Dynaform DF5921 training

In Sheet Forming window, click open the Blank page; 14.. Back in Blank Generator window, click Exit to finish... In Material Library window, select the material type DQ 36; click OK to c

DYNAFORM 5.9.2.1

Training

support@eta.com

March, 2015

2

Engineering Technology Associates, Inc (ETA)

Ø Established in 1983

Ø Engineering Offices

§  Headquarters: Troy, Michigan USA

Ø Global offices and network of

distributors in 4 Continents

Ø Primary Business – CAE

§  Software Development and Distribution

Brief History of DYNAFORM

Ø  1986 Coded C-Form for Chrysler

Ø  1993 Started the development of DYNAFORM

Ø  1996 Released first version to OEMs and Material Suppliers

Ø  1999 Released Windows/PC to Tool & Die Industry

Ø  2001 Unified Windows/Unix/Linux platforms

Ø  2003 Release BSE (Blank Size Engineering) module and MSTEP

Ø  2004 Delivered Die Structure Analysis (DSA)

Ø  2005 Delivered Springback Compensation (SCP) Module

Ø  2006 Released 5 th Generation of DYNAFORM with AutoSetup

Ø  2008 Released DYNAFORM 5.5 and 5.6

Ø  2009 Released DYANFORM 5.7

Ø  April 2010 Released DYNAFORM 5.7.3

Ø  January 2011 Released DYNAFORM 5.8

4

DYNAFORM Worldwide User Profile

NA Steel & Aluminum Industry

Tool & Die Industry

Korea

Hyundai / KIA GMDAT SsangYong HYSCO POSCO

Toyota Nissan Suzuki

Tool & Die Industry

Germany

Ford Cologne Porsche Thyssen Opel

UK

Land Rover Jaguar China ChangAn, TQM,

Wuling, Brilliance, BaoSteel, PoaSteel, NanJing, PuSie, Luo Yang Trucks

Toole & Die Industry

Kapco, National Auto Rad (NARMCO),

Canadian Eng., Russel, Electromac,

Woodbine, Walker Tool and Die, Digital

Forming Technology, Vollrath Company

LLC, QMC Die Technology, Fleetwood

Metal Industries, Fab-All

Manufacturing, Veltri Metal Products,

General Tool & Die (formerly SKD),

Superior Cam, Christy Ind., Wolverine

Tool and Die, Experi-Metal Inc.,

Cameron Tool, Diescan, Canadian Prog

Tool, D.R Tool and Design, On The Go

Die Design, Ascent Tool, Paulstra CRC,

Bes Tool & Die, Sabre Machine & Tool,

Wolverine Tool and Die, & Others

OEM Supplier

Malaysia

Sirim

DYNAFORM’s Major OEM Users

Ø  Ford Global

§  Ford North America, Ford Brazil, Ford Germany

Ø  DCX

§  Has been using DYNAFORM/LS-DYNA solution for 15+ years

§  Has been a Technology Development Partner since ’90

Ø  GM

§  GM North America, GM Brazil, GM Shanghai, GM Germany

Ø  Japan - Nissan, Honda, Suzuki,

Ø  Korea – Daewoo, KIA, Hyundai, SsangYong, POSCO,

6

DYNAFORM Capabilities

Ø  BSE (Blank Size Engineering with MSTEP One-Step Solution)

§  Blanking, Nesting, Material Cost Estimation

§  One-Step Formability Simulations

Ø  D-Eval (Die-face Evaluation)

§  INC Solver based fast incremental forming simulation

§  Quick setup with CAD die-face

§  Full capability drawbead setup

Ø  Formability (LS-DYNA-based forming simulation solution)

§  Accurate Solution, versatile tooling setup

§  Strength in Springback and Springback Compensation

§  Formability/Blank Outline/Trim Line Optimization capabilities

§  Hydro-forming, Hot forming, Tube bending, Roller hemming

Ø  DSA (LS-DYNA based Die System Analysis)

§  Die Structure Strength and Durability

§  Sheet Metal Handling and Transfer

§  Scrap Shedding/Removal

8

Inverted Draw (Single-Action)

Lower Ring

Lower Die Upper Die

Toggle Draw (Double-Action)

Upper Ring

Upper Die

Lower Die

10

Four-Piece Draw

 

DYNAFORM 5.9.2 Components

DYNAFORM Pre-processor

12

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

ACIS file name: filename.sat

CATIA4 database file name: filename.model

CATIA5 database file name: filename.CATPart

STEP file name: filename.stp

NX database file name: filename.prt

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

LS-DYNA input file name: filename.k

LS-DYNA input file name: filename.dynain

ABAQUS input file name: filename.inp

LS-DYNA Output Files

§  D3plot, d3plot01, d3plot02

§  D3plotaa, d3plotab, d3plotac For adaptive mesh

§  History files: rcforc, glstat, matsum, sleout, rbdout

§  D3hsp

§  D3dump

Sense switch (Ctrl + C)

