146707525 AutoForm Incremental

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<ul><li><p>iletisim: omarer25@hotmail.com</p></li><li><p>ALGHAFORM PAYLASIMIDIR</p><p>www.forum.alghaform.com</p><p>iletisim: omarer25@hotmail.com</p></li><li><p>12222 AutoFormIncrementalAutoFormIncrementalAutoFormIncrementalAutoFormIncremental</p><p>AutoFormIncremental is the AutoForm module to simulate sheet metal forming processes (conventional deep drawing, hydrome-chanical deep drawing) using the finite element method in many small steps. Using AutoFormIncremental it is possible to simulate all forming operations beginning with the plane blank sheet and ending with the finished car body part including springback calcu-lation.</p><p>In AutoFormIncremental the simulation of the following forming processes or phenomena is possible:</p><p> Impact of gravity when putting the blank sheet on the tool Binder closure (binderwrap) Drawing with/without drawbeads or lock beads Cutting Second forming Forming operations with cam slides Forming operations with die and punch inserts Springback Preforming the blank sheet by means of a fluid Hydromechanical deep drawing</p><p>Forming operations for steel and aluminum materials used in the automotive industry as well as tailored blanks can be simulated with AutoFormIncremental. In connection with the easytouse user interface the tool maker, the tool designer and the process engi-neer can quickly verify the forming process in all tools and where required optimize processes, to lay the foundations for high qual-ity parts at the computer.</p><p>When entering the simulation input data, the user is guided by the program and pointed at still necessary inputs. The movement of all tools can be checked prior to the real simulation. In general the cal-culation time for a simulation ranges from only a some minutes up to a few hours.</p><p>Color shaded post values such as sheet thickness, cracks, strain and stress as well as process parameters such as forces are available for the evaluation of the simulation. Wrinkles are identified by inspect-</p><p>www.alghaform.com</p></li><li><p>2ing the shaded representation of the model or by means of color shaded post values. These possibilities are completed by additional special evaluation criteria such as skid/impact lines.</p><p>In connection with AutoFormOptimizer, the user gets access to a numerical optimization algorithm by which process parameters such as binder force or restraining forces for drawbeads are auto-matically modified during several simulation iterations to obtain an optimally stretched part without cracks and wrinkles.</p><p>www.forum.alghaform.com</p></li><li><p>3Contents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncremental</p><p>Lesson 1Lesson 1Lesson 1Lesson 1 DeepDrawing on Double Action PressDeepDrawing on Double Action PressDeepDrawing on Double Action PressDeepDrawing on Double Action Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5555</p><p> CADImportIGES Binder definition Input generator Blank definition Gravity Starting the simulation Evaluation of the simulation</p><p>Lesson 2Lesson 2Lesson 2Lesson 2 DeepDrawing on Single Action PressDeepDrawing on Single Action PressDeepDrawing on Single Action PressDeepDrawing on Single Action Press. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .27272727</p><p> CADImportIGES Positioning of tools Positioning the blank sheet Process definition Evaluation of the simulation</p><p>Lesson 3Lesson 3Lesson 3Lesson 3 Drawbeads and Tailored BlanksDrawbeads and Tailored BlanksDrawbeads and Tailored BlanksDrawbeads and Tailored Blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47474747</p><p> Input generator Material definition Weld line Drawbead</p><p>Lesson 4Lesson 4Lesson 4Lesson 4 Drawbead generatorDrawbead generatorDrawbead generatorDrawbead generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64646464</p><p> Automatic determination of the width Automatic determination of the restraining force (Force-</p><p>factor) of a drawbead</p><p>Lesson 5Lesson 5Lesson 5Lesson 5 Tipping and CuttingTipping and CuttingTipping and CuttingTipping and Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70707070</p><p> Determination of the drawing direction