Dynaform Manual
Dynaform Manual
Dynaform Manual
Die Simulation
Training Manual
Version 5.9.2.1
TABLE OF CONTENTS
TABLE OF CONTENTS .............................................................................................................. 1
INTRODUCTION......................................................................................................................... 1
DATABASE MANIPULATION .................................................................................................. 2
I. Creating an eta/Dynaform Database and Analysis Setup...................................................................... 2
TOOL PREPARATION................................................................................................................ 4
I. Import Die Geometry............................................................................................................................ 4
II. Meshing Die ........................................................................................................................................ 5
III. Mesh Check and Repair ........................................................................................................................ 7
DIE SIMULATION SETUP........................................................................................................ 11
I. Die Simulation Interface ..................................................................................................................... 11
II. Define Tools........................................................................................................................................ 12
III. Define and Mesh Blank ...................................................................................................................... 16
IV. Defining the Blank Material ............................................................................................................... 20
V. Define Tool Control ............................................................................................................................ 22
VI. Define Drawbead ................................................................................................................................ 24
VII. Submit Job .......................................................................................................................................... 27
POST PROCESSING (with eta/POST) .................................................................................... 30
I. Reading the Results File into the Post Processor ................................................................................ 30
II. Animating FLD................................................................................................................................... 32
III. Plotting Single Frames ........................................................................................................................ 33
IV. Check the forming Result of FLD ...................................................................................................... 34
V. Check the forming Result of THICKNESS ........................................................................................ 34
INTRODUCTION
Welcome to the eta/DYNAFORM 5.9.2.1 Die Simulation Training Manual. The eta/DYNAFORM is the
unified version of the DYNAFORM-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.
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/DYNAFORM5.9.2.1.
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 FileSave as, type “Die_Simulation”, and click Save to dismiss the
dialogue window.
Database Unit
Click UserSetupAnalysis 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 UserSetupAnalysis 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.
2 eta/DYNAFORM Training Manual
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. LINE DATA (*.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. CATIA5 (*.CATPart; *.CATProduct) 17. ABAQUS (*.inp)
9. STEP (*.stp; *.step) 18. DYNAIN (*dynain*)
TOOL PREPARATION
Tool Preparation is a very important step contributing to a successful simulation. The tool will be imported and
meshed in Tool Preparation.
3. Go to the training files located. Locate the file: Die_upper.igs, and import it. Click OK to dismiss the
Import File dialogue window.
4. After reading in the data file, verify the display looks the same as the illustration shown below.
2. In the displayed Surface Mesh dialogue window, default values will be used for all fields.
3. All surfaces of Die will auto be selected. Click the Apply button on the Surface Mesh dialogue.
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.
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.
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.
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.
.
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.
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.
3. Select the surfaces on binder surface by using Select by surface. The elements on binder surface are
selected.
2. In the Blank Generator/Outline, click the Import button to import the blank outline.
3. Go to the training files located. Locate the file: Blank.igs, and import it. Click OK to dismiss the
Import File dialogue window.
4. Click the Select Line button in Blank Generator/Outline to select the imported blank outline.
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.
3. Select BH180 from the Unite States standard. Then exit Material definition dialog box.
4. Input blank thickness: 0.8mm.
3. Select Apply, and the program will automatically create mating tools, position the tools and generate
the corresponding travel curves.
4. Select Preview to check the tooling motion.
5. Compare your display with the illustration shown below.
3. Switch the file type to iges and select the drawbead file bead.igs.
4. Use the default mesh parameters and click Apply to generate the line drawbead..
5. Select all the Draw beads in the left side list. Click Select in Lock tool and select BNDR0000 from
the Select Part list. Click OK to exit. Lock the drawbead to part BNDR0000.
6. Once the sheet is defined, the program will calculate the full lock force and set Force Percentage
50.0% of each bead.
7. Set force percentage for each bead. The force percentages of all drawbeads is in the following table.
Bead ID 1 2 3 4 5 6 7 8 9 10 11 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
2. Toggle on Gravity Load to perform gravity loading analysis prior to Drawing analysis.
3. Set the Adaptive level to 4 and Select Multi from the CPU type button, as shown below.
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.
1. From the File menu of eta/POST, select Open. The Open File dialogue will be displayed.
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.
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.
FLD
4. Select THINNING from the Current Component list to plot thinning result.