•  SW1: stop the simulation

•  SW2: refresh screen display

•  SW3: write out d3dump file

•  SW4: write out d3plot file

DYNAFORM Mouse Button Operation

Ctrl

Rotation Translation Zoom

16

Training Contents

Ø  Workshop #1: Toggle Draw Simulation

Ø  Workshop #2: Inverted Draw Simulation

Ø  Workshop #3: Multi-Stage Simulation

Ø  Workshop #4: Springback Simulation

Ø  Workshop #6: Blank Size Engineering

Ø  On site project

Workshop #1: Toggle Draw (Double-Action)

18

3 4

1.  Start up eta/DYNAFORM Click File/Import;

2.  Select file WS1_Blank.igs in WorkShop1_Double_action folder

and click Import;

3.  Change the file type to NASTRAN (*.dat;*.nas) and select file

WS1_LowerDie.dat;

4.  Click OK to import the file Save the project in a separate

directory with a preferred name

1

2

Import Geometries

5.  Click Parts/Edit;

6.  Select the blank part and rename it to BLANK;

7.  Click the Modify to execute the change; click OK to exit the Edit Part window;

8.  Click Turn parts on/off and display only part BLANK Click OK to finish

Edit Parts – Change Part Names

5

7

6

8

20

9.  Select AutoSetup/Sheet Forming;

10.  Select the Process Type: Double action;

11.  Select Lower as the Original tool geometry;

12.  Click OK to open Sheet Forming window

Start a New Simulation - AutoSetup

13.  In Sheet Forming window, click open the Blank page;

14.  Click Define Geometry;

15.  Click Add Part in the Blank Generator window;

16.  Select the part BLANK from the part list;

17.  Click OK to exit the Select Part window

Define the Blank

13

14

15

16

22

18.  Back in Blank Generator window, click Blank mesh…;

19.  In Blank Mesh window, set the Element Size to 8;

20.  Click OK to execute meshing process and exit Blank Mesh window;

21.  Back in Blank Generator window, click Exit to finish

Create the Blank Mesh

18

21

20

19

Define the Blank Material

22.  Back in Blank page, click <None> under Material to define the blank material;

23.  In Material window, click Material Library ;

24.  In Material Library window, select the material type DQ (36); click OK to confirm;

25.  Back in Material window, click OK to finish

22

23

24

24

26.  Click Part on/off and display only part DIE; click OK to confirm;

27.  Click open the Tools page;

28.  Start with too Punch, click Define geometry

27

28

Define the Tool Punch

26

29.  Click open the Mesh page;

30.  Click Copy elements icon;

31.  In Copy Elements window, click Select;

32.  In Select Elements window, click Displayed

Define the Tool Punch

29

30

32

26

33.  Toggle on the Exclude option

34.  Select the Spread function with 2º spread angle, then Mouse_pick the elements on the binder area;

35.  Click OK to confirm selection;

36.  Back in Copy Elements window, click Apply to copy

the highlighted elements to tool Punch, a new part with name PUNCH is generated;

38.  Select tool Die to work on;

39.  Click Define tool icon;

40.  In Select Part window, select par DIE and click OK to confirm selection;

41.  Back in Define Tool window, click Exit to finish

Define the Tool Die

39

38

41

40

28

42.  Select the tool Binder to work on and click Copy elements

icon;

43.  In Copy Elements window, click Select;

44.  In Select Elements window, select Spread function and set 2º

spread angle, then mouse-pick the elements on the binder

area Click OK to confirm selection;

Back in Copy Elements window, Click Apply followed by Exit;

Back in Tool Preparation window, click Exit to finish

Define the Binder

42

43

44

45.  Back in Sheet Forming window, Tools page, select Positioning;

46.  In Positioning window, select On lowers Click OK to confirm

Position the Tools

45

46

30

47.  Click open Process page;

48.  Accept the default parameters for

51.  Click the Drawing process;

52.  Accept the default process parameters;

53.  Check on Fully match in Duration

Define the Process - Drawing

53

51

52

32

Preview – Tooling Animation

54.  Select Preview/Animation ;

55.  Click Play to start the tooling motion animation The sliding bar can be

used to alter animation speed;

56.  Click Stop to stop automated animation;

57.  Check on Individual Frames to enable manual-controlled animation Use

the four arrow buttons to either bring tools forward/backward one step

per mouse-click, or to take the tools to the starting/ending positions;

Checking off Individual Frames will go back to automated animation; clicking

Stop while in manual mode exits Animation window

54

55 56

57

58.  Back in Sheet Forming window, click open Control page;

59.  Click button shown to adjust the adaptive frequency based on tool travel

distance;

60.  Click OK to accept the calculated result;

61.  Click Setup and Save the database

Set Adaptive Mesh Control

61

58

59

34

Submit Job

62.  Click Job and select Job Submitter ;

63.  In the Job Options window, update No of CPU information click OK to submit the job

62

63

64.  Click open Drawbeads page;

65.  Click Import and select file drawbead.igs;

66.  Select Define;

67.  In Curve Editor window, click Select Line then mouse-pick one line on the screen;

68.  In Select Line window, click OK to confirm;

69.  Back in Curve Editor window, click OK to finish

36

70.  Select Die as the tool the drawead will be attached to, and click Apply;

71.  Key in 30 to assign the drawbead 30% of full-lock force, press Enter key

Define Drawbeads

70

71

72.  Click New to define another drawbead;

73.  Repeat steps 64 through 71 to define the

Drwabd2, using the other line;