Relief cut Trimming cut Holes Cutting direction</p><p>www.forum.alghaform.com</p></li><li><p>4Lesson 6Lesson 6Lesson 6Lesson 6OptimizationOptimizationOptimizationOptimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91919191</p><p> Numerical optimization Parameter study Optimization of the force factor of a drawbead Evaluating the optimization</p><p>Lesson 7Lesson 7Lesson 7Lesson 7Automatic Filleting with a Constant RadiusAutomatic Filleting with a Constant RadiusAutomatic Filleting with a Constant RadiusAutomatic Filleting with a Constant Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110110110110</p><p> Automatic Filleting Defining the blank sheet by arc Restart</p><p>Lesson 8Lesson 8Lesson 8Lesson 8Multiple Step process and Starting from Restart fileMultiple Step process and Starting from Restart fileMultiple Step process and Starting from Restart fileMultiple Step process and Starting from Restart file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120120120120</p><p> Starting from RestartFile Definition of additional tools Definition of additional process steps Filleting radii</p><p>Lesson 9Lesson 9Lesson 9Lesson 9Using CAM ToolsUsing CAM ToolsUsing CAM ToolsUsing CAM Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141141141141</p><p> Undercuts Adding tools Changing working direction Adding a process step Process type Flanging</p><p>Lesson 10Lesson 10Lesson 10Lesson 10Use of Pad and SpringbackUse of Pad and SpringbackUse of Pad and SpringbackUse of Pad and Springback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154154154154</p><p> Die insert (pad) Free contours, sharp edges and undercuts Definition of an additional tool Definition of additional process steps Altering tools Positioning of tools</p><p>Lesson 11Lesson 11Lesson 11Lesson 11Hydromechanical Deep DrawingHydromechanical Deep DrawingHydromechanical Deep DrawingHydromechanical Deep Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173173173173</p><p> Symmetry Forming by means of fluids Preforming Active hydromechanical deep drawing</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>5</p><p>2. 12. 12. 12. 1 Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>This lesson describes the deepdrawing process on a double action press. The CAD data of the die is available.</p><p>Fig. 1.1Fig. 1.1Fig. 1.1Fig. 1.1</p><p>Deep drawing on a double action press</p><p>Generation of a Simulation fileGeneration of a Simulation fileGeneration of a Simulation fileGeneration of a Simulation fileAt the beginning, a new simulation file (*.sim) has to be defined. The first input is the name of the simulation. During the generation of the input, this simulation file is filled with data, which is neces-sary for the simulation (geometrical data, specification of process, numerical data etc.).</p><p>The generation of the simulation file is done by the following input:</p><p>File &gt; New ... &gt; in_lesson_01 &gt; OK</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>6</p><p>Fig. 1.2Fig. 1.2Fig. 1.2Fig. 1.2</p><p>Options to create a new simulation file</p><p> File name: name of *.sim file, without extension Units: Units, which are used in this simulation file. This </p><p>should correspond to units used in CAD data. Geometric error tolerance: Acceptable chordal error of </p><p>mesh generation.</p><p>Preparation of tool geometries for the simulationPreparation of tool geometries for the simulationPreparation of tool geometries for the simulationPreparation of tool geometries for the simulationNormally the first input is the geometries of the tools used in this simulation. AutoForm requires these geometries in VDAFS or IGES format only. It is recommended that the user start with the input of the geometries, because possible errors or missing data in the CAD model can be checked and corrected early.</p><p>The tool geometries are read in VDAFS or IGES format. AutoForm automatically meshes the tool surfaces. All subsequent operations are based on this mesh. Only the mesh can be visualized in Auto-Form, not the original CAD data.