure 14)

Figure 14 III Define the Bending Parameters

12

1 Adjust the tool parameters (See Figure

15)

2 Toggle off Push Assist

3 Click the Create button to create the

13

1 Click the Tube tab

2 Click <None> to define the tube material (See Figure 16)

3 Click Material Library to select the tube material (See Figure 17)

4 Select the material: HRDQSK (See Figure 18)

5 Click the OK button to exit the Material dialog box (See Figure 19)

V Define the Tube Material

15

Figure 20

1 Click the Process tab

2 The default tool control:

‒ Add Angular velocity to Bend die

‒ Add Force and Velocity to Pressure die

‒ Add Velocity to Push assist

The user can check and modify load type

and value

VI Define the Process

16

1 Click the Control tab

2 Click … button, and the program will automatically calculate the time step

size according to the material parameters and the element size of tube

(See Figure 21)

Figure 21 VII Define the Time Step Size

17

1 Click the menu Preview->Animation (See Figure 22)

2 Click the Play Button to show the bending process, and the user can also

select the Individual Frames option to display the incremental tools movement (See Figure 23)

3 Click Stop to exit the Animate dialog box

4 Click Setup->Save to save the database

Figure 22

Figure 23 VIII.Animation

18

1 Click the menu Job->Job Submitter (Figure 24)

2 The program pops up the Save As dialog box

3 Click Save to output the input deck

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

Figure 24

IX Submit the Job

19

Open eta/POST to view the result

X Post-Processor

This tutorial illustrates how to set up multiple tube bending

by automatically creating tube mesh and tool mesh

20

Figure 1

1 Start eta/DYNAFORM

‒ For PC users: double click the icon on the desktop to start

eta/DYNAFORM

‒ For Linux and Unix users: enter df5921 in the command line and press the

Enter button to start eta/DYNAFORM

2 Click the menu File->Save As (See Figure 1)

3 Enter bending2.df as the filename

4 Click the Save button to save the database

22

1 Click the menu AutoSetup->Tube Bending/Forming->Tube Rotary Bending

(See Figure 2)

2 Key in the Outer diameter: 100 (mm)

3 Key in the Thickness: 2.4 (mm) (See Figure 3)

II Input the Geometry Parameters

Figure 2

Figure 3

23

1 Click the Bending tab

2 Click the Add button to add 7 stages (See Figure 5)

3 Input process information in Bending tab just like Figure 4

III Input the Bending Table

Figure 5 Figure 4

24

Figure 7 Figure 6

1 Click the Preview button (See Figure 6)

2 Check the bending process in the graphic area (See Figure 7)

IV Preview the Bending Process

25

1 Key in Element size: 10 (mm)

2 Click the Create button to generate

the tube mesh (See Figure 8)

Figure 8 Figure 9

V Create the Tube Mesh

26

1 Click the Tools tab

2 Key in Clamp die Length: 140(mm)

3 Key in Die insert Length: 140(mm)

4 Key in Ball thickness: 20(mm)

5 Click the Create button to generate

the tools mesh (See Figure 10)

Figure 10 Figure 11

VI Create the Tools Mesh

27

1 Click the OK button to enter the Rotary Bending setup page

Figure 12

Figure 13 VII Enter the Bending Setup

28

1 Click the Tube tab

2 Click <None> to define the tube material (See Figure 14)

3 Click Material Library to select the tube material (See Figure 15)

4 Select the material: HRDQSK (See Figure 16)

5 Click the OK button to exit the Material dialog box (See Figure 17)

VIII.Define the Tube Material

29

Figure 16

Figure 17 VIII.Define the Tube Material

30

Figure 18

1 Click the Process tab

2 The default tool control:

‒ Add Angular velocity to Bend die

‒ Add Force and Velocity to Pressure

die

‒ Add Velocity to Push assist

‒ The user can check and modify

load type and value

IX Define the Process

3 Select stage1 in the stages list

4 Change force curve type of pressure die to vs Bend angle percentage

5 Click the Define button (See Figure 19)

6 Click the Add button to input the data

7 Click Apply to generate the curve (See Figure 21)

8 Click OK to exit Load curve dialog box

9 Change load type of push assist to force

10 Input force of push assist: 5000(N)

11 Use the 2 parameters for all stages (See Figure 20)

31

IX Define the Process

32

Figure 21

IX Define the Process

33

1 Click the Control tab

2 Click … button, and the program will automatically calculate the time step

size according to the material parameters and the element size of tube

(See Figure 22)

Figure 22

X Define the Time Step Size

34

1 Click the menu Preview->Animation (See Figure 23)

2 Click the Play Button to show the bending process, and the user can also

select the Individual Frames option to display the incremental tools movement (See Figure 24)

3 Click Stop to exit the Animate dialog box

4 Click Setup->Save to save the database

Figure 23

Figure 24

XI Animation

35

1 Click the menu Job->LS-DYNA Input Deck (Figure 25)

2 The program pops up the Save As dialog box

3 Click Save to output the input deck

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

Figure 25

XII Input Deck

36

Open eta/POST to view the result

XIII.Post-Processor