When finished, save the project with a

different name, submit the job, and

compare the result with the previous one

Define Drawbeads

73

72

38

Use ETA/Post-Processor

74.  Double-click the shortcut icon from your desktop will start ETA/Post-Processor;

75.  Or, from DYNAFORM top menu, click PostProcessor and select eta/Post;

76.  From the top menu of ETA/Post-Processor, click File/Open With the default file type, d3plot, select the result files of the preferred project ;

77.  Or, from Job Submitter, highlight a project, no matter it is finished, aborted or

running, and click icon ETA/Post-Processor will start and read in the existing result files of the selected project

75

74

76

77

78.  Uses one of the keys in this group to play, pause or stop the automated animation;

79.  After the automated animation is paused, use one of the keys in this group to

manually perform animation;

80.  Switch to the Single Frame option and select the last frame from the list;

81.  FLD, Thinning/Thickness, Major/Minor Strain, etc., can be conveniently displayed

by using the icons on the top of the side menu;

82.  Select the Contour key to display more stress/strain contents

40

Plot Forming Limit Diagram

Without drawbeads With drawbeads

Plot Thinning

42

Plot Plastic Strain

Workshop #2: Inverted Draw (Single-Action)

44

1.  Open a new database file by selecting File/New, and Save the current project;

2.  Click File/Import In the directory WorkShop2_Single_action, select the file

WS2_Single_action.igs, and click OK;

3.  Click File/Save as…and save the new database file in a separate directory with

a preferred name

Geometry Preparation

1

2 3

4.  From DYNAFORM top menu, click Parts / Edit;

5.  Select the part with tool contents from the list;

6.  Change the name to UPRTOOL;

7.  Click Modify to confirm;

8.  Follow similar steps and change the name of the part with blank content

to BLANK Click OK to exit

Edit Parts – Change Part Names

5

7

8

46

9.  Click AutoSetup and select Sheet Forming;

10.  Key in 1.2 for the blank thickness;

11.  Select Single action;

12.  Select Upper for the Original tool geometry;

Define the Blank

16

14

17

14.  In Sheet Forming window, click open Blank page;

15.  Select Define Geometry;

16.  In Blank generator window, open Outline page and click Select Line;

17.  In Select Line window, select Chain Line mode and mouse-pick the blank outline from screen; click OK to confirm

48

18.  Back in Blank Generator window, click Blank mesh

19.  In Blank Mesh window, set the Element Size to 10;

20.  Click OK to proceed meshing the blank and generating

the BLK part Click OK to finish

Define the Blank – Create Blank Mesh

19

20

18

21.  Back in Blank page, click <None> to define the blank material;

22.  In Material window, select Material Library;

23.  In Material Library window, select DQSK (37); click OK to confirm;

24.  Back in Material window, click OK to finish

Define the Blank Material

21

22

23

50

25.  Back in Blank page, click Define in the Symmetry type field;

26.  In Symmetry Plane window, select Symmetry icon;

27.  Select VW-Plane; the symmetry condition is establish on the blank mesh;

28.  Click Exit to confirm and finish

Define the Blank – Symmetry Condition

25

26

27

28

29.  Click open Tools page and select tool Die;

30.  Click Define Geometry;

31.  In Tool Preparation window, select Define tool

icon and pick UPRTOOL from part list;

32.  In Define Tools window, click Exit;

33.  Back in Tool Preparation window, select Turn

Parts on/off icon and display UPRTOOL only

Define the Tools

29

33

31

52

34.  Click open Mesh page;

35.  Select Surface mesh icon;

36.  In Surface Mesh window, change Max.Size to

10;

37.  Select Apply;

38.  Select Yes to accept meshing result; click Exit to

finish defining the tool Die

Define the Tools - Create Tool Mesh

39.  Back in Tool Preparation window, select tool Punch to work on;

40.  Select Copy elements icon;

41.  In Copy Elements window, click Select;

42.  Select X-Y view from top menu;

43.  Toggle off Surfaces display from the display menu at lower-right corner

54

44.  In Select Elements window, click Displayed;

45.  Check on Exclude;

46.  Select Spread function and set Angle to 3 Mouse-pick the

elements in binder area;

47.  Switch to Drag window method to de-select the remain

highlighted elements in the binder area;

48.  Click OK to confirm and exit

Define the Tool Punch

49.  Back in Copy Elements window, click Apply to copy the selected

elements to tool Punch;

50.  Click Exit to finish defining tool Punch

49 50

Define the Tool Punch

56

51.  Back in the Tool Preparation window, select Binder to work on;

52.  Select Copy Elements icon;

53.  In Copy Elements window, click Select;

Define the Tool Binder

52

51

53

54.  In Select Elements window, select Spread function,

set Angle to 3 and mouse-pick the elements in the binder area;

55.  Switch to Drag window function and select the remain

elements in the binder area;

56.  Click OK to confirm element selection

Define the Binder

54

55