AutoForm Incremental

Download AutoForm Incremental

Post on 09-Feb-2016

598 views

Category:

Documents

0 download

Embed Size (px)

TRANSCRIPT

  • iletisim: omarer25@hotmail.com

  • ALGHAFORM PAYLASIMIDIR

    www.forum.alghaform.com

    iletisim: omarer25@hotmail.com

  • 12222 AutoFormIncrementalAutoFormIncrementalAutoFormIncrementalAutoFormIncremental

    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.

    In AutoFormIncremental the simulation of the following forming processes or phenomena is possible:

    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

    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.

    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.

    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-

    www.alghaform.com

  • 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.

    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.

    www.forum.alghaform.com

  • 3Contents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncrementalContents of the Workshop AutoFormIncremental

    Lesson 1Lesson 1Lesson 1Lesson 1 DeepDrawing on Double Action PressDeepDrawing on Double Action PressDeepDrawing on Double Action PressDeepDrawing on Double Action Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5555

    CADImportIGES Binder definition Input generator Blank definition Gravity Starting the simulation Evaluation of the simulation

    Lesson 2Lesson 2Lesson 2Lesson 2 DeepDrawing on Single Action PressDeepDrawing on Single Action PressDeepDrawing on Single Action PressDeepDrawing on Single Action Press. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .27272727

    CADImportIGES Positioning of tools Positioning the blank sheet Process definition Evaluation of the simulation

    Lesson 3Lesson 3Lesson 3Lesson 3 Drawbeads and Tailored BlanksDrawbeads and Tailored BlanksDrawbeads and Tailored BlanksDrawbeads and Tailored Blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47474747

    Input generator Material definition Weld line Drawbead

    Lesson 4Lesson 4Lesson 4Lesson 4 Drawbead generatorDrawbead generatorDrawbead generatorDrawbead generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64646464

    Automatic determination of the width Automatic determination of the restraining force (Force-

    factor) of a drawbead

    Lesson 5Lesson 5Lesson 5Lesson 5 Tipping and CuttingTipping and CuttingTipping and CuttingTipping and Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70707070

    Determination of the drawing direction Relief cut Trimming cut Holes Cutting direction

    www.forum.alghaform.com

  • 4Lesson 6Lesson 6Lesson 6Lesson 6OptimizationOptimizationOptimizationOptimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91919191

    Numerical optimization Parameter study Optimization of the force factor of a drawbead Evaluating the optimization

    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

    Automatic Filleting Defining the blank sheet by arc Restart

    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

    Starting from RestartFile Definition of additional tools Definition of additional process steps Filleting radii

    Lesson 9Lesson 9Lesson 9Lesson 9Using CAM ToolsUsing CAM ToolsUsing CAM ToolsUsing CAM Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141141141141

    Undercuts Adding tools Changing working direction Adding a process step Process type Flanging

    Lesson 10Lesson 10Lesson 10Lesson 10Use of Pad and SpringbackUse of Pad and SpringbackUse of Pad and SpringbackUse of Pad and Springback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154154154154

    Die insert (pad) Free contours, sharp edges and undercuts Definition of an additional tool Definition of additional process steps Altering tools Positioning of tools

    Lesson 11Lesson 11Lesson 11Lesson 11Hydromechanical Deep DrawingHydromechanical Deep DrawingHydromechanical Deep DrawingHydromechanical Deep Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173173173173

    Symmetry Forming by means of fluids Preforming Active hydromechanical deep drawing

    www.forum.alghaform.com

  • 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

    5

    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

    This lesson describes the deepdrawing process on a double action press. The CAD data of the die is available.

    Fig. 1.1Fig. 1.1Fig. 1.1Fig. 1.1

    Deep drawing on a double action press

    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.).

    The generation of the simulation file is done by the following input:

    File > New ... > in_lesson_01 > OK

    www.forum.alghaform.com

  • 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

    6

    Fig. 1.2Fig. 1.2Fig. 1.2Fig. 1.2

    Options to create a new simulation file

    File name: name of *.sim file, without extension Units: Units, which are used in this simulation file. This

    should correspond to units used in CAD data. Geometric error tolerance: Acceptable chordal error of

    mesh generation.

    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