</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>7</p><p>Import and meshing of CAD dataImport and meshing of CAD dataImport and meshing of CAD dataImport and meshing of CAD dataFile &gt; Import &gt; IGES &gt; OK</p><p>Fig. 1.3Fig. 1.3Fig. 1.3Fig. 1.3</p><p>Select a file: in_lesson_01.igs &gt; OK </p><p>Fig. 1.4Fig. 1.4Fig. 1.4Fig. 1.4</p><p>Window to mesh CAD data</p><p>Start meshing with the option: </p><p>Program: afmesh_3.1 &gt; OK</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>8</p><p>ParametersParametersParametersParameters Error tolerance: Acceptable chordal error for the meshing. Value is taken from New file dialog (Default: 0,1) (Fig 1.1), but it can be changed. For especially small radii (equal or lesser than 2 mm) 0.05 should be used as error tolerance.</p><p> Max side length: Maximum element side length</p><p>FacesFacesFacesFaces Treat only: Only specified faces will be meshed. Exclude: The specified faces are not taken into account for </p><p>meshing.</p><p>LayersLayersLayersLayers Treat only: Only specified layers will be meshed. Exclude: The specified layers are not taken into account for </p><p>meshing.</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>9</p><p>The meshed geometry is immediately displayed and the Geometry generator automatically pops up. At first, the tool setup in the Geometry generator has to be changed, so that the die is the lower tool (right Icon in Fig. 1.5).</p><p>Fig. 1.5Fig. 1.5Fig. 1.5Fig. 1.5</p><p>In this example the CAD data is binder (binder) and punch (punch). Later the die (die) is created with Offset. The two tools have to be separated first. This is done as follows:</p><p>Select faces of binder (right mouse button or Shift right mouse button for several faces).</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>10</p><p>Fig. 1.6Fig. 1.6Fig. 1.6Fig. 1.6</p><p>Selected faces of binder</p><p>PreparePreparePreparePrepareDefine objects: Binder</p><p>Binder is defined in Geometry generator and selected faces are put into the Binder register. The remaining unselected faces become the punch and all faces are defined as the die; hence all required tools for a standard simulation are now fully defined.</p><p>The next step is checking the geometry to see if it can be used for simulation. AutoForm can check for free edges, sharp edges or undercuts.</p><p>Control parameters can be found in Part boundary (Fig. 1.5): </p><p> Error tolerance is the acceptable chordal error of the CAD data describing the part boundary and the generated part boundary of AutoForm. </p><p> Concatenation distance is the minimum distance between points on the part boundary. </p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>11</p><p>Use button</p><p>Generate part boundary: Apply (Fig. 1.5 bottom right) </p><p>to start automatic calculation of the part boundary (shown in blue).</p><p>Fig. 1.7Fig. 1.7Fig. 1.7Fig. 1.7</p><p>Generated part boundary</p><p>If gaps occur in the geometry, several blue lines are displayed. This is one possible way of checking for gaps and untrimmed surfaces. If the generated part boundary needs to be changed, it can be done using the option</p><p>PreparePreparePreparePrepare Outer Trim &gt; Edit</p><p>Holes can be created with the option</p><p>Inner Trim &gt; Add</p><p>Correction of untrimmed surfaces should be performed in CAD system. Checking for sharp edges and undercuts can also be done in Geometry generator. This is described in detail in Lessons 5 and 7.</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>12</p><p>Check geometry for sharp edges:</p><p>FilletFilletFilletFilletGeometry generator &gt; Fillet &gt; Check radius: 2.00 &gt; Check</p><p>In the logwindow, it is displayed that (no) sharp edges have been found.</p><p>Close the window using Dismiss (Fig. 1.8).</p><p>Fig. 1.8Fig. 1.8Fig. 1.8Fig. 1.8</p><p>FilletFilletFilletFillet page of Geometry generator</p><p>www.forum.alghaform.com</p></li><li><p>Lesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action PressLesson 1: DeepDrawing on Double Action Press</p><p>13</p><p>Check geometry for undercuts using option:</p><p>Geometry generator &gt; Tip (Fig. 1.9)</p><p>Fig. 1.9Fig. 1.9Fig. 1.9Fig. 1.9</p><p>TipTipTipTip page of Geometry generator</p><p>All undercuts, marginal areas and undercut free areas are calcu-lated and displayed in different color for the current drawing direc-tion when the Tip page is opened. Undercut free ar...</p></li></ul>